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This is a division of application Ser. No. 08/585,971 filed Jan. 16, 1996, now U.S. Pat. No. 5,843,326.
BACKGROUND OF THE INVENTION
The present invention relates to a process for producing a mold intended for the molding of at least a portion of a tread of a tire. More particularly, it concerns a process for molding the mold of a tire on a countermold, said countermold being provided with separately made elements in relief which protrude from the molding surface of said countermold. The portion which protrudes is intended to be inserted and anchored in the mold during the pouring of said mold.
When it is desired to produce a tread pattern of a tire comprising one or more fine slits, that is to say relatively deep slits of a thickness less than or equal to 2.5 mm, elements in the form of metal blades are produced separately before incorporating them in the mold for said tread; the blades are in general of steel so as to have sufficient rigidity to permit a large number of moldings of tires without change in the geometry of said blades.
French patent 2 430 838 describes, for the production of a mold which has blades, a process which consists in machining a countermold on a lathe and then producing fine slits in said countermold by means of a spark erosion process, each slit having a geometry which corresponds precisely to the geometry of the blade which is intended to be inserted therein before proceeding with the pouring of aluminum for forming the mold.
Such a process permits the putting in place only of blades of removable shape, since once the casting has solidified, the blades are partially inserted in the mold and their extraction from the countermold can be effected only by relative sliding in their respective housings in the countermold in a predetermined direction of removal.
The improvement in the performance required from tires has led to the conceiving of tire tread patterns containing fine slits which have large variations in geometry in the thickness of the tread of said tire. One example of this type of slit is described, for instance, in French patent application FR 2 641 501. In such cases, the blades have non-removable shapes which makes the process described in French patent 2 430 838 entirely inoperative. It should be noted that, in connection with the molding of a tire tread, the removal of the blades from the mold is possible due to the deformability and elasticity of the materials constituting said tread.
French patent FR 1 203 290 describes another process for manufacturing a tire mold by molding on a plaster countermold in which metal blades are partially embedded at the time of the production of the countermold. After solidification of the pouring on said plaster countermold, the blades which are firmly anchored in the mold are freed from the plaster countermold by breaking the latter, which of course makes it impossible to use the countermold for another molding. While this process makes it possible readily to produce a mold having non-removable blades, it is unfortunately a lengthy one to carry out and is particularly expensive since it requires the production of a new plaster countermold upon each molding of a tire mold.
SUMMARY OF THE INVENTION
The object of the present invention is to propose both a molding process by pouring a mold intended for the molding of at least a portion of a tire tread which comprises at least one non-removable element which protrudes from said mold, said process not having the drawbacks of the processes which have just been described. Each non-removable element is separately made before being partially anchored in the mold at the time of the pouring of said mold.
Another object of the invention is to provide a device intended specifically for the carrying out of the process of the invention which assures a precise positioning of each non-removable protruding element in the countermold while permitting easy removal from the mold after solidification of the pouring of said mold.
In accordance with the invention, in order to produce a mold used for the molding of at least a portion of the tread of a tire having a tread pattern of given shape, said mold being provided with at least one non-removable motif, a molding process is defined which comprises the following steps:
for each non-removable motif, there is produced at least one molding element comprising a first portion which defines said motif and a second portion located in the extension of the first portion and which constitutes the anchoring of said element in said mold;
a countermold is produced, designed to be imparted thereto a mold-removal movement in a predetermined direction, having a molding surface which, aside from the non-removable motif or motifs, corresponds essentially to said tread pattern and in which there is present, at the place of each non-removable motif, a housing which opens via an opening in the molding surface and the contour of which includes at least the contour circumscribed on the projection, on said molding surface in the mold-removal direction, of all the points of said non-removable motif, said housing being defined in said countermold by the extension of the contour of said housing in the mold-removal direction;
with each molding element there is associated a means for producing the continuity of the surface of the countermold in the vicinity of said molding element when the latter is in place in the corresponding housing on the countermold, and for maintaining said molding element in place;
the countermold and the molding element or elements are assembled, each molding element being equipped with the associated means;
the molding of the mold on the countermold is effected by means of a suitable pourable and solidifiable material;
the mold is removed from its countermold by removing each molding element from its housing in the mold-removal direction, the second portion of each element remaining attached to said mold.
A non-removable motif can be defined as a motif which comprises at least one undercut in its shape, so that if the molding element used for the molding of said motif is imprisoned in a rigid material, there is no possible sliding between the element and the material covering it, and this whatever the direction of mold removal which can be contemplated. By rigid, there is understood a material which does not submit sufficient elastic deformation in order to be able to remove the element from the mold, in contrast to the material composing the tread of a tire.
The means associated with each molding element has the role of effecting the closing of the housing and therefore the tightness of the housing in which the first portion of said element is inserted in order to prevent the pouring material of the mold from filling said housing, while assuring the geometrical continuity of the surface of the countermold in the vicinity of said element. The associated means also has the role of permitting satisfactory holding of said element in its corresponding housing in the countermold so as to avoid any displacement of the element during the molding of the mold.
One of the advantages of the process forming the object of the invention is that it permits the manufacture, from the same countermold, of any number of molds having molding elements of non-removable shape within a shorter time and at a lower cost than with the processes used up to now.
The present invention also relates to a device which permits the putting in place and mold removal of at least one molding element in a countermold comprising a molding surface intended for the molding, by means of the pouring of a pourable material, of a mold for at least partially molding a tire tread. Each molding element comprises two portions separated by a frontier; a first portion defines a non-removable motif and is intended to be introduced into a housing developed in the countermold, and a second portion, located in the extension of the first part, protrudes from the molding surface of the countermold and is intended to be engaged in the pouring material forming the mold. By frontier, there is to be understood the trace on the surface of the molding element of the intersection of said surface with the molding surface of the mold.
The device in accordance with the invention comprises at least one part which can be placed in contact with the molding element at least at the frontier between the first portion and the second portion in order to form a drawer assembly, which assembly may first be introduced partially into the housing up to the desired position of the molding element in the countermold, said assembly, when in place in its housing, assuring the continuity of the surface of the countermold in the vicinity of the element while preventing the introduction of the pouring material into the housing during the pouring and, in a second stage, that is to say after solidification of the material of the pouring, capable of being extracted from said housing before being disassembled in order to free the first portion from the molding element.
The device in accordance with the invention assures both the closing of the housing in which the first portion of the element is placed and the holding of said element during the operation of the pouring of the mold.
In accordance with a first embodiment, at least one part is produced, which then completely clamps the first part of the molding element.
One manner of obtaining a device in accordance with this first embodiment is to mold a single part around the first portion of the molding element by means of a pourable and solidifiable material, such part reproducing on its outer faces the geometry of the housing into which it is intended to be introduced with the element. The material constituting the part molded around the first portion of the element is separable from said portion after extraction from the housing and removal from the mold.
In this latter case, the volume of the molding thus produced, including the first portion of the element, corresponds precisely to the volume of the housing provided in the countermold in order to receive the device clamping the first portion of the molding element. One may use either materials (plaster, sand, alloy of low melting point, etc.) which will be destroyed after removal from the mold or (thermoplastic, etc.) materials, which offer the advantage of permitting the reuse of the molding due to their elastic characteristics which permit the assembling and disassembling of said molding and of the element by simple elastic deformation of said molding .
In this latter case, this same molded part can advantageously be used again in order to surround another molding element of the same shape and produce another mold.
In accordance with a second embodiment of the device, it is composed of at least one part intended to partially or completely surround the portion of the molding element protruding from the molding surface of the countermold; in this second embodiment, the device is intended to be incorporated, in the same way as the second portion of the element, in final manner in the mold.
DESCRIPTION OF THE DRAWINGS
A better understanding of the invention and its advantages will be obtained from the figures accompanying the present description which show examples of use, these examples being in no way limitative:
FIG. 1 is a perspective view of a countermold ready for the molding of a tire mold and having an attached metal blade;
FIG. 2 is a detail view of the surface of the countermold of FIG. 1 in the vicinity of the blade;
FIG. 3 is a detail view of the surface of the countermold of FIG. 1, in which a drawer assembly including a blade has been partially introduced;
FIG. 4 is a sectional view of a device for putting in place a blade of Y-shaped cross section;
FIG. 5 is a sectional view of a device intended for placing and removing a blade a cross section of which has undulations;
FIG. 6 is a view in cross section of a housing made in a countermold into which there is partially introduced a blade the portion of which outside said countermold is in part clamped in a device intended to close said housing.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a metal countermold 1 intended for the casting of a mold, not visible in this figure, for the subsequent molding of a tread of a tire. The countermold 1 has a molding surface 2 the profile of which corresponds to that of the tread of a tire, and said surface 2 comprises, in the example described, several circumferentially oriented grooves 3. The countermold 1 can have imparted to it a mold-removal movement in a predetermined direction. A housing 5 is provided in the countermold 1 to receive a metal blade 4, which has been made separately; in the present case, this housing comprises four faces which are parallel in pairs, the corners formed by the intersections of said faces being parallel in a given direction corresponding to the mold-removal direction. The housing 5 debouches on one side into a groove 6 in said countermold 1.
FIG. 2 shows a detail view of FIG. 1 in the vicinity of the blade 4 in place in its housing 5, said blade extending in part through one of the lateral sides of the housing into the groove 6. A portion 8 of the blade 4 is located on the outside of the countermold 1 with respect to the molding surface 2 so as to be able to be embedded in the pouring material of the mold. In this portion 3, there are produced notches 7, 16 intended to assure a better anchoring of the blade 4 in the mold.
The portion 8 of the blade 4 is extended by a portion, not visible in FIGS. 1 and 2, which is clamped between metal parts 10 and 11 to form a drawer assembly 9. In FIG. 2 this drawer assembly is introduced into the housing 5 and is in a position ready for the effecting of the casting of a mold. The faces 12, 13, 14, 15 of said parts 10 and 11 are machined so as to be able to assure the continuity of the molding surface 2 of the countermold 1 in the vicinity of the blade 4 once the drawer assembly is in place in the housing 5, thus avoiding the penetration of the pouring material into the housing.
In order to facilitate an understanding of the invention, FIG. 3 shows this same drawer assembly 9 in position partially introduced into its housing 5.
The drawer assembly 9 is formed of two parts 10 and 11 which clamp the blade 4, only the portion 8 of which is visible. In the position shown, only two side faces 17 and 18 of the drawer assembly 8 can be seen; these faces, as well as the opposite faces of the drawer assembly are parallel to the faces of the housing 5 located opposite each other. The presence of suitable play between the assembly and the housing permits easy movement of said assembly in its housing in the direction of removal from the mold while assuring an excellent positioning of the blade 4 with respect to the countermold 1, without however permitting infiltration of the casting material forming the mold into the housing 5.
After solidification of the molding of the mold, the portion 8 of the blade 4 being then firmly anchored in said mold, it is possible, by displacing the countermold in the mold-removal direction and in the direction opposite the mold to extract the drawer assembly 9 from the countermold 1. Thereupon, the portion of the blade 4 clamped in the drawer assembly 9 is freed.
FIG. 4, in a view along a cross section taken along a plane containing the mold-removal direction, shows a drawer assembly 20 in which there is partially clamped a blade 24 at least one section of which, seen along this section plane, has the shape of a Y. On this cross section, the blade 24 is formed of a tail which is extended by two branches so as to from a Y.
The device employed in order to form the drawer assembly 20 comprises three metal parts 21, 22, 23 machined and assembled in such a manner as to clamp a first portion 26 of the blade 24 formed of the branches of the Y and a portion of the tail, the second portion 25 extending the first portion towards the outside of said drawer assembly.
This drawer assembly 20, if one excepts the portion 25 of the blade 24, has a cross section (shown in FIG. 4) of rectangular shape the large side of which has a length L which is greater than the maximum dimension h, measured in the same direction as the length L, of the portion 26 of the blade clamped in said assembly 20. Furthermore, the parts 21 and 22 are machined in such a manner as to be able snugly to fit the geometries of the side faces 27 and 28 and the geometries of the end faces 29 and 30 of the branches of the Y of the blade; finally, the part 23 which is inserted between the parts 21 and 22 is made in such a manner as to fill the regions located between the two branches of the blade 24, snugly fitting their facing inner faces.
The three parts 21, 22, 23 which, together with the blade 24, form the drawer assembly 20 are held firmly assembled by fastening means 35, such as pins, arranged close to the lower base of said assembly 20, that is to say on the end opposite the blade 24. Recesses 31 and 32, made in the parts 21 and 22, respectively, in their central portions and facing the intermediate part 23, make it possible to increase the flexibility in transverse flexure of the parts 21 and 22. It is thus possible to introduce and release the blade 24 by elastically moving the ends 34 and 33 of the parts 21 and 22 away from each other, said ends being located opposite the fastening means 35, without having to disassemble said assembly.
FIG. 5 shows the cross section of a blade 43 formed of two portions 44 and 45, the portion 45, which is corrugated in the sectional plane of the figure, being clamped between the two opposite faces 46 and 47 of the two metal parts 41 and 42 in order to constitute a drawer assembly 40. This drawer assembly 40 has, in the sectional plane of the figure, if one disregards the portion 44 of the blade 43, a rectangular cross section the large side of which has a length L which is greater than the maximum dimension h measured in the same direction as the length L of the first portion 45 of the blade 43.
Assembly means, such as pins 51, are positioned close to the end of the drawer assembly opposite the blade to assure the holding together of the assembly while permitting an elastic transverse moving apart of the ends 48 and 49 of the parts 41 and 42 located in the vicinity of the blade 43 in order to remove the latter from the drawer assembly 40 or to insert it. As in the case of FIG. 4, this opening movement, caused for instance upon the extraction of the blade 43 from the assembly 40 by pulling on said blade, is facilitated by the presence of a recess 50 provided on the inner face 46 of the part 41 so as to increase the flexibility of the part 41 in transverse flexure under the effect of said movement.
It can be noted that the device of the invention is also adapted to the case of blades which, seen in cross section, have shapes identical to those of the blades which have just been described but which furthermore may have either undulations in another plane or variations in geometry from one cross-sectional plane to another cross-sectional plane. It may be useful to produce parts in which the shapes of the surfaces opposite the faces of the blade to be clamped reproduce or come close to the geometry of said blade faces.
FIG. 6 shows in cross section another embodiment of a device which permits the production of a mold by molding on a countermold 60, said countermold 60 having at least one non-removable blade 61 and having an undulated portion 62 in the sectional plane of the figure. The device of the invention comprises two metal parts 65 and 66 which can be assembled with the blade 61 so as to produce a drawer assembly 69. The portion 63 of the blade 61 in the extension of the first portion 62, located on the outside of the housing, is clamped over only a portion of its length between the two metal parts 65 and 66.
The portion 62 of the blade 61 is, after production of the drawer assembly 69, introduced into a housing 64 the projection of which on the surface of the countermold along a removal direction corresponds to the projection, in said direction, of all the points of the portion 62 on said surface.
The parts 65 and 66 have faces 67 and 68 which are intended to come partially into contact with the molding surface of the countermold on opposite sides of the opening of the housing 64 on said surface. The faces 67 and 68 are furthermore made in such a manner that their geometry corresponding to the geometry of the mold in the vicinity of the blade 61 and in such a manner as to close the entire opening of the housing 64 on the molding surface of the countermold.
The device comprising the parts 65 and 66, assembled to the blade 61 so as to produce a drawer assembly 69, thus permits the production of a mold by the pouring of a castable material on the countermold 60, the casting material surrounding both the portion 63 of the blade 61 and the parts 65 and 66 of the said device which are assembled on said portion. In order to avoid any movement of the blade 61 during the casting operation, one can, for example, provide a temporary glued joint between the contact surfaces of the countermold and the parts 65 and 66. By temporary, there is to be understood a glued joint which assures sufficient holding of the parts 65 and 66 on the surface of the countermold during the pouring of the material constituting the mold without, however, preventing the ungluing at the time of the removal of the molds after solidification.
The devices described assure the removability of the blades and the holding of them during the pouring of the mold and furthermore offer the advantage of permitting a good positioning of said blades with respect to the countermold; it is, in fact, easy to produce in the countermold housings the dimensions of which are perfectly adapted to those of said devices, each blade being perfectly positioned with respect to the part or parts constituting the device surrounding said blade.
Another advantage of the process of the invention is that, while the countermold even retains the housings already produced, it permits a change in the shape of the molding elements by adapting for any new shape the number and geometry of the parts for forming the drawer assembly, said assembly having, of course, dimensions which are compatible with the dimensions of the corresponding housing in the countermold.
The present invention also relates to a countermold which can be reused, at least one surface of which is used in order to mold, by means of a pourable and solidifiable material, a mold which in its turn is used to at least partially mold a tread of a tire having a tread pattern of given form, said countermold having at least one molding element for molding a non-removable motif. Said molding element protrudes from the molding surface of the countermold and is produced separately. The countermold of the invention is characterized by the fact that it comprises, in the vicinity of each non-removable molding element, a housing which is inserted into the molding surface, said housing permitting the putting in place of a drawer assembly formed by the assembling of at least one part with the molding element and its removal, said drawer assembly having a surface which assures the continuity of the surface of the countermold in the vicinity of said element.
Finally, the invention also relates to a tire molded with a mold made in accordance with the process of the invention and comprising a tread provided with incisions molded by blades of non-deformable shape. For such a tire and around said incisions, the surface of the tread has traces located at the encounter between the surface of the countermold and the means assuring the continuity of said surface at the time of the casting. These traces are the reflection of the contours of the housings of the molding elements which were originally marked on the mold before being marked on the tread. It is to be noted that these traces, insofar as they are visible on the tread of a new tire, disappear very rapidly after a few miles of travel of said tire and definitely do not cause any decrease in the quality of the molded tread. | A device for making a mold for molding at least a portion of a tread of a re using a countermold and a pourable, solidifiable material. Molding elements are transferred from the countermold and imbedded in the tire tread mold in protruding fashion by placing each molding element in a housing of the countermold before the actual molding of the tire tread mold and in such a manner as to permit easy transfer from the countermold to the tire tread mold. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to improved valve constructions of the nozzle and impingement plate type.
By way of background, in a nozzle and impingement plate type valve, flow through the valve is controlled by varying the gap between the impingement plate and the tip of the nozzle. In many valves the gap dimension is quite small in relation to the diameter of the nozzle. This is particularly the case for servovalves that are controlled by torque motors which inherently have small angular impingement plate or flapper displacement capability. The fluid metering area in such valves (sometimes referred to as curtain area) is the product of the flow periphery times the nozzle gap. Another significant parameter in such valves is the force required to position the flapper or nozzle in relationship to each other, i.e., to vary the nozzle gap. This force may be expressed as the product of the projected nozzle area (on the flapper) times the pressure drop across the nozzle-impingement plate interface. Thus, for a valve with a given nozzle gap and pressure drop, the flow will increase linearly with nozzle diameter while the operating force increases as the square of the nozzle diameter. It is generally desirable for a valve to have a high ratio of total metering area to projected nozzle area.
SUMMARY OF THE INVENTION
It is accordingly one object of the present invention to provide an improved nozzle and impingement plate type of valve having a nozzle construction which will give a relatively high ratio of metering area to projected nozzle area so as to permit the use of actuation devices having smaller force output and therefore smaller size and weight and, in the case of torque-motor operated valves, lower electrical power requirements.
Another object of the present invention is to provide an improved servovalve having a nozzle and impingement plate type of valve in which the ratio of metering area to projected nozzle area can be increased by utilizing a plurality of cylindrical nozzles, rather than a single cylindrical nozzle, or by utilizing nozzles having shapes other than cylindrical. Other objects and attendant advantages of the present invention will readily be perceived hereafter.
The present invention relates to a nozzle and impingement plate valve comprising conduit means for conducting fluid, nozzle means in communication with said conduit means to receive fluid therefrom, said nozzle means being of completely continuous cross sectional area within its outer peripheral border and having a higher ratio of flow area to projected area than that of a single cylindrical nozzle, and an impingement plate proximate said nozzle means onto which said nozzle means project fluid. The various aspects of the present invention will be more fully understood when the following portions of the specification are read in conjunction with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a prior art nozzle and impingement plate valve associated with a two-way single-stage servovalve wherein the nozzle and flapper-type of the impingement plate are used to control flow through the servovalve;
FIG. 2 is a fragmentary enlarged cross sectional view of a conventional nozzle and impingement plate valve used in a servovalve of the type shown in FIG. 1;
FIG. 3 is a fragmentary cross sectional view similar to FIG. 2 showing one embodiment of the improved nozzle and impingement plate construction of the present invention;
FIG. 4 is a fragmentary end elevational view of another embodiment of the present invention utilizing four nozzles and taken substantially along line 4--4 of FIG. 5;
FIG. 5 is a fragmentary cross sectional view taken substantially along line 5--5 of FIG. 4;
FIG. 6 is a fragmentary cross sectional view of still another embodiment of the present invention taken substantially along line 6--6 of FIG. 7;
FIG. 7 is a fragmentary cross sectional view taken substantially along line 7--7 of FIG. 6;
FIG. 8 is a fragmentary end elevational view, partially in cross section, of another embodiment of the present invention taken substantially along line 8--8 of FIG. 9;
FIG. 9 is a fragmentary cross sectional view taken substantially along line 9--9 of FIG. 8;
FIG. 10 is a fragmentary end elevational view similar to FIG. 8 and showing another nozzle configuration embodiment;
FIG. 11 is a view similar to FIG. 8 and showing still another nozzle configuration embodiment;
FIG. 12 is a fragmentary cross sectional view, partially broken away, taken substantially along line 12--12 of FIG. 13 and showing another nozzle configuration embodiment;
FIG. 13 is a fragmentary cross sectional view taken substantially along line 13--13 of FIG. 12;
FIG. 14 is a fragmentary end elevational view, partially in cross section, taken subtantially along line 14--14 of FIG. 15 and showing still another nozzle and impingement plate configuration embodiment; and
FIG. 15 is a fragmentary cross sectional view taken substantially along line 15--15 of FIG. 14.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
By way of introduction, while certain portions of the following description will refer to a servovalave, and more particularly to the nozzle and flapper thereof, it will be appreciated that the present invention relates broadly to an improved nozzle and impingement plate type of valve. In valves of this type the impingement plate can be of any type whatsoever for the purpose of controlling fluid flow through the nozzle or being controlled by fluid flowing through the nozzle. Furthermore, in valves of this type there is relative movement between the nozzle and the impingement plate, with such relative movement being due to sole movement of the impingement plate, or sole movement of the nozzle, or movement of both. As is well understood, nozzle and impingement valves of the present type are used to control flow or pressure or both. It is to be expressly understood that while portions of the following description refer to a servovalve, the present invention is not limited thereto but is directed broadly to the nozzle and impingement plate type of valve. Furthermore, while the specific actuation structure is shown as being an electrically-operated torque motor associated with the flapper of a servovalve, it will be appreciated that different actuation devices may be employed for changing the gap between the nozzle and impingement plate, and such actuation devices may include, without limitation, fluid actuation diaphragms, springs, and other types of mechanical, electrical and fluid pressure devices.
It has been found, in accordance with the present invention, that if a single nozzle is divided into a plurality of smaller nozzles, the ratio of metering area to projected nozzle area can be increased, to thereby reduce the operating force, which, in turn, will require a less forceful actuating device. As an example, assume a single nozzle valve having a cylindrical nozzle with a diameter Dn and a nozzle gap x. For the same pressure drop and nozzle gap, this valve configuration will be compared to one having two nozzles each with a diameter of Dn/2. The dual nozzle valve has the same flow metering area as the single nozzle valve, but it has one-half of the projected area and consequently one-half the pressure drop induced force. The benefits of the foregoing multiple nozzle concept can be extended further as the number of nozzles is increased above two, in that there will be a reduced operating force which permits a given valve requirement to be met with a less forceful torque motor or other actuation device than would be required for a single nozzle type of valve. In the case of valves controlled by a torque motor, this allows operation with a motor of smaller size, weight and electrical power requirements.
Solely by way of example to show one possible environment for the improved valve, FIG. 1 depicts a system schematic for a typical prior art servovalve 10 having a cylindrical nozzle 11 which projects fluid onto the face 12 of an impingement plate in the form of a flapper 13 which is rigidly connected to an armature 14 positioned through the center of coils 15 and 16 which in turn act to control magnetic flux in the gaps 17 and 19 associated with frame-magnet 20. Fluid flow through the servovalve is through pressure inlet conduit 21 and out return conduit 22, both being located in valve housing 26. The nozzle 11 and impingement plate or flapper 13 are used to control the flow through the servovalve. The flow is controlled by adjusting the flow area known as the curtain area or metering area to be described hereafter. Magnetic flux paths exist in the two sets of air gaps 17 and 19 at all times. When the armature is in mid-position with no signal to the coils, the flux levels in the four gaps are balanced and equal and no flux exists through the length of the armature. When coils 15 and 16 are energized, on electromagnetic difference in potential is developed between the ends of the armature which in turn unbalances the flux distribution in the air gaps in a manner that may cause, for example, a force to act in the upward direction on the right end of armature 14 and in the downward direction on the left end. These forces translate to a torque about pivot point 23 that is transmitted to the flapper end which provides the variable curtain area. The foregoing operation can be used to control flow, pressure drop or a combination of both depending on the specific requirement. All of the foregoing is conventional in the art, and is being set forth to depict a specific device in which the improved nozzle and impingement plate type of valve can be used, it being appreciated that it can be used in other devices, as enumerated above.
By way of further background, FIG. 2 shows a typical arrangement of the conventional nozzle and impingement plate type of valve which employs an impingement plate or flapper 13 which is positioned to open or close the exit opening 24 of a cylindrical nozzle 11 through which fluid is flowing. In this instance, the nozzle and flapper may be mounted in a servovalve housing 26. The gap x between the impingement plate 13 and the end of the nozzle opening 24 is quite small in relation to the diameter Dn of the nozzle. This is particularly the case for servovalves which are controlled by torque motors which inherently have small angular displacement capability. In some cases the flapper-nozzle type valves of FIG. 2 are used to control relatively high flow rates and pressure drops. Such applications include metering of fuel flow on gas turbine engines and pressure control in various systems where it is advantageous to use a single stage type servovalve in lieu of a two-stage valve for reasons of cost and reliability.
In the foregoing type of applications, where a conventional cylindrical nozzle 11 is used, the flow and pressure drop specifications can require a relatively large diameter nozzle, high flapper displacement, and high operating force. These parameters dictate the size, weight and electrical power characteristics of the torque motor. In aerospace applications, all of these factors tend to be critical in varying degrees.
In accordance with the present invention, the improved nozzle configuration of FIGS. 3-15, provide more efficient control of flow and pressure. Thus, a given flow and pressure drop can be controlled by a flapper or impingement plate having a lower force and displacement capability, thus utilizing a smaller torque motor. Essentially the underlying concept of the present invention is the use of a multiplicity of cylindrical nozzles with the flow therefrom impinging upon a common impingement plate, or a specially shaped nozzle which has a large periphery in relation to the projected nozzle area.
One embodiment of the present invention is shown in FIG. 3. The operating principle of the improved nozzle and impingement plate valve 27 of FIG. 3 can best be understood when it is compared by analysis to the conventional nozzle and impingement plate valve of FIG. 2. In FIG. 2 the metering area or curtain area will be Dnπx, where x is the gap between the nozzle and the impingement plate. The fluid pressure force on the face of flapper 13 will be the projected nozzle area multiplied by the pressure drop ΔP across the nozzle, or π(Dn 2 /4)ΔP. However, referring to FIG. 3, each of the nozzles 29 shown are, for example, one-half the diameter Dn of the nozzle 11 in FIG. 2 or Dn/2. The total metering area of the nozzle of FIG. 3 would therefore be the same as that of FIG. 2, namely, 2(Dn/2)πx or Dnπx at the same impingement plate displacement x. However, the total projected nozzle area for the nozzle arrangement of FIG. 3 would be half that for the nozzle of FIG. 2, and the impingement plate force would be correspondingly reduced. In other words, the projected nozzle area in FIG. 3 would be 2π(Dn/2) 2 /4 or 1/2π(Dn 2 /4), and the fluid pressure force on the an impingement plate will be 1/2π(Dn 2 /4)ΔP. Thus, the embodiment of FIG. 2 requires an impingement plate force of one half of that required by the embodiment of FIG. 2 for the same metering area, and thus, as expressed above, a given flow and pressure drop can be controlled by an impingement plate having a lower force capability, thus utilizing a smaller torque motor or other type of actuating device.
In FIGS. 4-15, the benefits of the multiple nozzle concept of FIG. 3 are extended further as the number of nozzles is increased above two. However, several limiting factors must be considered in determining the optimum number of nozzles for a given application. As the nozzle cross section area begins to approach the peripheral metering area, the flow restriction becomes that of two orifices in series and the metering efficiency of the nozzle configuration is accordingly reduced. Another consideration is to provide spacing between the nozzles so that there are suitable passages for the flow that is issuing from the inside edges of a circular group of nozzles to pass radially outward to the exit chamber. The actual flow characteristics of any given nozzle arrangement will generally be determined by testing the valve configuration including the exit cavity and passaging in the valve housing.
FIGS. 4 and 5 are views of a valve construction having four nozzles 31 impinging on an impingement plate 32 of the configuration shown. The arrows in FIGS. 4 and 5 depict the flow paths of the fluid which would exist with this nozzle arrangement.
In FIGS. 6 and 7 a further modified embodiment of the present invention is disclosed wherein four nozzles 31' are utilized and thus the nozzle construction is the same as described above relative to FIGS. 4 and 5. However, the impingement plate 33 of FIGS. 6 and 7 has a central hole 34 between all the nozzles so that fluid flow can be in the direction of the arrows. It will be appreciated that other embodiments of the present invention can utilize a hole or a plurality of holes in the impingement plate to produce the desired fluid flow paths.
In FIGS. 8 and 9 still another embodiment of the present invention is disclosed wherein eight nozzles 36 project fluid onto impingement plate 37.
In FIG. 10 still another embodiment of the present invention is disclosed wherein twelve cylindrical nozzles 39 are used.
In FIG. 11 a further embodiment of the present invention is disclosed wherein a plurality of nozzles 40, in this instance eight, are used in conjunction with a plurality of nozzles 41 which also number eight.
The use of combinations of different sizes nozzles permits optimum flow path arrangements where a large number of nozzles are required.
While the foregoing descriptions refer to the more common arrangement with fluid flow emitting from nozzles against an impringement plate, it will be recognized that the present invention may also be used for valves where flow is in the opposite direction, i.e., from the chamber surrounding the plate, past the metering edges and into the multiple nozzle passages. For this configuration the force due to the pressure drop across the projected areas acts in the direction to tend to close off the nozzle openings. The multiple nozzle concept permits such a valve to control a given flow with significantly lower flapper closing force than would be encountered with the equivalent single opening nozzle.
It will be appreciated that the nozzles need not be cylindrical, as indicated above relative to FIGS. 1-11, but they may take other shapes which will provide a high ratio of metering area to projected area. In this regard, in FIG. 12, nozzle 43 is of cruciform shape having a peripheral or metering area determined by the length of its border and a projected area as determined by the area of the cruciform within its border. It can readily be seen that the projected area is small in relationship to the peripheral area. Thus, the nozzle shape can be tailored to provide the desired ratio of peripheral or metering area to projected area so as to achieve the necessary objectives of obtaining the optimum parameters for a system, namely, the relatively small diameter nozzle and low operating forces.
In FIGS. 14 and 15 another embodiment of the present invention is disclosed wherein the nozzle 44 has an oblong shape which includes a length D and a width E with semicircular ends. Again, this nozzle has a relatively high peripheral area as compared to its projected area. In this embodiment the impingement plate 45 has the side elevational shape shown in FIG. 14 which enhances the flow of fluid thereabout because it is essentially shaped like the shape of a nozzle.
One method of fabricating the nozzles of FIGS. 3, 4, 5, 6, 7, 14 and 15 is the insertion of tubes of the desired shape into openings in the main conduit. For example, in FIG. 2 short tubes 46 are inserted with a very tight fit in bores 47 and the joints therebetween are brazed or otherwise secured. By this procedure the ends of the nozzles 29 project outwardly from the face 49 of the conduit so that well defined fluid passages are produced. Another way of practicing the present invention is by making the nozzles in the manner shown in FIGS. 8, 9, 10, 11, 12 and 13, namely, by drilling bores in the end 50 of the fluid conduit 51, rather than inserting separate nozzles, such as 29, into the end of the conduit of FIG. 3. It will be recognized that many other types of nozzle-conduit constructions may be employed, e.g., electrical discharge machining, electrochemical milling, metal forming, powdered metal molding, etc. The parts also can be made of non-metallic materials.
In all of the embodiments of the present invention the nozzles have a complete and continuous cross-sectional area within their peripheral borders. In other words, for example, the cross-sectional areas of certain nozzles are circles because they have continuous cross-sectional areas, whereas if they did not have continuous cross-sectional areas as defined aove, the cross-sectional areas could be in the form of annuli.
It can thus be seen that the improved nozzle and impingement plate type of valve construction of the present invention is manifestly capable of achieving the above-enumerated objects, and while preferred embodiments of the present invention have been disclosed, it will be appreciated that the present invention is not limited thereto, but may be otherwise embodied within the scope of the following claims. | A valve construction including an impingement plate and a nozzle structure mounted for relative movement therebetween, a first conduit for conducting fluid to the nozzle structure, the nozzle structure consisting of a plurality of cylindrical nozzles at the end of the conduit proximate the plate for projecting fluid from the conduit onto the plate or into the conduit (for reverse flow applications), the plurality of cylindrical nozzles providing a greater ratio of total metering area to projected nozzle area than is obtained by a single cylindrical nozzle. As an alternate to the plurality of cylindrical nozzles, a shaped noncylindrical nozzle may be used which has a higher ratio of metering area to projected area than that of a single cylindrical nozzle. | 5 |
BACKGROUND OF THE INVENTION
The field of endeavor to which this invention pertains is the construction industries methods and materials used to repair and patch asphalt, cement road surfaces, parking lots, sidewalks, concrete floors, patios, and many other surfaces.
This invention is designed to eliminate many of the problems that exist with present methods and materials.
The existing problems related to road repair are forming a smooth transition from existing road surfaces and the repaired areas without the depressions and washboard like areas. To provide a more flexible structure, eliminating brittle concrete or loosely bonded asphalt that results in crumbling.
Cracking and a rapid deterioration of already repaired areas, caused by thawing and freezing, as it currently exists with the very porous asphalt patches, will be eliminated. This invention will create a very sound, resilient repair that is resistant to salt and other chemicals as well.
This invention will provide the ability for much smaller crews to be needed to repair damaged areas in a quicker and much more efficient manner.
This invention will provide long lasting, permanent repair and will eliminate the need to constantly redo existing work. This will result in a great cost savings, as well as much better road surfaces.
This system has many safety factors. Much less time is spent by the road crews actually repairing the surfaces, and with the quick setup time, the driving public does not experience the hazardous and possibly dangerous conditions associated with long periods of repair time. This system should serve the public extremely well.
BRIEF SUMMARY OF THE INVENTION
This invention is designed to greatly improve and simplify the process of repairing potholes and all other deterioration of asphalt and concrete surfaces.
The object of this invention is to provide a longer lasting and more efficient system of road repair. This material and system offer tremendous cost savings to all federal, state, and local municipalities. The driving public will benefit greatly as well by having smoother roads thus causing less damage to their vehicles. The present methods require repeated repairs to the same areas many times in the weeks and months ahead. This material will eliminate that problem.
The use of this composite will eliminate the use of most of the heavy equipment normally used in road repair.
The use of this composite will substantially reduce the down time of the roadways due to its very simple application and fast curing time. The elimination of surface distortion provides a great benefit to the driving public because it will efficiently upgrade the quality of the roadways and last much longer than previous methods.
DETAILED DESCRIPTION OF THE INVENTION
This invention is designed in two parts. One is the pavement and pothole repair composite, with reinforcing structures. The other is a method of application. They work together to formulate a very fast, efficient, permanent pavement repair material and application method. This is comprised of a specially formulated composite of a non aqueous liquid made of isophalic polyester casting resin mixed with 70% by volume of dry silica sand and 30% by volume liquid isotholic polyester casting resin and 0.1% to 0.250% cobalt combined with 250 parts per million of dimethylanaline to provide a gel time of 11 minutes and a cure time of 100 minutes or less. This also includes a number of reinforcement structures like industrial glass marbles, perforated sheet steel, rip rap, glass woven roving cloth 18 ounce—24 ounce, pre-molded fiberglass grid structure with ½″ to ¾″ diameter segments, pre-molded and sized to fit a number of repair conditions. The use of precut sections of used tire segments as a reinforcement, which solves the problem of what to do with millions of used tires. This makes an inexpensive recyclable use. The composite is catalyzed with a small container of Lupersol® DDM-9 (methyl ethyl ketone peroxide catalyst) at 1.25% by volume and mixed in a 5 gallon container with ½″ air drill with a mixing bit, for about two minutes. Black or gray color may be added at this time.
The repair area or pothole should be blown free of debris and all moisture with a blow gun powered by a truck mounted 15-20 horsepower air compressor. The composite is then poured from the 5-gallon container into the repair area or pothole. It is poured about half full at that time. The reinforcing structure is placed in the repair area or pothole so that it sets about half way up in the repair area. Continue to fill the repair area or pothole. Screed and finish off smooth. Proceed to the next repair area. The composite will cool in about 11 minutes and cure in about 100 minutes. This repair will result in a very smooth, nonporous, even repair with good road surface quality, excellent thermal shock resistance, and high impact strength, with excellent physical properties. This repair composite will be resistant to any chemicals, as well as salt.
The method and process using this pavement and pothole repair composite and equipment required is described as follows:
The equipment required will be one flatbed truck equipped with one 15-20 horsepower gas operated compressor to operate a blowgun for cleaning out repair areas or potholes; on ½″ air operated drill with mixing bit; one small air operated saw and several hand tools; one safety bucket containing acetone for tool cleaning; a full load of the repair composite in 5 gallon containers for convenient storage and handling.
Step One: Remove all debris and moisture from the repair area or pothole to make sure it is as dry as possible. Open container of composite and mix in the proper amount of catalyst and color, if desired, and mix for about 2-3 minutes using the air drill with mixing bit.
Step Two: Pour the composite into the repair area or hole about half full. Insert the reinforcing structure about half way up the wall of the repair area. Pour repair area full, then finish and screed off smoothly, placing any excess material into the next repair area or pothole.
Step Three: The material will gel in about 11 minutes and will cure hard in about 100 minutes or less, depending on temperatures and weather conditions, to form a nonporous repair structure with little or no water absorption.
The results will be a smooth, hard, nonporous finish with good traction capabilities. This operation may be performed many times a day very quickly and easily, unlike the normal repairs made with hot asphalt requiring time consuming labor and many different pieces of expensive equipment to complete the job. The repairs with asphalt are temporary, at best, and usually leave the repaired area with humps and bumps and very uneven surfaces. Summer heat attacks the repaired areas and distorts even more. In winter the thawing and freezing may destroy an asphalt repair in a matter of days. To leave the road condition worse than it was to start with. So the benefits of using the fast, efficient permanent pavement repair and material system are: much less equipment expense, less labor costs, not repeat repair, quality repair with no bumps or depressions, better appearance with color matching capabilities. There will be little or no water seepage between existing material and repaired areas, which eventually thaw and freeze and cause separation, cracking and erosion of existing material and repair materials. There will be less roadway downtime, as with concrete that requires 48 hours or longer to cure and not successfully seal the joint between existing materials and the repair, and requires the use of expensive concrete trucks and drivers. The concrete is very susceptible to salt and other corrosive material and to chip loose at the joints, spalling, cracking and crumbling. This repair composite may also be used to repair shallow cracks and pits very quickly. There is appreciable merit to the simplicity of this composite repair material and the application process. | Disclosed is a repair composite for pavement and pothole repair. The repair composite is composed of an amount of an isophalic polyester casting resin premixed with dry silica sand, cobalt in combination with dimethylanaline, and a catalyst, such as Lupersol® (methly ethyl ketone peroxide catalyst). Additionally, the composite may include reinforcing structures. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a non-provisional application of Applicants' provisional application Ser. No. 60/963,327 filed on 3 Aug. 2007.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a clothesline. Clotheslines are a popular means for drying clothes. In addition to the clothes attaining a fresh outdoors scent, the savings in electricity by not using an electric dryer, can be substantial. Typical clothesline systems provide a support onto which wet clothes are placed to dry. A common clothesline system includes an endless loop cable extending between two pulleys. The cable provides a suitable support on which to hang wet clothes. In order to set clothes onto the cable, clothes are first hung on the clothesline cable and then clothes pins are manually placed onto the clothes. When it is desired to remove the dried clothes from the clothesline cable, the clothes pins must be manually detached and stored.
2. Prior Art Statement
In order to overcome the cumbersome operation of manually applying and removing clothes pins, U.S. Pat. No. 4,519,509 issued May 28, 1985 to Rexford Doyle, suggests a means for automatically applying clothes pins onto clothes when the clothes are displaced away from the user and a means for automatically removing the clothes pins from the dry clothes when the clothes are displaced towards the user. The clothesline system includes an endless first cable extending between two pulleys. A pin lay wheel located between the two pulleys features a V-shaped recess acting to receiving a series of clothes pins in a normally closed position located on a second cable. The ends of the second cable are advantageously attached to the first cable such that when the first cable is displaced away from the user, the second cable is advantageously moved in a cooperative manner with the first cable bringing clothes pins secured on the second cable into engagement with the pin lay wheel. The pins are automatically brought into an opened configuration, releasing from the first cable and allowing them to travel over a substantially arcuate path as defined by the periphery of the lay wheel. Continued rotation of the pin lay wheel causes the pins to re-engage upon a section of the first cable on which wet articles of clothing are placed. As a result, the articles of clothing receive the closing clothes pins become detachably secured onto the first cable. Although the above-mentioned system facilitated the securement of clothes onto the clothesline system, it failed to provide means for preventing the first cable from sagging beyond an acceptable range. More specifically, upon placing clothes onto the first cable, the first cable tended to accordingly pull away from the second cable. In some instances, clothes will pull the first cable sufficiently downwards thus displacing the first cable from the second cable beyond a distance where a clothespin can engage the first cable.
To overcome the problem associated with U.S. Pat. No. 4,519,509, Doyle, et al., U.S. Pat. No. 6,454,109, issued Sep. 24, 2002, provides a clothesline lay-down arm with a first cable support configuration maintaining a preferred distance between a first and second cable at the point of engagement of the wet clothes with the second cable such that the clothespins attach the clothes to the second cable. The closeable clothespins are of unitary construction and provide multiple clothes holding positions as a means of successfully engaging articles of clothing placed over the first cable. Even with the preferred distance provided by the lay-down arm cable support, the weight of wet clothes on the first cable can stretch the first cable to the point that some clothespins will become disengaged from the clothes.
SUMMARY OF THE INVENTION
Though the above patents provide for a workable clothesline, neither device described in U.S. Pat. No. 4,519,509 nor U.S. Pat. No. 6,454,109 address the following issues:
a. Considerable difficulty of installation by a normal person in understanding the cable routing configuration. b. Unacceptable sag of the cable system when loaded with wet clothes. c. Uneven stretching of the first and second cables relative to one another other causing the clothes pins to cant unacceptably. d. Tension in the first cable can cause the first cable to partially unravel and twist. The twisting first cable causes the clothes pins and cable assembly to corkscrew in a spiral manner rendering the clothesline system either unusable or more difficult to use.
Thus, there is thus a need in the industry to provide a clothesline system that resolves the aforementioned issues and therefore, one object of this invention is to provide a clothes line system comprising at least two separate cables wherein the cables are independently tensionable.
A primary goal of this invention is to provide a clothes line system comprising at least two separate cables wherein the cables have separate cable tensioning devices wherein the tension devices are attached together to provide for common, parallel movement of the separate cables.
A significant feature of this invention is to provide a clothes line system comprising at least two separate cables wherein the cables are separately passed around separate pulleys at the remote end of the system.
A main purpose of this invention is to provide a clothes line system comprising at least two separate cables wherein the separate cables are wound in left and right windings to prevent unraveling of the braid of the cable.
A principal aim of this invention is to provide a clothes line system comprising at least two separate cables wherein the two cables add strength to the system.
A primary aspect of this invention is to provide a clothes line system comprising at least two separate cables wherein the assembly of the system is less complex as the two loops of cable are separate.
Another object of this invention is to provide a tensioning system that eliminates a Y connector which tended to strip off the vinyl covering from the cable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the preferred embodiment of the clothesline system of this invention.
FIG. 2 is an enlarged perspective view of the cable tensioning mechanism of the preferred embodiment showing separate cable tensioning devices joined together for simultaneous translation.
FIG. 3 is an enlarged side plan view of the remote end of the preferred embodiment showing separate pulleys for the separate cables mounted to a common bracket.
FIG. 4 is an enlarged perspective view of the loading end of an alternate embodiment showing a straight section between a primary cable pulley and a pin lay pulley.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the various features of this invention are hereinafter described and illustrated as a common clothesline system comprising at least two endless loop cables extending between separate pairs of pulleys wherein the cables have separate tensioning mechanisms, it is to be understood that the various features of this invention can be used singly or in various combinations thereof to provide a clothesline system operable in an endless loop as can hereinafter be appreciated from a reading of the following description.
Referring now to FIG. 1 , the clothesline system of the instant invention is generally depicted with the numeral 10 and comprises a remote end 12 , a loading end 11 , a pair of cables 43 , 44 separately disposed around remote end 12 and loading end 11 , a tensioning mechanism 45 and a plurality of clothespins 46 . Loading end 11 is substantially identical to the loading end as described in U.S. Pat. No. 6,454,109, the entire disclosure thereof incorporated into this invention by this reference thereto though an alternate, reduced height loading end yoke 13 for loading end 11 is shown in FIG. 4 , to be hereinafter described more fully. Referring to both FIG. 1 and FIG. 4 , loading end yoke 13 carries a primary cable pulley 14 and a pin lay pulley 15 , primary cable pulley 14 rotatable on an axle 16 disposed through side walls 17 , 18 of yoke 13 and pin lay pulley 15 disposed on an axle 19 disposed through side walls 17 , 18 of yoke 13 at a free end 20 of yoke 13 remote from a hanging end 21 of yoke 13 . Hanging end 21 is provided with an arm 22 extending from yoke 13 , arm 22 provided with an aperture 25 disposed vertically therethrough between side walls 17 , 18 for receiving a mounting hook 23 therein. Mounting hook 23 may be affixed to a stand alone pole 24 or to a side of a building such as a window frame of an apartment building (not shown) as is well known. Referring also to FIG. 3 , remote end 12 also comprises a yoke 26 carrying a primary cable pulley 27 and a pin cable pulley 28 , primary pulley cable pulley 27 of larger diameter than pin cable pulley 28 . Yoke 26 has side walls 29 , 30 , an arm 31 on one end 33 of yoke 26 and an arm 32 on an end 35 opposite end 33 , arm 31 provided with an aperture 36 therethrough between side walls 29 , 30 for receiving a remote mounting hook 34 therethrough, remote mounting hook 34 affixed to another stand alone pole or to a side of a building 24 ′. Primary cable pulley 27 of remote end 12 is rotatable on an axle 37 and pin cable return pulley 28 is separately rotatable on an axle 38 in arm 32 , axles 37 , 38 journaled in side walls 29 , 30 . Yoke 26 has at least one slot 39 disposed between side walls 29 , for receiving primary cable pulley 27 and pin cable return pulley 28 therein. Preferably, a separate slot 40 is provided for pin cable return pulley 28 to provide further strength to yoke 26 . Similarly, a slot 41 is provided in yoke 13 for primary cable pulley 14 and a separate slot 42 is provided in free end 20 of yoke 13 , separate slots 41 , 42 also provided to enhance strength of yoke 13 .
While continuing to refer to FIG. 1 , clothesline system 10 has tensioning mechanism 45 , best shown in FIG. 2 , to greatly reduce sag in cable 43 when loaded with wetted clothes, to provide for support to cable 43 through tensioning mechanism 45 and to provide for separate tensioning of cables 43 , 44 . Tension may be added to either, or both, cables 43 , 44 as desired by the user. Tensioning mechanism 45 comprises a pair of identical tensioning devices 47 , 48 for separately providing tension to pin carrying cable 43 and primary cable 44 , tensioning devices 47 , 48 joined together with a fastener 49 , fastener 49 disposed through a connection hole 63 in touching side walls 60 of an oval band 52 of tensioning devices 47 , 48 . Fastener 49 transfers some load of pin carrying cable 43 to primary cable 44 , though primary cable 44 also carries a primary portion of the load of clothes 50 pinned to clothespins 46 as clothes 50 are directly pinned to primary cable 44 by pinching clothes 50 against primary cable 44 in closeable apertures 51 disposed in clothespins 46 as is described in the aforementioned U.S. Pat. No. 6,454,109. In the instant invention, tensioning devices 47 , 48 are substantially identical, but disposed in an inverted, mirror image relationship for mating together with fastener 49 , tensioning devices 47 , 48 each comprising an oval band 52 , a spindle 53 , a ratchet 54 , a turnkey 57 and a cap nut 56 . Turnkey 57 is an unitary unit comprising an axle (not shown), a lock gear 58 and a key 55 , the axle extending from lock gear 58 through a journal bore 61 disposed through a first side wall 59 of oval band 52 , through a bore of spindle 53 , through a journal bore 62 disposed through a second side wall 60 of oval band 52 and is retained in oval band 52 by cap nut 56 . Turnkey 57 is rotatable within journal bores 61 , 62 and is affixed to spindle 53 with splines, keys, mating polygonal surfaces or any other means known to provide for rotational joinder of a spindle and an axle. Spindle 53 may further be provided with at least one anchor hole 69 therethrough for receiving one end 64 - 67 of cables 43 , 44 therein to affix cable ends 64 - 67 to spindle 53 . Preferably, spindle 53 has two anchor holes 69 , 68 disposed therethrough, spindle 53 of tensioning device 47 receiving ends 64 , 65 of primary cable 44 therein and spindle 53 of tensioning device 48 receiving ends 66 , 67 of pin carrying cable 43 therein. Oval band 52 also is provided with cable holes 70 , 71 bored through the bights 72 , 73 of oval band 52 , cable holes 70 , 71 adapted to receive ends 64 - 67 of cables 43 , 44 therethrough for insertion into anchor holes 68 , 69 in spindle 53 . In order to allow for tensioning of cable 44 , for instance, ends 64 , 65 of cable 44 are first passed through cable holes 70 , 71 respectively, of tensioning unit 47 , ends 64 , 65 are then passed through anchor holes 68 , 69 respectively, in spindle 53 and key 55 is rotated to wind cable 44 about spindle 53 . Key 55 is rotated sufficiently to overlap ends 64 , 65 of cable 44 over spindle 53 to retain cable 44 thereupon, key 55 rotated until a required tension is applied to cable 44 . Ratchet 54 , biased into constant engagement with lock gear 58 thus retains the wound tension in cable 44 . In a like manner, ends 66 , 67 of cable 43 are passed through cable holes 70 , 71 of tensioning device 48 , positioned in anchor holes 68 , 69 in spindle 53 and key 55 turned until cable 43 is properly tensioned. Relief of tension from cables 43 or 44 is accomplished by depressing thumb latch 74 though it is advisable to hold and turn key 55 in a tensioning direction while simultaneously depressing thumb latch 74 . It is readily apparent here that cables 43 , 44 may be tensioned separately thus overcoming a primary deficiency in the prior art devices.
Still referring to FIG. 4 , tensioning devices 47 , 48 are joined together in at least one place, preferably at hole 63 with fastener 49 . Separate tensioning devices 47 , 48 thus become unitary tensioning mechanism 45 when joined thus ensuring that cable 43 is translated at the same speed as cable 44 . Therefore, either cable 43 or 44 may be rotated while laying clothes upon cable 43 or upon taking clothes from cable 43 . As cables 43 , 44 are caused to translate at the same rate because cables 43 and 44 are joined by tensioning mechanism 45 , canting of clothespins 46 is eliminated, frictional markings are eliminated from clothes 50 , tearing of clothing is eliminated and clothespins 46 remain attached to cable 43 .
Referring now to FIGS. 1-3 , cables 43 , 44 preferably travel in parallel paths such that as clothespins 46 are presented to pin lay pulley 15 from either clothesline end 75 or storage end 76 , clothespins 46 enter pin lay pulley 15 in a vertical manner and straight away such that canting or cocking of clothespins 46 is prevented. In order to accomplish the parallel paths of cables 43 , 44 , cable 44 travels over one pair of pulleys 14 , 27 while cable 43 traverses a path over separate, smaller pulleys 15 , 28 . The pitch line diameter of pulleys 14 , 27 is greater than the pitch line diameter of pulleys 15 , 28 by twice the distance from a centerline 77 of a line clip 78 of clothespin 46 to a centerline 79 of cloth grip aperture 51 provided in clothespin 46 . Pin lay pulley 15 may also be provided with slots at the interior periphery thereof to accommodate line clip 78 though the difference in effective pitch diameter of pin lay pulley 15 is negligible without the slots at the interior periphery. It is unnecessary to provide slots in the interior periphery of pulley 28 if so provided in pin lay pulley 15 , as clothespins 46 do not rotate through pulley 28 though it is cost efficient to produce pulleys 15 and 28 as identical entities, both for interchangeability at assembly and stocking inventory. Likewise, pulleys 14 , 27 are manufactured as identical items substantially for the same reasons.
Yoke 13 comprises two distinct arms, a lower support arm 80 and an upper support arm 81 . Lower support arm 80 includes three continuous segments substantially as described in U.S. Pat. No. 6,454,109, namely a first oblique segment 82 which extends downward from axle 16 carrying pulley 14 connecting with a horizontal intermediate segment 83 extending parallel to and below cable 44 and a final oblique segment 84 that extends upward toward pin lay pulley 15 but terminates below and short of pin lay pulley 15 . As in U.S. Pat. No. 6,454,109 a guide 85 is provided at an extreme end 87 of final segment 84 to receive cable 44 and support cable 44 adjacent, and preferably, tangent to pulley 14 . Guide 85 includes mating components fastened together through which cable 44 can slide freely. In effect, lower support arm 80 provides support along a span 86 of cable 44 on which clothes 50 may be freely placed. Upper support arm 81 also includes three continuous segments; a first oblique segment 88 extending upwardly from axle 16 beyond pulley 14 but terminating below cable 44 , a horizontal segment 89 and a final oblique segment 90 extending downwardly from horizontal segment 89 terminating in an axle housing 91 beyond guide 85 . Final segment 90 of upper support arm 81 is a fork 92 that supports pin lay pulley 15 . Fork 92 carries axle housing 91 in its spaced apart members, each with an axle bore disposed therethrough which receive axle 16 to rotatably support pin lay wheel 15 . Thus, upper support arm 81 of this instant invention differs from prior art support arms as upper support arm 81 no longer carries cable 44 in guides to present cable 44 to pin lay wheel 15 as cable 44 is separate from, yet parallel to, cable 43 . Thus, cable 44 is payed off primary cable pulley 14 directly in line with apertures 51 in clothespins 46 . Accordingly a simpler manufacturing process for loading end yoke 13 is provided as well as a simpler assembly of clothesline system 10 .
One method of assembly of said clothesline system 10 comprises the steps of inserting primary cable pulley 27 in position between opposed sides 29 , 30 of remote end yoke 26 at a location of axle 37 and inserting axle 37 through either side 29 or 30 , through primary cable pulley 27 and finally through the opposed side 30 or 29 . Either side 29 or 30 may be adapted to receive axle 37 in a press fit relationship, however, preferably axle 37 receives cap nuts on both opposed ends thereof. Likewise, pin cable pulley 28 is inserted between opposed sides 29 , 30 with axle 38 disposed through sides 29 , 30 and pin cable pulley 28 to secure pin cable pulley 28 to remote end yoke 26 . Axle 38 may also be press fit into either of sides 29 , 30 or receive cap nuts on either or both ends thereof. Loading end yoke 13 is also assembled in a similar manner with primary cable pulley 14 inserted into yoke 13 adjacent hanging end 21 with axle 16 rotatably affixing primary cable pulley 14 to yoke 13 by disposing axle 16 through side wall 17 , primary cable pulley 14 and side wall 18 . As with axles 37 , 38 in remote end yoke 26 , axle 16 is preferably secured to loading end yoke 13 with cap nuts on the ends thereof, however, axle 16 may also be press fit into at least one side wall 17 , 18 . Pin opening pulley 15 is assembled to loading end yoke 13 at free end 20 in a similar manner and rotatably secured therein with axle 19 disposed through side walls 17 , 18 . Pin carrying cable 44 is then preferably trained around pulley 15 of loading end yoke 13 by passing one end 66 or 67 through pin slot 42 and training the selected end 66 , 67 through slot 40 and around pin cable pulley 28 in remote end yoke 26 . Tensioning device 48 then receives ends 66 , 67 through cable holes 70 , 71 in oval band 52 , through anchor holes 68 , 69 in spindle 53 whereupon key 55 of tensioning device 48 is rotated sufficiently to overlap at least ends 66 , 67 with a layer of cable 44 . In a similar manner, one end 64 , 65 of primary cable 43 is trained around primary cable pulley 14 in loading end yoke 13 , carefully inserted into guide 85 in extreme end 87 of oblique segment 84 and trained around primary cable pulley 27 in remote end yoke 26 whereupon ends 64 , 65 are disposed through cable holes 70 , 71 in oval band 52 and through anchor holes 68 , 69 in spindle 53 of tensioning device 47 , key 55 of tensioning device 47 also rotated sufficiently to secure ends 64 , 65 to tensioning device 47 . Upon assembly of cables 43 , 44 to loading end yoke 13 and remote end yoke 26 , loading end yoke 13 has aperture 25 preferably secured to a mounting hook 23 on a stand alone pole 24 or the side 24 ′ of a building and remote end yoke 26 likewise has aperture 36 disposed on remote mounting hook 34 on another stand alone pole 24 or a side 24 ′ of an opposed building at a distance from loading end yoke 13 . Once yokes 13 , 26 are secured to hooks 23 , 34 , cables 43 , 44 may be loosened from spindles 53 of tensioning devices 47 , 48 and pulled through anchor holes 68 , 69 to provide an initial length to system 10 . Key 55 in each of tensioning devices 47 , 48 is then rotated to provide an initial tension to cables 43 , 44 whereupon at least one end 64 - 67 of cables 43 , 44 is cut and key 55 in tensioning devices 47 , 48 is rotated until a proper tension is achieved in cables 43 , 44 . Clothespins 46 may then be spaced along pin cable 43 at spaced distances by clipping line clip 78 to pin cable 43 .
Loading end yoke 13 and remote end yoke 26 are preferably molded from thermoplastic materials which may include reinforced thermoplastics, thermoplastic elastomers or combinations thereof, however, yokes 13 , 26 may also be manufactured from wood or metals without departing from the scope of this invention. Preferably, yokes 13 , 26 are of I-beam cross section with reinforcing braces 93 supporting the flanges 94 , 95 of yokes 26 , 13 respectively. By providing reinforcing braces 93 , yokes 13 , 26 are made as strong as possible while reducing the mass thereof. It is, though, fully within the scope of this invention to manufacture yokes 13 , 26 of solid construction, with smooth side surfaces 96 of side walls 17 , 18 and smooth side surfaces 97 of side walls 29 , 30 in order to provide for ease of wiping off surfaces 96 , 97 prior to loading clothes 50 thereupon. Thus, yokes 13 , 26 may be tubular, solid with mass reducing holes disposed longitudinally therethrough or of expanded thermoplastic material having internally generated closed cells.
Preferably, cables 43 , 44 are elastomeric coated stranded steel cables, however, it is within the scope of this invention to provide cables 43 , 44 of hemp, textiles, elastomeric materials, uncoated steel cable or combinations of the above in braided, woven, twisted or straight strands or combinations thereof. Preferably, cables 43 , 44 are comprised of a plurality of small diameter wound steel cable strands, each cable strand wound in a first hand, such as counterclockwise, and the plurality of strands wound in an opposite hand, ie., clockwise prior to coating cable 43 , 44 with an elastomeric substance. By winding the strands of cables 43 , 44 in opposite hand to the final cable structure, stability is provided to cable 43 , 44 to essentially eliminate twisting of cable 43 , or 44 during operation of clothesline system 10 further allowing straight and vertical entrance of clothespins 46 to pin lay pulley 15 .
While the present invention has been described with reference to the above described preferred embodiments and alternate embodiments, it should be noted that various other embodiments and modifications may be made without departing from the spirit of the invention. Therefore, the embodiments described herein and the drawings appended hereto are merely illustrative of the features of the invention and should not be construed to be the only variants thereof nor limited thereto. | A clothesline system comprises at least two separate cables that are independently tensionable through separate cable tensioning devices. The tension devices are attached together to provide for common, parallel movement of the separate cables though the cables are separately passed around separate pulleys at the both ends of the system. The two separate cables add strength to the system. The separate cables are preferably wound in left and right windings to prevent unraveling of the braid of the cable. By providing separate cables, assembly of the system is less complex as the two loops of cable are separate. | 3 |
BACKGROUND
There is a class of sweeping machines which contact the floor or ground being swept with a cylindrical brush that lifts debris from the surface and throws it forward directly into a debris hopper located in front of the brush. Such machines are referred to as direct forward throw sweepers, and it is sometimes said that they use a "broom and dustpan" sweeping principle. The debris hopper of such a machine is open at the rear for entrance of debris, and the hopper floor is set close to the ground, at least in the entrance area. A rubber lip is commonly attached to the rear edge of the hopper floor and made so it drags on the ground, so the hopper is in fact built somewhat like a dust pan, and the rotating broom sweeps debris into it. U.S. Pat. No. 3,189,931 (Peabody) and U.S. Pat. No. 3,304,572 (Wendel) show representative sweepers of this class. In this discussion we will refer to the sweeping principle used in such machines as the conventional sweeping mode.
Such sweepers have been used for many years, and their operating characteristics are well known. They are recognized as being extremely efficient in sweeping fine, dense debris such as sand and gravel. Starting from ground level, they throw such material in a low trajectory well forward in the hopper and easily load the hopper to its capacity. However, they do less well in sweeping and hopper loading of light debris such as, for example, crumpled paper items or dry leaves. This is primarily because air resistance checks the flight of light debris to the front of the hopper. Much of it falls in the rear of the hopper, where it builds up and blocks the hopper entrance before the hopper is full.
In the mid '80's a two-tool sweeper design emerged which was much superior in loading light debris. Shown in U.S. Pat. No. 4,624,026 (Olson), it used the conventional sweeping brush, but in addition a smaller cylindrical brush or paddle wheel was placed in front of the brush so it just cleared the ground and was rotated opposite to the sweeping brush rotation. These two tools cooperatively threw debris in a much higher trajectory than direct forward throw sweepers. In this trajectory the debris entered the hopper at a higher level than before. Even light debris travelled farther forward in the hopper before it came to rest, so almost a full hopper load of it could be collected. Sweepers built to this design were outstanding in their ability to sweep and hopper load light debris.
However, they did not sweep sand and gravel as well as the direct forward throw sweepers. Sand, when thrown by a sweeper brush, fans out to some degree, like a shotgun pattern. This did not affect the low trajectory of the direct forward throw sweepers, but in the high trajectory of the two-tool sweepers a small portion of the sand fanned out enough to fall back into the top of the sweeping brush rather than flying forward into the hopper. The rotating brush carried it backward and dropped it behind the brush, where it could not be swept up. Only a small percentage of the sand was lost in this way, but it was enough to create dissatisfaction with sweeper operation.
A need exists for a sweeper that will sweep dense debris such as sand and gravel as efficiently as a conventional direct forward throw sweeper, and also will sweep and hopper load light debris such as crumpled paper items or dry leaves as efficiently as a two-tool sweeper. A mixture of dense and light debris should also be efficiently swept and hopper loaded.
SUMMARY OF THE INVENTION
The present invention discloses a convertible sweeper which can be selectively operated in any one of three sweeping modes. In one mode, referred to as conventional direct forward throw mode, it uses a single sweeping brush, and is highly efficient in sweeping and hopper loading dense debris such as sand or gravel. In a second mode, termed a two-tool mode, it becomes a two-tool sweeper like those described earlier and does an outstanding job of sweeping and hopper loading debris which consists primarily of light material such as crumpled paper items or dry leaves. A third mode is also disclosed which may be optimum for sweeping and hopper loading mixed dense and light debris. Thus it provides in one machine three diverse sweeping modes, two of which previously were found only in separate sweepers, and a third which is believed to be new and novel.
In the sweeper of the present invention a conventional sweeping brush is provided, which will be referred to as the rear brush, and a conventional hopper is placed in front of it. The hopper has the usual rear opening and rubber sweeping lip, the latter dragging on the surface being swept. These components are used alone in the conventional direct forward throw sweeping mode, and they provide excellent sweeping and hopper loading of small, dense debris such as, for example, sand and gravel.
The present sweeper also has a second rotatable tool, which in this discussion will be referred to as the front brush. However, unlike the design described in U.S. Pat. No. 4,624,026, this second tool, or front brush, in the present invention is mounted on a movable structure which permits it to be placed in either of two positions. In the conventional sweeping mode it is retracted into a location where it does not interfere with the direct forward throw of dense debris into the hopper by the rear brush, which is operational. But in the two-tool mode it is moved to a location in front of the rear brush, behind the hopper opening and adjacent to or contacting the surface being swept. In use it is rotated opposite to the direction of rotation of the rear brush, as described in '026, and this results in a very superior sweeping and hopper loading of light debris such as, for example, crumpled paper items or dry leaves.
The present invention recognized that a sweeper can be built having the advantages of both conventional direct forward throw sweepers and known two-tool sweepers by providing both conventional and two-tool components in one sweeper, so arranged that one or the other mode can be used, depending on the type of debris to be swept. In this invention the two-tool sweeper design of the '026 patent was modified and installed in a sweeper having a conventional hopper entrance and sweeping lip at the rear of the hopper. This permits two-tool operation, and also allows conventional direct forward throw sweeping by selectively removing the front brush when desired from in front of the sweeping brush and close to the surface being swept. In the present invention a front brush was installed in a conventional sweeper with an innovative mounting comprising a lift system, related linkages and controls so that a sweeper operator could selectively place the front brush in operative position and activate it or place it in a storage position. This latter position was high in the hopper entrance where it did not interfere with the low trajectory of conventionally swept dense debris thrown by the rear brush acting alone.
The rotation of the front brush may be stopped when it is in storage position, but under some circumstances there is an advantage to rotating it Primarily this advantage occur when sweeping a mixture of dense debris such as sand and light debris such as paper in the conventional sweeping mode. The rear brush throws the sand directly into the hopper in good fashion, but the paper tends to lob into the top of the hopper entrance, often striking the front brush stored there, and dropping short into the rear of the hopper.
However, if the front brush when located in the upper part of the hopper entrance is rotated in the same direction as the rear brush, any paper striking it will be propelled well forward in the hopper. This has come to be known as assisted conventional mode, and results in better hopper loading of paper than is experienced in unassisted conventional mode, though not as good as in two-tool mode. It may be a preferred mode of operation in situations where the emphasis is on highly efficient sand sweeping, but there is some light debris mixed with the sand. Placing the front brush in the upper part of the hopper entrance does not interfere with the trajectory of sand being thrown directly into the hopper by the rear brush, irrespective of whether the front brush is or is not rotated.
Thus the objective of the invention is to provide a conventional direct forward throw sweeping mode and a two-tool sweeping mode in one sweeper, with an option to provide an assisted conventional mode, and convenient means to convert the operation of the sweeper from one to another of the modes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a sweeper with portions broken away to show the front brush and rear brush of the present invention sweeping light debris in the so-called two-tool sweeping mode.
FIG. 2 is similar to FIG. 1, but shows the front brush lifted and the rear brush sweeping dense debris in the so-called conventional sweeping mode. The front brush may be considered to be not rotating, as in the conventional sweeping mode, or it may be considered to be rotating as in the assisted conventional mode, with the direction of its rotation indicated.
FIG. 3 is a schematic diagram of a sweeper having only conventional mode and two-tool mode, showing the hydraulic means for lifting, lowering and rotating the brushes, also the electrical controls for those means.
FIG. 4 is similar to FIG. 3, but shows a hydraulic circuit and its electrical controls for a sweeper which can operate in conventional mode, assisted conventional mode or two-tool mode.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, at 10 there is shown a sweeper which uses a preferred embodiment of the present invention. The sweeper has a frame, shown generally at 12, and is supported on a surface to be swept 14 by two free rolling front wheels 16 (only one shown) and one steerable, powered rear wheel 18. Provisions for a driver are indicated generally by a seat 20 and a steering wheel 22. Other conventional controls are also provided, but are not shown.
A conventional cylindrical sweeping brush 24, which will be referred to as the rear brush, is mounted in a conventional manner and extends across most of the transverse width of the machine. It is supported between two brush arms 26 (only one shown) which are attached in pivotal manner to the sides of the frame 12 at two transversely aligned points 28 (only one shown). A cross shaft 30 joins the two brush arms 26 together so that both ends of brush 24 are maintained in alignment. A lift arm 32 is welded or otherwise attached to one brush arm, and is pivotally connected at its upper end to a cable assembly 33. This connects to a hydraulic cylinder 34 by means of which the brush 24 can be raised off the surface 14 for transport, or lowered to its working position which is shown in FIGS. 1 and 2. In working position cable assembly 33 may be slack and the engagement of rear brush 24 with surface 14 may be controlled by an adjustable down stop (not shown). This may be made in any one of several conventional ways. Commonly such a stop is a heavy screw bearing against a lug welded to cross shaft 30. A knob on the opposite end of the screw will be accessible to the driver. By turning the knob he or she can set the brush height for a desired floor contact, or pattern, and can re-set it when needed as the brush wears. Brush 24 is rotated by a hydraulic motor indicated at 25 which is attached to the in-board side of one brush arm 26. This motor is supplied by hoses indicated at 36. The hydraulic system will be described in greater detail later. The opposite brush arm 26 (not shown) carries an idler bearing assembly which rotatably supports the opposite end of brush 24.
A second tool 38 may be a cylindrical brush or a paddle wheel. In this discussion it will be referred to as the front brush. In purpose, function and construction it is similar to the rotary lip described in U.S. Pat. No. 4,624,026. It extends essentially across the transverse width of the machine, being essentially equal in length to the rear brush. It may be approximately half the diameter of the rear brush 24. When in use in the so-called two-tool mode of operation as shown in FIG. 1, it is located directly in front of the rear brush 24, which is to say it is immediately to the left of brush 24 as seen in FIG. 1, and is set so it clears the surface 14 by a half-inch or so. Alternatively it can be set to contact the surface, but this wears out the front brush rapidly. Rear brush 24 rotates clockwise as shown in FIG. 1 or FIG. 2, and front brush 38 rotates counterclockwise as seen in FIG. 1. The speed of front brush 38 may be set within rather wide limits; for example, if rear brush 24 is set at 400 RPM, the speed of front brush 38 may be set between 500 and 1000 RPM, with 650 RPM being perhaps a preferred speed.
Front brush 38 is supported between two brush arms 40 (only one shown). A hydraulic motor 42 is mounted on one brush arm 40 to rotate front brush 38 and is supplied by hydraulic hoses indicated at 44. The opposite brush arm 40 (not shown) carries an idler bearing assembly which rotatably supports the opposite end of front brush 38. A torsionally stiff cross member 46 connects brush arms 40 together so that both ends of front brush 38 stay in alignment. Brush arms 40 are pivotally mounted at two transversely aligned points 28, near the side members of frame 12. As shown in FIGS. 1 and 2, front brush arms 40 and rear brush arms 26 are pivoted at the same points 28. This is only a matter of convenience; separate pivot points might be selected.
A hydraulic cylinder 48 is connected by a cable assembly 50 to one of the front brush arms 40 as shown in FIG. 1, or optionally the cable assembly 50 may be connected to a lug welded to cross member 46. Cylinder 48 can lower the front brush 38 to a working position shown in FIG. 1 or raise it to a stowed position shown in FIG. 2. When front brush 38 is in the position shown in FIG. 1, the brush arms 40 will rest against the outside of brush wrap 52, which will control the height of front brush 38 relative to surface 14. Cable assembly 50 may be slack.
The sweeper has structure which cooperates with rear brush 24 and on occasion also with front brush 38 to sweep debris off of surface 14. For the most part this structure is very similar to the equivalent structure found in a conventional direct forward throw sweeper, for example, as shown in U.S. Pat. Nos. 3,189,931 and 3,304,572. This structure includes a conventional brush wrap 52, which is a heavy gauge sheet steel wrapper behind and above the brushes. In a conventional sweeper the brush wrap may have slots in its rear wall through which the brush arms pass, and these slots are used in the present invention, with rear brush arms 26 passing through them. Two additional slots are added in the present invention near the top of the brush wrap for the front brush arms 40 to pass through. In conventional fashion, each slot is sealed against air leakage by a sheet rubber diaphragm (not shown) with a slit in it through which the brush arm passes. A conventional recirculation lip 54 assists in clean sweeping, and a conventional rubber drag skirt 56 assists in dust control. A door (not shown) on each side of the sweeper gives access to the brushes. Below these doors and the sweeper frame 12 there are rubber side skirts 58 which hang down almost to the surface 14 to assist in dust control. These side skirts 58 are conventional except for one feature. They have arcuate slits 60 which accommodate the hydraulic motor 42 and the idler bearing assembly that drive and support the front brush 38. These elements are mounted outside of the side skirts 58, so they need access through the skirts to the front brush 38. A top cross slit 62 (FIG. 1) and a bottom cross slit 64 (FIG. 2) assist the side skirt 58 to fit snugly around the hydraulic motor and the idler bearing with a minimum of air leakage. The frame side members to which the side skirts are attached have deep arcuate notches 66 cut in them, also to accommodate the front brush drive motor and idler bearing.
A conventional debris hopper 68 is located in front of the rear brush 24 and the front brush 38, or to the left of them as seen in FIGS. 1 and 2. It has a flexible rubber sweeping lip 70 which lifts up to admit debris to the brushes. This lip, which is entirely conventional, drags on surface 14 and serves as a ramp or "dust pan lip" to prevent the dense debris such as sand thrown forward by brush 24 from being thrown under the hopper. The hopper 68 is sealed to the brush wrap 52 by a compressible seal 72. When the hopper gets full there are hydraulic means that separate it from the rest of the machine along this seal, then move and tip it as necessary for dumping it. The hopper and the means for dumping it are entirely conventional, and so will not be further described.
In FIG. 2 a group of arrows indicates the general trajectory followed by debris when thrown only by brush 24 into hopper 68. Note that it is a relatively low trajectory. This works well for dense debris such as sand and gravel, and full hopper loads are obtained. However, less dense debris tends to follow a higher trajectory and is slowed or stopped by air resistance before it has travelled far, so much of it falls in the rear of the hopper, near sweeping lip 70. Such debris piles up and blocks the hopper entrance before the hopper is fully loaded.
In FIG. 1 a group of arrows shows the general trajectory followed by debris when thrown into hopper 68 by the cooperative action of rear brush 24 and front brush 38 in the so-called two-tool mode of operation. It is a much higher trajectory than shown in FIG. 2. This extra height keeps the debris airborne longer, so it has time to move to the front of the hopper before it settles to the hopper floor. Good hopper loads of light debris ar obtained by this method.
In the so-called conventional mode of operation the front brush 38 is raised to the position shown in FIG. 2, and it does not rotate. However, it is possible to rotate it, if desired, by using suitable hydraulic and electric control circuitry. It has been found advantageous under certain circumstances to rotate it in a clockwise direction as shown by arrow 102 in FIG. 2, thus providing the so-called assisted conventional mode of operation which was discussed earlier.
It should be noted that a person versed in the art of sweeper construction would recognize that if one wished to do so one could build a sweeper having only the conventional mode and the assisted conventional mode and not the two-tool mode. In such a sweeper the front brush would be permanently mounted in a rotatable fashion in the position that it occupies in FIG. 2 and one would dispense with the mechanism for raising and lowering it.
Refer now to FIG. 3, which is a schematic diagram of the hydraulic system used to rotate and to lift or lower front brush 38 and rear brush 24, together with the electrical circuitry used to control these functions in a sweeper equipped only for conventional mode and two-tool mode operation. FIG. 3 as drawn shows the condition when both brushes are raised for transport and are not rotating. Both brushes are operated in similar manner.
A hydraulic pump 74 is mechanically coupled to the engine which powers the sweeper. Hydraulic oil is supplied from a reservoir 76, and passes through a filter screen 78 to enter the suction side of pump 74. Hydraulic cylinder 34 raises and lowers the rear brush 24 and is controlled by solenoid valve 80, while hydraulic cylinder 48 raises and lowers front brush 38 and is controlled by solenoid valve 82. Hydraulic motor 25 rotates the rear brush 24 and is controlled by solenoid valve 84, while hydraulic motor 42 rotates the front brush 38 and is controlled by solenoid valve 86. Relief valve 88 protects the system in the event of an overload condition in either of the brush motors. The hydraulic oil passes in series through an oil cooler 90 and a final filter 92 and then returns to reservoir 76.
One double pole double throw switch 94 is located where the sweeper operator can reach it conveniently. It is supplied by a 12-volt battery 96 on the sweeper. It controls the raising and lowering and the rotation of both the front brush 38 and the rear brush 24. Switch 94 can be placed in any one of three positions. In a centered position as shown in FIG. 3 and termed position 94A, both brushes are raised to transport position and neither one will rotate. In a lower switch position, termed position 94B, both brushes will be lowered to the surface to be swept and both will rotate, thus providing a two-tool sweeping mode for sweeping light debris such as paper items or dry leaves. In an upper switch position, termed position 94C, the front brush 38 will be raised and shut off while the rear brush 24 will be lowered to the surface 14 and will rotate, thus providing a conventional direct forward throw sweeping mode for sweeping small, dense debris such as sand and gravel.
Consider the centered switch position 94A, which is the switch position shown in FIG. 3. No current flows through the switch 94, so the solenoid valves 80, 82, 84, and 86 are not activated, and when they are not activated the oil flow passages in them are aligned as shown in FIG. 3. Thus oil from pump 74 passes directly through valves 84 and 86, bypassing the brush motors 25 and 42, and passing in series through oil cooler 90 and final filter 92 before returning to the reservoir 76. The combined pressure drop through the oil cooler and the final filter, together with the loss in the connecting lines and fittings, is about 100 psi. This pressure is in the system, and is exerted through valves 80 and 82 on the rod ends (lower ends as seen in FIG. 3) of hydraulic cylinders 34 and 48. These cylinders are equipped with helper springs 98, and the combined forces of the springs and the 100 psi pressure acting on the cylinder pistons are enough to lift the brushes and hold them up so long as the pump 74 is running. During machine shut downs the check valves 100 will hold the oil in the cylinders and keep the brushes up. Thus centered switch position 94A stops the rotation of both front brush 38 and rear brush 24 and places both of them in their lifted, transport positions.
In the lower switch position 94B all four solenoid valves (80, 82, 84 and 86) are activated. The flow of oil through valves 84 and 86 is blocked, forcing it to pass through brush motors 25 and 42 in series, which causes brushes 24 and 38 to rotate. Doing this work builds up substantial pressure in the system. Valves 80 and 82 now direct oil to the head ends of cylinders 34 and 48 (upper ends as seen in FIG. 3). Check valves 100 are pilot operated, and pressure in the lines going to the head ends of the cylinders will unseat the checks, so oil from the rod ends of the cylinders will be released to the low pressure side of the system. The pressure in the system will overcome the helper springs 98 and the brushes will lower to their working positions on the surface 14 being swept. Thus the lower switch position 94B gives the two-tool sweeping mode for sweeping light debris such as crumpled paper objects or dry leaves.
In the upper switch position 94C only valves 80 and 84 are activated. These will lower the rear brush 24 to the surface being swept and cause it to rotate, as described above in discussing switch position 94B. Since valves 82 and 86 are not activated, the front brush 38 will be held up and not rotated, as described above in discussing switch position 94A. Thus the upper switch position 94C gives conventional sweeping mode with the rear brush only for sweeping small dense debris such as sand and gravel.
FIG. 4 shows hydraulic and electrical circuitry similar to that shown in FIG. 3, but modified to provide for the assisted conventional sweeping mode in addition to the conventional mode and the two-tool mode. In assisted conventional mode the rear brush 24 is down and rotating as in the conventional and two-tool modes. The front brush 38, however, is raised as shown in FIG. 2 and rotated clockwise as shown by arrow 102, which is opposite to its rotation in the two-tool mode as shown in FIG. 1. Somewhat different hydraulic valving and electric controls are required to provide these features.
In FIG. 4 a 3-way spring-centered solenoid valve 186 has replaced valve 86 and two switches 194 and 196 have replaced switch 94. Hydraulic motor 42 is unchanged, but its capability for bidirectional rotation is indicted. With the valve and switch positions as shown both brushes are raised and not rotating.
When switch 194 is closed, valves 80 and 84 will be energized, causing rear brush 24 to be lowered by cylinder 34 and rotated by motor 25. In addition, current will be available to single pole double throw switch 196, which controls valves 82 and 186. In its neutral (off) position 196A, valves 82 and 186 will not be energized, which will result in front brush 38 being lifted and not rotated. In the lower switch position 196B, valve 82 and a first end of valve 186 will be energized, so front brush 38 will be lowered by cylinder 48 and caused to rotate by motor 42. Its direction of rotation will be controlled by how the hydraulic lines 44 are attached to hydraulic motor 42, and should be set up to be counterclockwise as seen in FIG. 1. In the upper switch position 196C, valve 82 will not be energized, so front brush 38 will not be lowered, but a second end of valve 186 will be energized to cause motor 42 to rotate opposite to its rotation resulting from switch position 196B, or clockwise as seen in FIG. 2.
Thus closing switch 194 and placing switch 196 in its open position 196A gives conventional sweeping mode, with front brush 38 up and not rotating. While switch 194 is closed, moving switch 196 to position 196B gives two-tool mode, with front brush 38 down and rotating counterclockwise as seen in FIG. 1. Again with switch 194 closed, moving switch 196 to position 196C gives assisted conventional mode, with front brush 38 up and rotating clockwise as seen in FIG. 2. In all three modes rear brush 24 rotates clockwise as seen in FIGS. 1 and 2. Both brushes will be raised and stopped from rotating when switch 194 is open.
While the preferred form of the invention has been shown and described, it should be realized that there can be many modifications, substitutions and alterations thereto. We therefore wish that the invention be unrestricted except as by the appended claims. | A convertible sweeper has a main rotating cylindrical brush and a second rotatable cylindrical tool. The second tool is movable between a first position in front of the main brush where it rotates to assist in very effectively loading debris comprised mainly of dry leaves, paper, etc. into the hopper, and a second position in the upper part of the hopper entrance. There it may be held stationary when the debris to be swept is mainly sand, which is very efficiently swept by the main brush alone, or it may be rotated if the debris also includes some light material, because such rotation assists to a degree in loading that material. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a joint-arm awning comprising two joint arms disposed on a support pipe, it being possible by means of fastening brackets to join the support pipe to a wall of a housing, and devices being provided for the adjustment of the angle of inclination of the awning arms.
2. Background Art
Joint-arm awnings of the generic type are known as box-type awnings or open awnings. Conventionally, in particular with open awnings, adjustment of the angle of inclination of the joint arms relative to the wall or the ground is effected by each joint arm being provided with an arrangement for the adjustment of the angle of inclination. Correspondingly, conventional constructions are comparatively complicated and expensive.
SUMMARY OF THE INVENTION
Proceeding from this, it is the object of the invention to embody a joint-arm awning of the type mentioned at the outset in such a way that adjusting the angle of inclination is simplified constructionally and that defined retraction conditions are given, which are constant regardless of the adjusted angle of inclination.
According to the invention, this object is attained in that the support pipe is substantially round, having a longitudinal groove, in that each fastening bracket has a bearing section on which to place the support pipe by partially positive engagement with the bearing section, in that a securing section of the fastening bracket partially positively and detachably fits over the upper side of the support pipe placed on, and in at least the vicinity of the fastening brackets, the support pipe has a recess with which an actuating and arresting cam adjustable in height relative to the bearing section engages in such a way that the support pipe are pivotable and the angle of inclination of the joint arms is adjustable by height adjustment of the cam.
As a result of this arrangement, it is easily possible to pivot the support pipe and thus the engaged joint arms as well as the entire awning and to adjust a desired angle of inclination.
Favorably, it is provided that the cam has a section of parallel motion which is guided parallel in the bearing section of the fastening bracket and which is provided with a threaded hole with which engages a setscrew supporting itself by its head on the bearing section. From below the setscrew can be inserted approximately parallel to the surface of wall, on which the fastening bracket rests so that easy actuation of the cam from below is ensured.
Favorably, the recess of the support pipe can be a groove-type, in particular semi-circular impression, the outer end of the cam, which is of corresponding shape, being able to engage positively with this groove.
Finally, it is advantageously provided that by means of a projection, one end of the securing section positively engages with a corresponding recess of the fastening bracket and that at its other end, the securing section has a threaded hole for a locking screw to engage which passes through a flush threaded hole on the outside of the bearing section. In this way, it is easily possible to fix an adjusted angle of inclination.
In keeping with another variant, it is provided that a bearing section of the fastening brackets or of support pipe holders substantially fits around the support pipe and has threaded holes offset by an angle into which to screw a locking screw depending on the desired angular adjustment, the locking screw engaging with at least one longitudinal groove of the support pipe. In other words, depending on the desired angular adjustment, one of the available threaded holes is chosen for the locking screw to be screwed in.
Provision can also be made for the support pipe to have a plurality of longitudinal grooves or longitudinal bulgings offset by an angle along its circumference. Accordingly, only a single threaded hole can then be provided and the support pipe is pivoted correspondingly.
In keeping with another embodiment it is provided that arm brackets are provided, positively fitting around the support pipe at least in sections and having threaded holes offset by an angle for a locking screw to be inserted, which engages with the at least one longitudinal groove of the support pipe for adjustment of the angle of inclination of the joint arms. In this embodiment, it is not the support pipe as such that is pivoted, but the joint arms relative to the support pipe.
In this variant, too, it is possible, instead of or additionally to a plurality of threaded holes, to provide a plurality of longitudinal grooves which are disposed on the circumference of the support pipe, offset by an angle.
In the foregoing, embodiments are dealt with, in which longitudinal recesses are provided on the support pipe. By kinematic reversal, it can of course also be provided that the support pipe has longitudinal bulgings and that corresponding recesses therefor are disposed in the holder or in cams that act on the support pipe.
In another embodiment, a joint-aRm bracket also fits around the support pipe in the way of a U-shaped bow, a cam nose which engages with the groove of the support pipe, being displaceable by means of a setscrew, which engages with the thread of a set-cam, adjustment of the angle of inclination thus being feasible.
Details of the invention will become apparent from the ensuing description of a preferred embodiment, taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 to 3 are lateral views (partially cut) of the support-pipe bearing portion with various adjusted angles of inclination in a first embodiment,
FIGS. 4 and 5 are diagrammatic views of a second embodiment,
FIGS. 6 and 7 illustrate a third embodiment, in which the joint arms are pivoted relative to the support pipe, and
FIGS. 8 and 9 illustrate various adjusted angles of inclination in another embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawing illustrates a support pipe 1 which can be mounted on the wall by means of two fastening brackets 2. Joint arms 1a are fixed to the support pipe 1. Further, a cloth shaft comprising a bearing arrangement (not shown) is mounted on the support pipe 1, from which the awning cloth--to the front edge of which a drop-out section is fixed--is unwound when the joint arms are extended by the joint arms acting pivotally on the outer sides of the drop-out section. Since the joint arms 1A are non-rotatably joined to the support pipe 1, pivoting of the support pipe 1 about its longitudinal axis 3 corresponds to a change of the angle of inclination of the joint arms 1A. The mounting and the possibility of pivoting of the support pipe 1 is described in detail in the following:
The fastening bracket 2 comprises a plate-type section 4 to be fixed to a wall and having drilled holes 5 for fastening screws. A bearing section 6 extends outward from the lower end of the wall section 4 and is provided, on its outside, with a threaded hole 7 for a holding screw 8. Between the wall section 4 and the hole 7, the bearing section 6 is provided with a recess 9 in the shape of a segment of a circle, the radius of which corresponds to the radius of the support pipe 1. During the mounting job, the support pipe 1 can be placed on this bearing section 6. A securing section 10 of the fastening bracket 2 has a projection 11 which engages positively with a corresponding recess 12 on a support 13 of the wall section 4. The securing section 10 also has a recess 14, which, in cross-section, exhibits the shape of a segment of a circle and a radius corresponding to that of the support pipe 1 and which can positively fit from above over the support pipe 1. At the outer end of the securing section 10, provision is made for a threaded hole 15 which is in alignment with the threaded hole 7 of the bearing section 6 so that a holding screw 8 can be screwed in from below, which braces the securing section 10 and the bearing section 6, thus arresting the support pipe 1.
The support pipe has a lateral recess 16 in the form of a groove which, in cross-section, has the shape of a segment of a circle and with which engages a cam 17 of corresponding shape; a section of parallel motion 18 adjoins the cam 17, the section 18 being approximately perpendicular to the longitudinal extension of the cam and being guided in a corresponding section of parallel motion 19 of the wall section 4 parallel to the surface 20, resting on the wall, of the fastening bracket 2. The section of parallel motion 18, which is connected with the cam 17, comprises a threaded hole, with which a setscrew 21 engages, the head 22 of which supports itself on the bottom 23 of a blind hole and which is screwed from below into the wall section 4.
A comparison of FIGS. 1 to 3 shows that the cam 17 is adjustable in height by means of the setscrew 21. By the cam 17 engaging with the groove-type recess 16, the support pipe 1 is pivoted, starting from the position seen in FIG. 1, clockwise to the right by 15° into the position seen in FIG. 2 and by 30° into the position seen in FIG. 3.
Consequently, simple and highly accurate adjustment of the angle of inclination is possible, the position of the substantial parts of the awning relative to each other remaining unchanged so that the function and retraction behavior of the awning are totally independent of the chosen adjustment of the angle of inclination.
In the embodiment seen in FIGS. 4 and 5, support pipe holders 23 are provided, having a circular recess 24 for the accommodation of the support pipe 1. Threaded holes 25 are disposed around the recess 24, offset by an angle, it being possible to screw a locking screw 26 into the holes 25, the inner end 27 of which engages with a groove 16 of the support pipe 1.
A comparison of FIGS. 4 and 5 shows that angular adjustment is possible by a certain threaded hole 25 being chosen into which the locking screw 26 is screwed.
In the embodiment seen in FIGS. 6 and 7, the support pipe itself is not mounted pivotally.
Two arm brackets 28 are disposed on the support pipe 1, which are in the form of a U-shaped bow and fit positively around the support pipe by an angle of 180°. An inner joint-arm section 32 lodges in the two legs of the U 29, 30 pivotally about a pivot axis 31, the inner joint-arm section 32 being pivotally connected with an outer joint-arm section 33. Starting from the leg of the U 29, a screw 34 engages with a threaded hole 25 on the opposite leg of the U 30 and a spacing sleeve 35 is provided between the two legs of the U 29, 30.
The section 36 of the U-shaped bow 28 which positively fits around the support pipe 1 is provided with several threaded holes 37, which are offset by an angle and into which a locking screw 38 can be inserted, the inner end 39 of which engages with the groove 16 of the support pipe 1. The comparison of FIGS. 6 and 7 shows that angular adjustment can be effected, depending on the selection of one of the threaded holes 37.
The drawing does not show a variant in which bulgings are provided on the support pipe instead of one or several longitudinal recesses, the bulgings positively engaging with corresponding recesses on the side of the holder.
The embodiment seen in FIGS. 8 and 9 either provides for angular adjustment of the joint arms relative to the support pipe when the support pipe is stationary or for superimposed angular adjustment of the support pipe in the way described above and additional angular adjustment of the joint arms so that on the whole very wide ranges of adjustment or very fine graduations can be accomplished.
By analogy to the embodiment according to FIGS. 6 and 7, arm brackets 40 are provided, on which the inner joint-arm section 32 is mounted pivotally about a pivot bearing pin in the form of a screw 34. The arm brackets 40 are of the type of a U-shaped bow, consisting of two parts, a part 41 positively fitting around the support pipe by a curved section 42 and comprising a leg of the U 43 and the other part 44 comprising the second leg of the U 45, it being possible to connect both legs of the U 43, 45 by means of a screw 46.
The part 45 is provided with a hooked appendix 47, which fits positively over a corresponding projection 48 of the other part 43.
A setscrew 50 engages with a drilled hole 49 of the second part 45, by means of an internal thread 51 displacing a set-cam 52 in the axial direction, a cam nose 53 of which engages with the groove 16 of the support pipe 1 so that the cam nose 53 is adjustable by means of the setscrew 50, as a result of which the angle of inclination of the joint-arm section 32 and of the entire corresponding joint arm, respectively, is adjustable as seen in the comparison of FIGS. 8 and 9. | In a joint-arm awning comprising two joint arms disposed on a support pipe, it being possible by fastening brackets to join the support pipe to the wall of a housing, and devices being provided for adjustment of the angle of inclination of the awning in order to constructionally simplify the adjustment of the angle of inclination and obtain defined retraction conditions regardless of the adjusted angle of inclination, that the support pipe is substantially round, having a longitudinal groove, with which engages a locking element for adjustment of the angle of inclination. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. Provisional Application Ser. No. 61/484,394 filed May 10, 2011. This application is also related to U.S. Provisional Application No. 61/599,711 filed Feb. 12, 2012. Each of the aforementioned applications is incorporated herein by reference in its entirety.
BACKGROUND
The present disclosure relates to an improved tactical flotation safety system having a flotation safety vest attachment and method for adapting a tactical vest for use as a flotation device. The flotation safety vest attachment disclosed herein may advantageously be used in conjunction with a military or tactical field vest. However, it will be recognized that the present tactical flotation safety system may be used to help users float when immersed in water under a variety of circumstances. Without limiting the foregoing, the present tactical flotation safety system may be adapted for attachment to a variety of articles worn by people, or, alternatively, may be adapted for use independently.
SUMMARY
A tactical vest to be worn about the torso region of a user includes a front panel, a rear panel, and first and second spaced apart shoulder straps. Each of the first and second shoulder straps secures an upper end of the front panel to an upper end of the rear panel. A first side panel extends between the front panel and the rear panel. A second side panel opposite the first side panel extends between the front panel and the rear panel. Each of said first and second side panels define a covering which houses an inflatable bladder when the bladder is in a deflated condition and a source of compressed gas coupled to the inflatable bladder. An actuator is coupled to each of the inflatable bladders for selectively inflating the inflatable bladders when necessary.
In one aspect of the present disclosure, a tactical flotation safety vest system for enabling its wearer to float when submerged in water is provided.
In a more limited aspect, a method for converting a tactical vest into a flotation safety system, e.g., for use as a life vest, using a military, law enforcement, or like tactical vest is provided.
One advantage of the present flotation safety vest attachment resides in its compatibility with existing tactical vests.
Another advantage of the present development is that the tactical flotation safety vest attachment is compact and may be deployed with very little effort on the part of the user.
Still further advantages will become apparent to those of ordinary skill in the art upon reading and understanding the detailed description of the preferred embodiments.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the general description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.
FIG. 1 is a perspective view of the tactical flotation vest attachment according to an exemplary embodiment of the present invention operably coupled to a tactical vest.
FIG. 2 is a perspective view of the tactical flotation vest attachment and tactical vest appearing in FIG. 1 with one of the inflatable bladders deployed.
FIG. 3 is an elevational view of the outward facing side of the tactical flotation vest attachment.
FIG. 4 is a partially exploded view of the tactical flotation vest attachment of FIG. 3 , with the outside flaps opened to illustrate the bladders and the deployment mechanism.
FIG. 5 is an elevational view of the tactical flotation vest attachment showing the inward facing side of the flotation vest attachment.
FIG. 6 is a perspective view of the tactical vest of FIG. 1 with the front flap in the open position.
FIG. 7 is a plan view of the tactical vest of FIG. 6 having the front portion of the tactical vest in a flipped up portion and having the panels of the tactical flotation vest attachment attached to the rear portion of the tactical vest and showing the interior of the tactical vest and tactical flotation vest attachment.
FIG. 8A is a perspective view of the left side tactical flotation vest attachment.
FIG. 8B is a perspective view of the interior of the right side tactical flotation vest attachment.
FIG. 8C is a cross-section view taken along the lines A-A of FIG. 8B .
FIG. 9 is a perspective view of the tactical flotation vest attachment and tactical vest appearing in FIG. 1 .
FIG. 10 is a perspective view of the tactical flotation vest attachment and tactical vest appearing in FIG. 1 with the front panel in the open position.
FIG. 11 is a rear view of the tactical flotation vest attachment according to an exemplary embodiment of the present invention operably coupled to a tactical vest.
FIG. 12 is a rear view of an alternative embodiment of the tactical flotation vest attachment and tactical vest appearing in FIG. 1 with both of the inflatable bladders deployed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-12 , and with particular reference to FIGS. 1 , 2 , and 9 - 12 , there appears an exemplary tactical flotation safety system 100 of the present invention. The tactical flotation safety system 100 includes a tactical vest 102 and an inflatable flotation vest attachment 104 . The flotation vest attachment 104 has a left side panel 108 a and a right side panel 108 b . As best seen in FIGS. 6 and 7 , the tactical vest 102 includes a front side 200 having a front panel 106 , a back side 202 having a rear panel 204 , two straps 206 a and 206 b connecting the front side 200 to the back side 202 at the user's shoulders, and a belt 208 for securing the front side 200 and back side 202 together at the user's waist. In the exemplary depicted embodiment the belt 208 passes through loops 210 a and 210 b on the inside of rear panel 204 and through the buckles 212 a and 212 b , respectively, on the front side 200 of the tactical vest 102 . The front and rear panels of the tactical vest may include a ballistic-resistant material, such as a hard or soft ballistic panel or plate.
The front panel 106 , rear panel 204 , and side panels 108 a , 108 b may each have a one or more rows of webbing 168 , such as nylon webbing. In the exemplary depicted embodiment there are three rows of webbing per panel, e.g., attached at each end and at spaced apart intervals, e.g., at 1.5 inch intervals. The upper portion of the front side 200 and back side 202 of the tactical vest 102 may also have a plurality of rows of webbing 168 . In the exemplary depicted embodiment there is one row of webbing on the front side 200 and three rows of webbing on the back side 202 . The webbing 168 enables the user to attach various types of modular gear, pouches, body armor, holsters, etc., which they may need to the flotation vest 104 and the front panel 106 . It will be recognized that other webbing configurations are possible. The webbing grid 168 may be formed of nylon and may conform to promulgated standards, such as the Pouch Attachment Ladder System (PALS) or the like.
As best seen in FIG. 2-5 , each side panel 108 a and 108 b also has a pull handle 114 a and 114 b , respectively. The pull handles 114 a and 114 b each engage an inflation bladder 112 a and 112 b , respectively, located within the left and right side panels 108 a and 108 b . When pull handle 114 a is tugged, the inflation bladder 112 a is released through an opening 116 a and inflates. Similarly, when pull handle 114 b is tugged, the inflation bladder 112 b releases through a like opening, not shown, on the user's right side and inflates. If the inflation bladder 112 a fails to inflate the user may manually inflate the inflation bladder 112 a using an oral inflation valve 122 a located on the bladder 112 a . Likewise, if the inflation bladder 112 b fails to inflate the user may also manually inflate the inflation bladder 112 b using an oral inflation valve. In the depicted preferred embodiment, the oral inflation valve is located on the front lobe so as to be positioned near the user's mouth.
In an alternative embodiment as best seen in FIG. 12 , when pull handle 114 a is tugged, the inflation bladder 312 a is released thereby forcing the closures 144 to disengage and the outer flap 142 a to open and fold back onto itself as inflation bladder 312 a inflates. Similarly, when pull handle 114 b is tugged, the inflation bladder 312 b releases thereby forcing the closures 144 to disengage and the outer flap 142 b to open and fold back onto itself as inflation bladder 312 b inflates.
In the depicted preferred embodiments, the bladders 112 a , 112 b are generally heart-shaped including a front lobe 118 a and rear lobe 120 a , not shown for bladder 112 b , and the bladders 312 a , 312 b including a front lobe 318 a , 318 b and rear lobe 320 a , 320 b , thereby defining a space for the user's arms to extend between the front and rear lobes when the bladders are inflated. In certain embodiments, the bladder may be as described in my U.S. Pat. No. 7,335,078 issued Feb. 26, 2008, entitled “Tactical Flotation Support System,” which is incorporated herein by reference in its entirety.
As best seen in FIGS. 3-5 and 8 A- 8 C, and with continued reference to FIGS. 1 , 2 , 6 , 7 , and 9 - 12 , the flotation vest attachment 104 has a left side panel 108 a and a right side panel 108 b , which in turn have a rear tab 124 a and a rear tab 124 b , respectively. The side panels 108 a and 108 b are secured together at the rear tabs 124 a and 124 b . In the preferred embodiment, the side panels 108 a and 108 b are attached using an adjustable corset type closure, although other closure means including hook and loop fasteners, straps, buckles, and the like are also contemplated. The adjustable corset closure has a string 126 which is alternately laced through a plurality of openings or eyelets 128 a and 128 b on the rear tabs 124 a and 124 b . In the depicted embodiment, each rear tab 124 a and 124 b has three eyelets 128 a and 128 b . The adjustable closure enables users to make the flotation vest attachment 104 larger or smaller based on the size of their body.
In use, the flotation vest attachment 104 wraps around the lower portion of the tactical vest 102 at the waist of the user. The rear tabs 124 a and 124 b of the flotation vest attachment 104 align with the lower back of the user and are secured to the tactical vest 102 using rear panel 204 . The side panels 108 a and 108 b of the flotation vest attachment 104 cover the user's sides. Advantageously, the rear tabs 124 a and 124 b are adapted to secure to the existing, complimentary rear panel 204 , allowing the flotation vest attachment 104 to be retrofit to existing vests 102 . However, it will be recognized that other types of fasteners could also be used, including buttons, hook and loop fasteners, zippers, ties, hooks, buckles, snap lock type fasteners, or the like. The side panels 108 a and 108 b of the flotation vest attachment 104 also include a left front tab 132 a and a right front tab 132 b which align generally with the abdominal region of the user. Advantageously, the front tabs 132 a and 132 b are adapted to secure to the existing, complimentary front panel 106 , allowing the flotation vest attachment 104 to be retrofit to existing vests 102 . Each front tab 132 a and 132 b has a cord 134 a and 134 b which attaches to the respective front tab 132 a or 132 b through openings 136 . The cords 134 a and 134 b may be used for easy removal of the front tabs 132 a and 132 b from the front side 200 of the tactical vest 102 . The tabs 164 and 166 are also provided to aid a user in quick and easy removal of the flotation vest attachment 104 from the tactical vest 102 when necessary.
The flotation vest attachment 104 may include a radio pouch 172 . The radio pouch 172 having a closure 138 a , 138 b with a snap 174 for securing the radio within the flotation vest attachment. The radio pouch 172 may also have an optional lanyard 164 a , 164 b which may be secured to a radio via an optional lanyard interface on the radio, not shown. While the lanyard and lanyard interface are optional, the use of a lanyard maybe advantageous in preventing damage to the radio, not shown, in the event it comes out of the radio pouch 172 or is dropped by the user.
As best seen in FIGS. 3 , 4 and 8 A- 8 C, and with continued reference to FIGS. 1 , 2 , 5 - 7 , and 9 - 12 , the side panels 108 a and 108 b each have an inner flap 140 a and 140 b , respectively, and an outer flap 142 a and 142 b , respectively. The outer flaps 142 a and 142 b are secured to the inner flaps 140 a and 140 b via closures 144 , which may be of the snap fit type although other fasteners, including buttons, hook and loop, etc. are also contemplated. When the inflation bladders 112 a , 112 b , 312 a and 312 b are undeployed they are folded and secured between the inner flaps 140 a and 140 b and the outer flaps 142 a and 142 b of the side panels 108 a and 108 b . An inflation mechanism 146 is attached to the side panels 108 a and 108 b and sits within each of the folded inflation bladders 112 a , 112 b , 312 a and 312 b to provide the mechanism for inflating the bladders 112 a , 112 b , 312 a and 312 b when the handles 114 a and 114 b are pulled. The handles 114 a and 114 b each have a rear attachment portion 156 a and 156 b which secures the handles 114 a and 114 b to the inner flaps 140 a and 140 b , respectively, at attachment flaps 162 a and 162 b using closures 158 .
Each inflation mechanism 146 has a pressurized gas (e.g., carbon dioxide) canister or cartridge 148 . The outlet of the cartridge 148 is coupled to a valve 150 . The valve 150 may be threaded valve for receiving an threaded end of a gas canister such as a CO 2 cartridge and a piercing pin mechanically coupled to the handle 114 a or 114 b . The valves 150 are also coupled to an inlet of the bladders 112 a , 112 b , 312 a and 312 b to enable the gas stored in the canisters 148 to fill the bladders 112 a , 112 b , 312 a and 312 b when the handles 114 a , 114 b are pulled. When a user pulls the handles 114 a , 114 b , the pins 152 which attach to the rear attachment portions 156 a , 156 b of the handles 114 a , 114 b at hooks 154 disengage the valve members 150 , thereby opening the valves 150 and allowing the gas from the canisters 148 to inflate the bladders 112 a , 112 b , 312 a and 312 b . The rear attachment portions 156 a , 156 b of the handles 114 a , 114 b also connect to one or more cords 160 at a first end to prevent the handles 114 a , 114 b from being lost after they are pulled to deploy the bladders 112 a , 112 b , 312 a and 312 b . The cords 160 connect at a second end to the connection member 150 at one or more different points and the connection member 150 attaches to the inner flaps 140 a , 140 b of the side panels 108 a , 108 b . In the exemplary depicted embodiment of FIG. 4 there are two cords 160 . In the alternative exemplary depicted embodiment of FIGS. 8A-8C there is one cord 160 . A comfort pad or anti-chaffing pad 170 is attached to the inner flaps 140 a and 140 b providing a cushion between the inflation mechanism 146 and the users sides.
The flotation vest attachment 104 may also be equipped with an automatic inflation switch, not shown, which causes the inflation mechanism 146 to automatically activate and fill the bladders 112 a , 112 b , 312 a and 312 b when the automatic inflation switch is completely submerged in water. For example, the switch may comprise spaced apart electrodes or contacts which are triggered when water bridges the contacts, or any other electronic actuator which senses water. Advantageously, accidental or inadvertent inflation may be prevented by delaying the automatic inflation until the switch as been fully submerged in water for a prespecified period of time prior to activating the inflation mechanism 146 , e.g., by providing an outer covering over the sensor which slows the rate at which water reaches the switch or sensor. The automatic inflation of the flotation vest attachment 104 enables the flotation vest attachment 104 to be inflated when the user is submerged in water and unable to manually activate the inflation of the bladders 112 a , 112 b , 312 a and 312 b using the handles 144 a and 114 b.
In alternative embodiments, auto-inflation may be provided using an auto actuator be of the type which uses a compressed member such as a spring which is actuated in the presence of water (e.g., by using a soluble bobbin or pill) which, in turn, drives a piercing member to pierce the cartridge and to allow the pressurized gas to enter the bladder chamber. In an especially preferred embodiment, delayed inflation may be provided by enclosing the soluble bobbin within a water resistant cover so as to slow or delay the entry of water. In this manner, environmental moisture such as rain, water spray, or the like will not cause inadvertent inflation of the bladder, but which will admit water to actuate the auto inflation in the event of submersion in water. The auto-actuator may be of the type commercially available from Halkey-Roberts and others.
The invention has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. Therefore, it is not desired to limit the invention to the specific examples disclosed or the exact construction and operation shown and described. Rather, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A tactical flotation safety system having a tactical flotation safety vest attachment removably attached to a tactical vest. The tactical flotation safety vest attachment has two side panels adjustably attached at the back and which are secured at the front and back of the tactical vest with cover panels. The two side panels include inner flaps and outer flaps enclosing inflation bladders and inflation mechanisms. The inflation mechanisms are secured to the interiors of the side panels and connected to exterior handles. When necessary, a user may deploy the inflation bladders by pulling on the handles to activate a pressurized gas source, such as liquid carbon dioxide cartridges of the inflation mechanism thereby inflating the bladders to provide buoyancy to the user. | 5 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to rotary saw blades, and more particularly circular saw blades for use on circular saws or the like. Specifically, the invention is directed to a variable tooth saw blade that cuts faster and smoother while reducing harmonic vibrations.
2. Background Information
Circular saw blades are readily available for use in cutting wood and other materials using a portable, hand-held circular saw, or a fixed table or radial saws, or other like saws. The saw blades are formed of flat, circular discs made of steel or other like metals. As is well known in the art, circular saw blades include a peripheral edge from which a plurality of circumferentially-spaced teeth project radially outwardly for cutting.
Users continually desire to purchase blades that allow for faster cutting without negative effects such as “burning” of the blade, dulling of the teeth, or jamming of the saw. The ability of the teeth to efficiently cut the material and thus maintain the blade speed is critical. As a result, users continue to desire improved blades providing for faster and/or more efficient cutting.
Users also desire smooth cuts. Often the speed of a cut is inversely correlated to the smoothness of the cut, that is, the faster the user cuts, the rougher is the end cut, and vice versa. As a result, users continue to desire improved smoothness coupled with faster cutting.
Users further desire reduced noise. The high speed at which blades rotate often causes high levels of harmonic vibration leading to excessive noise, undesirable saw or saw blade vibration, and if the vibration is significant, a less than desirable cut. Users thus desire, and often government agencies require, blades providing for reduced noise and thus reduced harmonic vibration.
Consequently, there is a need for an improved saw that cuts faster and smoother while also reducing noise and harmonic vibration.
SUMMARY OF THE INVENTION
The present invention provides a saw blade comprising a flat, circular disc having a peripheral outer edge and a center hole; a plurality of circumferentially-spaced teeth each having a cutting edge and projecting radially outwardly from the peripheral outer edge; a first group of the cutting edges defining a first circumferential width between each adjacent pair of the cutting edges in the first group; a second group of the cutting edges defining a second circumferential width between each adjacent pair of the cutting edges in the second group; the second circumferential width differing from the first circumferential width; and a third group having at least one cutting edge defining a third circumferential width as one of the distance between adjacent cutting edges in the third group and, the distance between the at least one cutting edge in the third group and the adjacent cutting edge in the adjacent group; the third circumferential width differing from the first and second circumferential widths.
The invention further provides a saw blade comprising a flat, circular disc having a peripheral outer edge and a center hole, the disc being divided into a first half and a second half, each half being a copy exact of the other half positioned in a diametrically opposite manner; a plurality of circumferentially-spaced teeth each having a cutting edge and projecting radially outwardly from the peripheral outer edge; a first group in each half having five cutting edges including a first cutting edge and a last cutting edge defining therebetween a first group circumferential width of approximately sixty degrees; a second group in each half having three cutting edges including a first cutting edge and a last cutting edge defining therebetween a second group circumferential width of approximately forty degrees; a third group in each half having one cutting edge and having a third group circumferential width defined between the one cutting edge of the third group and the last cutting edge of the second group, the third group circumferential width being approximately thirty-six degrees; a first circumferential space being between the first and second groups in each half and having an approximately twenty-degree circumferential width; and a second circumferential space being between the third group in each half and the first group in the respective other half and having an approximately twenty-four-degree circumferential width.
The invention further provides a saw blade comprising a flat, circular disc having a peripheral outer edge and a center hole, the disc being divided into a first half and a second half, each half being a copy exact of the other half positioned in a diametrically opposite manner; a plurality of circumferentially-spaced teeth each having a cutting edge and projecting radially outwardly from the peripheral outer edge; a first group in each half having seven cutting edges including a first cutting edge and a last cutting edge defining a first group circumferential width therebetween which is approximately thirty-six degrees; a second group in each half having six cutting edges including a first cutting edge and a last cutting edge defining a second group circumferential width therebetween which is approximately forty-five degrees; a third group in each half having three cutting edges including a first cutting edge and a last cutting edge defining a second group circumferential width therebetween which is approximately thirty degrees; a fourth group in each half having two cutting edges defining a second group circumferential width therebetween which is approximately twenty degrees; a first circumferential space being between the first and second groups in each half and having an approximately nine-degree circumferential width; a second circumferential space being between the second and third groups in each half and having an approximately ten-degree circumferential width; a third circumferential space being between the third and fourth groups in each half and having an approximately ten-degree circumferential width; and a fourth circumferential space being between the fourth group in each half and the first group in the respective other half and having an approximately twenty-degree circumferential width.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention, illustrative of the best modes in which the applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 is a side view of a first embodiment of the saw blade of the present invention;
FIG. 2 is the same side view of the first embodiment of the saw blade as in FIG. 1 with the sections clearly marked;
FIG. 3 is an enlarged view of a few teeth from the saw blade of the first embodiment in FIGS. 1–2 ;
FIG. 4 is a side view of a second embodiment of the saw blade of the present invention;
FIG. 5 is the same side view of the second embodiment of the saw blade as in FIG. 4 with the sections clearly marked; and
FIG. 6 is an enlarged view of a few teeth from the saw blade of the second embodiment in FIGS. 4–5 ;
DESCRIPTION OF THE PREFERRED EMBODIMENT
The improved saw blade of the present invention is shown in two embodiments in the Figures although other embodiments are contemplated as is apparent to one of skill in the art. Specifically, the first embodiment of the improved saw blade is indicated generally at 20 as shown in FIGS. 1–2 , while a second embodiment of the improved saw blade is indicated generally at 120 as shown in FIGS. 4–5 .
The first embodiment is saw blade 20 embodied as a standard seven and one quarter inch diameter saw blade although it may be of any other diameter used or contemplated by those of skill in the art. The saw blade whether embodied as blade 20 or 120 is a flat, circular disc 22 , made of steel or other like metals, with a center arbor hole 24 as is well known in the art. The disc 22 includes a peripheral edge 30 with a plurality of circumferentially-spaced teeth projecting radially outwardly therefrom for cutting and generally referred to as 32 . Each tooth 32 has a cutting edge 44 and is more fully described below.
In accordance with one of the features of the invention, the blade is divided into an even number of groups or sections, and in more detail the blade 20 in the first embodiment is divided into two halves of six sections while the blade 120 in the second embodiment is divided into two halves of eight sections. Each section along the peripheral edge has a matching or copy exact section diametrically opposite thereto such that a symmetry-like line divides the blade into two halves of a repeating pattern.
In further accordance with one of the features of the invention, the sections in each half do not have the same number of teeth or teeth of the same size as the other sections. More particularly, there are a different number of cutting edges 44 in each section in each half and the circumferential width between each of the adjacent cutting edges 44 within a given section is different than that of each other section in a given half.
Preferably in accordance with another feature of the invention, the size of the teeth remains the same and/or decreases in each section from a largest size to a smallest size in the direction of cutting (or vice versa), while the number of teeth increases or remains the same in each section in the direction of cutting (or vice versa respectively). More particularly, the circumferential width between each adjacent pair of cutting edges 44 remains the same and/or decreases in each section from largest to smallest in the direction of cutting (or vice versa), while the number of cutting edges 44 increases or remains the same in each section in the direction of cutting (or vice versa respectively).
Each tooth 32 includes a tooth body 40 defined as a sloped face or land 42 culminating in outwardly extending cutting edge 44 . On the opposite side of cutting edge 44 from land 42 is a notch or void 54 which communicates with the land 42 of an adjacent tooth 32 . Notch 54 thus separates the cutting edge 44 of one tooth 32 from the land 42 of an adjacent tooth 32 . More specifically, notch 54 includes a radial face 46 extending inwardly toward hole 24 adjacent cutting edge 44 of one tooth 32 into a bend 56 which communicates with land 42 of an adjacent tooth 32 . Land 42 may include an optional additional cutting or finishing edge 52 in the middle thereof for reducing kick-back and providing smoother cuts, whereby such land 42 in the embodiment shown includes a first steep tapered section 48 and a second slightly tapered section 50 separated by the additional cutting edge 52 although other configurations are contemplated including only one tapered section of a constant taper or a gradually changing taper. Specifically, land 42 may be any form of a surface behind tooth 32 that transitions into notch 54 . Cutting edge 44 may be a sharpened edge, or, as in the embodiments, an L-shaped seat 60 in which an insert such as a carbide or diamond tip 62 is seated and secured. The insert has a cutting face 64 . Where an insert is used, cutting edge 64 becomes the cutting edge of a tooth 32 and thus the term “cutting edge” includes “cutting face” in that scenario.
In accordance with yet another feature of the invention, the hook angle a of each tooth is most preferably between 15° (fifteen degrees) and 25° (twenty-five degrees). The hook angle a is specifically the angle between the tangent to the cutting face 44 and a radius line through hole 24 .
In more detail as to the first embodiment of the blade referred to as 20 , teeth 32 are arranged in a unique eighteen-tooth design that is divided into two copy exact sections, namely a first side 70 A and a second side 70 B divided by axis 72 . Since the blade as shown in FIGS. 1–2 has a right and left copy exact side (sides 70 A and 70 B respectively), only the right side will be described below (except where necessary to refer to the other or left side where transitions occur). The first side 70 A includes nine teeth, namely teeth 32 A, 32 B, 32 C, 32 D, 32 E, 32 F, 32 G, 32 H, and 32 I separated by voids 54 .
In accordance with another feature of the invention, the nine teeth 32 A, 32 B, 32 C, 32 D, 32 E, 32 F, 32 G, 32 H, and 32 I of each side 70 A and 70 B are not identical all in size and spacing. Specifically in the embodiment shown, first side 70 A is divided into three sections 80 , 82 and 84 (and thus the saw blade 20 has six sections over sides 70 A and 70 B) of varying circumferential distance with differing number of teeth and size of teeth in each.
Section 80 includes cutting edges 44 of five teeth 32 , namely teeth 32 A, 32 B, 32 C, 32 D, and 32 E, and these cutting edges define a first circumferential width between each adjacent pair of the cutting edges. Section 80 also includes the trailing components of four teeth 32 , namely teeth 32 B, 32 C, 32 D, and 32 E, so that those four teeth are fully within section 80 , and those teeth within section 80 are substantially identical to one another. These trailing components include land 42 having tapered sections 48 and 50 , and optional additional cutting edge 52 . Thereafter, section 82 includes cutting edges 44 of three teeth, namely teeth 32 F, 32 G and 32 H, and these cutting edges define a second circumferential width between each adjacent pair of the cutting edges that is different from the first circumferential width. Section 82 also includes the trailing components of two teeth, namely teeth 32 G and 32 H, so that those two teeth are fully within section 82 , and those teeth within section 82 are substantially identical to one another. Further thereafter, section 84 includes cutting edge 44 of one tooth, namely tooth 32 I, along with its trailing components, so that tooth 32 I is fully within section 84 .
Each of sections 80 , 82 and 84 is specifically measured as the group circumferential width from the cutting edge 44 of the first tooth 32 of a section to the cutting edge 44 of the last tooth in the same section except where a section has only one tooth 32 and thus its group circumferential width is defined from the cutting edge 44 of the last tooth 32 of the previous section to the cutting edge 44 of the only tooth 32 in the section. Specifically, section 80 is the group circumferential width from the cutting edge 44 of the first tooth 32 A of the section 80 to the cutting edge 44 of the last tooth 32 E in the same section 80 , which is defined as angle b. Section 82 is the group circumferential width from the cutting edge 44 of the first tooth 32 F of the section 82 to the cutting edge 44 of the last tooth 32 H in the same section 82 , which is defined as angle c. Section 84 with only one tooth is the group circumferential width from the cutting edge 44 of the last tooth 32 H of the previous section 82 to the only cutting edge 44 of the only tooth 32 I in the section 84 , which is defined as angle d. The previous section for the first section is the last section, which would mean the last section of the other side where the blade has two copy exact sides, or simply the last section in the case where the sections span the entire circumference of the blade. For example, the section previous to section 80 of side 70 A is section 84 of side 70 B.
In between each of the sections are transitions or circumferential spaces 90 , 92 , and 94 . Specifically, transition 90 is the space between sections 80 and 82 , transition 92 is the space between sections 82 and 84 but since the section 84 has only one tooth then no transition exists as section 84 and transition 92 have the same definition, and transition 94 is the space between sections 84 and 80 of the next side (the left side). This space is defined as the circumferential width from the cutting edge 44 of the last tooth of a section to the cutting edge 44 of the first tooth in the next section. Specifically, transition 90 is the circumferential width from the cutting edge 44 of the tooth 32 E of section 80 to the cutting edge 44 of the tooth 32 F in the next section 82 , which is defined as angle e. Transition 92 does not exist due to the one-tooth nature of section 84 . Transition 94 is the circumferential width from the cutting edge 44 of the tooth 32 I of section 84 to the cutting edge 44 of the tooth 32 A in the next section 80 (which is on the other side or left side in this case), which is defined as angle f.
In accordance with one of the features of the invention, the section angle b is 60°, the section angle c is 40°, the section angle d is 36°, the transition angle e is 20°, and the transition angle f is 24°. The effect is a design where section 80 has cutting edges 44 for five teeth, section 82 has cutting edges 44 for three teeth, and section 84 has cutting edges for one tooth, with uneven transitions between sections 80 and 82 , and between 84 and 80 of the other side (the left side). Although it is noted above that no transition 92 exists between sections 82 and 84 because the definition of transition 92 is the same as section 84 , nonetheless, it is also seen that what might be considered as transition 92 also differs from the either of transitions 90 and 94 .
In more detail as to the second embodiment of the blade referred to as 120 , teeth 32 are arranged in a unique thirty-six tooth design that is divided into two copy exact sections, namely a first side 170 A and a second side 170 B by axis 172 . Since the blade as shown in FIGS. 4–5 has a right and left copy exact side (sides 170 A and 170 B respectively), only the right side will be described below (except where necessary to refer to the left side). The first side 170 A includes eighteen teeth, namely teeth 132 A, 132 B, 132 C, 132 D, 132 E, 132 F, 132 G, 132 H, 132 I, 132 J, 132 K, 132 L, 132 M, 132 N, 132 O, 132 P, 132 Q, and 132 R.
As with the first embodiment and in accordance with one of the features of the invention, the eighteen teeth 132 A, 132 B, 132 C, 132 D, 132 E, 132 F, 132 G, 132 H, 132 I, 132 J, 132 K, 132 L, 132 M, 132 N, 132 O, 132 P, 132 Q, and 132 R of each side 170 A and 170 B are not all identical in size and spacing. Specifically in the embodiment shown, first side 170 A is divided into four sections 180 , 182 , 184 and 186 (and thus saw blade 120 has eight sections) of varying circumferential distance with differing number of teeth and size of teeth in each. Section 180 includes cutting edges 44 of seven teeth, namely teeth 132 A, 132 B, 132 C, 132 D, 132 E, 132 F, and 132 G, and these cutting edges define a first circumferential width between each adjacent pair of the cutting edges. Section 180 also includes the trailing components of six teeth, namely teeth 132 B, 132 C, 132 D, 132 E, 132 F and 132 G, so that those six teeth are fully within section 180 , and those teeth within section 180 are substantially identical to one another. As noted above, the trailing components include land 42 including tapered sections 48 and 50 , and optional additional cutting edge 52 . Thereafter, section 182 includes cutting edges 44 of six teeth, namely teeth 132 H, 132 I, 132 J, 132 K, 132 L and 132 M, and these cutting edges define a second circumferential width between each adjacent pair of the cutting edges that is different from the first circumferential width. Section 182 also includes the trailing components of five teeth, namely teeth 132 I, 132 J, 132 K, 132 L and 132 M, so that those five teeth are fully within section 182 , and those teeth within section 182 are substantially identical to one another. Further thereafter, section 184 includes cutting edges 44 of three teeth, namely teeth 132 N, 132 O and 132 P, and these cutting edges define a third circumferential width between each adjacent pair of the cutting edges that is different from the first and second circumferential widths. Section 184 also includes the trailing components of two teeth, namely teeth 132 O and 132 P, so that those two teeth are fully within section 184 , and those teeth within section 184 are substantially identical to one another. Finally thereafter, section 186 includes cutting edges 44 of two teeth, namely teeth 132 Q and 132 R, along with the trailing components of tooth 132 R, so that tooth 132 R is fully within section 186 .
In the same manner as described above with reference to the first embodiment, each section is specifically measured as the group circumferential width from the cutting edge 44 of the first tooth of a section to the cutting edge 44 of the last tooth in the same section except where a section has only one tooth 132 and thus its group circumferential width is defined from the cutting edge 44 of the last tooth 132 of the previous section to the cutting edge 44 of the only tooth 132 in the section. Specifically, section 180 is the group circumferential width from the cutting edge 44 of the first tooth 132 A of the section 180 to the cutting edge 44 of the last tooth 132 G in the same section 180 , which is defined as angle g. Section 182 is the group circumferential width from the cutting edge 44 of the first tooth 132 H of the section 182 to the cutting edge 44 of the last tooth 132 M in the same section 182 , which is defined as angle h. Section 184 is the group circumferential width from the cutting edge 44 of the first tooth 132 N of the section 184 to the cutting edge 44 of the last tooth 132 P in the same section 184 , which is defined as angle j. Section 186 is the group circumferential width from the cutting edge 44 of the first tooth 132 Q of the section 186 to the cutting edge 44 of the last tooth 132 R in the same section 186 , which is defined as angle k.
In between each of the sections are transitions or circumferential spaces 190 , 192 , 194 and 196 . Specifically, transition 190 is the space between sections 180 and 182 , transition 192 is the space between sections 182 and 184 , transition 194 is the space between sections 184 and 186 , and transition 196 is the space between sections 186 and 180 of the next side (the left side). This space is defined as the circumferential width from the cutting edge 44 of the last tooth of a section to cutting edge 44 of the first tooth in the next section. Specifically, transition 190 is the circumferential width from cutting edge 44 of tooth 132 G of section 180 to cutting edge 44 of tooth 132 H in the next section 182 , which is defined as angle I. Transition 192 is the circumferential width from cutting edge 44 of tooth 132 M of section 182 to cutting edge 44 of tooth 132 N in the next section 184 , which is defined as angle m. Transition 194 is the circumferential width from cutting edge 44 of tooth 132 P of section 184 to cutting edge 44 of tooth 132 Q in the next section 186 , which is defined as angle q. Transition 196 is the circumferential width from cutting edge 44 of tooth 132 R of section 186 to cutting edge 44 of tooth 132 A in the next section 180 (which is on the other side or left side in this case), which is defined as angle s.
In accordance with one of the features of the invention, the circumferential width or section angle g is 36.015°, the section angle h is 44.985°, the section angle j is 30.015°, the section angle k is 20°, the transition angle I is 9°, the transition angle m is 9.985°, the transition angle q is 10°, and the transition angle s is 20°.
In accordance with yet one more feature of the invention, it has been discovered that alternating the number of teeth in adjacent sections from odd to even provides additional benefits including noise reduction.
Accordingly, the improved saw blade of the above embodiments is simplified, provides an effective, safe, inexpensive, and efficient device which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.
In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
Having now described the features, discoveries and principles of the invention, the manner in which the improved saw blade is constructed and used, the characteristics of the construction, and the advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims. | An apparatus for cutting materials and more specifically an improved saw blade includes a plurality of variable teeth thereon. The variable tooth saw blade cuts faster and smoother while reducing harmonic vibrations. Specifically, the teeth on the saw blade are grouped into sections with differing circumferential widths and differing spacing between the sections. | 8 |
RELATED APPLICATIONS/PRIORITY BENEFIT CLAIM
This application claims the benefit of U.S. Provisional Application No. 61/209,184 filed Mar. 4, 2009 by the same inventor (Hughey), the entirety of which provisional application is incorporated herein by reference.
FIELD
The subject matter of the present application is in the field of clamping apparatus for use in producing corners from mating corner pieces with mitered mating edges, by securely retaining the corner pieces in a corner arrangement.
BACKGROUND
Devices relating to frame and corner clamps and miters are known. U.S. Pat. No. 4,056,030 to Hahn is directed to a combination miter box, corner clamp, and measuring gauge based on a machined metal, V-shaped structure. However, the Hahn apparatus is not capable of generating longitudinal axis compression of framing strips or corner pieces. Further, the arrangement of the clamping screws in the Hahn apparatus limits its capability for clamping wide frame strips. Finally, the Hahn apparatus is a complex design requiring customized metal machining.
U.S. Pat. No. 4,247,090 to Hahn et al teaches a corner clamp using a similar machined metal, V-shaped structure. This apparatus adds a z-plane member capable of clamping to a work bench. However, the apparatus is otherwise subject to the same limitations as the prior Hahn device.
U.S. Pat. No. 7,168,693 to Sjuts et al is directed to an adjustable angle clamp. This apparatus uses adjustable clamping jaws disposed on opposing arm members to provide adjustable-angle clamping of two pieces to be joined along a seam. However, the Sjuts et al reference is limited in the width of material it will clamp, and does not readily allow for adjusting the miter seam.
BRIEF SUMMARY
What is disclosed and claimed herein is an adjustable corner clamping apparatus including, in combination, first, second, and third rigid L supports and first, second, third, and fourth clamping feet. A first rigid L support includes first and second legs. A second rigid L support also includes first and second legs. The first legs of the first and second rigid L supports are slidingly coupled together. As a result, the second legs of the first and second rigid L supports are held in parallel. Further, the distance between the second legs of the first and second rigid L supports is adjustable.
A third rigid L support includes first and second legs. The second legs of the first and third rigid L supports are slidingly coupled together. As a result, the first legs of the first and third rigid L supports are held in parallel. Further, the distance between the first legs of the first and third rigid L supports is adjustable.
A first clamping foot is adjustably retained in the first leg of the first rigid L support. A second clamping foot is adjustably retained in the second leg of the first rigid L support. A third clamping foot is adjustably retained in the second leg of the second rigid L support. A fourth clamping foot is adjustably retained in the first leg of the third rigid L support. As a result of this unique arrangement of supports and clamping feet, cooperative action between the first, second, third, and fourth clamping feet is operative to receive and securely retain a pair of frame strips or similarly mitered pieces in a corner arrangement.
While the terms “frame strips” or “framing strips” has been used so far to generally describe the pieces held together by my clamping apparatus, the term “corner piece” will be used in their place hereafter. All of these terms should be construed to include any mating frame or corner pieces with opposingly-angled or mitered mating edges with which it is desirable to form a tight, clean, even seam where the pieces are joined to form a right-angle corner. For example, the preferred use of my clamping apparatus is in securing, aligning, and retaining mitered wood stock, for example common “1×” or “2×” wood stock used to form right-angle corner trim on a house or a cabinet. Another possible use of the clamping apparatus, without implying limitation, is in forming square newel posts.
My clamping apparatus optimally addresses several critical issues typical to corner clamping. These issues include the need (1) to adjust for different corner piece lengths, (2) to adjust for different corner piece widths, (3) to generate adequate compression between the mated corner pieces, (4) to compensate for variations in the miter seam, and (5) to provide an economical and easy to manufacture clamping apparatus.
The clamping apparatus functions by receiving corner pieces therein to form a corner or by being applied to already-mated corner pieces to secure them in place while they are more permanently fastened, for example by allowing previously-applied adhesive to set, and/or by nailing or screwing the joined corner pieces together.
These and other features and advantages of the invention will become apparent from the detailed description below, in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a corner clamping apparatus according to a preferred example of the present invention.
FIG. 2 is a perspective view of the corner clamping apparatus of FIG. 1 .
FIG. 3 is a top view of the corner clamping apparatus of FIG. 1 , further showing the clamping apparatus receiving and retaining a pair of corner pieces in a corner arrangement.
FIG. 4 is a partially exploded perspective view of several corner clamps according to FIGS. 1-3 applied to the corner trim of a house.
DETAILED DESCRIPTION
Referring to FIGS. 1 through 4 , a corner clamping apparatus is shown in exemplary form in order to teach how to make and use the claimed invention.
In FIG. 1 , a corner clamping apparatus 10 includes a first rigid L support 14 , a second rigid L support 26 , a third rigid L support 38 , a first clamping foot 50 , a second clamping foot 66 , a third clamping foot 78 , and a fourth clamping foot 94 . The rigid L supports 14 , 26 , and 38 are so named for their general “L” shapes. The first rigid L support 14 has a first leg 18 and a second leg 22 . The second rigid L support 26 also has a first leg 30 and a second leg 34 .
The first leg 18 of the first rigid L support 14 and the first leg 30 of the second rigid L support 26 are slidingly coupled together. For example, the rigid L supports may be fabricated from square steel tubing. In the illustrated embodiment, the first rigid L support 14 is fabricated tubing stock of somewhat larger cross section than the second rigid L support 26 . As a result, the first leg 30 of the second rigid L support 26 slides into the first leg 1 of the first rigid L support 14 . Alternatively, the second rigid L support 26 could be made larger such that the first rigid L support 14 could slide into the second rigid L support. The position of the coupling of the first and second rigid L supports 14 and 26 may be fixed using, for example, a set screw 36 that is retained in one of the legs while frictionally coupled to the other. As a result of such a coupling, the second leg 22 of the first rigid L support 14 and second leg 34 of the second rigid L support 26 are held in parallel. Further, the distance between the second leg 22 of the first rigid L support 14 and the second leg 34 of the second rigid L support 26 is adjustable based on the position of the sliding coupling as fixed by the set screw 36 .
A third rigid L support 38 has a first leg 42 and second leg 46 . The second leg 22 of the first rigid L support 14 and the second leg 46 of the third rigid L support 38 are slidingly coupled together. In the illustrated embodiment, the second leg 46 of the third rigid L support 38 slides into the second leg 22 of the first rigid L support 14 . Alternatively, the first rigid L support 14 may be made to slide into the third rigid L support 38 . The position of the coupling of the first and third rigid L supports 14 and 38 may also be fixed using a set screw 48 retained in one of the legs while frictionally coupled to the other. As a result of such a coupling, the first leg 18 of the first rigid L support 14 and first leg 42 of the third rigid L support 38 are held in parallel. Further, the distance between the first leg 18 of the first rigid L support 14 and the first leg 42 of the third rigid L support 38 is adjustable based on the position of the sliding coupling as fixed by the set screw 48 .
A first clamping foot 50 is adjustably retained in the first leg 18 of the first rigid L support 14 . A second clamping foot 66 is adjustably retained in the second leg 22 of the first rigid L support 14 . A third clamping foot 78 is adjustably retained in the second leg 34 of the second rigid L support 26 . A fourth clamping foot 94 is adjustably retained in the first leg 42 of the third rigid L support 38 . The first, second, third, and fourth clamping feet 50 , 66 , 78 , and 94 are preferably each attached to a separate threaded spindle 54 , 70 , 82 , and 98 to provide a means both for retention in their respective legs and for making adjustments to the feet positions. The position of each threaded spindle may be adjusted by turning the spindle clockwise or counterclockwise. As each spindle is turned, the relative positions of each clamping foot may be adjusted to accommodate a work piece, not shown.
Each of the clamping feet 50 , 66 , 78 , and 94 are preferably each further attached, via the spindles, to operating ends 58 , 74 , 86 , and 102 . The operating end preferably includes a transverse pin handle 62 , 90 , or equivalent, to provide a means for the operator to create torque on the spindle—torque that is converted into compression force as the clamping feet cooperatively couple onto or engage a work piece, i.e. two corner-forming pieces.
Each of the clamping feet 50 , 66 , 78 , and 94 are each preferably operative to swivel on their respective spindles to accommodate uniquely shaped corner pieces and to accommodate deviations in the miter joint or the assembled corner pieces. Also, each of the clamping feet 50 , 66 , 78 , and 94 preferably includes treading 106 , or knurling, to provide frictional coupling between the foot and a work piece. This feature promotes accommodation of uniquely shaped work pieces.
Referring now to FIG. 2 , a full isometric view of the corner clamping apparatus 10 according to the exemplary and currently preferred embodiment of the present invention is shown. Steel square tubing, which is the preferred support material, allows the second and third rigid L supports 26 and 38 to slide into the first rigid L support 14 , as shown in phantom lines.
Referring now to FIG. 3 , a full top view of the corner clamping apparatus according to the preferred embodiment of the present invention is shown. The clamping apparatus 10 is shown receiving and retaining a work piece—a pair of corner pieces C that could be a pair of frame strips or could be a pair of corner trim pieces—for example serving when held together to form a right angle corner on a finished item such as a window frame or the corner trim of a house. As a result of this unique arrangement of supports 14 , 26 , and 38 , and of clamping feet 50 , 66 , 78 , and 94 , cooperative action between the first, second, third, and fourth clamping feet is operative to receive and securely retain a pair of frame strips in a corner arrangement.
It can be seen from FIG. 3 that the four clamping feet all put pressure on the mitered joint in a direction tending to force and hold the mitered edges of the corner pieces tightly together. The interior clamping feet 50 and 66 that engage the corner at the seam are believed to be the most important for aligning the seam.
Referring to FIG. 4 , several clamps 10 are shown in use with corner pieces C, here shown forming a corner trim 104 on a house 100 . Once corner pieces C are joined with their mitered inside edges abutting to form a miter seam 104 a , clamps 10 are applied at multiple locations along the corner 104 to retain the corner pieces in a tight fit until they can be permanently joined, for example by allowing previously-applied glue to set or by nailing or screwing them together. The mitered edges 104 e of the corner pieces C are mitered at 45-degree angles to form a 90-degree corner as shown in FIGS. 3 and 4 . The infinite adjustability of the clamping feet on clamps 10 allows small variations in the end or outside faces of the corner pieces to be accommodated. The four-point adjustable clamping pressure of the feet also allows corner pieces C to be minutely adjusted to overcome variations or imperfections in the alignment or evenness of their mitered edges, so that seam 104 a can be adjustably clamped as tightly and evenly as possible. The number of clamps 10 applied to a given work piece or corner is in the discretion of the user.
It will finally be understood that the disclosed embodiments are representative of presently preferred examples of how to make and use the claimed invention, but are intended to be explanatory rather than limiting of the scope of the invention as defined by the claims below. Reasonable variations and modifications of the illustrated examples in the foregoing written specification and drawings are possible without departing from the scope of the invention as defined in the claims below. It should further be understood that to the extent the term “invention” is used in the written specification, it is not to be construed as a limiting term as to number of claimed or disclosed inventions or the scope of any such invention, but as a term which has long been conveniently and widely used to describe new and useful improvements in technology. The scope of the invention is accordingly defined by the following claims. | A corner clamping apparatus capable of adjustably clamping two joined, mitered corner pieces to form a 90-degree corner with a single clamp. The clamping apparatus includes three rigid L-shaped supports, adjustably mounted relative to one another to accommodate differently sized corner pieces and/or variations in the corner pieces or their mitered edges. Four adjustable clamping feet retained in the rigid L serve to adjust the corner pieces to produce an exact miter joint or seam, and to hold the adjusted corner pieces until they can be more permanently joined. | 1 |
This application is a 35 U.S.C. §371 National Stage Application of PCT/EP2009/007590, filed Oct. 23, 2009, which claims the benefit of priority to Serial No. 08019066.3, filed Oct. 31, 2008 in Europe, the disclosures of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The disclosure relates to a method and an apparatus for controlling a linear motion system having a linear synchronous motor, to a corresponding computer program, and to a corresponding computer program product.
BACKGROUND
Linear synchronous motors comprise a longitudinal stator on which at least one translator is freely moveable. A magnetic travelling-field is generated for moving the translator(s). The stator includes separate coil units, each comprising at least one coil. Usually, the magnetic travelling-field is generated by applying a three-phase current to said coil units. One example of a well known linear motor is disclosed in DE 39 00 511 A1. A current with variable frequency and amplitude is applied to the coil units of the longitudinal stator depending on the actual location of the translator, in order to move the translator relative to the stator.
NL 1024992 discloses a prior art linear motion system, which comprises an apparatus for moving carriers in a circulating transport circuit using magnetic movement devices, which comprise magnetic units working together and controllable coil units. Such an apparatus is often used in automated and specific product facilities, where a product is placed on the product carrier. During the circulation through the transport circuit, the product has to undergo several similar process steps. An application of such an apparatus relates to a semiconductor substrate placed on a product carrier, where various ultra-thin layers are to be deposited (e.g. chemical or physical vapour deposition CVD/PVD).
In such an application field, precise control of the movement of the various product carriers through the circulating transport circuit is essential for the correct performance of the various process actions on the products placed on the product carriers. Magnetic movement devices are used to move the product carriers through the transport circuit, particularly where very high requirements are set for the accuracy of the various process actions, such as the placement of an electronic component or the deposition of a semiconductor layer on a substrate.
The actuation occurs without contact between stator and translator, and without detrimental influences that can disturb the movement of the product carriers through the transport circuit, with the possibility to manipulate different product carriers independently of each other. The apparatus corresponding to the prior art comprises sensor devices, which are provided to detect the magnets of one product carrier and on the basis thereof to generate a position signal of the product carrier. This detection signal is used to activate the movement devices for the accurate positioning of the product carrier in the transport circuit. This, in combination with the independently controllable coil units, allows for an activation of each product carrier separately and for movement/position of each product carrier independently of the other product carriers.
In view of this prior art, it is an object of the disclosure to provide a method and an apparatus for controlling such a linear motion system so that a train comprising at least two carriers can be formed.
According to the disclosure a method and an apparatus for controlling a linear motion system, further a corresponding computer program and a computer program product, according to the independent claims are provided. Advantageous embodiments are defined in the dependent claims.
SUMMARY
The disclosure provides a method for forming a train comprising at least two carrier units which can be moved as a single unit. Therefore, e.g. during a CVD process the room required for a process chamber can be reduced. Especially, forming a train of carrier units according to the disclosure can used advantageously for moving the carriers through a process station which deposits material at high temperature. The smaller this oven, the cheaper in production and the smaller the machine footprint. In addition, less chemicals are needed, since the carrier units cover a larger areas. Another exemplary application, wherein the disclosure can be implemented advantageously is the sputtering process for the production of hard discs. Running the carriers in train formation allows for a ‘spray-paint’-type of processing, required for next-generation hard discs. The current state of the art is that a carrier moves into a process chamber, stops, gets processed, and leaves. The ‘spray-paint’-way of processing is faster, as the carrier is moved through the chamber at continuous speed and get processed during the movement. This can be done without requiring any buffers when the train formation is available. Furthermore, the disclosure can advantageously be used for logistic or transport systems. Especially, it is possible to provide local buffering on the track using a train formed by carriers.
According to the disclosure, a method of controlling a linear motion system having a linear synchronous motor comprising a stator and at least two carrier units moveable in relation to said stator is disclosed. Said stator comprises a number of coil units, each of said at least two moveable carrier units comprising a magnetic unit including an array or a series of alternate-pole magnets having a regular magnet pole-pitch, i.e. said alternate-pole magnets are arranged so that the distance between two neighbouring identically poled magnets is constant. This distance is defined as the magnetic pole-pitch. Within said series of alternate-pole or alternatingly poled magnets, the magnets are arranged so that the north pole of the first magnet lies adjacent to the south pole of the second magnet, which in turn lies adjacent to the north pole of the third magnet etc.
In order to form a train said at least two carrier units are arranged relative to each other so that the mutual distance between two identically poled magnets of two different magnetic units is an integer multiple of the magnet pole-pitch.
According to a preferred embodiment, said train is moved along the stator by applying a current to the stator coil units, said current corresponding to a current being applied to the stator coil units in order to move a single carrier unit. As the carrier units forming a train are arranged so that the distance of identically poled magnets equals the magnetic pole-pitch, the carrier units forming the train advantageously appear as one carrier unit and thus can be controlled as one carrier unit (i.e. the train).
According to a preferred embodiment, the stator coil unit includes at least one sensor for determining the position of a carrier unit, and at least one coil for moving the carrier unit. The sensors can be magnetic sensors (e.g. Hall sensors) for detecting the magnetic field of the carrier magnetic units. This embodiment allows for a accurate determination of the current position of the carrier unit. For further details, NL 1024992 is referred to in its entirety.
Advantageously, a train is formed by a first carrier unit being positioned over a first coil unit and a second carrier unit being positioned over a second coil unit with said second coil unit being adjacent to said first coil unit, so that the mutual distance between two identically poled magnets of the magnetic units of said first and second carrier units, respectively, is an integer multiple of the magnet pole-pitch. Thus, a train can easily be formed, while two carrier units are controlled by two separate coil units. If the setpoint of the first carrier unit is determined in such a way that this carrier unit enters the second coil unit that controls the second carrier, with the correct velocity and mutual distance, a smooth train is formed.
Appropriately, said train is moved along said stator by a current being applied to a coil unit below said train, said current commutation being calculated for only one of said carrier units forming said train. Thus, once having formed said train as described above, said train can be moved like a single carrier unit due to the correct distance of the magnets of adjacent carrier units.
According to a preferred embodiment, while said train passes from a first coil unit to a second coil unit, the current commutation is calculated for a first carrier unit being positioned over said first coil unit, then for said first and said second coil unit carrier unit being positioned over said first coil unit, and then for said first carrier unit being positioned over said second coil unit. Therefore, the train can easily be moved along the stator by applying a travelling-current to adjacent coil units.
Advantageously, a train is formed and moved through the process chamber of a wafer coating process, especially a semiconductor depositing process such as CVD or PVD. The present disclosure can advantageously be implemented in wafer coating processes, as there is the need to move carrier units slowly, continuously and with the same speed through the process chambers. By forming a train these objects can be accomplished. Furthermore, the space needed for the process chamber(s) can be reduced and the track inside the chamber can be covered by the carrier units forming a train and thus can be protected from being coated.
An inventive apparatus performs all steps of the inventive method.
An inventive computer program comprising program code means is configured to perform all steps of the inventive method, when the computer program is executed on a computer or a corresponding processing unit, in particular on an inventive apparatus.
An inventive computer program product comprising program code means stored on a computer readable data carrier is provided for performing the inventive method, when the computer program is executed on a computer or a corresponding processing unit, in particular on an inventive apparatus.
Further advantages and embodiments of the disclosure will become apparent from the description and the appended figures.
It should be noted that the previously mentioned features and the features to be elucidated in the following are usable not only in the respectively indicated combination, but also in further combinations or taken alone, without departing from the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic plan view of a linear motion system suitable for use with the present disclosure;
FIG. 2 shows a schematic side view of the linear motion system of FIG. 1 ;
FIG. 3 shows a schematic side view of a linear motion system with two carriers forming a train according to an embodiment of the disclosure; and
FIG. 4 shows a magnified detail of FIG. 3 .
Like parts are indicated with identical reference numbers in the description below for a better understanding of the disclosure.
DETAILED DESCRIPTION
FIG. 1 shows a schematic plan view of a linear motion system (LMS) suitable for use with the present disclosure. LMS 1 comprises a frame that forms a transport circuit 2 , including different stators being formed as transport segments 2 a , 2 b , 2 c and 2 d . Various product carrier units 10 a - 10 k are placed movably above the circulating transport circuit 2 a - 2 d.
Various products (not shown) can be placed on the product carriers 10 a - 10 k , which can undergo various process steps during the circulating movement through the transport circuit 2 . For example, the products placed on the product carrier 10 a - 10 k can include electronic printed boards, on which the various electronic components must be placed. In another application, the products can be semiconductor substrates, whereon various thin metallic or semiconductor layers are deposited during various processing steps, e.g. the manufacture of solar cells, chips, or LEDs.
FIG. 2 shows a schematic side view of a detail of the linear motion system of FIG. 1 including magnetic based transport devices. For this purpose, a number of coil units 30 a , 30 b , 30 c , etc. including coils 5 a , 5 b , 5 c , etc. and sensor units 7 a , 7 b , 7 c , etc., respectively, are installed in the transport circuit 2 and in the transport direction of the product carriers 10 a - 10 k . The coil units 30 a , 30 b , 30 c , etc. interact with magnetic units 6 a , 6 b , etc, which have been fitted on each product carrier 10 a , 10 b , etc. The magnetic units 6 a , 6 b , etc, are composed of an array or a series of alternating poled magnets. The alternating poled magnets of each magnetic unit 6 a , 6 b , etc. on each product carrier are designated 6 a ′, 6 a ″ (for product carrier 10 a ); 6 b ′, 6 b ″ (for product carrier 10 b ); etc.
By sequentially activating the coil units 30 a , 30 b , 30 c , etc. in a specific way, the product carriers 10 a , 10 b , etc. are moved through the transport circuit 2 by commutation and the magnetic action of the various alternating poled magnets (attraction and repulsion). The actuation therefore occurs without contact, which improves the accuracy of the process actions that must be performed on the products placed on the product carriers 10 a , 10 b , etc.
In order to provide an improved and more versatile LMS, which is able to manipulate various product carriers 10 a , 10 b , etc. independently of each other and more particularly, to position them more accurately for the process actions to be performed, sensor devices 7 a , 7 b , 7 c , etc. are provided, which are equipped to detect the presence and position of a product carrier 10 a , 10 b , etc. The sensor devices 7 a , 7 b , 7 c , etc. are composed of various sensor units 7 a ′, 7 a ″, 7 b ′, etc., which in this example are arranged, viewed in the transport direction of the product carriers, before and after a coil 5 a , 5 b , 5 c , etc. As shown in FIG. 2 , each sensor unit 7 a ′, 7 a ″, 7 b ′, etc. of the sensor devices 7 a , 7 b , 7 c comprises two Hall sensors C and S.
The sensor units 7 a ′, 7 a ″, 7 b ′, etc. generate a detection signal, when a product carrier 10 a , 10 b , etc. passes under the influence of the sequential series of the alternatingly poled magnets with the movement/position of the product carrier. The detection signal is, for example, a voltage signal and, due to the two Hall sensors C and S used, both generate a sine-derived voltage signal with a mutual phase difference. This phase difference depends on the mutual distance between the Hall sensors C and S. In particular, this distance equals one quarter of the distance P (pole-pitch)+an integer multiple of half the distance P between successive identically poled magnets.
The voltage signal respectively induced by the alternatingly poled magnets, which is generated by each of the Hall sensors C and S, on the one hand provides information concerning the direction of the moved product carrier and on the other hand is a measure of the position of the product carrier with respect to these Hall sensors (and therefore to the corresponding coil unit). This information can advantageously be used to form a train as described below.
FIG. 3 shows a flow diagram, wherein over time t two carriers 10 a , 10 b form a train and said train is moved as a single unit. In the diagram, subsequent views are arranged vertically along the time axis t according to their point in time.
Firstly, a single carrier unit 10 b is arranged above a coil unit 30 a . The coil unit 30 a comprises a number of coils 5 and a number of sensors 7 as described above. A three-phase travelling-current is applied to the coils 5 in order to move the product carrier units.
Then, a second carrier unit 10 a approaches the first carrier unit 10 b from the left. As shown in area 40 (cf. FIG. 4 ), the carrier unit 10 a is arranged relative to the carrier unit 10 b so that the mutual distance of two identically poled magnets is an integer multiple of the magnet pole-pitch. Thus, a train is formed. Once the carrier unit 10 a has reached its train forming position, the resulting train 20 is moved as a single unit by the coil units 30 a , 30 b.
In order to move the train to the right, the carrier unit 10 b is moved to the right by the coil unit 30 a until it reaches the coil area of the coil unit 30 b . Simultaneously, the carrier unit 10 a is moved to the right by the coil unit (not shown) to the left of the coil unit 30 a until it reaches the coil area of the coil unit 30 a . At this point in time, the carrier unit 10 b is controlled by both magnetic units 30 a and 30 b , whereas the carrier unit 10 a is controlled by the coil unit (not shown) to the left of the coil unit 30 a and is only indirectly controlled by the coil unit 30 a due to the same commutation. So to say, the carrier unit 10 a is hitched to the carrier unit 10 b above the coil unit 30 a , due to the defined mutual distance D, whereby the current applied to the coil unit 30 a , which is calculated for the carrier unit 10 b , is also suitable to move the carrier unit 10 a.
Subsequently, the train moves to the right and the carrier units 10 a , 10 b leave the coil area of their respective underlying coil units. At this point in time, the control of the carrier units 10 a , 10 b is changed so that the carrier unit 10 b is controlled by the coil unit 30 b and the carrier unit 10 a is controlled by the coil unit 30 a . It is understood that the current applied to the coil units 30 a and 30 b , respectively, is suitable to maintain the train formation.
Over time, the train is moved further to the right until the carrier unit 10 a reaches the coil area of the coil unit 30 b and the carrier unit 10 b reaches the coil area of a coil unit (not shown) to the right of the coil unit 30 b . Then, the procedure is repeated as described above, if required.
FIG. 4 shows a magnified view of detail 40 of FIG. 3 , wherein the two carriers 10 a , 10 b form a train 20 . Each carrier comprises alternatingly poled magnets 6 a ′, 6 a ″ and 6 b ′, 6 b ″, respectively. In order to form the train 20 , the carrier units 10 a and 10 b are arranged relative to each other so that the mutual distance D between two identically poled magnets 6 a ′ and 6 b ′ is an integer multiple of the magnet pole-pitch P, in the shown embodiment D=P.
The described steps of the method according to the disclosure may be performed in combination, in different order or alone. Use of the method is not limited to the field of semiconductor coating and the scope of the disclosure is only limited by the appended claims. | A method of controlling a linear motion system has a linear synchronous motor comprising a stator and at least two carrier units moveable in relation to the stator, the stator comprising a number of coil units, each of the at least two carrier units comprising a magnetic unit including an array of alternate-pole magnets having a regular magnet pole-pitch, wherein in order to form a train the at least two carrier units are arranged relative to each other so that the mutual distance between two identically poled magnets of two different magnetic units is an integer multiple of the magnet pole-pitch. | 7 |
[0001] The present application claims priority to U.S. Ser. No. 60/396,989 filed May 24, 2002, to U.S. Ser. No. 60/403,868 filed Aug. 14, 2002, to U.S. Ser. No. 60/430,284 filed Dec. 2, 2002, and to U.S. Ser. No. 60/461,175 filed Apr. 8, 2003, the entire contents of each is hereby incorporated by reference.
[0002] The present invention relates to rare earth metal compounds, particularly rare earth metal compounds having a porous structure. The present invention also includes methods of making the porous rare earth metal compounds and methods of using the compounds of the present invention. The compounds of the present invention can be used to bind or absorb metals such as arsenic, selenium, antimony and metal ions such as arsenic III + and V + . The compounds of the present invention may therefore find use in water filters or other devices or methods to remove metals and metal ions from fluids, especially water.
[0003] The compounds of the present invention are also useful for binding or absorbing anions such as phosphate in the gastrointestinal tract of mammals. Accordingly, one use of the compounds of the present invention is to treat high serum phosphate levels in patients with end-stage renal disease undergoing kidney dialysis. In this aspect, the compounds may be provided in a filter that is fluidically connected with a kidney dialysis machine such that the phosphate content in the blood is reduced after passing through the filter.
[0004] In another aspect, the compounds can be used to deliver a lanthanum or other rare-earth metal compound that will bind phosphate present in the gut and prevent its transfer into the bloodstream. Compounds of the present invention can also be used to deliver drugs or to act as a filter or absorber in the gastrointestinal tract or in the blood stream. For example, the materials can be used to deliver inorganic chemicals in the gastrointestinal tract or elsewhere.
[0005] It has been found that the porous particle structure and the high surface area are beneficial to high absorption rates of anions. Advantageously, these properties permit the compounds of the present invention to be used to bind phosphate directly in a filtering device fluidically connected with kidney dialysis equipment.
[0006] The use of rare earth hydrated oxides, particularly hydrated oxides of La, Ce, and Y to bind phosphate is disclosed in Japanese published patent application 61-004529 (1986). Similarly, U.S. Pat. No. 5,968,976 discloses a lanthanum carbonate hydrate to remove phosphate in the gastrointestinal tract and to treat hyperphosphatemia in patients with renal failure. It also shows that hydrated lanthanum carbonates with about 3 to 6 molecules of crystal water provide the highest removal rates. U.S. Pat. No. 6,322,895 discloses a form of silicon with micron-sized or nano-sized pores that can be used to release drugs slowly in the body. U.S. Pat. No. 5,782,792 discloses a method for the treatment of rheumatic arthritis where a “protein A immunoadsorbent” is placed on silica or another inert binder in a cartridge to physically remove antibodies from the bloodstream.
[0007] It has now unexpectedly been found that the specific surface area of compounds according to the present invention as measured by the BET method, varies depending on the method of preparation, and has a significant effect on the properties of the product. As a result, the specific properties of the resulting compound can be adjusted by varying one or more parameters in the method of making the compound. In this regard, the compounds of the present invention have a BET specific surface area of at least about 10 m 2 /g and may have a BET specific surface area of at least about 20 m 2 /g and alternatively may have a BET specific surface area of at least about 35 m 2 μg. In one embodiment, the compounds have a BET specific surface area within the range of about 10 m 2 /g and about 40 m 2 /g.
[0008] It has also been found that modifications in the preparation method of the rare earth compounds will create different entities, e.g. different kinds of hydrated or amorphous oxycarbonates rather than carbonates, and that these compounds have distinct and improved properties. It has also been found that modifications of the preparation method create different porous physical structures with improved properties.
[0009] The compounds of the present invention and in particular, the lanthanum compounds and more particularly the lanthanum oxycarbonates of the present invention exhibit phosphate binding or removal of at least 40% of the initial concentration of phosphate after ten minutes. Desirably, the lanthanum compounds exhibit phosphate binding or removal of at least 60% of the initial concentration of phosphate after ten minutes. In other words, the lanthanum compounds and in particular, the lanthanum compounds and more particularly the lanthanum oxycarbonates of the present invention exhibit a phosphate binding capacity of at least 45 mg of phosphate per gram of lanthanum compound. Suitably, the lanthanum compounds exhibit a phosphate binding capacity of at least 50 mg PO 4 /g of lanthanum compound, more suitably, a phosphate binding capacity of at least 75 mg PO 4 /g of lanthanum compound. Desirably, the lanthanum compounds exhibit a phosphate binding capacity of at least 100 mg PO 4 /g of lanthanum compound, more desirably, a phosphate binding capacity of at least 110 mg PO 4 /g of lanthanum compound.
[0010] In accordance with the present invention, rare earth metal compounds, and in particular, rare earth metal oxychlorides and oxycarbonates are provided. The oxycarbonates may be hydrated or anhydrous. These compounds may be produced according to the present invention as particles having a porous structure. The rare earth metal compound particles of the present invention may conveniently be produced within a controllable range of surface areas with resultant variable and controllable adsorption rates of ions.
[0011] The porous particles or porous structures of the present invention are made of nano-sized to micron-sized crystals with controllable surface areas. The rare earth oxychloride is desirably lanthanum oxychloride (LaOCl). The rare earth oxycarbonate hydrate is desirably lanthanum oxycarbonate hydrate (La 2 O(CO 3 ) 2 .xH 2 O where x is from and including 2 to and including 4). This compound will further be referred to in this text as La 2 O(CO 3 ) 2 .xH 2 O. The anhydrous rare earth oxycarbonate is desirably lanthanum oxycarbonate La 2 O 2 CO 3 or La 2 CO 5 of which several crystalline forms exist. The lower temperature form will be identified as La 2 O 2 CO 3 and the form obtained at higher temperature or after a longer calcination time will be identified as La 2 CO 5 .
[0012] One skilled in the art, however, will understand that lanthanum oxycarbonate may be present as a mixture of the hydrate and the anhydrous form. In addition, the anhydrous lanthanum oxycarbonate may be present as a mixture of La 2 O 2 CO 3 and La 2 CO 5 and may be present in more than a single crystalline form.
[0013] One method of making the rare earth metal compound particles includes making a solution of rare earth metal chloride, subjecting the solution to a substantially total evaporation process using a spray dryer or other suitable equipment to form an intermediate product, and calcining the obtained intermediate product at a temperature between about 5000 and about 1200° C. The product of the calcination step may be washed, filtered, and dried to make a suitable finished product. Optionally, the intermediate product may be milled in a horizontal or vertical pressure media mill to a desired surface area and then further spray dried or dried by other means to produce a powder that may be further washed and filtered.
[0014] An alternative method of making the rare earth metal compounds, particularly rare earth metal anhydrous oxycarbonate particles includes making a solution of rare earth metal acetate, subjecting the solution to a substantially total evaporation process using a spray dryer or other suitable equipment to make an intermediate product, and calcining the obtained intermediate product at a temperature between about 400° C. and about 700° C. The product of the calcination step may be washed, filtered, and dried to make a suitable finished product. Optionally, the intermediate product may be milled in a horizontal or vertical pressure media mill to a desired surface area, spray dried or dried by other means to produce a powder that may be washed, filtered, and dried.
[0015] Yet another method of making the rare earth metal compounds includes making rare earth metal oxycarbonate hydrate particles. The rare earth metal oxycarbonate hydrate particles can be made by successively making a solution of rare earth chloride, subjecting the solution to a slow, steady feed of a sodium carbonate solution at a temperature between about 30° and about 90° C. while mixing, then filtering and washing the precipitate to form a filter cake, then drying the filter cake at a temperature of about 100° to 120° C. to produce the desired rare earth oxycarbonate hydrate species. Optionally, the filter cake may be sequentially dried, slurried, and milled in a horizontal or vertical pressure media mill to a desired surface area, spray dried or dried by other means to produce a powder that may be washed, filtered, and dried.
[0016] Alternatively, the process for making rare earth metal oxycarbonate hydrate particles may be modified to produce anhydrous particles. This modification includes subjecting the dried filter cake to a thermal treatment at a specified temperature between about 400° C. to about 700° C. and for a specified time between 1 h and 48 h. Optionally, the product of the thermal treatment may be slurried and milled in a horizontal or vertical pressure media mill to a desired surface area, spray dried or dried by other means to produce a powder that may be washed, filtered, and dried.
[0017] In accordance with the present invention, compounds of the present invention may be used to treat patients with hyperphosphatemia. The compounds may be made into a form that may be delivered to a mammal and that may be used to remove phosphate from the gut or decrease phosphate absorption into the blood stream. For example, the compounds may be formulated to provide an orally ingestible form such as a liquid solution or suspension, a tablet, capsule, gelcap, or other suitable and known oral form. Accordingly, the present invention contemplates a method for treating hyperphosphatemia that comprises providing an effective amount of a compound of the present invention. Compounds made under different conditions will correspond to different oxycarbonates or oxychlorides, will have different surface areas, and will show differences in reaction rates with phosphate and different solubilization of lanthanum or another rare-earth metal into the gut. The present invention allows one to modify these properties according to the requirements of the treatment.
[0018] In another aspect of the present invention, compounds made according to this invention as a porous structure of sufficient mechanical strength may be placed in a device fluidically connected to a dialysis machine through which the blood flows, to directly remove phosphate by reaction of the rare-earth compound with phosphate in the bloodstream. The present invention therefore contemplates a device having an inlet and an outlet with one or more compounds of the present invention disposed between the inlet and the outlet. The present invention also contemplates a method of reducing the amount of phosphate in blood that comprises contacting the blood with one or more compounds of the present invention for a time sufficient to reduce the amount of phosphate in the blood.
[0019] In yet another aspect of the present invention, the compounds of the present invention may be used as a substrate for a filter having an inlet and outlet such that the compounds of the present invention are disposed between the inlet and the outlet. A fluid containing a metal, metal ion, phosphate or other ion may be passed from the inlet to contact the compounds of the present invention and through the outlet. Accordingly, in one aspect of the present invention a method of reducing the content of a metal in a fluid, for example water, comprises flowing the fluid through a filter that contains one or more compounds of the present invention to reduce the amount of metal present in the water.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a general flow sheet of a process according to the present invention that produces LaOCl (lanthanum oxychloride).
[0021] FIG. 2 is a flow sheet of a process according to the present invention that produces a coated titanium dioxide structure.
[0022] FIG. 3 is a flow sheet of a process according to the present invention that produces lanthanum oxycarbonate
[0023] FIG. 4 is a graph showing the percentage of phosphate removed from a solution as a function of time by LaO(CO 3 ) 2 .xH 2 O, (where x is from and including 2 to and including 4), made according to the process of the present invention, as compared to the percentage of phosphate removed by commercial grade La carbonate La 2 (CO 3 ) 3 .4H 2 O in the same conditions.
[0024] FIG. 5 is a graph showing the amount of phosphate removed from a solution as a function of time per g of a lanthanum compound used as a drug to treat hyperphosphatemia. The drug in one case is La 2 O(CO 3 ) 2 .xH 2 O (where x is from and including 2 to and including 4), made according to the process of the present invention. In the comparative case the drug is commercial grade La carbonate La 2 (CO 3 ) 3 .4H 2 O.
[0025] FIG. 6 is a graph showing the amount of phosphate removed from a solution as a function of time per g of a lanthanum compound used as a drug to treat hyperphosphatemia. The drug in one case is La 2 O 2 CO 3 made according to the process of the present invention. In the comparative case the drug is commercial grade La carbonate La 2 (CO 3 ) 3 .4H 2 O.
[0026] FIG. 7 is a graph showing the percentage of phosphate removed as a function of time by La 2 O 2 CO 3 made according to the process of the present invention, as compared to the percentage of phosphate removed by commercial grade La carbonate La 2 (CO 3 ) 3 .4H 2 O.
[0027] FIG. 8 is a graph showing a relationship between the specific surface area of the oxycarbonates made following the process of the present invention and the amount of phosphate bound or removed from solution 10 min after the addition of the oxycarbonate.
[0028] FIG. 9 is a graph showing a linear relationship between the specific surface area of the oxycarbonates of this invention and the first order rate constant calculated from the initial rate of reaction of phosphate.
[0029] FIG. 10 is a flow sheet of a process according to the present invention that produces lanthanum oxycarbonate hydrate La 2 (CO 3 ) 2 .xH 2 O
[0030] FIG. 11 is a flow sheet of a process according to the present invention that produces anhydrous lanthanum oxycarbonate La 2 O 2 CO 3 or La 2 CO 5 .
[0031] FIG. 12 is a scanning electron micrograph of lanthanum oxychloride, made following the process of the present invention.
[0032] FIG. 13 is an X-Ray diffraction scan of lanthanum oxychloride LaOCl made according to the process of the present invention and compared with a standard library card of lanthanum oxychloride.
[0033] FIG. 14 is a graph showing the percentage of phosphate removed from a solution as a function of time by LaOCl made according to the process of the present invention, as compared to the amount of phosphate removed by commercial grades of La carbonate La 2 (CO 3 ) 3 —H 2 O and La 2 (CO 3 ) 3 .4H 2 O in the same conditions.
[0034] FIG. 15 shows a scanning electron micrograph of La 2 O(CO 3 ) 2 Ox H 2 O, where x is from and including 2 to and including 4.
[0035] FIG. 16 is an X-Ray diffraction scan of La 2 O(CO 3 ) 2 .xH 2 O produced according to the present invention and includes a comparison with a “library standard” of La 2 O(CO 3 ) 2 .xH 2 O where x is from and including 2 to and including 4.
[0036] FIG. 17 is a graph showing the rate of removal of phosphorous from a solution by La 2 O(CO 3 )2.xH 2 O compared to the rate obtained with commercially available La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .H 2 O in the same conditions.
[0037] FIG. 18 is a scanning electron micrograph of anhydrous lanthanum oxycarbonate La 2 O 2 CO 3 .
[0038] FIG. 19 is an X-Ray diffraction scan of anhydrous La 2 O 2 CO 3 produced according to the present invention and includes a comparison with a “library standard” of La 2 O 2 CO 3 .
[0039] FIG. 20 is a graph showing the rate of phosphorous removal obtained with La 2 O 2 CO 3 made following the process of the present invention and compared to the rate obtained for commercially available La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .H 2 O.
[0040] FIG. 21 is a scanning electron micrograph of La 2 CO 5 made according to the process of the present invention.
[0041] FIG. 22 is an X-Ray diffraction scan of anhydrous La 2 CO 5 produced according to the present invention and includes a comparison with a “library standard” of La 2 CO 5 .
[0042] FIG. 23 is a graph showing the rate of phosphorous removal obtained with La 2 CO 5 made following the process of the present invention and compared to the rate obtained for commercially available La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 30.4 H 2 O.
[0043] FIG. 24 is a scanning electron micrograph of TiO 2 support material made according to the process of the present invention.
[0044] FIG. 25 is a scanning electron micrograph of a TiO 2 structure coated with LaOCl, made according to the process of the present invention, calcined at 800° C.
[0045] FIG. 26 is a scanning electron micrograph of a TiO 2 structure coated with LaOCl, made according to the process of the present invention, calcined at 600° C.
[0046] FIG. 27 is a scanning electron micrograph of a TiO 2 structure coated with LaOCl, made according to the process of the present invention, calcined at 900° C.
[0047] FIG. 28 . shows X-Ray scans for TiO 2 coated with LaOCl and calcined at different temperatures following the process of the present invention, and compared to the X-Ray scan for pure LaOCl.
[0048] FIG. 29 shows the concentration of lanthanum in blood plasma as a function of time, for dogs treated with lanthanum oxycarbonates made according to the process of the present invention.
[0049] FIG. 30 shows the concentration of phosphorous in urine as a function of time in rats treated with lanthanum oxycarbonates made according to the process of the present invention, and compared to phosphorus concentration measured in untreated rats.
[0050] FIG. 31 shows a device having an inlet, an outlet, and one or more compounds of the present invention disposed between the inlet and the outlet.
DESCRIPTION OF THE INVENTION
[0051] Referring now to the drawings, the process of the present invention will be described. While the description will generally refer to lanthanum compounds, the use of lanthanum is merely for ease of description and is not intended to limit the invention and claims solely to lanthanum compounds. In fact, it is contemplated that the process and the compounds described in the present specification is equally applicable to rare earth metals other than lanthanum such as Ce and Y.
[0052] Turning now to FIG. 1 , a process for making a rare earth oxychloride compound, and, in particular a lanthanum oxychloride compound according to one embodiment of the present invention is shown. First, a solution of lanthanum chloride is provided. The source of lanthanum chloride may be any suitable source and is not limited to any particular source. One source of lanthanum chloride solution is to dissolve commercial lanthanum chloride crystals in water or in an HCl solution. Another source is to dissolve lanthanum oxide in a hydrochloric acid solution.
[0053] The lanthanum chloride solution is evaporated to form an intermediate product. The evaporation 20 is conducted under conditions to achieve substantially total evaporation. Desirably, the evaporation is conducted at a temperature higher than the boiling point of the feed solution (lanthanum chloride) but lower than the temperature where significant crystal growth occurs. The resulting intermediate product may be an amorphous solid formed as a thin film or may have a spherical shape or a shape as part of a sphere.
[0054] The terms “substantially total evaporation” or “substantially complete evaporation” as used in the specification and claims refer to evaporation such that the resulting solid intermediate contains less than 15% free water, desirably less than 10% free water, and more desirably less than 1% free water. The term “free water” is understood and means water that is not chemically bound and can be removed by heating at a temperature below 150° C. After substantially total evaporation or substantially complete evaporation, the intermediate product will have no visible moisture present.
[0055] The evaporation step may be conducted in a spray dryer. In this case, the intermediate product will consist of a structure of spheres or parts of spheres. The spray dryer generally operates at a discharge temperature between about 120° C. and about 500° C.
[0056] The intermediate product may then be calcined in any suitable calcination apparatus 30 by raising the temperature to a temperature between about 500° C. to about 1200° C. for a period of time from about 2 to about 24 h and then cooling to room temperature. The cooled product may be washed 40 by immersing it in water or dilute acid, to remove any water-soluble phase that may still be present after the calcination step 30 .
[0057] The temperature and the length of time of the calcination process may be varied to adjust the particle size and the reactivity of the product. The particles resulting from calcination generally have a size between 1 and 1000 μm. The calcined particles consist of individual crystals, bound together in a structure with good physical strength and a porous structure. The individual crystals forming the particles generally have a size between 20 nm and 10 μm.
[0058] In accordance with another embodiment of the present invention as shown in FIG. 2 , a feed solution of titanium chloride or titanium oxychloride is provided by any suitable source. One source is to dissolve anhydrous titanium chloride in water or in a hydrochloric acid solution. Chemical control agents or additives 104 may be introduced to this feed solution to influence the crystal form and the particle size of the final product. One chemical additive is sodium phosphate Na 3 PO 4 . The feed solution of titanium chloride or titanium oxychloride is mixed with the optional chemical control agent 104 in a suitable mixing step 110 . The mixing may be conducted using any suitable known mixer.
[0059] The feed solution is evaporated to form an intermediate product, which in this instance is titanium dioxide (TiO 2 ). The evaporation 120 is conducted at a temperature higher than the boiling point of the feed solution but lower than the temperature where significant crystal growth occurs and to achieve substantially total evaporation. The resulting intermediate product may desirably be an amorphous solid formed as a thin film and may have a spherical shape or a shape as part of a sphere.
[0060] The intermediate product may then be calcined in any suitable calcination apparatus 130 by raising the temperature to a temperature between about 400° C. to about 1200° C. for a period of time from about 2 to about 24 h and then cooling to room temperature (25° C.). The cooled product is then washed 140 by immersing it in water or dilute acid, to remove traces of any water-soluble phase that may still be present after the calcination step.
[0061] The method of manufacture of the intermediate product according to the present invention can be adjusted and chosen to make a structure with the required particle size and porosity. For example, the evaporation step 120 and the calcination step 130 can be adjusted for this purpose. The particle size and porosity can be adjusted to make the structure of the intermediate product suitable to be used as an inert filter in the bloodstream.
[0062] The washed TiO 2 product is then suspended or slurried in a solution of an inorganic compound. A desirable inorganic compound is a rare-earth or lanthanum compound, and in particular lanthanum chloride. This suspension of TiO 2 in the inorganic compound solution is again subjected to total evaporation 160 under conditions in the same range as defined in step 120 and to achieve substantially total evaporation. In this regard, the evaporation steps 120 and 160 may be conducted in a spray drier. The inorganic compound will precipitate as a salt, an oxide, or an oxy-salt. If the inorganic compound is lanthanum chloride, the precipitated product will be lanthanum oxychloride. If the original compound is lanthanum acetate, the precipitated product will be lanthanum oxide.
[0063] The product of step 160 is further calcined 170 at a temperature between 500° and 1100° C. for a period of 2 to 24 h. The temperature and the time of the calcination process influence the properties and the particle size of the product. After the second calcination step 170 , the product may be washed 180 .
[0064] The resulting product can be described as crystals of lanthanum oxychloride or lanthanum oxide formed on a TiO 2 substrate. The resulting product may be in the form of hollow thin-film spheres or parts of spheres. The spheres will have a size of about 1 μm to 1000 μm and will consist of a structure of individual bound particles. The individual particles have a size between 20 nm and 10 μm.
[0065] When the final product consists of crystals of lanthanum oxychloride on a TiO 2 substrate, these crystals may be hydrated. It has been found that this product will effectively react with phosphate and bind it as an insoluble compound. It is believed that, if this final product is released in the human stomach and gastrointestinal tract, the product will bind the phosphate that is present and decrease the transfer of phosphate from the stomach and gastrointestinal tract to the blood stream. Therefore, the product of this invention may be used to limit the phosphorous content in the bloodstream of patients on kidney dialysis.
[0066] According to another embodiment of the present invention, a process for making anhydrous lanthanum oxycarbonate is shown in FIG. 3 . In this process, a solution of lanthanum acetate is made by any method. One method to make the lanthanum acetate solution is to dissolve commercial lanthanum acetate crystals in water or in an HCl solution.
[0067] The lanthanum acetate solution is evaporated to form an intermediate product. The evaporation 220 is conducted at a temperature higher than the boiling point of the lanthanum acetate solution but lower than the temperature where significant crystal growth occurs and under conditions to achieve substantially total evaporation. The resulting intermediate product may desirably be an amorphous solid formed as a thin film and may have a spherical shape or a shape as part of a sphere.
[0068] The intermediate product may then be calcined in any suitable calcination apparatus 230 by raising the temperature to a temperature between about 400° C. to about 800° C. for a period of time from about 2 to about 24 h and then cooled to room temperature. The cooled product may be washed 240 by immersing it in water or dilute acid, to remove any water-soluble phase that may still be present after the calcination step. The temperature and the length of time of the calcination process may be varied to adjust the particle size and the reactivity of the product.
[0069] The particles resulting from the calcination generally have a size between 1 and 1000 μm. The calcined particles consist of individual crystals, bound together in a structure with good physical strength and a porous structure. The individual crystals generally have a size between 20 nm and 10 μm.
[0070] The products made by methods shown in FIGS. 1, 2 , and 3 comprise ceramic particles with a porous structure. Individual particles are in the micron size range. The particles are composed of crystallites in the nano-size range, fused together to create a structure with good strength and porosity.
[0071] The particles made according to the process of the present invention, have the following common properties:
a. They have low solubility in aqueous solutions, especially serum and gastro-intestinal fluid, compared to non-ceramic compounds. b. Their hollow shape gives them a low bulk density compared to solid particles. Lower density particles are less likely to cause retention in the gastro-intestinal tract. c. They have good phosphate binding kinetics. The observed kinetics are generally better than the commercial carbonate hydrates La 2 (CO 3 ) 3 —H 2 O and La 2 (CO 3 ) 3 .4H 2 O. In the case of lanthanum oxychloride, the relationship between the amount of phosphate bound or absorbed and time tends to be closer to linear than for commercial hydrated lanthanum carbonates. The initial reaction rate is lower but does not significantly decrease with time over an extended period. This behavior is defined as linear or substantially linear binding kinetics. This is probably an indication of more selective phosphate binding in the presence of other anions. d. Properties a, b, and c, above are expected to lead to less gastro-intestinal tract complications than existing products. e. Because of their particular structure and low solubility, the products of the present invention have the potential to be used in a filtration device placed directly in the bloodstream.
[0077] Different lanthanum oxycarbonates have been prepared by different methods. It has been found that, depending on the method of preparation, lanthanum oxycarbonate compounds with widely different reaction rates are obtained.
[0078] A desirable lanthanum oxycarbonate is La 2 O(CO 3 ) 2 .xH 2 O, where 2≦x≦4. This lanthanum oxycarbonate is preferred because it exhibits a relatively high rate of removal of phosphate. To determine the reactivity of the lanthanum oxycarbonate compound with respect to phosphate, the following procedure was used. A stock solution containing 13.75 g/l of anhydrous Na 2 HPO 4 and 8.5 g/l of HCl is prepared. The stock solution is adjusted to pH 3 by the addition of concentrated HCl. 100 ml of the stock solution is placed in a beaker with a stirring bar. A sample of lanthanum oxycarbonate powder is added to the solution. The amount of lanthanum oxycarbonate powder is such that the amount of La in suspension is 3 times the stoichiometric amount needed to react completely with the phosphate. Samples of the suspension are taken at intervals, through a filter that separated all solids from the liquid. The liquid sample is analyzed for phosphorous. FIG. 4 shows that after 10 min, La 2 O(CO 3 ) 2 .xH 2 O has removed 86% of the phosphate in solution, whereas a commercial hydrated La carbonate La 2 (CO 3 ) 3 .H 2 O removes only 38% of the phosphate in the same experimental conditions after the same time.
[0079] FIG. 5 shows that the La 2 O(CO 3 ) 2 .xH 2 O depicted in FIG. 4 has a capacity of phosphate removal of 110 mg PO 4 removed/g of La compound after 10 min in the conditions described above, compared to 45 mg PO 4 /g for the commercial La carbonate taken as reference.
[0080] Another preferred lanthanum carbonate is the anhydrous La oxycarbonate La 2 O 2 CO 3 . This compound is preferred because of its particularly high binding capacity for phosphate, expressed as mg PO 4 removed/g of compound. FIG. 6 shows that La 2 O 2 CO 3 binds 120 mg PO 4 /g of La compound after 10 min, whereas La 2 (CO 3 ) 3 .4H 2 O used as reference only binds 45 mg PO 4 /g La compound.
[0081] FIG. 7 shows the rate of reaction with phosphate of the oxycarbonate La 2 O 2 CO 3 . After 10 min of reaction, 73% of the phosphate had been removed, compared to 38% for commercial lanthanum carbonate used as reference.
[0082] Samples of different oxycarbonates have been made by different methods as shown in Table 1 below.
TABLE 1 Initial Example number BET Fraction of 1st order corresponding to surface PO 4 rate constant manufacturing area remaining k 1 Sample Compound method m 2 /g after 10 min (min −1 ) 1 La 2 O(CO 3 ) 2 .xH 2 O 11 41.3 0.130 0.949 2 La 2 O(CO 3 ) 2 .xH2O 11 35.9 0.153 0.929 3 La 2 O(CO 3 ) 2 .xH 2 O 11 38.8 0.171 0.837 4 La 2 CO 5 (4 h milling) 7 25.6 0.275 0.545 5 La 2 O 2 CO 3 5 18 0.278 0.483 6 La 2 CO 5 (2 h milling) 7 18.8 0.308 0.391 7 La 2 O 2 CO 3 7 16.5 0.327 0.36 8 La 2 CO 5 (no milling) 5 11.9 0.483 0.434 9 La 2 (CO 3 ) 3 .4H 2 O commercial 4.3 0.623 0.196 sample 10 La 2 (CO 3 ) 3 .1H 2 O commercial 2.9 0.790 0.094 sample
[0083] For each sample, the surface area measured by the BET method and the fraction of phosphate remaining after 10 min of reaction have been tabulated. The table also shows the rate constant k 1 corresponding to the initial rate of reaction of phosphate, assuming the reaction is first order in phosphate concentration. The rate constant k 1 is defined by the following equation:
d[ PO 4 ]/dt=−k 1 [PO 4]
where [PO 4 ] is the phosphate concentration in solution (mol/liter), t is time (min) and k 1 is the first order rate constant (min −1 ). The table gives the rate constant for the initial reaction rate, i.e. the rate constant calculated from the experimental points for the first minute of the reaction.
[0084] FIG. 8 shows that there is a good correlation between the specific surface area and the amount of phosphate reacted after 10 min. It appears that in this series of tests, the most important factor influencing the rate of reaction is the surface area, independently of the composition of the oxycarbonate or the method of manufacture. A high surface area can be achieved by adjusting the manufacturing method or by milling a manufactured product.
[0085] FIG. 9 shows that a good correlation is obtained for the same compounds by plotting the first order rate constant as given in Table I and the BET specific surface area. The correlation can be represented by a straight line going through the origin. In other words, within experimental error, the initial rate of reaction appears to be proportional to the phosphate concentration and also to the available surface area.
[0086] Without being bound by any theory, it is proposed that the observed dependence on surface area and phosphate concentration may be explained by a nucleophilic attack of the phosphate ion on the La atom in the oxycarbonate, with resultant formation of lanthanum phosphate LaPO 4 . For example, if the oxycarbonate is La 2 O 2 CO 3 , the reaction will be:
½ La 2 O 2 CO 3 +PO 4 3− +2H 2 O→LaPO 4 +½ H 2 CO 3 +3OH −
If the rate is limited by the diffusion of the PO 4 3− ion to the surface of the oxycarbonate and the available area of oxycarbonate, the observed relationship expressed in FIG. 9 can be explained. This mechanism does not require La to be present as a dissolved species. The present reasoning also provides an explanation for the decrease of the reaction rate after the first minutes: the formation of lanthanum phosphate on the surface of the oxycarbonate decreases the area available for reaction.
[0087] In general, data obtained at increasing pH show a decrease of the reaction rate. This may be explained by the decrease in concentration of the hydronium ion (H 3 O+), which may catalyze the reaction by facilitating the formation of the carbonic acid molecule from the oxycarbonate.
[0088] Turning now to FIG. 10 , another process for making lanthanum oxycarbonate and in particular, lanthanum oxycarbonate tetra hydrate, is shown. First, an aqueous solution of lanthanum chloride is made by any method. One method to make the solution is to dissolve commercial lanthanum chloride crystals in water or in an HCl solution. Another method to make the lanthanum chloride solution is to dissolve lanthanum oxide in a hydrochloric acid solution.
[0089] The LaCl 3 solution is placed in a well-stirred tank reactor. The LaCl 3 solution is then heated to 80° C. A previously prepared analytical grade sodium carbonate is steadily added over a period of 2 hours with vigorous mixing. The mass of sodium carbonate required is calculated at 6 moles of sodium carbonate per 2 moles of LaCl 3 . When the required mass of sodium carbonate solution is added, the resultant slurry or suspension is allowed to cure for 2 hours at 80° C. The suspension is then filtered and washed with demineralized water to produce a clear filtrate. The filter cake is placed in a convection oven at 105° C. for 2 hours or until a stable weight is observed. The initial pH of the LaCl 3 solution is 2, while the final pH of the suspension after cure is 5.5. A white powder is produced. The resultant powder is a lanthanum oxycarbonate four hydrate (La 2 O(CO 3 ) 2 .xH 2 O). The number of water molecules in this compound is approximate and may vary between 2 and 4 (and including 2 and 4).
[0090] Turning now to FIG. 11 another process for making anhydrous lanthanum oxycarbonate is shown. First, an aqueous solution of lanthanum chloride is made by any method. One method to make the solution is to dissolve commercial lanthanum chloride crystals in water or in an HCl solution. Another method to make the lanthanum chloride solution is to dissolve lanthanum oxide in a hydrochloric acid solution.
[0091] The LaCl 3 solution is placed in a well-stirred tank reactor. The LaCl 3 solution is then heated to 80° C. A previously prepared analytical grade sodium carbonate is steadily added over 2 hours with vigorous mixing. The mass of sodium carbonate required is calculated at 6 moles of sodium carbonate per 2 moles of LaCl 3 . When the required mass of sodium carbonate solution is added the resultant slurry or suspension is allowed to cure for 2 hours at 80° C. The suspension is then washed and filtered removing NaCl (a byproduct of the reaction) to produce a clear filtrate. The filter cake is placed in a convection oven at 105° C. for 2 hours or until a stable weight is observed. The initial pH of the LaCl 3 solution is 2.2, while the final pH of the suspension after cure is 5.5. A white lanthanum oxycarbonate hydrate powder is produced. Next the lanthanum oxycarbonate hydrate is placed in an alumina tray, which is placed in a high temperature muffle furnace. The white powder is heated to 500° C. and held at that temperature for 3 hours. Anhydrous La 2 C 2 O 3 is formed.
[0092] Alternatively, the anhydrous lanthanum oxycarbonate formed as indicated in the previous paragraph may be heated at 500° C. for 15 to 24 h instead of 3 h or at 600° C. instead of 500° C. The resulting product has the same chemical formula, but shows a different pattern in an X-Ray diffraction scan and exhibits a higher physical strength and a lower surface area. The product corresponding to a higher temperature or a longer calcination time is defined here as La 2 CO 5 .
[0093] Turning now to FIG. 31 , a device 500 having an inlet 502 and an outlet 504 is shown. The device 500 may be in the form of a filter or other suitable container. Disposed between the inlet 502 and the outlet 504 is a substrate 506 in the form of a plurality of one or more compounds of the present invention. The device may be fluidically connected to a dialysis machine through which the blood flows, to directly remove phosphate by reaction of the rare-earth compound with phosphate in the bloodstream. In this connection, the present invention also contemplates a method of reducing the amount of phosphate in blood that comprises contacting the blood with one or more compounds of the present invention for a time sufficient to reduce the amount of phosphate in the blood.
[0094] In yet another aspect of the present invention, the device 500 may be provided in a fluid stream so that a fluid containing a metal, metal ion, phosphate or other ion may be passed from the inlet 502 through the substrate 506 to contact the compounds of the present invention and out the outlet 504 . Accordingly, in one aspect of the present invention a method of reducing the content of a metal in a fluid, for example water, comprises flowing the fluid through a device 500 that contains one or more compounds of the present invention to reduce the amount of metal present in the water.
[0095] The following examples are meant to illustrate but not limit the present invention.
EXAMPLE 1
[0096] An aqueous solution containing 100 g/l of La as lanthanum chloride is injected in a spray dryer with an outlet temperature of 250° C. The intermediate product corresponding to the spray-drying step is recovered in a bag filter. This intermediate product is calcined at 900° C. for 4 hours. FIG. 12 shows a scanning electron micrograph of the product, enlarged 25,000 times. The micrograph shows a porous structure formed of needle-like particles. The X-Ray diffraction pattern of the product ( FIG. 13 ) shows that it consists of lanthanum oxychloride LaOCl.
[0097] To determine the reactivity of the lanthanum compound with respect to phosphate, the following test was conducted. A stock solution containing 13.75 g/l of anhydrous Na 2 HPO 4 and 8.5 g/l of HCl was prepared. The stock solution was adjusted to pH 3 by the addition of concentrated HCl. An amount of 100 ml of the stock solution was placed in a beaker with a stirring bar. The lanthanum oxychloride from above was added to the solution to form a suspension. The amount of lanthanum oxychloride was such that the amount of La in suspension was 3 times the stoichiometric amount needed to react completely with the phosphate. Samples of the suspension were taken at time intervals, through a filter that separated all solids from the liquid. The liquid sample was analyzed for phosphorous. FIG. 14 shows the rate of phosphate removed from solution.
EXAMPLE 2
Comparative Example
[0098] To determine the reactivity of a commercial lanthanum with respect to phosphate, the relevant portion of Example 1 was repeated under the same conditions, except that commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O was used instead of the lanthanum oxychloride of the present invention. Additional curves on FIG. 14 show the rate of removal of phosphate corresponding to commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ).4H 2 O. FIG. 14 shows that the rate of removal of phosphate with the commercial lanthanum carbonate is faster at the beginning but slower after about 3 minutes.
EXAMPLE 3
[0099] An aqueous HCl solution having a volume of 334.75 ml and containing LaCl 3 (lanthanum chloride) at a concentration of 29.2 wt % as La 2 O 3 was added to a four liter beaker and heated to 80° C. with stirring. The initial pH of the LaCl 3 solution was 2.2. Two hundred and sixty five ml of an aqueous solution containing 63.59 g of sodium carbonate (Na 2 CO 3 ) was metered into the heated beaker using a small pump at a steady flow rate for 2 hours. Using a Buchner filtering apparatus fitted with filter paper, the filtrate was separated from the white powder product. The filter cake was mixed four times with 2 liters of distilled water and filtered to wash away the NaCl formed during the reaction. The washed filter cake was placed into a convection oven set at 105° C. for 2 hours, or until a stable weight was observed. FIG. 15 shows a scanning electron micrograph of the product, enlarged 120,000 times. The micrograph shows the needle-like structure of the compound. The X-Ray diffraction pattern of the product ( FIG. 16 ) shows that it consists of hydrated lanthanum oxycarbonate hydrate (La 2 O(CO 3 ) 2 .xH 2 O), with 2≦x≦4.
[0100] To determine the reactivity of the lanthanum compound with respect to phosphate, the following test was conducted. A stock solution containing 13.75 g/l of anhydrous Na 2 HPO 4 and 8.5 g/l of HCl was prepared. The stock solution was adjusted to pH 3 by the addition of concentrated HCl. An amount of 100 ml of the stock solution was placed in a beaker with a stirring bar. Lanthanum oxycarbonate hydrate powder made as described above was added to the solution. The amount of lanthanum oxycarbonate hydrate powder was such that the amount of La in suspension was 3 times the stoichiometric amount needed to react completely with the phosphate. Samples of the suspension were taken at time intervals through a filter that separated all solids from the liquid. The liquid sample was analyzed for phosphorous. FIG. 17 shows the rate of phosphate removed from solution.
EXAMPLE 4
Comparative Example
[0101] To determine the reactivity of a commercial lanthanum with respect to phosphate, the second part of Example 3 was repeated under the same conditions, except that commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O was used instead of the lanthanum oxychloride of the present invention. FIG. 17 shows the rate of phosphate removed using the commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O. FIG. 17 shows that the rate of removal of phosphate with the lanthanum oxycarbonate is faster than with the commercial lanthanum carbonate hydrate (La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O).
EXAMPLE 5
[0102] An aqueous HCl solution having a volume of 334.75 ml and containing LaCl 3 (lanthanum chloride) at a concentration of 29.2 wt % as La 2 O 3 was added to a 4 liter beaker and heated to 80° C. with stirring. The initial pH of the LaCl 3 solution was 2.2. Two hundred and sixty five ml of an aqueous solution containing 63.59 g of sodium carbonate (Na 2 CO 3 ) was metered into the heated beaker using a small pump at a steady flow rate for 2 hours. Using a Buchner filtering apparatus fitted with filter paper the filtrate was separated from the white powder product. The filter cake was mixed four times with 2 liters of distilled water and filtered to wash away the NaCl formed during the reaction. The washed filter cake was placed into a convection oven set at 105° C. for 2 hours until a stable weight was observed. Finally, the lanthanum oxycarbonate was placed in an alumina tray in a muffle furnace. The furnace temperature was ramped to 500° C. and held at that temperature for 3 hours. The resultant product was determined to be anhydrous lanthanum oxycarbonate La 2 O 2 CO 3 .
[0103] The process was repeated three times. In one case, the surface area of the white powder was determined to be 26.95 m 2 /gm. In the other two instances, the surface area and reaction rate is shown in Table 1. FIG. 18 is a scanning electron micrograph of the structure, enlarged 60,000 times. The micrograph shows that the structure in this compound is made of equidimensional or approximately round particles of about 100 nm in size. FIG. 19 is an X-ray diffraction pattern showing that the product made here is an anhydrous lanthanum oxycarbonate written as La 2 O 2 CO 3 .
[0104] To determine the reactivity of this lanthanum compound with respect to phosphate, the following test was conducted. A stock solution containing 13.75 g/l of anhydrous Na 2 HPO 4 and 8.5 g/l of HCl was prepared. The stock solution was adjusted to pH 3 by the addition of concentrated HCl. An amount of 100 ml of the stock solution was placed in a beaker with a stirring bar. Anhydrous lanthanum oxycarbonate made as described above, was added to the solution. The amount of anhydrous lanthanum oxycarbonate was such that the amount of La in suspension was 3 times the stoichiometric amount needed to react completely with the phosphate. Samples of the suspension were taken at intervals, through a filter that separated all solids from the liquid. The liquid sample was analyzed for phosphorous. FIG. 20 shows the rate of phosphate removed.
EXAMPLE 6
Comparative Example
[0105] To determine the reactivity of a commercial lanthanum with respect to phosphate, the second part of Example 5 was repeated under the same conditions, except that commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O was used instead of the La 2 O 2 CO 3 of the present invention. FIG. 20 shows the rate of removal of phosphate using the commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O. FIG. 20 shows that the rate of removal of phosphate with the anhydrous lanthanum oxycarbonate produced according to the process of the present invention is faster than the rate observed with commercial lanthanum carbonate hydrate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O.
EXAMPLE 7
[0106] A solution containing 100 g/l of La as lanthanum acetate is injected in a spray-drier with an outlet temperature of 250° C. The intermediate product corresponding to the spray-drying step is recovered in a bag filter. This intermediate product is calcined at 600° C. for 4 hours. FIG. 21 shows a scanning electron micrograph of the product, enlarged 80,000 times. FIG. 22 shows the X-Ray diffraction pattern of the product and it shows that it consists of anhydrous lanthanum oxycarbonate. The X-Ray pattern is different from the pattern corresponding to Example 5, even though the chemical composition of the compound is the same. The formula for this compound is written as (La 2 CO 5 ). Comparing FIGS. 21 and 18 shows that the compound of the present example shows a structure of leaves and needles as opposed to the round particles formed in Example 5. The particles may be used in a device to directly remove phosphate from an aqueous or non-aqueous medium, e.g., the gut or the bloodstream.
[0107] To determine the reactivity of the lanthanum compound with respect to phosphate, the following test was conducted. A stock solution containing 13.75 g/l of anhydrous Na 2 HPO 4 and 8.5 g/l of HCl was prepared. The stock solution was adjusted to pH 3 by the addition of concentrated HCl. An amount of 100 ml of the stock solution was placed in a beaker with a stirring bar. La 2 CO 5 powder, made as described above, was added to the solution. The amount of lanthanum oxycarbonate was such that the amount of La in suspension was 3 times the stoichiometric amount needed to react completely with the phosphate. Samples of the suspension were taken at intervals through a filter that separated all solids from the liquid. The liquid sample was analyzed for phosphorous. FIG. 23 shows the rate of phosphate removed from solution.
EXAMPLE 8
Comparative Example
[0108] To determine the reactivity of a commercial lanthanum with respect to phosphate commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O was used instead of the lanthanum oxycarbonate made according to the present invention as described above. FIG. 23 shows the rate of phosphate removal for the commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O. FIG. 23 also shows that the rate of phosphate removal with the lanthanum oxycarbonate is faster than the rate of phosphate removal with commercial lanthanum carbonate hydrate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O.
EXAMPLE 9
[0109] To a solution of titanium chloride or oxychloride containing 120 g/l Ti and 450 g/l Cl is added the equivalent of 2.2 g/l of sodium phosphate Na 3 PO 4 . The solution is injected in a spray dryer with an outlet temperature of 250° C. The spray dryer product is calcined at 1050° C. for 4 h. The product is subjected to two washing steps in 2 molar HCl and to two washing steps in water. FIG. 24 is a scanning electron micrograph of the TiO 2 material obtained. It shows a porous structure with individual particles of about 250 nm connected in a structure. This structure shows good mechanical strength. This material can be used as an inert filtering material in a fluid stream such as blood.
EXAMPLE 10
[0110] The product of Example 9 is re-slurried into a solution of lanthanum chloride containing 100 g/l La. The slurry contains approximately 30% TiO 2 by weight. The slurry is spray dried in a spray dryer with an outlet temperature of 250° C. The product of the spray drier is further calcined at 800° C. for 5 h. It consists of a porous TiO 2 structure with a coating of nano-sized lanthanum oxychloride. FIG. 25 is a scanning electron micrograph of this coated product. The electron micrograph shows that the TiO 2 particles are several microns in size. The LaOCl is present as a crystallized deposit with elongated crystals, often about 1 μm long and 0.1 μm across, firmly attached to the TiO 2 catalyst support surface as a film of nano-size thickness. The LaOCl growth is controlled by the TiO 2 catalyst support structure. Orientation of rutile crystals works as a template for LaOCl crystal growth. The particle size of the deposit can be varied from the nanometer to the micron range by varying the temperature of the second calcination step.
[0111] FIG. 26 is a scanning electron micrograph corresponding to calcination at 600° C. instead of 800° C. It shows LaOCl particles that are smaller and less well attached to the TiO 2 substrate. FIG. 27 is a scanning electron micrograph corresponding to calcination at 900° C. instead of 800° C. The product is similar to the product made at 800° C., but the LaOCl deposit is present as somewhat larger crystals and more compact layer coating the TiO2 support crystals. FIG. 28 shows the X-Ray diffraction patterns corresponding to calcinations at 600°, 800° and 900° C. The figure also shows the pattern corresponding to pure LaOCl. The peaks that do not appear in the pure LaOCl pattern correspond to rutile TiO 2 . As the temperature increases, the peaks tend to become higher and narrower, showing that the crystal size of the LaOCl as well as TiO 2 increases with the temperature.
EXAMPLE 11
[0112] An aqueous HCl solution having a volume of 334.75 ml and containing LaCl 3 (lanthanum chloride) at a concentration of 29.2 wt % as La 2 O 3 was added to a 4 liter beaker and heated to 80° C. with stirring. The initial pH of the LaCl 3 solution was 2.2. Two hundred and sixty five ml of an aqueous solution containing 63.59 g of sodium carbonate (Na 2 CO 3 ) was metered into the heated beaker using a small pump at a steady flow rate for 2 hours. Using a Buchner filtering apparatus fitted with filter paper the filtrate was separated from the white powder product. The filter cake was mixed four times, each with 2 liters of distilled water and filtered to wash away the NaCl formed during the reaction. The washed filter cake was placed into a convection oven set at 105° C. for 2 hours or until a stable weight was observed. The X-Ray diffraction pattern of the product shows that it consists of hydrated lanthanum oxycarbonate La 2 O(CO 3 ) 2 .xH 2 O, where 2≦x≦4. The surface area of the product was determined by the BET method. The test was repeated 3 times and slightly different surface areas and different reaction rates were obtained as shown in Table 1.
EXAMPLE 12
[0113] Six adult beagle dogs were dosed orally with capsules of lanthanum oxycarbonate La 2 O(CO 3 ) 2 .xH 2 O (compound A) or La 2 O 2 CO 3 (compound B) in a cross-over design using a dose of 2250 mg elemental lanthanum twice daily (6 hours apart). The doses were administered 30 minutes after provision of food to the animals. At least 14 days washout was allowed between the crossover arms. Plasma was obtained pre-dose and 1.5, 3, 6, 7.5, 9, 12, 24, 36, 48, 60, and 72 hours after dosing and analyzed for lanthanum using ICP-MS. Urine was collected by catheterization before and approximately 24 hours after dosing and creatinine and phosphorus concentrations measured.
[0114] The tests led to reduction of urine phosphate excretion, a marker of phosphorous binding. Values of phosphate excretion in urine are shown in Table 2 below.
TABLE 2 Median phosphorus/ creatinine ratio (% La Oxycarbonate reduction compared 10 th and 90 th compound to pre-dose value) percentiles A 48.4% 22.6-84.4% B 37.0% −4.1-63.1%
[0115] Plasma lanthanum exposure: Overall plasma lanthanum exposure in the dogs is summarized in Table 3 below. The plasma concentration curves are shown in FIG. 29 .
TABLE 3 Mean (sd) Area Under the Curve 0-72 h Maximum concentration La oxycarbonate (ng · h/mL); C max (ng/mL); (standard compound tested (standard deviation) deviation) A 54.6 (28.0) 2.77 (2.1) B 42.7 (34.8) 2.45 (2.2)
EXAMPLE 13
First In Vivo Study in Rats
[0116] Groups of six adult Sprague-Dawley rats underwent ⅚th nephrectomy in two stages over a period of 2 weeks and were then allowed to recover for a further two weeks prior to being randomized for treatment. The groups received vehicle (0.5% w/v carboxymethyl cellulose), or lanthanum oxycarbonate A or B suspended in vehicle, once daily for 14 days by oral lavage (10 ml/kg/day). The dose delivered 314 mg elemental lanthanum/kg/day. Dosing was carried out immediately before the dark (feeding) cycle on each day. Urine samples (24 hours) were collected prior to surgery, prior to the commencement of treatment, and twice weekly during the treatment period. Volume and phosphorus concentration were measured.
[0117] Feeding—During the acclimatization and surgery period, the animals were given Teklad phosphate sufficient diet (0.5% Ca, 0.3% P; Teklad No. TD85343), ad libitum. At the beginning of the treatment period, animals were pair fed based upon the average food consumption of the vehicle-treated animals the previous week.
[0118] ⅚ Nephrectomy—After one week of acclimatization, all animals were subjected to ⅚ nephrectomy surgery. The surgery was performed in two stages. First, the two lower branches of the left renal artery were ligated. One week later, a right nephrectomy was performed. Prior to each surgery, animals were anesthetized with an intra-peritoneal injection of ketamine/xylazine mixture (Ketaject a 100 mg/ml and Xylaject at 20 mg/ml) administered at 10 ml/kg. After each surgery, 0.25 mg/kg Buprenorphine was administered for relief of post-surgical pain. After surgery, animals were allowed to stabilize for 2 weeks to beginning treatment.
[0119] The results showing urine phosphorus excretion are given in FIG. 30 . The results show a decrease in phosphorus excretion, a marker of dietary phosphorus binding, after administration of the lanthanum oxycarbonate (at time >0), compared to untreated rats.
EXAMPLE 14
Second In Vivo Study in Rats
[0120] Six young adult male Sprague-Dawley rats were randomly assigned to each group. Test items were lanthanum oxycarbonates La 2 O 2 CO 3 and La 2 CO 5 (compound B and compound C), each tested at 0.3 and 0.6% of diet. There was an additional negative control group receiving Sigmacell cellulose in place of the test item.
[0121] The test items were mixed thoroughly into Teklad 7012CM diet. All groups received equivalent amounts of dietary nutrients.
[0122] Table 4 outlines the dietary composition of each group:
TABLE 4 Sigmacell Group ID Treatment Test Item cellulose Teklad Diet I Negative 0.0% 1.2% 98.8% control II Compound B - 0.3% 0.9% 98.8% Mid level III Compound B - 0.6% 0.6% 98.8% High level IV Compound C - 0.3% 0.9% 98.8% Mid level V Compound C - 0.6% 0.6% 98.8% High level
[0123] Rats were maintained in the animal facility for at least five days prior to use, housed individually in stainless steel hanging cages. On the first day of testing, they were placed individually in metabolic cages along with their test diet. Every 24 hours, their output of urine and feces was measured and collected and their general health visually assessed. The study continued for 4 days. Food consumption for each day of the study was recorded. Starting and ending animal weights were recorded.
[0124] Plasma samples were collected via retro-orbital bleeding from the control (I) and high-dose oxycarbonate groups, III and V. The rats were then euthanized with CO 2 in accordance with the IACUC study protocol.
[0125] Urine samples were assayed for phosphorus, calcium, and creatinine concentration in a Hitachi 912 analyzer using Roche reagents. Urinary excretion of phosphorus per day was calculated for each rat from daily urine volume and phosphorus concentration. No significant changes were seen in animal weight, urine volume or creatinine excretion between groups. Food consumption was good for all groups.
[0126] Even though lanthanum dosage was relatively low compared to the amount of phosphate in the diet, phosphate excretion for 0.3 or 0.6% La added to the diet decreased as shown in Table 5 below. Table 5 shows average levels of urinary phosphate over days 2 , 3 , and 4 of the test. Urine phosphorus excretion is a marker of dietary phosphorous binding.
TABLE 5 Urinary phosphate excretion (mg/day) Control 4.3 Compound B = La 2 O 2 CO 3 2.3 Compound C = La 2 CO 5 1.9
EXAMPLE 15
[0127] Tests were run to determine the binding efficiency of eight different compounds for twenty-four different elements. The compounds tested are given in Table 6.
TABLE 6 Test ID Compound Preparation Technique 1 La 2 O 3 Calcined the commercial (Prochem) La 2 (CO 3 ) 3 .H 2 O at 850° C. for 16 hrs. 2 La 2 CO 5 Prepared by spray drying lanthanum acetate solution and calcining at 600° C. for 7 hrs (method correspond- ing to FIG. 3 ) 3 LaOCl Prepared by spray drying lanthanum chloride solution and calcining at 700° C. for 10 hrs (method corre- sponding to FIG. 1 ) 4 La 2 (CO 3 ) 3 .4H 2 O Purchased from Prochem (comparative example) 5 Ti carbonate Made by the method of FIG. 11 , where the LaCl 3 solution is replaced by a TiOCl 2 solution. 6 TiO 2 Made by the method corresponding to FIG. 2 , with addition of sodium chloride. 7 La 2 O(CO 3 ) 2 .xH 2 O Precipitation by adding sodium carbonate solution to lanthanum chloride solution at 80° C. (Method corresponding of FIG. 10 ) 8 La 2 O 2 CO 3 Precipitation by adding sodium carbonate solution to lanthanum chloride solution at 80° C. followed by calcination at 500° C. for 3 hrs. (Method of FIG. 11 )
[0128] The main objective of the tests was to investigate the efficiency at which the compounds bind arsenic and selenium, in view of their use in removing those elements from drinking water. Twenty-one different anions were also included to explore further possibilities. The tests were performed as follows:
[0129] The compounds given in Table 6 were added to water and a spike and were vigorously shaken at room temperature for 18 hrs. The samples were filtered and the filtrate analyzed for a suite of elements including Sb, As, Be, Cd, Ca, Cr, Co, Cu, Fe, Pb, Mg, Mn, Mo, Ni, Se, TI, Ti, V, Zn, Al, Ba, B, Ag, and P.
[0130] The spike solution was made as follows:
1. In a 500 ml volumetric cylinder add 400 ml of de-ionized water. 2. Add standard solutions of the elements given above to make solutions containing approximately 1 mg/l of each element. 3. Dilute to 500 mls with de-ionized water.
[0134] The tests were conducted as follows:
1. Weigh 0.50 g of each compound into its own 50 ml centrifuge tube. 2. Add 30.0 ml of the spike solution to each. 3. Cap tightly and shake vigorously for 18 hrs. 4. Filter solution from each centrifuge tube through 0.2 μm syringe filter. Obtain ˜6 ml of filtrate. 5. Dilute filtrates 5:10 with 2% HNO 3 . Final Matrix is 1% HNO 3 . 6. Submit for analysis.
[0141] The results of the tests are given in Table 7.
TABLE 7 % of the Analyte Removed Sb As Be Cd Ca Cr Co Cu Fe Pb Mg Mn La 2 O 3 89 85 97 95 21 100 69 89 92 92 0 94 La 2 CO 5 96 93 100 83 0 100 52 97 100 99 0 99 LaOCl 86 76 89 46 0 100 28 88 100 99 0 28 La 2 (CO 3 ) 3 .4H 2 O 84 25 41 37 28 94 20 0 56 90 0 20 Ti(CO 3 ) 2 96 93 100 100 99 99 99 98 100 98 79 100 TiO 2 96 93 8 4 0 6 0 11 49 97 0 1 La 2 O(CO 3 ) 2 .xH 2 O 87 29 53 37 28 100 20 10 58 98 0 25 La 2 O 2 CO 3 97 92 100 85 21 100 59 98 100 99 0 99 % of the Analyte Removed Mo Ni Se Tl Ti V Zn Al Ba B Ag P La 2 O 3 89 28 72 8 90 95 95 85 23 0 47 96 La 2 CO 5 98 17 79 8 100 99 100 93 0 0 73 99 LaOCl 94 0 71 13 100 99 24 92 7 0 96 96 La 2 (CO 3 ) 3 .4H 2 O 98 1 78 5 100 99 16 11 23 0 48 71 Ti(CO 3 ) 2 91 98 97 96 24 100 100 92 100 0 99 98 TiO 2 97 0 97 62 0 86 0 0 0 30 99 66 La 2 O(CO 3 ) 2 .xH 2 O 99 0 79 8 100 99 16 60 26 0 44 74 La 2 O 2 CO 3 99 34 81 12 100 99 100 92 23 0 87 99
[0142] The most efficient compounds for removing both arsenic and selenium appear to be the titanium-based compounds 5 and 6. The lanthanum oxycarbonates made according to the process of the present invention remove at least 90% of the arsenic. Their efficiency at removing Se is in the range 70 to 80%. Commercial lanthanum carbonate (4 in Table 6) is less effective.
[0143] The tests show that the lanthanum and titanium compounds made following the process of the present invention are also effective at removing Sb, Cr, Pb, Mo from solution. They also confirm the efficient removal of phosphorus discussed in the previous examples.
[0144] While the invention has been described in conjunction with specific embodiments, it is to be understood that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and scope of the appended claims. | Rare earth metal compounds, particularly lanthanum, cerium, and yttrium, are formed as porous particles and are effective in binding metals, metal ions, and phosphate. A method of making the particles and a method of using the particles is disclosed. The particles may be used in the gastrointestinal tract or the bloodstream to remove phosphate or to treat hyperphosphatemia in mammals. The particles may also be used to remove metals from fluids such as water. | 1 |
This is a division of application Ser. No. 08/736,166, filed Oct. 28, 1996, pending.
This application is based on application no. 19539861.0 filed in Germany on Oct. 26, 1995, the content of which is incorporated hereinto by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the use of 4-amino-4-(4-fluoro-benzylamino)-1-ethoxycarbonylaminobenzene of the formula I (designated "compound I") ##STR2## or its pharmaceutically utilizable salts for the production of medicaments for the prophylaxis and treatment of the sequelae of acute and chronic reduced cerebral blood supply and neurodegenerative disorders.
2. Background Information
Compound I is under development as an anticonvulsive agent. It has a broad spectrum of action against various experimentally produced convulsions and in genetic animal models. The activity in animals is higher than that of many anticonvulsive agents introduced. Muscle-relaxant, antipyretic and analgesic actions have furthermore been described (DE 42 00 259).
A problem with many anticonvulsive agents introduced, especially the GABA-increasing substances such as phenobarbital, diazepam and clonazepam but also phenytoin, a blocker of the sodium channel, is the adverse effect on mental powers. By increasing the inhibition in the brain, in addition to the anticonvulsive action a central sedation also occurs, both of which reduce the power of absorption of the patients.
These anticonvulsive agents moreover have neuroprotective activity neither in animal experiments nor in patients. The consequences of a reduced cerebral blood supply, as occurs, for example, in stroke, are not diminished.
In epileptic attacks, an undersupply of the affected areas of the brain also occurs which, however, is attributed not to a reduced blood supply, but to the strong cell activation, as a result of which the reserves are stressed and the supply is no longer adequate.
An anticonvulsive agent which displays a neuroprotective action in the stressed brain is therefore desirable.
A neuroprotective action is also necessary for the therapy of other neurodegenerative disorders. To be counted among these are, for example, Alzheimer's disease, Huntington's chorea, multiple sclerosis, AIDS-induced encephalopathy and other infection-related encephalopathies such as rubella viruses, herpes viruses, borrelia and unknown pathogens, Creutzfeld-Jakob disease, amyotrophic lateral sclerosis (ALS), Parkinson's disease, trauma-induced neuro-degenerations and neuronal hyperexcitation states, such as in medicament withdrawal, or by intoxication, and neurodegenerative disorders of the peripheral nervous system such as polyneuropathies and polyneuritides.
Several strategies are at present followed for the treatment of reduced cerebral blood supply and of stroke. Prophylactically, medicaments can be used which inhibit thrombus formation and increase the flow properties of the blood, such as acetylsalicylic acid. Such a treatment, however, only has a purely prophylactic action; therapy is thus not possible.
If there is a chronic reduced cerebral blood supply, medicaments are used which have vasodilatory activity, such as calcium antagonists.
For the therapy of stroke as acute reduced blood supply, preparations can also be employed which have thrombolytical activity in order to eliminate a possible vascular occlusion. However, these can only be employed if in detailed investigations it has been clearly elucidated that the stroke is not caused by cerebral haemorrhage. In clinical testing for the therapy of stroke, preparations having NMDA-antagonistic action are found which directly inhibit the overactivation of the undersupplied cells. These substances, however, have a high side effect potential. According to the present point of view, they can therefore only be employed with intensive medical care after clear diagnosis. Moreover, NMDA antagonists, due to the inhibition of the plasticity of the brain, have a negative effect on learning power. Prophylactic use of these preparations therefore appears to be excluded from the present point of view, despite the good prophylactic action in animal experiments.
SUMMARY OF THE INVENTION
It is the object of the present invention to make available a medicament having good neuroprotective properties and a low side effect potential for the prophylaxis and treatment of stroke, of reduced cerebral blood supply and of other nerve cell-stressing conditions.
Surprisingly, it has now been found that the compound I has important neuroprotective actions in animal experiments.
Thus, completely new possibilities are opened up for the prophylaxis and treatment of the sequelae of acute and chronic reduced cerebral blood supply, in particular of stroke, and for neurodegenerative disorders.
DETAILED DESCRIPTION OF THE INVENTION
Pharmacological Investigations
The aim of the investigation with compound I in models of learning power and neuroprotection was to estimate the possible effects of these parameters, since compound I, inter alia, displays a GABA-ergic action. Since the epilepsy patient as a result of the repeated attacks often already suffers from a learning power deficit, these experiments were carried out on animals which had been exposed to an amnesic factor and whose learning power was thus reduced. To do this, the animals were either repeatedly treated with electroshock or exposed to alcohol withdrawal; to estimate the direct neuroprotective action, a chronic reduced blood supply to the brain was produced by tying off afferent blood vessels. All this damage leads to a reduction in the learning power, which is to be assessed as an indicator of nerve cell damage. GABA-increasing antiepileptically active medicaments such as diazepam and sodium channel blockers such as phenytoin do not have any positive effects in these models and in higher doses adverse effects on the learning power can even occur.
Investigation Models
Learning power damage due to reduction of the blood supply to the brain
In this model, one of the carotid arteries of rats is tied off under anaesthesia.
The animals wake from the anaesthesia and then have a decreased learning power. This was determined by means of the rod jumping test. In this test, the animals must learn to escape a slight electric shock to the foot, which is announced to them beforehand by an acoustic signal, by jumping onto a vertical rod suspended above the floor.
The learning power of the animals is measured in percent as the number of reactions caused (jumping onto the rod during the acoustic signal phase).
Untreated and sham-operated animals (anaesthetized and vessels exposed, but no ligature performed) learn the combination of acoustic signal and the following unpleasant shock to the foot very rapidly. After 4 test days with 10 exposures daily, the animals react almost with each sound signal with a jump onto the vertical rod.
As a result of the ligature of the left carotid, this learning power is reduced to approximately half. Animals pretreated with 2 mg/kg i.p. of compound I an hour before each test phase unexpectedly learnt just as well, despite existing injury due to the ligature, with a tendency to be even better than non-operated animals. However, if the animals were pretreated with diazepam (0.3 mg/kg i.p., 1 hour before each training phase), then the learning power remained just as poor as in the untreated injured animals.
The same applies to treatment with the anticonvulsive agent phenytoin (3 and 10 mg/kg); it was not possible to improve the learning power.
An improvement in the learning power despite the existing reduced blood supply is to be regarded as an indicator of a cytoprotective action, as only fully functional nerve cells are capable of learning.
It is therefore to be expected that compound I manifests a cytoprotective action, for example in the peripheral region of an infarct, where a reduced blood supply is also present or on stressed cells which are subject to a relative energy deficiency. As a result, the infarct volume and thus the damage should remain lower and survival should be made possible for severely stressed cells.
TABLE 1______________________________________Number of reactions indicated in % in the rod junp testafter injury as a result of logature of the leftcarotid.Left carotidligature 1st day 2nd day 3rd day 4th day______________________________________Compound I 20 ± 2.6 59 ± 7.7 * 64 ± 9.1* 70 ± 6.5**2 mg/kgControl 16 ± 2.2 30 ± 3.7++ 36 ± 3.1++ 39 ± 3.8++ligatureControl sham 18 ± 2.0 55 ± 6.9 59 ± 5.9 62 ± 5.9ligatureDiazepam 9 ± 1.8 37 ± 4.2 * 38 ± 5.1 44 ± 5.00.3 mg/kgControl 13 ± 3.0 + 30 ± 2.1 ++ 37 ± 2.6 ++ 38 ± 3.6 ++ligaturecontrol sham 21 ± 2.3 52 ± 5.1 64 ± 4.8 71 ± 3.8ligaturePhenytoin 13 ± 2.1 38 ± 4.2 45 ± 5.6 48 ± 4.410 mg/kgPhenytoin 14 ± 1.6 38 ± 3.6 39 ± 4.1 42 ± 4.73 mg/kgControl 13 ± 3.0 + 30 ± 2.1 ++ 37 ± 2.6 ++ 38 ± 3.6 ++ligatureControl sham 21 ± 2.3 52 ± 5.1 64 ± 4.8 71 ± 3.8ligature______________________________________
Significant differences between the sham-operated control group and the control group with a ligature (t test) are marked by + p<0.05 and ++ p<0.01.
Significant differences between the control group with a ligature and the treated group are marked by * p<0.05 and ** p<0.01.
Compound I not only exhibited an excellent action in this model, it was also possible to reduce the decrease in learning power produced by repeated application of electroshock by pretreatment with 2 mg/kg of the compound I an hour before the test.
While on the 4th test day injured test animals only showed 32±2.9% of reactions caused, the treated animals were able to carry out 45±4.5% of reactions caused correctly. This action was also detectable after a pretreatment time of 2 hours. The number of reactions caused rose here from 35±3.7% in the control group to 52±3.9% in the treated group.
It was also possible to positively affect the decrease in learning power due to alcohol withdrawal.
Compound I can thus be employed as a highly specific active compound for the treatment of the sequelae of acute and chronic reduced cerebral blood supply, in particular of stroke, and in all conditions during and after stressing of nerve cells.
On account of the low side effects of the substance in animal experiments, compound I can also be employed for the prophylaxis of the abovementioned disorders and conditions.
Compound I is structurally related to flupirtin, a clinically introduced central analgesic agent. While in the case of flupirtin an NMDA-antagonistic action was found (WO 95/05175), it was possible to exclude such an action for compound I through in vitro experiments. Neither an affinity for the various binding sites of the NMDA receptor nor a direct effect on the flow induced by NMDA was found.
In more involved investigations on the central analgesic action of the compound I in the hot plate test, in contrast to flupirtin it was possible to exclude a central analgesic action, as has been detected in the hot plate test on mice for flupirtin with an average effective dose of 30 mg/kg.
NMDA antagonists can cause severe psychotic disorders, such as ataxia with stereotypic symptoms.
Compound I and processes for its preparation are known (DE 42 00 259).
The compound can be converted in a known manner into the customary formulations such as tablets, capsules, coated tablets, pills, granules, syrups, emulsions, suspensions and solutions, using inert, non-toxic, pharmaceutically suitable excipients and/or auxiliaries.
The daily dose of the compound I in the case of oral or parenteral administration should be 50-500 mg. If necessary, it is possible to deviate from the amounts mentioned, namely depending on the body weight and the specific type of administration route. | The use of the compound I ##STR1## or its pharmaceutically utilizable salts for the propylaxis and treatment of the sequel of chronic reduced cerebral blood supply, in particular of stroke, and for the treatment of neurodegenerative disorders is claimed. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] 1. Eye tracker, mounted on a helmet or headset. Foster-Miller, Inc., 350 Second Ave., Waltham, Mass. 02451
[0002] 2. Eye Tracking System, Applied Science Laboratories, 175 Middlesex Turnpike, Bedford, Mass. 01730, USA
[0003] 3. Ergomeasure™, a tool to adjust office furniture, including computer keyboards and monitor. Herman Miller, Inc. Zeeland, Mich., USA
[0004] 4. Ergoscale™—the Office Ergonomics Solutions Kit—a tool to adjust office furniture, including computer keyboard and monitor. Ergo Design, Inc. Englewood Cliffs, N.J.
BACKGROUND—FIELD OF THE INVENTION
[0005] This invention relates to human visual performance as well as to the engineering anthropometry.
[0006] In anthropometric theory and practice, there are many occasions where there is a need to determine eyesight and use it as a reference point. For example, a horizontal eyesight level is used as the reference point (Standard Sight Line) in anthropometric theory as eye height while sitting or standing. Designers of vehicle or truck's cabin, airliner's cockpit, etc. are using the horizontal eyesight level as the reference point to lay out the operator's workplace. According to the American National Standards Institute (ANSI), the top of the VDT-computer's monitor should be positioned at the operator's eye level.
[0007] There are many ways, methods and tools to measure human eye level. Human eyes are too sensitive to be touched by direct techniques of detecting the eye level in static or dynamic measurement. The eyes are so easily hurt by undue pressure that indirect methods, such as optical sighting, are desirable in the traditional engineering anthropometry. However, setting up a surveyor's transit is often too cumbersome and time consuming. A compromise method developed by J. A. Roebuck, Jr. is very often used. This method includes a device containing two transparent parallel planes, scribed with a grid as coordinate lines. One aligns the grid lines in the two planes and records the location of the eye on these grids, estimating the distance between the lines on the plane by balancing the offset of the more distant lines between the nearer set of lines. More modem methods are high speed anthropometric scanners for static measurements and the Eye Tracking System (U.S. Pat. No. 4,852,988) of the Applied Science Laboratories (ASL) Bedford, Mass., (www.a-s-l.com) and the Eyetracker of the Foster-Miller, Inc., Waltmann, Mass. (www.foster-miller.com) are very useful for dynamic measurements. The above eyetracers have been originally designed as a helmet head set system only for eyes tracing, but not antropometry.
SUMMARY
[0008] Existing methods and the apparatus' used for the determination of eyesight or eye tracking systems are sophisticated and expensive, need special software and specially trained specialists, and need substantial time to get results of a measurement, etc. At the same time, some special tools (“ergomeasure™”, Herman Miller, Inc., Zeeland, Mich.) that are designed for adjustment of office furniture are less expensive and less sophisticated compared with the apparatus' described above, but they are not precise enough.
[0009] Objects and Advantages
[0010] The determination of the eyesight's (line of eyesight) direction in the presented invention is based on the concept of a firearm's sight (for example rifle, gun, etc.). Thus, when we are looking through the firearm's rear back sight—“V” block and front bead, a virtual straight line from eye's pupil (lens) passing through the back sight is in the direction of our eyesight. The coordinates of this line determine the eyesight.
[0011] The presented apparatus and method is precise and inexpensive, compact and simple to use with immediate results of measure. The most of it application is in engineering anthropometry, operator work place design, architecture, out-door advertising (positioning billboard), etc. The special application of the patent is visible in an area when the PC user has to position the top of the VDT screen at the user's eye level while adjusting the PC workstation or lay out the VDT's in a dispatcher room.
DRAWING AND PHOTOGRAPH FIGURES
[0012] The reference numerals in the drawing and photographs have slightly different numbers.
[0013] [0013]FIG. 1 shows the actual optical head (housing) that applied for patent.
[0014] [0014]FIG. 2 shows a photograph of the optical head attached to manual moving mechanism.
[0015] [0015]FIG. 3 shows a photograph of the optical head attached to motor moving mechanism and digital display of its vertical movement.
[0016] [0016]FIG. 4 shows a photograph detecting the PC user's eye level.
LIST OF REFERENCE NUMERALS IN THE DRAWING 1 = Optical head (housing) 2 = Laser activating switch 3 = Rear sight “V” block 4 = Level 5 = Front bead 6 = Laser pointer (laser beam) 7 = Inclination measuring system (protractor) 8 = Receptacle 9 = Means for tilting and swiveling optical head 10 = 360° circular scale 11 = Vertical scale 12 = Vertically moving part 13 = Linear mechanism 14 = Digital display 15 = Platform 16 = Circular level 17 = Adjustable feet d = Distance between top point of front bead and laser beam (center of laser pointer)
DESCRIPTION
[0017] The significant part of the apparatus is an optical head (a housing) 1 comprising a firearm's sight systems. For example, this is two elements—a rear sight “V” block 3 and a front bead 4 of the open-sight system of firearms and a level 4 to positioning the head in the horizontal level. A built-in inclination measuring system (protractor) 7 is used to read out angles of the optical head position/movement in a vertical plane. A laser pointer 6 with an activating switch 2 is functioning as an eye tracker and determines the gazing point. A built-in receptacle 8 joins pivotably the optical head (housing) 1 with tilting in the vertical plane and swiveling in the horizontal plane mechanism 9 . A vertically moving part 12 of a linear driving mechanism 13 is moving the optical head 1 up or down. A vertical movement of the head is read-out on a scale 11 or on a digital display 14 . Angles of the head movement in the horizontal plane are read-out on a 360-degree scale 10 . The linear driving mechanism 13 is installed vertically on a platform 15 . Adjustable feet 17 and a circular level 16 of the platform 15 are used for installing it in the horizontal plane.
[0018] Operation
[0019] There could be at least two circumstances (A, B) of measurements of eyesight's directions and angles within the interior/exterior space:
[0020] Circumstance A. There is a need to look at specific eyesight directions, for example a subject is asked to look straight horizontally.
[0021] A horizontal eyesight level is used as the reference point (Standard Sight Line) in anthropometric theory as eye height (while sitting or standing) for the designer of a vehicle's cabin or airliner's cockpit, etc. Another application is to properly position of a VDT (video display terminal) on a desk for the PC user. According to the ANSI recommendations, the top of the desktop PC monitor should be placed at eye level. So, the need is to determine horizontal eye level and point of view on the VDT screen.
[0022] Circumstance B. The person is gazing at a specific subject (area) during a task performance or just browsing within the interior/exterior space. There is a need to determine the angle of the eyesight's direction and the gazing point.
[0023] The measurement procedures in circumstances “A” and “B” are quite different.
[0024] The measurement procedure in circumstance “A” is as the follows:
[0025] 1. The hypothetical PC user should be asked to relax and sit straight in a properly adjusted chair according to his or her anthropometric data.
[0026] 2. The apparatus' support platform 15 should be installed in a horizontal position by adjustable feet 17 and checked by a circular level 16 . Thus, the optical head's up and down moving part 12 is positioned vertically.
[0027] 3. The optical head 1 is placed in the front of a PC user in the horizontal position. It is checked by the level 4 and moved up or down by the mechanism 13 . The rear sight “V” block 3 should be positioned approximately at eye level and as close as possible to one of the eyes to look through (similar to targeting a firearm). One of the eyes should be covered up with an eye paddle.
[0028] 4. The optical head 1 should be attuning (moving up or down) until the user looks straight through the rear sight's “V” block 3 and the front bead 5 . Thereby this line will indicate a PC user's visual line direction or user's personal eye level in a sitting posture.
[0029] 5. The distance of the eyesight's level from the desktops (or floor) will be read out on a vertical movement scale 11 or a digital display 14 .
[0030] 6. Activated by a switch 2 , the laser pointer 6 will detect the user's gaze point on the VDT screen. Some corrections should be made considering the distance (d) between the top point of front bead and the laser beam (the center of the laser pointer).
[0031] The procedure for PC users in a standing posture will be the same.
[0032] The measurement procedure in circumstance “B”, when there is a need to determine the angle of the eyesight's direction and the gazing point, will be as follows:
[0033] 1. The person is told to relax while gazing at a specific subject or area during a task performance or just browsing within the interior/exterior space in a sitting, standing or other posture position.
[0034] 2. The optical head's platform 15 should be installed in the horizontal position by using adjustable feet 17 and checked by a circular level 16 . Thus, the optical head's up and down moving part 12 is positioned vertically.
[0035] 3. The optical head 1 is placed in the front of the person at approximately eye level and oriented at a direction of gazing a selected object or an area.
[0036] 4. The rear sight “V” block 3 should be positioned as close as possible to the left or right eye to look through (similar to targeting a firearm). One of the eyes should be covered up with an eye paddle.
[0037] 5. The optical head should be attuning (moving) by a linear driving mechanism 13 up or down and tilted or swiveled by mechanism 9 until the person looks straight through the rear sight's “V” block 3 and front bead 5 at viewing subject or area. Thereby the angle of this sight's line will indicate the person's eyesight direction while performing the task of gazing a selected object or a selected area in a sitting or standing posture position.
[0038] 6. Activated by a switch 2 , the laser pointer 6 will indicate the operator's gazing point of viewing the subject or the area. Some corrections should be made considering the distance (d) between the top point of the front bead and the laser beam (the center of the laser pointer). | An apparatus and method for detecting eyesight direction, angle and gaze point is an optical instrument attached to supporting means (platform, helmet or headset, etc.) and positioned by hand utilizing a firearm's type sight aiming system. This procedure determines the individual's eyesight direction. The instrument's integral inclination measuring system and laser pointer determine eyesight's angle gazing point. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a high-pressure injector having an injector unit, having a drive unit for driving the injector unit and having a high-pressure connection. In an advantageous embodiment of the present invention, the high-pressure injector can furthermore have a high-pressure storage unit for supplying the injector unit with fuel.
Such a high-pressure injector is known, for example, from document WO 2007/009279 A1. In this respect, each high-pressure injector includes a high-pressure storage unit (accumulator) to which the injector unit is connected at the front side via a cap nut. The drive unit for driving the injector unit is integrated into the high-pressure storage unit. The high-pressure injector therefore has a relatively complicated construction and is therefore expensive in manufacture.
SUMMARY OF THE INVENTION
The present invention will therefore present a high-pressure injector which has a simple construction and which can be manufactured inexpensively.
This object is achieved in accordance with the invention by a high pressure injector described herein.
The high-pressure injector in accordance with the invention in this respect includes an injector unit, a drive unit for driving the injector unit and a high-pressure connection. In an advantageous embodiment of the present invention, the high pressure injector can furthermore include a high pressure storage unit for supplying the injector unit with fuel. Provision is now made In accordance with the invention that the high-pressure injector has a housing in which a plurality of assemblies are arranged behind one another in the longitudinal direction of the injector, wherein the housing completely envelops at least a first assembly, in particular the drive unit and/or the high-pressure storage unit. A particularly simple design of the high-pressure injector in accordance with the invention hereby results.
The assemblies arranged within the housing in this respect advantageously have fuel-conducting high-pressure zones which are closed toward the housing so that the housing serves as a second envelope for the fuel-conducting zones of the assemblies.
Further advantageously, the housing can in this respect serve the mechanical connection of the assemblies which are arranged behind one another in the longitudinal direction of the injector. The assemblies are in this respect in particular pressed onto one another via the housing.
The housing in this respect advantageously connects at least three assemblies, in particular three of the following assemblies: injector unit, drive unit for driving the injector unit, high-pressure storage unit for supplying the injector unit with fuel, high-pressure connection. The present invention is, however, not restricted to such an embodiment. One of the three assemblies can, for example, also be an intermediate piece which has high-pressure bores for conducting high-pressure fluid between two other assemblies.
The assemblies advantageously abut one another in at least two contact zones within the housing in accordance with the invention. They are there advantageously pressed tightly onto one another, with this pressing taking place by a force generated or transferred via the housing. The contact zones in this respect are advantageously contact planes which extend perpendicular to the longitudinal direction of the high-pressure injector. The high-pressure injector in accordance with the invention is hereby given a layer-wise structure in which the individual assemblies are arranged behind one another in the housing in the longitudinal direction of the injector.
The two contact zones are advantageously the contact zones of the first assembly, which is completely enveloped by the housing, with further assemblies. Further advantageously, still further contact zones are arranged between further assemblies in the housing.
In accordance with the invention, at least one of the assemblies advantageously has cut-outs in a contact zone to increase the contact pressure. The cut-outs thus provide that the contact surface between the assemblies is as small as possible in order thus to enable a tight connection via the higher contact pressure. In this respect, the cut-outs are advantageously configured symmetrically with respect to the center axis of the high-pressure injector to enable a uniform distribution of forces.
Further advantageously, at least two of the assemblies in accordance with the invention have axial high-pressure bores in the contact zones, said high-pressure zones being in communication with one another there. These axial high-pressure bores are in this respect in particular surrounded by contact surfaces which lie on one another in the contact zones and are so pressed with one another in a sealing manner.
In this respect, a plurality of parallel high-pressure zones are advantageously provided which are advantageously arranged symmetrically.
The assemblies advantageously form a contiguous high-pressure zone, which is closed toward the housing, within the housing for conducting the fuel, wherein leakage flows which may arise at the contact zones are collected in the region between the outer walls of the assemblies and the inner wall of the housing.
Further advantageously, in the high-pressure injector in accordance with the invention, leakage flows are collected within the housing and are conducted out of the housing via a common outlet. This outlet for the leakage flow is in this respect advantageously arranged in the region of the high-pressure connection. The high-pressure connection in this respect advantageously serves as a connection to a double-wall high-pressure line.
In accordance with the invention, the housing of the high-pressure injector is advantageously outwardly sealed by one or more O rings.
Further advantageously, in accordance with the invention, the housing has a connection zone for the shape-matched connection to a second assembly. In this respect, the housing can advantageously be screwed to a second assembly via the connection zone. The shape-matched connection in this respect advantageously allows a clamping of the housing to the assembly. A connection of the housing to the high-pressure connection advantageously takes place in so doing.
In a particularly preferred embodiment of the present invention, the housing is configured as a cap nut. The housing accordingly has an internal thread with which it can be screwed to the second assembly. The housing furthermore has an elongate enveloping body in which the further assemblies are arranged.
In addition to the embodiment of the connection zone of the housing as a threaded zone, alternative embodiments of the housing are also conceivable in which the connection zone is configured e.g. as a web zone on which a threaded element is supported. This also allows a connection of the housing to the second assembly by which the assemblies arranged in the housing are pressed onto one another in their contact zones and are thus sealingly connected to one another.
Further advantageously, the housing has an opening with an undercut with which it lies on a support zone of a third assembly of the high-pressure injector. The third assembly is thus held within the housing by the undercut and transmits the contact pressure of the housing onto the assemblies arranged in the interior of the housing. The support region is in this respect advantageously arranged at the injector unit.
A part region of the third assembly in this respect advantageously projects from the housing. In this respect, the nozzle arrangement of the injector unit advantageously projects out of the housing.
Further advantageously, the housing has a second opening through which the assemblies can be pushed into the housing or via which the housing can be pushed over the assemblies. The second opening is in this respect advantageously arranged in the connection zone and is in particular surrounded by it.
Further advantageously, the assemblies can be displaced in the housing in the longitudinal direction of the high-pressure injector on the assembly and are only fixed in the housing via the shape-matched connection of the housing to the second assembly.
Further advantageously, the housing in accordance with the invention in this respect has a rotationally symmetrical shape.
In a preferred embodiment of the present invention, the housing completely envelops at least two assemblies arranged behind one another in the longitudinal direction of the injector. These two assemblies are in particular the drive unit and the high-pressure unit.
As already mentioned above, the present invention can in particular be used in such high-pressure engines which have a high-pressure storage unit for supplying the injector unit with fuel. The integration of the high-pressure storage unit into the high-pressure injector has the advantage that a common rail system can be dispensed with since the fuel can in each case be buffered in the high-pressure injector.
In accordance with the invention, the first assembly, which is completely enveloped by the housing, is advantageously the drive unit and/or the high-pressure storage unit. The drive unit or the high-pressure storage unit are in this embodiment completely surrounded by the housing in the radial direction, wherein the housing advantageously additionally serves the connection of the drive unit or of the high-pressure storage unit to further assemblies of the high-pressure injector.
The high-pressure storage unit in accordance with the invention advantageously has a storage volume which corresponds to more than ten times a maximum injection volume during a cylinder cycle; further advantageously more than 10 times this volume; further advantageously more than 50 times this volume.
The high-pressure storage unit of the high-pressure injector in accordance with the invention advantageously has a jacket region in whose interior the storage zone of the high-pressure storage element is located. This jacket region in this respect advantageously serves the transfer of force between the assemblies within the housing. Further advantageously, the jacket forms an envelope closed toward the housing. The storage zone can in this respect be formed by an axial bore.
In a further advantageous manner, the high-pressure unit has a filter unit and/or restriction valve unit. In this respect, it is advantageously arranged to the side of the high-pressure connection at the high-pressure storage unit so that fuel can pass through the filter unit and/or restriction valve unit on flowing into the high-pressure store. The filter unit and/or restriction valve unit is in this respect advantageously pressed into the jacket of the high-pressure storage unit in an end region. The filter unit and/or restriction valve unit is in this respect advantageously arranged in a cartridge which is pressed into the jacket of the high-pressure storage unit. For this purpose, the jacket advantageously has a bore in the longitudinal direction of the high-pressure injector which receives the filter unit and/or restriction valve unit and opens into the storage zone.
The drive unit advantageously has a jacket region in which one or more high-pressure bores is or are arranged for supplying the injector unit with fuel. These bores in this respect advantageously connect the high-pressure store to the injector unit. Further advantageously, the drive zone of the drive unit is in this respect arranged within the jacket region. The high-pressure bores then conduct the fuel outwardly past the drive zone from the high-pressure store to the injector unit.
In this respect, in accordance with the invention, a plurality of bores are advantageously provided which lead to the injector unit. The bores are in this respect advantageously arranged symmetrically to ensure a uniform force distribution.
Further advantageously, the jacket region further serves the conducting of a drive element, in particular of an electromagnet or of a piezo element. The drive unit can in this respect work electromechanically or piezoelectrically. The drive zone of the drive unit is advantageously arranged in an axial bore of the jacket region which is in particular centrally arranged.
The injector unit advantageously also has a plurality of high-pressure lines which are connected to the high-pressure store, advantageously via the high-pressure lines in the drive element.
The injector unit in accordance with the invention advantageously has a central valve passage in which a valve plunger is arranged displaceably in the longitudinal direction of the injector. In this respect, the valve plunger is advantageously biased via a spring. Further advantageously, the valve plunger is moved via the drive unit in accordance with the invention.
The injector unit advantageously has a nozzle arrangement which serves the injection of fuel. In this respect, a plurality of high-pressure bores which supply the nozzle with fuel are advantageously provided in the injector jacket. In this respect, one or more high-pressure lines can advantageously be provided. They are advantageously arranged symmetrically.
The nozzle arrangement in the present invention can in this respect be arranged as a separate assembly at the tip of the injector unit. In a preferred embodiment, the nozzle arrangement is in this respect fastened to the tip of the injector unit via a cap nut. The injector unit together with the nozzle arrangement fastened thereto naturally has to be dimensioned in this respect so that it can be pushed through the front opening of the housing.
Further advantageously, electric contacts for controlling the drive unit are furthermore arranged in the region of the high-pressure connection of the high-pressure injector in accordance with the invention. The high-pressure connection thus furthermore serves the electric connection of the drive unit to a control in addition to the connection to a high-pressure system. Further advantageously, electric lines for controlling the drive unit can be arranged in the jacket region of the high-pressure store so that the drive unit is electrically connected via the high-pressure storage unit.
The high-pressure injector in accordance with the invention advantageously serves the fuel injection at a pressure of more than 200 bar, in particular at more than 1000 bar, in particular at more than 1500 bar. In this respect, the fuel is correspondingly pressurized via a pump and is provided to the high-pressure injector via the high-pressure connection. In this respect, the fuel is advantageously buffered in the high-pressure storage unit of the high-pressure injector.
In addition to the high-pressure injector, the present invention furthermore includes an internal combustion engine having one or more high-pressure injectors such as were described above. In this respect, the high pressure injector or injectors is/are advantageously fastened by means of the high-pressure connection in the cylinder block. In accordance with the invention, in those cases in which the injectors have an integrated high-pressure storage unit, a common rail arrangement can be dispensed with. The internal combustion engine in accordance with the invention is advantageously a diesel engine.
The present invention furthermore includes a method for manufacturing a high-pressure injector such as was presented above, comprising the steps: arranging at least three assemblies behind one another in the longitudinal direction of the injector as well as arranging the housing around the assemblies so that it envelops at least a first assembly completely. The first assembly is in this respect in particular the drive unit and/or the high-pressure storage unit. The housing in this respect advantageously envelops both the drive unit and the high-pressure storage unit completely.
Advantageously, in the method in accordance with the invention, the individual functional layers or assemblies of the high-pressure injector are arranged behind one another in the longitudinal direction of the injector on the assembly and are orientated toward one another so that high-pressure bore is arranged on high-pressure bore.
The housing is now advantageously installed, whereby the assemblies are pressed with one another. The installation of the housing in this respect advantageously takes place via a screw connection by which the contact pressure between the assemblies is also provided.
The nut of the screw connection can advantageously be elongated by hydraulic devices. The screwing process can then take place without force up to the release of the nut tensile force. Alternatively, the assemblies are pre-tensioned and are screwed to one another via the housing in accordance with the invention which is advantageously configured as a cap nut.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in more detail with reference to an embodiment and to drawings.
There are shown
FIG. 1 the embodiment of a high-pressure injector in accordance with the invention in a sectional view through the longitudinal axis of the high-pressure injector; and
FIG. 2 a sectional view transversely to the longitudinal axis of the high-pressure injector along the sectional plane B-B in FIG. 1 , that is, in a contact region between two assemblies.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of a high-pressure injector in accordance with the invention is shown in FIGS. 1 and 2 . The high-pressure injector in this respect includes an injector unit 1 , a drive unit 2 for driving the injector unit 1 , a high-pressure storage unit 3 for supplying the injector unit 1 with fuel and a high-pressure connection 4 . The high-pressure injector in accordance with the invention furthermore has a housing 5 . The injector unit 1 , the drive unit 2 , the high-pressure storage unit 3 as well as the high-pressure connection 4 are in this respect arranged behind one another in the longitudinal direction of the high-pressure injector and abut one another or an intermediate piece 15 in contact zones (which each lie between two assemblies).
The mechanical connection of the individual assemblies now takes place in accordance with the invention via the housing 5 which completely envelops the drive unit 2 and the high-pressure unit 3 . The assemblies are in this respect arranged layer-wise behind one another in the longitudinal direction of the high-pressure injector within the housing and are pressed with one another via the housing.
The high-pressure zones arranged in the assemblies are sealingly connected to one another by the pressing in the contact zones between the individual assemblies so that the housing represents a second wall.
The housing 5 in the embodiment in this respect has the form of a hollow cylinder in which the drive unit 2 and the high-pressure storage unit 3 are arranged behind one another. The injector unit 1 is in this respect only arranged partly within the housing and its front-face part projects out of a front-face opening of the housing. In this respect, the housing 5 is supported by an undercut 11 on a supporting edge 12 of the injector unit.
On the rear side, the housing 5 has an opening through which the assemblies can be pushed into the housing. In this respect, the housing 5 has a connection zone 10 for connection with the high-pressure connection 4 . In this respect, in the embodiment, the invention takes place via a screw connection with the high-pressure connection, for which purpose the housing has, in the connection zone 10 , an internal thread by which the housing can be screwed onto an external thread of the high-pressure connection. Alternatively to this arrangement, however, a separate threaded element for connection to the high-pressure connection would also be conceivable.
In the embodiment, the housing 5 is configured rotationally symmetrically so that it can be screwed to the high-pressure connection like a normal cap nut and presses the assemblies arranged layer-wise with one another. In the embodiment, the housing thus has the form of a cap nut which is pushed over the stack of injector unit 1 , drive unit 2 and high-pressure store 3 and clamps them with the high-pressure connection.
The assemblies in this respect each abut one another in contact planes 6 to 9 and are pressed onto one another there by the pressure of the housing so that the high-pressure lines of the assemblies ending in the contact surfaces are tightly connected to one another. Such a contact plane 7 , here between the drive unit 2 and the intermediate piece 15 , is shown in FIG. 2 in this respect. As can be recognized in FIG. 2 , in this respect cut-outs 13 are provided to increase the contact pressure in the contact zone 19 . An improved sealing of the high-pressure line 14 is hereby made possible. The exposure through the cut-outs 13 is in this respect carried out symmetrically to the surface center or to the longitudinal axis of the high-pressure injector.
As can likewise be recognized in FIG. 2 , in this respect a plurality of high-pressure lines for connecting the high-pressure store to the injector unit are provided in the embodiment. In this respect, they are arranged symmetrically to achieve a uniform pressure distribution. In this respect, a jacket region 26 is provided in the region of the drive unit 2 and a receiving bore for the drive apparatus is located in the interior thereof. The high-pressure lines 14 in this respect extend outwardly in the jacket region around the centrally arranged receiving zone.
The high-pressure storage unit 3 also has a jacket region 17 which has an axial bore 18 which serves as a high-pressure store. In this respect, a cartridge assembly 27 having a filter and a restriction valve is pressed into the jacket region 17 toward the high-pressure connection.
Furthermore, in this respect, an intermediate piece 15 in which bores 16 for connecting the high-pressure storage zone 18 to high-pressure lines 14 in the jacket of the drive unit 2 are arranged is arranged between the drive unit 2 and the high-pressure storage unit 3 .
The intermediate element 15 in this respect has bores 16 which connect the centrally arranged storage zone 18 to the high-pressure lines 14 of the drive unit 2 arranged in the jacket region. In the injector unit, corresponding high-pressure lines 25 are in turn provided which connect the high-pressure lines 14 arranged in the jacket region to the central valve passage. A valve plunger 21 which is moved via the drive apparatus 20 is arranged in the latter. The drive apparatus can in this respect takes place electromagnetically as in the embodiment or piezoelectrically, for example.
A nozzle arrangement 22 which is in turn fastened to the tip of the injector unit via a cap nut 23 is provided at the tip of the injector unit 1 projecting out of the housing 5 . Potential breakage leaks at the contact zones of the assemblies 6 to 9 are collected within the housing 5 and are conducted outwardly in a common outlet in the region of the high-pressure connection 4 . For this purpose, the high-pressure connection is connected to a conventional double-wall high-pressure line. For this purpose, conventional connection nipples 24 are accordingly screwed in the high-pressure connection, with the high-pressure connection in this respect taking over the function of the high-pressure inflow and outflow. The injector is then fastened via the high-pressure connection in the cylinder block.
The high-pressure connection furthermore also includes the electric contacts for the connection of the drive unit 2 . The electric lines are in this respect conducted through the jacket region 17 of the high-pressure store 3 and the intermediate piece 15 to the drive unit 2 .
For installation, the individual functional layers are arranged orientated toward one another so that high-pressure bore is aligned with high-pressure bore. The functional layers are then tensioned and screwed to the housing 5 configured as a cap nut. The housing 5 can in this respect be pushed over the stacked assemblies until its undercut 11 lies on the supporting plane 12 of the injector unit. The tensioning of the stack then takes place by screwing to the high-pressure connection 4 .
In summary, the following innovations over the prior art result in the present invention.
The housing can be configured as a closed cap nut which completely envelops the drive region of the injector. The cap nut can furthermore also completely envelop the high-pressure store. The cap nut in this respect is supported at the front face on the injector unit and is screwed at the rear side to the high-pressure connection.
Potential breakage leaks at the contact zones of the assemblies are collected within the cap nut and are conducted to a common outlet which is preferably arranged in the vicinity of the high-pressure connection. The potential breakage leak is then connected to a standardized double-wall high-pressure line and thus drained off. The cap nut can be outwardly sealed by O rings.
The high-pressure injector is fastened via the high-pressure connection in the cylinder block. In this respect, standardized connection nipples are advantageously screwed in. The high-pressure connection furthermore advantageously includes the function of the electric contacting of the drive unit.
The high-pressure connection takes over the function of the high-pressure inflow, high-pressure outflow and sealing of the pressure store and is screwed tight by the cap nut. Furthermore, a cartridge assembly having a filter and a restriction valve can also be pressed in the pressure store.
A plurality of preferably symmetrically arranged bores are provided in the injector jacket for the low-loss linking of the fuel high-pressure between the store and the nozzle. In this respect, one or more high-pressure lines are advantageously provided.
The jacket of the drive assembly can furthermore also take over the function of a pressure screw and the conducting function of the magnets of the drive assembly.
In accordance with the invention, the pressure store, the jacket of the drive assembly and the injector unit are arranged behind one another in the longitudinal direction of the high-pressure injector. The individual planes in this respect abut one another in contact zones. The planes are in this respect advantageously exposed at the separation points so that a sufficient contact pressure remains for sealing the high-pressure conducting. The exposure in this respect advantageously takes place symmetrically to the surface center.
The functional layers are advantageously oriented in the installation, high-pressure bore to high-pressure bore, clamped and screwed to a cap nut. Alternatively, the nut can also be elongated by hydraulic devices and the screwing process then takes place force-free until the nut tensile force is released.
An extremely compact arrangement with a simple structure results by the present invention, wherein the housing serves as a second envelope of the assemblies arranged in the housing and serves their mechanical connection. The assemblies are in this respect in particular pressed onto one another in their contact zones by the pre-tension applied by the housing. | The present invention shows a high-pressure injector having the following assemblies: an injector unit ( 1 ), a drive unit ( 2 ) for driving the injector unit ( 1 ), preferably a high-pressure storage unit ( 3 ) for supplying the injector unit ( 1 ) with fuel, and a high-pressure connection ( 4 ). Provision is made in this respect that the high-pressure injector has a housing ( 5 ) in which a plurality of the named assemblies are arranged behind one another in the longitudinal direction of the injector, wherein the housing ( 5 ) completely envelops at least one of the named assemblies, in particular the drive unit ( 2 ) and/or the high-pressure storage unit ( 3 ). The high-pressure injector with the injector unit can be used in all types of internal combustion engines, preferably in diesel engines. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 11/322,528, filed Dec. 30, 2005, which application is incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention relates to systems and methods for introducing and withdrawing equipment into an environment, and in particular, introducing and withdrawing a camera into a high temperature environment.
BACKGROUND
[0003] Industrial processes should be closely monitored so that all process parameters can be verified as being within specification. This monitoring can take on many forms, and usually falls into two broad categories. Physical inspection and monitoring by humans, or physical inspection and monitoring by computer systems. In both cases, inspections and monitoring are aided by many other pieces of equipment such as all types of sensors (temperature, air quality, viscosity, density, visual appearance, etc.).
[0004] In some situations however, the environment that must be monitored is too harsh and extreme for either a human or a standard device or piece of equipment. Harsh and extreme environments include high temperature environments such as the inside of a furnace, caustic chemical environments, and high pressure environments. The extremes of these environments however do not lessen the need for the monitoring of the industrial process. Consequently, industries would benefit from a system that could monitor industrial processes under extreme conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 illustrates an example embodiment of a transport system in a home position.
[0006] FIG. 1 a illustrates a detailed view of an embodiment of a mechanical actuator, in a compressed mode, that can be used in connection with an example embodiment of the invention.
[0007] FIG. 2 illustrates an example embodiment of a transport system in a deployed position.
[0008] FIG. 2 a illustrates a detailed view of an embodiment of a mechanical actuator, in expanded mode, that can be used in connection with an example embodiment of the invention.
[0009] FIG. 3 is an exploded view of an industrial camera and housing that can be used in connection with an example embodiment of the invention.
[0010] FIG. 4 illustrates a flowchart of a process control that can be used in connection with an example embodiment of the invention.
DETAILED DESCRIPTION
[0011] In the following detailed description, reference is made to the accompanying drawings that show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that the various embodiments of the invention, although different, are not necessarily mutually exclusive. For example, a particular feature, structure, or characteristic described herein in connection with one embodiment may be implemented within other embodiments without departing from the scope of the invention. In addition, it is to be understood that the location or arrangement of individual elements within each disclosed embodiment may be modified without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims, appropriately interpreted, along with the full range of equivalents to which the claims are entitled. In the drawings, like numerals refer to the same or similar functionality throughout the several views.
[0012] FIGS. 1 and 2 illustrate an embodiment of a transport system that moves a visible and/or an infrared (IR) camera enclosed in an industrial housing along a rail. While the embodiment of FIGS. 1 and 2 show a transport system of the invention in connection with an IR camera, those of skill in the art will readily realize that the invention is not limited to an IR camera, but that embodiments of the transport system of FIGS. 1 and 2 could also transport other pieces of equipment as well. Additionally, while the embodiment of FIG. 1 is discussed in connection with an industrial furnace, those of skill in the art will readily realize that the transport system of FIGS. 1 and 2 can be used in connection with other pieces of industrial equipment also. Moreover, while the transport system of FIGS. 1 and 2 is described as operating with a pneumatic system, one of skill in the art will realize that other means of powering the transport system such as electric powered motors in combination with gears, belts, chains, and/or pulleys could also be used.
[0013] The support and transport structure 100 of FIG. 1 has a frame 105 . Attached to the frame 105 is a first motion transport system. In an embodiment, the first motion transport system is a pneumatic transport system that consists of a rail 110 and a trolley structure 115 . In another embodiment, the rail 110 is one that is manufactured by Tol-o-matic® of Hamel, Minn. (www.tolomatic.com). In an embodiment, the frame 105 is attached to the outside of the wall of an industrial housing 140 , and the pneumatic transport system is attached to the frame 105 . In one particular embodiment, the wall of the industrial housing 140 is an outside wall of a furnace. Positioned on top of the trolley structure 115 is an enclosure 120 . The enclosure 120 contains a stepper motor 126 and a shaft 127 . The stepper motor and shaft have wheels 128 , 129 attached thereto respectively, and wheels 128 , 129 are coupled via a belt, a chain, a gearing system or other means 130 . (See FIG. 2 ).
[0014] Connected to the enclosure 120 via a cable 136 is a control box 137 that houses a control processor and electrical and pneumatic controls. Also attached to the control box 137 is a reservoir 138 for the storage of pneumatic air. A second industrial housing 135 is connected to the end of shaft 127 opposite that of the wheel 129 . In an embodiment, the industrial housing 135 encloses a camera, such as an IR camera. Also attached to the frame 105 is a second motion transport system that, like the first motion transport system, may be a pneumatic transport system. In the embodiment of FIG. 1 , such a pneumatic transport system has a rail 150 , a second trolley structure 156 , and a door 154 . The second trolley structure is attached to the door 154 with attachments 157 and tension springs 153 that attach the door 154 to the pneumatic transport system via a door trolley structure 156 . The door trolley 156 in FIGS. 1 and 2 is depicted in generic form to indicate that several connecting mechanisms known in the art could be used to connect the door 154 to the trolley structure 156 . In one particular embodiment, the details of which are illustrated in FIGS. 1 a and 2 a , the attachment 157 includes a triangular bracket 157 a and a roller 158 b to connect the bracket 157 a to the trolley structure 156 . The door covers an opening 160 in the industrial housing wall 140 ( FIG. 2 ).
[0015] The transport system 100 supports and transports the industrial housing 135 into and out of an industrial environment. In an embodiment, the industrial environment is a furnace, and the industrial housing 135 encloses an IR camera. An exploded view of an embodiment of an industrial housing 135 and an IR camera is illustrated in FIG. 3 . The housing 135 has a bottom plate 171 , and encloses a camera 170 . An opening 172 receives the camera lens (not shown in FIG. 3 ) that is attached to the camera 170 . The camera lens is enclosed and protected by a window 173 and lens housing 174 that is attached to the industrial housing. A coupling unit 175 attaches onto the housing wall, and serves to connect the housing 135 to the shaft 127 . In an embodiment, the industrial housing 135 is manufactured out of hardened stainless steel, and the window 173 is made out of sapphire. In different embodiments, the lens attached to the camera may be a wide angle lens, a narrow angle lens, and/or a telescoping lens.
[0016] Referring now to FIG. 2 , the door 154 has been moved in the direction of arrow A. As will be explained in detail in connection with FIG. 4 , the movement of the door along arrow A occurs by activating the second pneumatic transport system, which moves door trolley 156 and the door 154 along rail 150 , thereby exposing opening 160 in the industrial wall 140 . Referring now to FIG. 2A , in an embodiment, attachments 157 A&B and tension springs 153 A&B secure the door 154 to the door trolley 156 . The attachment 157 between door trolley 156 and the door 154 has compression springs 157 C to ensure a tight seal between the door 154 and the wall 140 when the door trolley 156 is in the lowered position. Tension springs 153 A&B between door 154 and door trolley 156 is to ensure the door is held against the door trolley and away from the wall 140 when the door trolley is in the upper position. When the door trolley 156 first begins to rise, the compression spring force of attachments 157 A&B releases and tension springs 153 A&B pull door 154 toward door trolley 156 and away from the wall 140 . This ensures that there is no interference between the door 154 and the wall 140 or other structure. As the door trolley 156 continues to raise, both the door trolley 156 and door 154 move in the direction of arrow A. When the door 154 and door trolley 156 are lowered by activating the second pneumatic transport system, the door first moves with the door trolley down in the direction of arrow B until roller 158 A, which is fixed to door 154 , contacts the horizontal portion of the frame 105 a . The trolley 156 continues to move down while the door 154 can not, causing compression spring loaded attachment 157 B to move the door toward the industrial wall 140 . The detail of the attachment 157 B, roller 158 A and tension spring 153 B is illustrated in FIGS. 1 a and 2 a . Referring to FIG. 1 a , as the door trolley 156 is moved down by the second pneumatic transport system with the roller 158 B preventing any further movement in the direction of arrow B, attachment 157 A pushes the door 154 away from the door trolley 156 toward wall 140 . When the door trolley 156 is raised by the second pneumatic system, the tension spring 153 A first pulls the door 154 back away from the industrial wall 140 and then door trolley 156 and door 154 move together in the direction of arrow A. In situations in which the industrial housing 140 is cylindrical-like in shape, or the surface of a flat housing wall is not perfectly planar, an adapter can be welded or otherwise coupled onto the wall of the industrial housing. The surface of the adapter that contacts the door 154 can then be machined to accurately mate with the door.
[0017] FIG. 2 further shows that enclosure 120 , shaft 127 , and housing 135 have been moved along rail 110 via the activation of the first pneumatic transport system. The housing 135 itself has been moved through opening 160 into the industrial housing 140 . FIG. 2 further illustrates that the industrial housing 135 has been rotated from a home position as illustrated in FIG. 1 (as determined by the direction that the window 173 and lens housing 174 is pointed), to a deployed position as illustrated in FIG. 2 . In another embodiment, the industrial housing is attached to the shaft 127 by a mechanism that allows the industrial housing 135 to tilt when it is in the industrial housing 140 .
[0018] In an embodiment, the transport structure 100 is connected to a processor housed in control box 137 that controls the functions of the transport system 100 . A flowchart outlining an embodiment of the control process is illustrated in FIG. 4 . In FIG. 4 , the control process 400 at block 405 (a process control computer) transmits a signal to the camera 170 to determine the temperature of the camera. If the temperature of the camera is too high, for example because of a recent incursion into a furnace, the process control will not move the camera into the furnace. In one embodiment, a timed loop is programmed into the processor logic to poll the temperature again, and see if the temperature is low enough to be inserted into the furnace. In other embodiments, the insertion of the camera is on a timed and scheduled basis, and the system then waits for the next scheduled time to insert the camera into the furnace. In yet another embodiment, an operator provides a command to the processor to move the camera into the furnace, and if insertion does not occur because the temperature of the camera is too high, the operator can wait before reissuing the command.
[0019] In an embodiment, if the temperature of the camera is found to be within operating conditions in block 410 , image and rotation angle commands are transmitted from the camera to a programmable logic controller (PLC) housed in control box 137 (block 412 ). The image command readies the IR camera 170 for capturing images, and the rotation command is sent to the PLC which communicates with the stepper motor controller, housed in control box 137 , which rotates the camera so that the window 173 and lens housing 174 will be pointed in the desired direction at 427 . At 415 , the PLC checks to see if the industrial housing 135 , the enclosure 120 , and the control box 137 have been successfully purged. A purge system 139 , housed in control box 137 , establishes a positive pressure in the enclosure 120 , the control box 137 , and the housing 135 . This positive pressure keeps contaminants from leaking into these structures. If the Purge is OK, the PLC then checks in block 420 whether the camera 135 is out and the door 154 is closed. If the camera is out and the door 154 to the housing 140 is closed, the PLC checks in block 425 to see if the camera window 173 and lens housing 174 are located in the home position. If the camera is home, signals are then sent to the stepper motor at 427 so that the camera is rotated the desired number of degrees to the desired angle (i.e. the deployed position). If the purge was not OK in block 415 , or the camera was not out and/or the door was not closed in block 420 , or the stepper motor was not in a home position in block 425 , a variable representing the health or status of the PLC is set to zero and sent to the camera in block 430 , and the camera communicates a PLC health error indication to the process computer.
[0020] In block 440 , the processor sends a signal to energize a pneumatic valve which opens the door 154 that seals the housing 140 . In block 445 , the processor checks to see if the door successfully opened. If the door did not open successfully, the PLC health status is set to zero at 430 , and the PLC sends the information to the camera. If the door successfully opened, the first pneumatic transport system is energized at 447 , and the housing 135 and camera 170 are moved through the housing wall 140 . The processor then determines if the camera was moved into the housing successfully at 450 . If it was not, the PLC status is once again set to zero. If the processor determines that the camera was moved into the furnace successfully, images are captured by the camera at 460 . The camera then communicates with the process computer in block 405 and transfers the images. These images may be transmitted via wired or unwired means. Then, after a short time in the furnace at 465 (three seconds in one embodiment), the PLC sends a signal to the first pneumatic transport system at 470 to energize the valve again so that the housing and camera are removed from the furnace. The PLC checks to see if the camera was successfully removed from the furnace at 475 . If it was not, the PLC status is set to zero. If the camera was successfully removed from the furnace, the close door valve of the second pneumatic transport system is reenergized at 480 , and the door 154 is closed. The PLC checks to see if the door was successfully closed ( 485 ), and if it was not, PLC status is set to zero.
[0021] When the transport system senses any of the problems outlined above (e.g. the door 154 did not successfully close at 485 ), or any other problems such as loss of electrical power or loss of pneumatic pressure, the processor status is set to zero and the system goes into a failsafe state. If instrument air is lost in the failsafe state, the pneumatic air in the reservoir 138 is used by the system to remove the camera from the furnace (if the camera is in the furnace when the problem occurs), and to shut the door 154 (if once again the door is open when the problem occurs). This failsafe operation prevents the situation where the furnace door remains open because of a failure of some part of the system. In an embodiment that uses an electric motor to move said industrial housing 135 and said door 154 , an alternative power supply, such as a battery or gas-powered generator, could be used to put the system into the failsafe mode.
[0022] In the foregoing detailed description of embodiments of the invention, various features are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the detailed description of embodiments of the invention, with each claim standing on its own as a separate embodiment. It is understood that the above description is intended to be illustrative, and not restrictive. It is intended to cover all alternatives, modifications and equivalents as may be included within the scope of the invention as defined in the appended claims. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein,” respectively. Moreover, the terms “first,” “second,” and “third,” etc., are used merely as labels, and are not intended to impose numerical requirements on their objects. | A system transports a device into a piece of industrial equipment for the purpose of collecting data inside of the industrial equipment. In an embodiment, the industrial equipment is a furnace and the device is an IR camera. The system opens a door covering an opening on the furnace, moves the IR camera inside of the furnace for a short time, the IR camera captures images, and the system removes the camera from the furnace and closes the door. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to forming textile fabrics with selectively placed interlocking high tensile modular filaments to produce garments and articles having enhanced performance characteristics. More particularly, the invention relates to protective work garments. The invention also relates to a method of producing a unilayer textile fabric where high tensile modular filaments are knitted into pre-selected locations on the textile fabric and the process is controlled by a computer.
[0003] 2. Brief Description of the Prior Art
[0004] The prior art has provided fabric of specific constructive design to overcome particular hazards encountered on the work environment. Generally in such construction, the patents disclose composite requiring layers of high tensile modular filaments which may be further treated by dipping to form a protective fiber or by heat treatment. Such is the case in providing cut resistant fabric for gloves for use by metal working glass handlers, meat cutters, and medical personnel. Each requires protection from a different hazard. The metal workers and glass handlers typically do not need protection from fluids. On the other hand, meat cutters and medical personnel do need this fluid protection to prevent bacterial or viral infection.
[0005] U.S. Pat. No. 4,004,295 discloses a glove constructed of yarn of metal wire and a non-metalic fiber such as an aramide fiber as protection from knife cuts.
[0006] U.S. Pat. No. 4,651,514 relates to a yarn composed of a monofilament nylon core that is wrapped with at least one strand of aramide fiber and a strand of nylon fiber. This yarn is electrically nonconductive.
[0007] Other special fabrics are designed for firefighters, foundry workers, and personnel in the chemical and related industries. Again, additional protection beyond the cut and puncture resistance is required. Generally, this again involves protecting the skin from hazardous liquid chemicals. These include solvents, paints, varnishes, glues, cleaning agents, degreasing agents, drilling fluids, inter alia.
[0008] U.S. Pat. Nos. 4,479,368 and 4,608,642 which are herein incorporated by reference disclose programmable knitting machines which may be used in preparing the fabrics of the invention.
[0009] U.S. Pat. No. 4,302,851 to Adair discloses a heat resistant protective hand covering in which a wool knit liner is enclosed within an outer layer of woven KEVLAR® aromatic polyamide fiber material with layers of aluminum foil and flexible fiberglass sandwiched there between. A pleated pad of flexible material woven from fiberglass yarns.
[0010] U.S. Pat. No. 4,433,479 to Sidman et al., relates to a heat resistant glove having first and second shells formed of temperature-resistant aromatic polyamide fibers such as KEVLAR® with the first shell section being made of a twill weave fabric and the second shell being made of a knitted fabric. A liner is formed of two sections, both are made of a felt fabric of temperature resistant aromatic polyamide fiber with the section forming the palm being provided with a flame resistant elastomeric coating.
[0011] U.S. Pat. No. 5,965,223 to Andrews et al, which is herein incorporated by reference discloses a composite layered protective fabric having an outer primary layer of an abrasive material and an inner layer of a cut resistant material positioned below the outer layer.
[0012] In each case the prior art patents discussed above requires a plurality of layers to achieve the protection desired. Usually each layer being fabricated of a uniform composite structure. Thus the weight of the fabric is in increased and flexibility and comfort level of the wearer of the garment produced decreased. Furthermore, the extensive use of high performance filaments makes the articles of manufacture more expensive.
[0013] Therefore, there exists a need for a flexible and comfortable textile performance protect fabric that is less expensive, more efficient to fabricate, reduces the amount of high performance filaments yet provides the necessary protective characteristics.
SUMMARY OF THE INVENTION
[0014] In accordance with the present invention a flexible unilayer fabric is produced in which the interlocking or intertwining of at least one dissimilar filament into pre-selected pattern at definite locations or regions of a base fabric by essentially conventional textile manipulating techniques controlled by a computer. The base fabric is formed from natural material or synthetic organic polymers that have a tensile modulus of about 3,000 kg/mm 2 or less. The performance filaments usable in the present invention have a high tensile modulus of elasticity of about 5,000 kg/mm 2 or more. The high tensile modulus filaments used may vary widely and include inorganic and organic filaments depending on the functional use. However, these high performance materials are very expensive and reducing the amounts without sacrificing performance is accomplished by the present invention.
[0015] For comfort and economic reasons the base fabric is manufactured preferably from a less expensive natural fiber such as cotton. As mentioned above type of high tensile modulus filament to be used is predicated on improving the effectiveness of the fabric for an intended function. For example, if garments are expected to provide protection to the wearer from hazards such as abrasions, cuts and punctures, a cut resistant filament is knittingly secured into the base fabric by a computer controlled pattern device. The encoded pattern information (design and location data) will direct the manipulation of the needles to interlock the filaments, for example, only in the finger and thumb stalls and in the palm region of the glove. Preferably the interlocking step is done by knitting. The high tensile modulus filaments are selected from the group consisting of aramides extended chain polyethylene, extended chain polypropylene, liquid crystal polyester, polyolefins, polyesters, polyamides, carbon fibers, metal fibers, fiberglass, and mixtures thereof.
[0016] The invention provides a method of manufacturing a unilayer flexible performance textile fabric having at least one high performance filament interlocked or intertwined within the base fabric to enhance an intended function. The first step involves manipulating the performance filament using substantially conventional textile fabric forming technology such as stitching to form a base fabric. The next step also follows conventional techniques such as by knitting the high modulus filament into the base fabric wherein the placement and design of the pattern of the high modulus filament is controlled by the pattern data supplied to a microprocessor to which the manipulations of the knitting needles are responsive providing the pattern programmed in the same single layer as the base fabric
[0017] It is the primary object of the invention to provide a unilayer fabric that enhances the performance of an intended function, yet reduces the weight of the apparel or article of manufacture with single layer construction.
[0018] Another object of the present invention is to provide a fabric containing high tensile modulus filaments in pre-selected locations within the fabric.
[0019] A further object of the invention is to provide a large variety of apparel and articles fabricated from the fabric of the invention.
[0020] A still further object of the present invention is to provide performance apparel used for protection against numerous potential hazards.
[0021] Yet another object of the present invention is to maximize the effectiveness of expensive high performance material.
[0022] Still another object of the present invention relates to articles of manufacture fabricated totally or in part a glove from fabric of this invention.
[0023] Another object of the present invention is to provide a glove construction of a unilayer fabric with high tensile modular filaments knitted into the base fabric conforming to the pattern and location programmed and controlled by a computer to form “islands of reinforcement” in the finger, thumb and palm regions against sharp objects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 is a knit glove formed by the method of the invention;
[0025] [0025]FIG. 2A shows a prior art method of chain looping two different fibers together in a single layer.
[0026] [0026]FIG. 2B illustrates the prior art double layer method of chain linking two different fibers.
[0027] [0027]FIG. 3 shows a flow diagram of the process of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] As shown in FIG. 1 there is provided a fabric in the form of a knit glove with an elastic band 13 and having a substantial area of cotton and two areas of a high modulus synthetic fiber 12 such as KEVLAR®. Both the cotton fibers 11 and the synthetic fibers are single layered. The prior art method to provide a reinforcement has generally been to over knit an area so as to form a double layer.
[0029] [0029]FIG. 2A illustrates a prior art method of incorporating a high modulus fiber 14 to form a single layer fabric by primarily alternating the looping of a synthetic fiber onto a natural fiber 15 .
[0030] [0030]FIG. 2B illustrates the prior art method of forming fabrics with a layer of a double layer natural fiber 15 that is looped with a high modulus fiber 14 .
[0031] [0031]FIG. 3 shows a flow diagram of the composite controlled process used in the process wherein a microprocessor 20 receives a program in the data input unit 21 . The microprocessor then signals the function selector 23 to decide on the type of weave, namely, knitting, weaving, or stitching depending upon the location. With the desired information there is a selection of needles by the needle selection unit 24 . The operation is continuous by storing the process in the memory storage unit 22 .
[0032] The product of the invention is made using chain stitches. The machine picks up the programmed material carrier and at the same time preselected needles raise up to knit the material. Then this material is dropped off and another material carrier is picked up which then knits this material in a preselected location. Using this process one is able to put material in any location on the product.
[0033] The present invention in its broadest aspect is a flexible unilayer textile performance fabric comprising a base fabric formed from a first fiber having the design of a desired pattern formed therein by intertwining or interlocking in the same layer at least one dissimilar performance fiber which can be manipulated in accordance with conventional textile fabric manufacturing process but wherein such manipulation is computer controlled. A programmed computer encodes the location(s) and the design of the desired pattern. After such data is entered, this enables the manipulation processes to place such designs in designated locations. This effectively maximizes the benefits of the expensive high performance material while reducing the amount of material needed. For example, if abrasion resistance is needed in an anti-wear garment only those areas requiring this added performance, i.e., elbows and knees would have the performance filaments to provide the desired characteristics.
[0034] Broadly, a method of manufacture of the unilayer flexible performance textile fiber comprises the steps of:
[0035] (a) manipulating a first fiber in a conventional manner to form a base textile fabric in a single layer; and
[0036] (b) manipulating at least one dissimilar performance fiber into the base textile fabric wherein this step of manipulating is computer controlled to produce a predetermined design for a pattern at a pre-selected location within the base textile fabric to form a performance fabric having enhanced performance function.
[0037] The first manipulative step (step (a)) involves a stitching operation which is performed by a knitting, sewing, or weaving machine to form a base textile fabric having a mesh or web configuration. The base is then downloaded into a knitting machine.
[0038] The type of stitching in the first manipulative step may vary widely. Stitching and sewing methods such as chain stitching, lock stitching and the like are illustrative of the type of stitching for use in this invention. The nature of the stitching fiber or thread will also vary widely and any type of fiber can be used depending on the garment and its use.
[0039] More specifically in step (b) the manipulation of the dissimilar performance fiber into the base textile fabric is conducted on a programmed knitting machine. The programming means comprises a microprocessor connected electronically to a programming matrix that controls a fiber carrier while simultaneously activating a needle selection means responsive to an output signed from the microprocessor and then to a pre-selected needle which knits the performance fiber into the web of the base fabric. This fiber carrier is released and in response sends a corresponding impulse to the microprocessor consistent with the input of the pattern and location data; another fiber carrier carrying another performance fiber supplies the fiber to the pre-selected needle which knits the filament into the proper location in the web of the base fabric. This sequence is repeated for each course in the base fabric in a sequential order of knitting. Thus, the fibers can be knitted in any location within the base fabric.
[0040] The invented fabric can be produced on essentially conventional textile fiber manufacturing equipment to produce such textile mechanical manipulative functions of sewing, knitting or weaving that are capable of producing the interlocking or intertwining steps of at least one dissimilar performance fibers into the base fabric and where this equipment is modified to effect the computer controlled processes described.
[0041] Several advantages flow from this arrangement. The design of a pattern and the textile mechanical manipulation steps or steps may be places into coding matrix electrically connected to the microprocessor unit. This input data may be stored as electrical data on any desired medium, such as a disc or tape. Once this data has been entered, the manipulative steps, i.e. knitting, can take place normally without any necessity to stop the machine or in general terms where to locate the design on the base fabric and where the pattern should begin and end. Units of pattern information so stored are read in sequential order of knitting and are translated into pattern data for needle selection in each knitting course and/or control data for controlling knitting, transfer, rocking and like operations in each knitting course.
[0042] The following definitions are supplied in order to more clearly point out the present invention and to avoid ambiguity.
[0043] The term “fiber” is meant any thread, filament or the like, alone or in groups of multifilaments, continuous running lengths or short lengths such as staple. Fiber is defined as an elongated body, the length dimensions of which is much greater than the dimensions of width and thickness. Accordingly, the term fiber, as used herein includes a monofilament elongated body, a multifilamented elongated body, and the like having regular or irregular cross sections. The term fibers includes a plurality of any one or a combination of the above.
[0044] The cross section of fibers for use in this invention may vary widely. Useful fibers may have a circular cross section oblong cross section or irregular or regular multi-lobal cross section having one or more regular or irregular lobes projecting from the linear or longitudinal axis of the fibers. In the particularly preferred embodiments of the invention, the fibers are of substantially circular or oblong cross section and in the most preferred embodiment are of circular or substantially circular cross section.
[0045] In this disclosure the terms “fiber” and “filament” are used interchangeably. The term “yarn” is meant any continuous running length of fibers, which may be wrapped with similar or dissimilar fibers, suitable for further processing into fabric by braiding, weaving, fusion bonding, tufting, knitting or the like, having a denier less than 10,000.
[0046] The term “strand” is meant either a running length of multifilament end or a monofilament end of continuous fiber or spun staple fibers, preferably untwisted having a denier of less than 2000.
[0047] The term “performance fiber” is meant any fiber or filament having a high tensile modular of elasticity of about 5,000 kg/mm 2 or more that provides an enhanced performance function, such as in cut resistance, abrasion resistance, heat resistance or the like.
[0048] In general the specific filament or fiber combination is employed in any particular situation will depend to a large intent to the functional use of the apparel or outside. In the present invention along with enhancing the performance characteristics of the garment or article, the single layer construction reduces the weight and increases the flexibility and comfort factor. Furthermore, since the performance fiber can be specifically located anywhere on the fabric the amount of high performance fiber along with the expense can be reduced.
[0049] The type of fibers used in the fabrication of the present unilayer flexible performance textile fabric include organic polymer and inorganic fibers.
[0050] Preferably, filaments having a high tensile modulus of elasticity of 5,000 kg/mm 2 or more are usable for the performance fibers which are knitted into the base fabric. Illustrative of useful organic fibers having a high tensile modulus are those selected from the group consisting of aramid fibers, liquid crystal, copolyester fibers, nylon fibers, polyacrylonitrile fibers, polyester fibers, high modular weight polyvinylalcohol fibers and ultra high modular weight polyolefin fibers and mixtures thereof.
[0051] High modular weight polyethylene and polypropylene fibers are polyolefin fibers which may be used as performance fibers in preferred embodiments. In the use of polyethylene, suitable fibers are those which have a molecular weight of at least 150,000, preferably at least one million, and more preferably between two and five million. Such extended-chain polyethylene (EC PE) fibers are a high tensile material which are inherently resistant, as well as, being abrasion resistant and flexible providing a superior cut resistant yarn especially for protective gloves. SPECTRA® is a tradename of an ultra high molecular weight extended-chain polyethylene that is marketed.
[0052] Similarly, high oriented polypropylene fibers of molecular weight at least of 20,000 preferably at least one million, and more preferably at least two million may be used. Such high molecular weight polypropylene may be formed into reasonably well oriented fibers by techniques prescribed in U.S. Pat. No. 4,551,293 which is herein incorporated by reference. The particularly preferred ranges for the above-described parameters can advantageously provide improved performance in the final article and employed as a performance fiber.
[0053] High molecular weight polyvinyl alcohol fibers having a high tensile are described in U.S. Pat. No. 4,440,711 which is herein incorporated by reference. In the case of polyvinyl alcohol (PV-OH), PV-OH fibers having a weight average molecular weight of at least 200,000 may be used. Particularly useful PV-OH fibers should have a tensile modulus of at least 5,000 kg/mm 2 or more. Most preferred fibers are poly-pphenylene terephthalate KEVLAR® filaments marketed under the tradename KEVLAR® and poly-m-phenylene terphthalate marketed under the tradename NOMEX® each by E. I. DuPont de Nemours &Co., Inc., Wilmington, Del. Each such aramid fiber has strong, high temperature resistant, cut resistant, puncture, and abrasion resistant properties. Most preferred are para-aramide fibers having a tensile modulus of elasticity of about 7,100 kg/mm 2 .
[0054] Another high tensile fiber useful in certain applications of this invention is formed from polybenzimidazole polymers available from Celanese Corporation, Chatham N.J., under the tradename P.B.I.® fibers.
[0055] Polyacrylonitrite (PAN) fibers of a molecular weight of at least 400,000 are suitable. Since fibers are disclosed in U.S. Pat. No. 4,535,027 which is incorporated herein by reference.
[0056] Liquid crystal copolyester suitable in this invention are disclosed in U.S. Pat. Nos. 3,975,487 4,118,372 and 4,161,470 all hereby incorporated by reference.
[0057] In the case of nylon fibers, suitable fibers include those formed from nylon 6, nylon 10 and the like.
[0058] Suitable polyester fibers include polyethylene terephthalate.
[0059] Illustrative of useful inorganic fibers having a high tensile modulus are those selected from the group consisting of S-glass fibers, E-glass fibers, steel filaments, carbon fibers, boron fibers, aluminum fibers, zirconic-silica fibers, aluminum-silica fibers and mixtures thereof. Preferred are glass fibers having a tensile modulus of elasticity of about 7,000 kg/mm 2 . Preferred steel filaments have a tensile modulus of elasticity of about 20,000 kg/mm 2 .
[0060] Low tensile modulus fibers having a tensile modulus of 3,000 kg/mm 2 or less are effective for importing the high degree of flexibility to the unilayer base fabric and the susequent garment manufactured therefrom.
[0061] The synthetic fibers are preferably selected from the group consisting of viscose rayon fibers, aliphatic polyamide fibers, polyacrylic fibers, polyester fibers, water insoluble modified polyvinyl alcohol fibers and mixtures thereof. Most preferred fibers for the base fabric are natural fibers such as cotton and wool. Both fibers have the flexibility characteristics desired and provide a proper comfort level to wearer. For these reasons they can be positions proximate to wearers skin.
[0062] Fibers having a relatively low tensile modulus can be used independently or together with ordinary relatively low tensile modulus fibers, without difficulty, in the method of this invention.
[0063] The performance fiber can also be a blend of mixed fibers, i.e. a lower strength fiber with the high strength fiber. Likewise, the performance fiber could be a composite fiber wherein the matrix is a softer material impregnated with a hard material such as carbon or glass fibers.
[0064] In addition, the fibers can be composed of fibers with anti-microbial additives or otherwise impregnated with an anti-microbial agent.
[0065] Even one skilled in the art might assume that the hard fibrous materials used as part of this invention would be very brittle and therefore of limited use in protective garments where flexibility and comfort are of major concern. The glass or steel filaments which would normally be used in this invention are extremely small in diameter. If a larger diameter is required, an impregnated fiber, described above, can be used. As a result, these hard materials are still very flexible and can be bent around a very small radius without breaking. In this embodiment it is preferred that the hard fibrous material is located within the matrix of the yarn. By placing the hard material in the matrix of the yarn, the hard material is exposed to the least stress during bending of the yarn. Furthermore, by placing the hard material within the matrix, the outer portion of flexible material helps to protect the more brittle, harder component.
[0066] In many cases, it will be preferred that the hard fibrous material be coated with a continuous layer of elastic material. This coating has several functions. For example, if the hard material is a multifilament fiber, the coating holds the fiber bundle together and helps protect it from stresses that develop during the manufacturing process. Furthermore, the coating may provide a physical or chemical barrier for the hard material. Finally, if the hard material is broken during use, the coating will trap the material so that it will not leave the fibrous structure.
[0067] It is to be understood that the present invention provides for a multiplicity of embodiments by using any of a large number of protective materials in combination to form a composite in a single layered fabric. Consequently, the invented fabric can be made into a large variety of articles and protective apparel used for protection against numerous potential hazards.
EXAMPLE 1
[0068] A cut-resistant glove having isolated patterns of high tensile modulus fibers in critical locations is prepared.
[0069] The method of manufacture involves first chain-stitching a 100 percent cotton fiber on a programmed flat knitting machine, such as describer in U.S. Pat. No. 4,479,368, to form a base fabric in a mesh and web construction having a weight of about 4 to 7 oz/sq yd. After the base fabric is formed it is downloaded into a knitting machine into which the design of the isolated patterns have been programmed. KEVLAR® having a denier of the individual filament of 1.5 and a tensile modulus of 5900 kg/mm 2 is knitted into the same layer as the mesh and web of the base fabric. The movement of the knitting needle with respect to the palm portion and the finger and thumb stalls is controlled by a computer.
[0070] To complete the assembly of the glove, the edges of the back and palm portions, along with the finger and thumb stalls are secured by sewing aromatic polyamide fibers on a conventional industrial machine.
[0071] The glove has the desired qualities of high gripability, cut-resistance, puncture resistance, abrasion resistance, flexibility and softness.
[0072] It should be apparent to those skilled in the art, that other embodiments, improvements, details and uses can be made consistent with the letter and spirit of the foregoing disclosure and within the scope of this patent, which is limited only by the following claims construed in accordance with the patent statutes, including the doctrine of equivalents. | The present invention relates to a unilayer flexible performance fabric which may be fabricated into apparel and articles having high performance fibers, such as high tensile modulus fibers positioned within a base fabric in at least one preselected location only where required to import performance characteristics which are equal to or exceed the specifications for the garment. For example, if cut resistance is a requirement, performance fibers which provide such protection from this hazard would be used. Likewise, if abrasion resistance is intended for an apparel such as coveralls, only the knees and elbows would require the performance fiber. Thus, reducing the amount of expensive fibers normally used. The invented fabric is manufacturede in a method in which the placement of the fabric in preselected locations is computer controlled. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] Embodiments of the present disclosure are related in general to the field of installation of supports for uprights of fences, traffic signs, real estate signage, etc., and in particular to post supports that can be permanently installed, and from which one post can be removed and another emplaced.
[0003] 2. Description of the Related Art
[0004] A post is a substantially straight, elongated columnar structure that is anchored at one end so as to stand upright, and that supports thereon another structure. A post can be made of any appropriate material, including wood, metal, concrete, or plastic. Posts of various lengths and compositions are used in a wide range of applications, including supporting fences, traffic control signs, temporary structures, etc. Where a post is intended to be substantially permanent, it is often placed in a hole and anchored in a concrete footing to increase its cross section so as to be held firmly in place by the surrounding earth. One problem that is commonly encountered in such situations is that posts, especially wooden posts, are subject to breakage, warpage, and decomposition. Replacing a post that has been anchored in concrete is difficult, wasteful, and unfriendly to the environment for reasons that include excessive use of natural resources and the generation of landfill material. The concrete footing must be removed from the ground in order to make room for the new post. This requires that a much larger hole must be dug around the concrete footing. In turn, this requires a much larger volume of concrete or re-compaction of the surrounding soil, to fill the hole around the new post and create the new footing in proper contact with undisturbed or adequately compacted soil.
[0005] One of the most common causes of deterioration in wooden posts is water trapped around the end of the post inside the concrete. For example, when the post is damp or wet for an extended period of time, the wood absorbs water and draws it by capillary action downward into the concrete footing. Water becomes trapped between the wood and the inside wall of the concrete, so that the end of the post remains wet even while the upper portion is dry. This is especially true in cases where the end of the post is completely encapsulated in concrete, preventing water from escaping through the bottom of the footing, in which case the majority of the water escapes only through the wicking action of the end grain of the post.
[0006] To reduce this problem, installers often pour several inches of gravel into the bottom of a post hole and place the post directly on the gravel before they pour concrete around it. This prevents the concrete from completely sealing up the bottom of the post by flowing under it, and thus provides a channel for water to escape into the gravel. However, this is only a partial solution. Often the drainage gravel is not fully compacted and settles, causing more need for repair and replacement. Furthermore, with this common method, it takes substantial time for water, once having entered the footing, to work its way all the way through the footing and out the bottom. If the post is subjected to frequent or extended wet periods, the end of the post inside the footing may remain constantly wet even though water continues to drain out the bottom. Additionally, because of the direct contact with the ground on the end of the post, water can move upward into the footing when the ground is wet, due to the capillary or wicking effect of the end grain. This constant dampness encourages the growth of organisms that digest the wood fiber and eventually destroy the post, or in the case of steel, rusts the post away. Additionally, the bottom of the footing is substantially open to insects, which can enter unobstructed from the gravel below to attack and eat the post.
[0007] Another approach that is used to protect wood posts and other lumber in direct contact with the ground or with concrete is commonly referred to as pressure treating. In this process, protective chemicals are forced into an outer surface of the post under high pressure. The chemicals provide the post with protection from common funguses and other organisms that cause deterioration. Pressure treatment generally extends the useful life of a post by a factor of five to ten. However, the chemicals used in pressure treatment are often toxic to humans and non-target organisms, and can leach into the water supply. In other cases, the chemicals are highly corrosive, tending to cause corrosion in fasteners and structures that are attached thereto. An additional problem with pressure treatment is that the wood cannot generally be recycled when it is replaced, and should not be composted, because of the chemicals still present. This means that it must be deposited in a landfill which in turn is a result of the need to install a post in direct contact with the ground and or concrete.
[0008] A third approach to this problem is the use of prefabricated anchors or sleeves, i.e., pockets or sleeves that are placed in the ground or anchored in a concrete footing. These anchors permit a post to be removed and replaced without requiring that the sleeve itself be replaced. Some examples of such anchors and methods of installation are disclosed in the following U.S. patents and patent application Publications, all of which are incorporated herein by reference in their entireties: US Publication No. 2009/0320396; US Publication No. 2010/0277290; U.S. Pat. No. 5,632,464; U.S. Pat. No. 6,098,353; U.S. Pat. No. 7,325,790; and U.S. Pat. No. 7,861,434.
BRIEF SUMMARY
[0009] According to an embodiment, a post sleeve installation assembly includes an elastomeric sleeve core shaped to form a post sleeve when positioned in an uncured concrete footing, a stiffener removably positioned inside the core with an aperture extending lengthwise therein, a locking element positioned within the sleeve core, and an assembly plate coupled to the stiffener. The assembly plate is configured to attach to a prefabricated sleeve element, with the sleeve core and stiffener positioned within a post cavity of the sleeve element. An installation stake is positioned in the aperture and prevented from sliding upwards by the locking element. A release point on the assembly plate permits an operator to release the locking element and permit removal of the stake.
[0010] To install a post sleeve, the operator positions the installation assembly, including a prefabricated sleeve element clamped thereto, in a post hole with the stake resting on the bottom. The hole is filled with concrete, and while wet, the operator positions the assembly as desired. The operator can manipulate the upper end of the stake to position the sleeve, or can use other positioning means. When the concrete is cured, the operator drives the stake a few inches downward to break through any concrete that may have hardened below the stake, thereby ensuring drainage of the post sleeve to below the concrete footing. The operator then releases and withdraws the stake, removes the assembly plate and stiffener, and finally removes the elastomeric sleeve core, leaving a complete post sleeve formed in part by the sleeve element and in part by the sleeve core.
[0011] According to an embodiment, a prefabricated sleeve element is provided, including a post cavity extending therethrough. A post sleeve sock is attached to a lower end of the post cavity, and is configured to receive the lower end of a post positioned in the cavity. To form a complete post sleeve, a post is positioned in the sleeve element with its lower end encased in the sock. The assembly is placed in a post hole which is then filled with concrete. The sock prevents the concrete from adhering to the post, and is preferably of a thickness and pliancy sufficient to permit removal of the post. The sock may be configured to deteriorate over time, so that, initially, the post is held firmly in the concrete footing. After the sock has deteriorated, removal of the post is possible.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a post sleeve assembly according to an embodiment.
[0013] FIG. 2 is a perspective view of a sleeve cap of the assembly of FIG. 1 .
[0014] FIG. 3 is a perspective view of an elastomeric core according to an embodiment.
[0015] FIG. 4 is a side elevation view of an installation assembly according to the embodiment of FIG. 1 .
[0016] FIG. 5 is a top plan view of the installation assembly of FIG. 4 .
[0017] FIGS. 6 and 7 are cross-sectional views of portions of the post sleeve assembly of FIG. 1 taken along lines 6 - 6 and 7 - 7 , respectively, of FIG. 5 .
[0018] FIG. 8 is a side cut-away view of a post hole with a post sleeve assembly positioned therein.
[0019] FIG. 9 is a side cut-away view of the post hole of FIG. 8 showing the permanent elements of the post sleeve.
[0020] FIG. 10 is a diagrammatic perspective view of an elastomeric post sleeve core according to another embodiment.
[0021] FIG. 11 is a diagrammatic cross-sectional view of the elastomeric post sleeve core of FIG. 10 .
[0022] FIGS. 12 and 13 are, respectively, a perspective view and a cross-sectional view of a post sleeve assembly 300 according to another embodiment.
[0023] FIG. 14 shows a portion of a sock 330 made from bubble wrap, according to an embodiment, which includes a plurality of bubbles on a web layer.
[0024] FIG. 15 is a diagrammatic cross section of the portion of FIG. 14 , taken along lines 15 - 15 .
[0025] FIG. 16A is a perspective view of a plurality of post sleeve assemblies, according to an embodiment.
[0026] FIG. 16B is an enlarged view of the portion of FIG. 16A indicated in FIG. 16A at 16 B.
DETAILED DESCRIPTION
[0027] FIG. 1 shows a post sleeve assembly 100 according to an embodiment, that includes an elastomeric core 102 , a prefabricated sleeve cap 104 , and an installation assembly 106 . Also shown are a reference index 103 and an installation stake 109 . The reference index 103 includes a position scale 105 .
[0028] The installation assembly 106 includes a top plate 107 to which other components of the assembly are attached, including handles 108 , clamps 110 , a bullseye level 112 , alignment guides 116 , and cam release buttons 118 . Each of these elements will be described later in more detail. A central cavity 114 is provided in the top plate and sized to receive the reference index 103 for use during installation of a post sleeve.
[0029] FIG. 2 is a perspective view of the sleeve cap 104 . The sleeve cap 104 is a prefabricated component that is made, preferably, from high-strength concrete, and is configured to be fixed in a concrete footing as the upper portion of a post sleeve. The sleeve cap 104 includes various features configured to be engaged by the wet concrete of the footing during installation to provide a secure lock between the cap and the footing. These features include a plurality of cavities 140 spaced around the outer sides of the cap, and tabs 141 extending from the bottom edge of the cap. In addition to providing structure to which the concrete footing can lock, the tabs 141 also provide advantages during transport of the sleeve cap, as will be explained in detail later. The sleeve cap 104 includes an upper rim 142 that extends at an angle out from the body of the cap, and serves to drain rain water away from the post sleeve. The upper rim 142 can be provided with graphics, such as, e.g., the name or logo of the manufacturer, as shown in FIG. 2 , or can be textured to resemble stone, or otherwise decorated. A post cavity 144 extends through the sleeve cap 104 , configured to receive a post having selected dimensions. Stand-off ribs 146 are sized to contact the surface of a post having the selected dimensions, when such a post is positioned therein. The ribs 146 define between them channels that permit water to drain to the bottom of the post cavity 144 , even with a post positioned in the cavity.
[0030] FIG. 3 is a perspective view of an elastomeric core 102 , according to an embodiment. The core 102 includes an upper portion 124 , a main body 126 , and a lower portion 128 . An upper rim 122 extends above the upper portion 124 and has lateral dimensions that are greater than those of the upper portion. A seal ridge 132 defines the transition between the upper portion and the main body. A stiffener cavity 120 extends through the core. The upper portion 124 of the core 102 is configured to fit inside the post cavity 144 of the sleeve cap 104 . Because the core is made from an elastomeric material and is hollow, it can be collapsed onto itself to permit insertion into, and removal from the post cavity 144 of the post sleeve cap 104 . The elastomeric material of the post sleeve core 102 can be, for example, synthetic rubber or silicone.
[0031] Selected features 134 of the upper portion 124 of the core 102 are provided to mate with corresponding features in the interior of the post cavity 144 , such as, for example, the stand-off ribs 146 . When the elastomeric core 102 is positioned in the post cavity 144 , the seal ridge 132 of the core lies against the bottom of the sleeve cap 104 . The seal ridge 132 acts to retain the core 102 in its proper position and to prevent wet concrete from oozing into the post cavity 144 during installation.
[0032] The main body 126 and lower portion 128 of the core 102 are provided with negative shapes corresponding to selected features to be formed within the post sleeve. In the embodiment of FIG. 3 , exemplary shapes are shown that correspond, for example, to plate stops 130 , drain channels 131 , and a universal socket formed in the lower portion 128 . These and other elements are described in detail in the '396 and '290 publications referenced and incorporated above. An aperture 129 is provided in the lower portion 128 , through which the installation stake 109 passes.
[0033] Turning now to FIGS. 4 and 5 , the installation assembly 106 is shown, according to an embodiment, in a side elevation view and top plan view, respectively. The installation assembly 106 includes a stiffener 158 , as shown in FIG. 4 , that is coupled to the top plate 107 , positioned so as to fit within the stiffener cavity 120 of the elastomeric core 102 when the top plate and core are both properly coupled to the sleeve cap 104 . The stiffener 158 fits snuggly in the stiffener cavity 120 to prevent distortion of the shape of the core under the weight and pressure of uncured concrete during formation of a post sleeve. A lower end 160 of the stiffener fits within the lower portion 128 of the elastomeric core 102 , and includes, according to some embodiments, a replaceable tip 157 that extends through the aperture 129 of the core. According to other embodiments, the aperture 129 of the core 102 extends below the lower end 160 of the stiffener and provides a resilient seal against the stake 109 . Because rubber and the like are not compressible, and pressure exerted by wet concrete at any given depth is substantially isostatic, the core 102 will not appreciably distort, except in response to the difference in pressure at different depths, provided there are no underlying gaps or cavities into which it can be moved by the pressure of the wet concrete. Distortion caused by fluid pressure differentials can be calculated and compensated for in the dimensions of the core 102 , so that the core takes the desired final dimensions once it is submerged in the wet concrete. Thus, the elastomeric core 102 will produce a substantially accurate post sleeve shape in the concrete as it cures. On the other hand, when the stiffener 158 is absent, the core can be easily collapsed into itself for insertion and removal.
[0034] The stiffener 158 can be made of any material that is sufficiently strong to withstand the pressure of the uncured concrete in which the core 102 is positioned without appreciably deforming. It can be made, for example, from extruded aluminum, sheet metal, structural foam, or rigid plastic.
[0035] The clamps 110 of the installation assembly 106 include inwardly extending clamp flanges 156 configured to engage the rim 142 of the sleeve cap 104 as shown in FIG. 1 , and are inwardly biased by springs 152 so that the assembly, the core 102 , and the sleeve cap remain securely locked together until released by an operator. With the clamp flanges 156 engaging the rim 142 of the sleeve cap 104 , the top plate 107 of the installation assembly 106 presses down on the rim 122 of the elastomeric core 102 . The elastomeric material of the core 102 acts as a spring to bias the top plate 107 upward, which maintains the elements of the post sleeve assembly 100 in correct relative position. The operator releases the installation assembly 106 by grasping handles 154 of the clamps 110 and puling the clamps outward against the bias of the springs 152 , as shown in FIG. 4 . In this position, the clamps release the rim 142 of the sleeve cap. When the clamps 110 are released, the top plate 107 is pushed upward a small distance as the rim 122 of the elastomeric core 102 returns to its resting shape. This raises the clamp flanges 156 above the rim 142 of the sleeve cap 104 and prevents the clamps 110 from relocking when the operator allows them to return toward their normal positions.
[0036] The alignment guides 116 and bullseye level 112 are provided as means by which the operator can position the post sleeve assembly 100 during installation, so that it is plumb and properly oriented, or aligned with other post sleeves. The central cavity 114 of the installation assembly 106 is sized to receive the reference index 103 . The index 103 is placed in the central cavity 114 and rests on a seat 117 (shown in FIG. 6 ) so as to extend from the installation assembly 106 . A method for positioning a plurality of post sleeves using reference indices is described in the '434 patent previously referenced and incorporated. It will also be recognized that various embodiments of the present disclosure can be adapted for use with others of the installation structures and methods disclosed in the '434 patent.
[0037] An aperture 115 is provided with a top end at the bottom of the central cavity 114 , coaxially with the central cavity, extending through the length of the stiffener 158 , and sized to receive the installation stake 109 . A corresponding aperture is provided at the bottom of the elastomeric core 102 to permit the installation stake to traverse the entire post sleeve assembly 100 along its longitudinal axis, so as to extend some selected distance from the bottom of the core. A locking mechanism is provided, preferably inside the stiffener to hold the installation stake at a selected position.
[0038] FIGS. 6 and 7 are cross-sectional views of portions of the post sleeve assembly 100 taken along lines 6 - 6 and 7 - 7 , respectively, of FIG. 5 , and showing details of the interior of the stiffener 158 . As shown in FIG. 6 , the cam release buttons 118 are coupled to first ends of cam release links 162 inside the top plate 107 . The cam release links 162 extend inside the stiffener from the top plate toward the bottom end of the sleeve core 102 , and are coupled at their second ends to a release pivot 161 which is in turn coupled to a pair of cams 164 of a locking mechanism 159 , as shown in FIG. 7 . A pair of cam springs 167 bias arms 165 of the cams 164 , generally urging the cams to rotate outwardly around cam pivots 163 . Outward rotation of the cam arms 165 causes jaws at the bottom edges of the cams to rotate inwardly. When an installation stake 109 is passed down through the aperture 115 it passes between the cams 164 , causing them to rotate slightly away from the stake and permitting it to pass between them. However, if upward pressure is applied to the stake 109 while it is positioned between the cams 164 , it applies a bias that cooperates with the cam springs 167 , causing the jaws of the cams to grip the stake tightly, and preventing upward movement of the stake. When the operator presses the cam release buttons 118 , the cam release links 162 move the cam release pivot downwardly, causing the cams to rotate against the cam springs 167 , and releasing the installation stake 109 , which can thus be removed. The installation stake is of particular use when deep footings are used, and explained below.
[0039] When a post is anchored in ground that is subject to a seasonal freeze/thaw cycle, the post can, over the course of a few seasons, be ejected from the ground by the expansion of water as it freezes. This occurs when water trapped below the footing of the post freezes, forcing the footing upward a small amount. In the spring, the ice thaws, leaving a gap that fills with more water, so that when the temperature drops and the water refreezes, the footing is raised further. One solution to this problem is the make the footing sufficiently deep that it extends below the local frost line. In some high-latitude regions, this depth can be more than four feet. Normally, to install a post sleeve an operator provides a post hole a few inches deeper than the length of the post sleeve plus the depth of any gravel drainage required. The post sleeve is placed in the hole and wet concrete is poured around it to fill the hole to about three-quarters of its depth. The operator then manually moves the post sleeve into the desired position, and finishes filling the hole. Buoyancy of the sleeve can be adjusted by adding weight to prevent the sleeve from floating too high in the wet concrete, and final adjustments are made to plumb and align the sleeve.
[0040] However, if the footing must extend below a deep frost line, placing the post sleeve assembly in the hole might leave the top of the assembly two or three feet below ground level, which can complicate the installation. According to an embodiment, the installation stake 109 is provided to assist in such situations. FIG. 8 is a side elevation view of the post sleeve assembly 100 positioned in a post hole 166 and including the installation stake 109 . In the example shown, the post hole 166 has a layer of gravel 168 for drainage, and is filled with concrete 170 to form a footing. The installation stake is preferably a steel bar, although it can be any material capable of supporting the weight of the post sleeve assembly 100 .
[0041] Prior to placing the post sleeve assembly 100 in the hole 166 , the stake 109 is positioned in the assembly 100 so as to extend a selected distance from the bottom of the assembly. The assembly 100 is then positioned in the post hole 166 so that the bottom end of the stake 109 rests on the bottom of the hole, supporting the post sleeve assembly at approximately the desired depth. As previously noted, the stake can easily slide downward, relative to the cams 164 , so the operator can increase the height of the post sleeve assembly above the bottom of the hole 166 by lifting upward on one of the handles 108 of the installation assembly 106 while holding the stake 109 in place, causing the stake to slide downward between the cams 164 . Once the post sleeve assembly 100 is at about the correct height, the hole 166 is filled and the final position and orientation of the sleeve assembly is adjusted, as previously described. The concrete footing 170 is allowed to cure, and the installation assembly is removed, leaving a complete post sleeve embedded in the footing 170 , as shown in FIG. 9 .
[0042] The installation stake 109 is preferably coated with a release agent to facilitate its removal after the footing is sufficiently cured. When the stake is withdrawn, it leaves a channel 180 in the footing, which permits water to drain to the gravel 168 below. It is anticipated that during the process of making the final adjustments to the position of the post sleeve assembly 100 , the bottom end of the stake 109 may be lifted a few inches from the gravel bed 168 , as shown in FIG. 8 , permitting concrete to flow underneath, which would prevent drainage of water to the gravel. To overcome this problem, the operator strikes the top of the stake 109 with a hammer or small maul before removing the stake. This causes the stake 109 to drive down through the “green” concrete, fracturing the material directly below, as shown at 184 ( FIG. 9 ), and opening a passage to the gravel 168 . This can be done without any concern for the integrity of the footing as a whole because when concrete is freshly cured, it is relatively soft, so that any damage remains local to the point of impact, and does not propagate.
[0043] To remove the stake 109 from the installation assembly 106 , the operator presses the cam release buttons 118 and pulls the stake from the assembly 100 . To remove the installation assembly 106 , the operator pulls outward on the handles 154 of the installation assembly, disengaging the clamps 110 from the rim 142 of the sleeve cap 104 . The operator applies upward force to the handles 108 , which lifts the installation assembly 106 from the sleeve cap 104 and pulls the stiffener 158 from the stiffener cavity 120 . The operator can leave the installation stake 109 engaged by the locking mechanism and remove the stake and installation assembly 106 as a unit, or can remove the installation assembly and stake separately.
[0044] With the stiffener 158 removed, the post sleeve core 102 is pliable. The operator grasps the rim 122 of the core 102 and manipulates it to cause it to collapse sufficiently to be pulled from the sleeve cap 104 and the concrete footing. If necessary, the core 102 can be coated with a release agent prior to being placed in the post hole, to facilitate its later removal. In one embodiment, a vacuum attachment can be pressed on the top surface of the core 102 to cause it to collapse for removal. The concrete footing, having cured around the sleeve core 102 , retains the features of the sleeve core, thereby forming the lower portion 176 of the post sleeve. In the embodiment of FIG. 9 , the lower portion 176 includes plate stops 182 , and a universal socket 178 , which are described in detail in the detail in the '396 and '290 publications referenced and incorporated above.
[0045] The stiffener 158 has been described as part of the installation assembly 106 , while the elastomeric core 102 has been described as a separate element. These relationships are for convenience and ease of description, but do not limit the scope of the claims. For example, according to various embodiments, the stiffener and elastomeric core comprise elements of a post sleeve core; according to other embodiments, the stiffener is configured to be positioned within a complete prefabricated post sleeve to guide and support the installation stake, so that no sleeve form, such as the elastomeric core, is required.
[0046] According to other embodiments that employ an installation stake, various alternative locking mechanisms are provided. For example, according to an embodiment, dimensions of the aperture 129 of the lower portion 128 of the elastomeric core 102 are selected to grip the installation stake 109 with sufficient force to support the weight of the post sleeve assembly 100 , so that the stake will support the post sleeve assembly at the selected position during installation. According to another embodiment, a locking mechanism is provided in the tip 157 of the stiffener 158 , such as a friction or compression coupling that provides adequate resistance to movement of the stake. During removal of the installation assembly 106 , the tip 157 detaches from the stiffener 158 and remains attached to the stake 109 .
[0047] According to an embodiment, a length of pipe or rigid tubing is coupled to the lower end 160 of the installation assembly 102 and serves, during installation, as an installation stake. When the installation assembly is removed, the pipe remains in the concrete footing to act as a drain channel for the post sleeve. The tip 157 can be configured to couple to the length of pipe, and can also be configured to be detachable from the stiffener so as to remain with the pipe when the stiffener and core are removed.
[0048] FIGS. 10 and 11 are, respectively, a perspective view and a cross-sectional view of an elastomeric post sleeve core 200 according to another embodiment. FIG. 11 also shows a stiffener 202 positioned in a stiffener cavity 204 of the core 200 . The core 200 includes main body 206 , a lower portion 208 , and an upper portion 214 . The main body 206 includes features 212 for forming, e.g., drain channels, stand-off ribs, and plate stops. Walls 216 of the stiffener 202 fit snuggly into the stiffener cavity 204 to provide the necessary support for the sleeve core 200 . As shown in FIG. 11 , a weight 222 can be positioned inside the stiffener 202 to give the combined core 200 and stiffener near neutral buoyancy in wet concrete, which allows the operator to more easily position and orient the combination before the concrete cures.
[0049] An extension portion 218 of the stiffener 202 extends from an opening at the bottom of the lower portion 208 of the core 200 . The extension portion 218 is configured to be engaged by a piece of hose or tubing which remains in the footing after the stiffener 202 and core 200 are removed, to provide a drain passage to gravel or other drainage below. According to an embodiment, elastomeric ridges 220 are provided on the end of the extension portion 218 , sized and configured to engage the threads of a standard garden hose coupling. An operator can cut an old garden hose to the necessary length and slide the bib coupling onto the extension portion 218 of the stiffener 202 . The other end of the hose is buried in the gravel at the bottom of the hole before the hole is filled with wet concrete. After the footing has cured, the stiffener is pulled from the core, with the ridges 220 releasing the threads of the coupling as the stiffener is removed. The core is then also removed, as previously discussed.
[0050] The embodiment of FIGS. 10 and 11 is provided for use without a prefabricated sleeve cap. Instead, the operator places the core 200 in the footing at a depth at which the top of the footing reaches somewhere on the upper portion 210 . When the core 200 is removed from the footing, post sleeve defined in the concrete by the core 200 has a corresponding upper portion that is smooth and regular in shape, and that can receive a collar that fits snuggly around a post positioned therein, to provide some protection from water and debris entering the sleeve.
[0051] FIGS. 12 and 13 are, respectively, a perspective view and a cross-sectional view of a post sleeve assembly 300 according to another embodiment. FIG. 12 shows the assembly 300 with a post 310 in place, while the cross section of FIG. 13 shows details of the assembly in an enlarged view. The post sleeve assembly 300 includes a sleeve cap 302 , an end cap 303 , and a connecting “sock” 304 , which is a sleeve in which the post 310 is placed for installation. The sock 304 can be made from any suitable material, including, for example, Tyvek®, polyethylene plastic, bubble wrap, etc.
[0052] The end cap 303 includes a first end cap segment 306 and a second end cap segment 308 that fit together in a friction or snap fit. The sock 304 is attached at a first end to a snap ring 312 that snaps into the lower end of the post aperture 144 of the sleeve cap 302 . The sock 304 is attached at a second end to a sock flange 314 of the first end cap segment 306 . The sock flange 314 is also configured to engage the lower end of the post aperture 144 by friction fit. While in storage and transit, the sock 304 is folded and positioned in the post aperture 144 , with the sock flange 314 of the first end cap segment 306 engaged with the lower end of the post aperture 144 directly below the snap ring 312 .
[0053] In addition to elements described above, the first end cap segment 306 includes standoff knobs 316 , configured to receive the bottom end of a post and provide space for water to drain into a reservoir cavity 313 provided in the second end cap segment 308 . A mating flange 315 extends downward from the first end cap segment 306 , and is configured to couple with the second end cap segment 308 .
[0054] A sidewall 318 of the second end cap segment 308 is configured to couple with the mating flange 315 of the first end cap segment 306 along a top edge 317 via a snap fit, and defines lateral dimensions of the reservoir 313 . Additionally, the sidewall 318 is configured to couple with the mating flange 315 at a bottom edge 319 via a friction fit (as will be discussed in more detail below with reference to FIG. 16 ). The sidewall 318 is reinforced by ribs 320 to provide sufficient strength to support the post 310 and the sleeve cap 302 during installation. A storage flange 321 extends upward from a bottom plate 326 of the second end cap segment 308 , and is configured to engage the upper end of the post aperture 144 of the sleeve cap 302 via a friction fit. During storage and transport, the second end cap segment 308 is positioned upside-down relative to the post sleeve 302 with the storage flange 321 engaged with the upper end of the post aperture 144 .
[0055] A drain aperture 324 permits water to drain from the reservoir 313 to soil or gravel below the post sleeve. The drain aperture 324 can be sealed with a suitably durable adhesive sticker or degradable material to allow a stake to penetrate or water to escape after it degrades. A snap-in or twist-in aperture ring 322 is positioned in the drain aperture 324 . The aperture ring 322 of the pictured embodiment provides a connection for a drain tube for drainage, for use in post sleeves where the second end cap segment 308 does not rest directly on soil or gravel. According to various embodiments, the aperture ring 322 can be removed or replaced with other elements that can be twisted (or snapped) into place, such as, e.g., a screen to prevent debris from passing through the drain aperture and clogging a drain field, an increased-volume drain reservoir, a holder for a slow-dissolving insecticide or insect repellant, etc.
[0056] During preparation for installation, an operator pulls the first and second end cap segments 306 , 308 from the post aperture 144 , snaps the top edge 317 of the second end cap segment to the bottom of the first end cap segment, and unfolds the sock 304 to its full length. The post 310 is positioned in the post sleeve assembly 300 and inside the sock 304 , with the bottom end of the post engaging the sock flange 314 . The sleeve cap 302 is positioned on the post so that the sock is fully extended, as shown in FIG. 12 . The sleeve cap 302 can be fixed to the post during installation by any appropriate means, including, for example, by friction, jamming shims, a nail driven through a fastener aperture into the post, or by any of the fasteners described in the previously incorporated '396 and '290 patent application publications. The post 310 and post sleeve assembly 300 are then placed into a pre-prepared post hole, with the second segment 308 of the end cap 303 resting on the bottom of the hole. The hole is filled with wet concrete to a depth reaching a little below the rim of the sleeve cap 302 , and the sleeve assembly is positioned and made plumb by manipulation of the post 110 . Once properly positioned, the weight of the post is generally sufficient to overcome any buoyancy so as to keep the end cap firmly at the bottom of the hole, and all other forces are balanced. Thus, the post 310 and post sleeve assembly 300 will remain in position until the concrete cures. Alternatively, the post can be fixed in position until the concrete has cured, using any of a number of well known methods.
[0057] After the concrete has cured, the post can be left in place, or can be removed and replaced. The sock 304 prevents the concrete from adhering to the post, enabling later removal of the post without damage to the concrete footing. According to an alternative embodiment, a core having the appropriate lateral dimensions is used in place of the post, then removed after the concrete has cured.
[0058] One advantage of using a core is that it can be made fractionally larger than the dimensions of the selected post size, which will leave a post sleeve cavity that will permit easier removal and insertion of the post. Another advantage is that the core can be provided with features that the sock will follow when encapsulated by the concrete, permitting the formation in the post sleeve of drainage channels etc. On the other hand, if a post is used, installation of the combined post/post sleeve assembly is nearly identical to the installation of a typical fence or sign post. Thus, for example, a consumer can purchase post sleeve assemblies for the support posts of a residential fence. Once the assemblies are assembled on the respective posts, they can be fixed in concrete footings substantially as they would be if the posts were emplaced directly in the footings. After the footings have cured, the consumer or contractor can leave the posts in place and proceed to assemble the fence as normal, while still obtaining the benefit of a post sleeve with a durable and decorative opening, and from which the post can be removed and replaced without damage to the sleeve.
[0059] As noted above, the sock 304 can be made from any of a number of suitable materials. The selection of the material is a design consideration that may depend on a number of factors, such as the frequency with which the post is likely to be removed or replaced; the material and uniformity of the post; the climate where the post sleeve is to be installed, i.e., the amount of moisture that is likely to be introduced into the post sleeve over a given period; etc. If the post is smooth and uniform in shape, a thin sock material can be used, producing a post sleeve cavity that is very close in size to the dimensions of the post. Multiple layers of such thin material can also be used to make removal of the post easier. A thicker sock material can also simplify post removal and permit efficient drainage, and can also compensate for some irregularities in the shape of the post.
[0060] According to an embodiment, the sock is made from bubble wrap, which is a common and inexpensive material generally used in packaging. As is well known, bubble wrap typically comprises a first layer of polyethylene plastic in which round depressions are formed, and which is then laminated to a second layer of plastic, trapping air in the depressions. The result is a web layer with bubbles formed on one side. The thickness of the bubble wrap can be any appropriate value. For example, bubble wrap having a thickness of about ⅛ inch is commonly available. A sock made from such material will produce a sleeve cavity that is ¼ inch larger than the post, which permits simple removal and replacement of the post.
[0061] FIG. 14 shows a section of a sock 330 made from bubble wrap, according to an embodiment, which includes a plurality of bubbles 332 on a web layer 334 . FIG. 15 is a diagrammatic cross section taken along lines 15 - 15 of FIG. 14 , showing the section 330 positioned between a post 310 and wet concrete 336 , with the bubbles 332 on the side facing the post, and the web layer 334 on the side facing the wet concrete.
[0062] As compared to typical bubble wrap, selected ones of the plurality of bubbles 332 are absent from the exemplary pattern of FIG. 14 , resulting in gaps at selected intervals. The pressure of the wet concrete 336 against the web layer 334 causes the web layer to sag inwards at the locations of the gaps, and touch, or nearly touch the post 310 at the centers 338 of the gaps. After the concrete cures, the bubble wrap can be removed, or left in place to deflate and disintegrate over time. In either case, the resulting post sleeve is formed with a plurality of small knobs in locations corresponding to the centers 338 . A post positioned in the sleeve will be supported by the knobs, while moisture can easily drain around them to the bottom of the sleeve.
[0063] While bubble wrap can be manufactured according to any desired pattern, including the pattern shown in FIG. 14 , it may be economically advantageous to use bubble wrap that is commercially available, instead of going to the expense of producing the tooling to make a custom pattern. According to an embodiment, a pattern of pin points is provided on a roller, over which lengths of standard bubble wrap are passed. The pin points are positioned so as to perforate selected ones of the bubbles, which then deflate, producing a desired pattern, such as, e.g., the pattern shown in FIG. 14 .
[0064] Turning now to FIGS. 16A and 16B , a plurality of post sleeve assemblies 300 are shown, according to an embodiment; one post sleeve assembly 300 a is shown in a partial cut-away view. FIG. 16B shows an enlarged view of the portion of FIG. 16A indicated at 16 B, showing additional detail. A sock is not shown in FIGS. 16A and 16B in the post aperture 144 a , but would normally be coupled at one end to the sock flange 314 a and at the other end to the snap ring 312 a and folded into the post aperture for storage and transport. The sleeve assemblies 300 are shown as they would be positioned relative to each other during storage and transport. The first end cap segment 306 of each is coupled to the lower end of the respective post aperture 144 and the second end cap segment 308 is coupled to the upper end, as previously described. The sleeve assemblies 300 are positioned top-side down on a pallet or equivalent supporting structure (not shown). Tabs 141 provided around the bottom of each sleeve cap 302 interlock with those of adjacent sleeve caps, and serve to prevent shifting of the sleeve caps relative to each other.
[0065] Post sleeve assembly 300 a is shown stacked on top of post sleeve assembly 300 b . The bottom edge 319 a of the second end cap segment 308 a of the post sleeve assembly 300 a engages the mating flange 315 b of the first end cap segment 306 b of post sleeve assembly 300 b . This maintains the post sleeve assembly 300 a in alignment with the post sleeve assembly 300 b , and prevents shifting of one relative to the other during transport. Portions of the first end cap segment 308 a and of the second end cap segment 308 b are interposed between the top of the sleeve cap 302 a and the bottom of the sleeve cap 302 b , preventing direct contact between the sleeve caps. This serves to protect from damage the upper rim 148 a of the sleeve cap 302 a , which will be visible after installation, and which may, in some embodiments, include decorative detail.
[0066] It can be seen that because of the interlocking elements of the post sleeve assemblies 300 , they can be securely stacked and assembled, and will resist relative movement or shifting, thus improving safety and reducing breakage losses. FIG. 16 shows only a small number of post sleeve assemblies 300 . In practice, the number of post sleeve assemblies per layer, and the number of layers will vary according to a number of factors, including size of the pallet, lifting capacity of handling machinery, available space for storage or transport, etc. While the post sleeve assemblies 300 are shown stacked in a top-side-down arrangement, they can also be stacked top-side-up, in which case provisions are preferably made to accommodate the mating flanges 315 of the first end cap segments 306 , so that the weight of a stack of sleeve caps does not rest entirely on the mating flange of the lower-most assembly in each stack. Such provisions can include, e.g., appropriately positioned spacers or shims, or cavities formed in the top surface of a transport pallet, sized to receive the flanges.
[0067] According to another embodiment, a sock is provided, that is pulled over the bottom end of a post prior to placing the post in a wet concrete footing. The sock is preferably made of a material that has sufficient thickness that the post can be easily removed from the footing after it has cured. A plastic collar is provided, which permits the top of the sock to be stapled or nailed to the post.
[0068] It is well known that concrete continues to cure and harden for many years after being poured. Thus, the term cure, when used with reference to poured concrete, can be relative. For the purposes of the specification and claims, cured, and related terms, are to be construed as meaning sufficiently cured. Accordingly, where a claim recites, e.g., “removing the post sleeve core from the cured concrete,” the “cured concrete” is concrete that is cured sufficiently for removal of the core without causing damage or distortion to the newly formed post sleeve.
[0069] In describing the embodiments illustrated in the drawings, directional references, such as upper, lower, top, bottom, etc., are used to refer to elements as they would be oriented when installed, or during installation. To the extent that such terms are used in the claims, they are to be construed accordingly.
[0070] Ordinal numbers, e.g., first, second, third, etc., are used according to conventional practice, i.e., for the purpose of clearly distinguishing between disclosed or claimed elements or features thereof. The use of such numbers does not suggest any other relationship, e.g., order of operation or relative position of such elements, nor does it exclude the possible combination of the listed elements into a single, multiple-function, structure or housing. Furthermore, ordinal numbers used in the claims have no necessary correspondence to those used in the specification to refer to elements of disclosed embodiments on which those claims read.
[0071] Where a claim limitation recites a structure as an object of the limitation, that structure itself is not an element of the limitation, but is a modifier of the subject. For example, in a hypothetical limitation that recites “a post sleeve configured to receive a post,” the post is not an element of the claim, but instead serves to define the scope of the term post sleeve. Additionally, subsequent limitations or claims that recite or characterize additional elements relative to the post do not render the post an element of the claim.
[0072] The term coupled, as used in the claims, includes within its scope indirect coupling, such as when two elements are coupled with one or more intervening elements even where no intervening elements are recited.
[0073] The abstract of the present disclosure is provided as a brief outline of some of the principles of the invention according to one embodiment, and is not intended as a complete or definitive description of any embodiment thereof, nor should it be relied upon to define terms used in the specification or claims. The abstract does not limit the scope of the claims.
[0074] Aspects and features of the various embodiments described above can be combined to provide further embodiments. All of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, and foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, including U.S. patent application Ser. No. 13/243,843, filed Sep. 23, 2011 and U.S. Provisional Application No. 61/533,702 filed Sep. 12, 2011, are incorporated herein by reference in their entireties. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.
[0075] These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure. | A method of forming a post sleeve within a post hole in the ground to include a post receiving cavity to insertably receive and support a post is provided. The method includes positioning a post sleeve core within the post hole with the aid of an elongate installation member and depositing uncured material into the post hole to at least partially surround the post sleeve core while the post sleeve core is attached to the elongate installation member. The method further includes allowing the uncured material to harden around the post sleeve core to form at least a portion of the post-receiving cavity of the post sleeve and removing the post sleeve core from the hardened material to expose the post receiving cavity to receive and support the post. Other related methods of forming post sleeves are also provided. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to devices for enclosing elongate objects for example pipes or cables and in particular to dimensionally-recoverable devices for enclosing such objects.
Dimensionally-recoverable wrap-around devices have become widely employed for sealing, insulating or otherwise protecting a substrate where the use of a preformed tubular cover, such as a sleeve, is not possible or convenient, for example where the end of an elongate substrate is not accessible. In general, a wrap-around device comprises a cover which is adapted to be wrapped around the substrate to be enclosed, and a closure arrangement for securing the cover in tubular form about the substrate. After being secured about the substrate, the cover may be recovered onto the substrate by the application of heat or by another appropriate method. Examples of wrap-around devices are described in U.S. Pat. Nos. 3,379,218, 3,455,336, 3,530,898, 3,542,077, U.K. Patent Specification No. 1,561,125 and in German Offenlegungsschrift No. 1,947,057, the disclosures of which are incorporated herein by reference.
Whilst the above wrap-around devices are suitable for enclosing straight substrates of generally uniform dimensions, no previously proposed device is entirely satisfactory for sealing a substrate against ingress of fluids, where the shape or dimensions of the substrate vary abruptly, for example where a tubular substrate has a sharp bend or branch e.g. in the form of a "T", or where the substrate is in the form of a "transition", i.e. where the diameter of the substrate increases or decreases abruptly along its length. It has been found that the closure arrangements of such substrates either are not susceptible to being located about abrupt changes in the surface of the substrate or, if they are, cannot form a reliable seal against ingress of fluids.
SUMMARY OF THE INVENTION
The present invention provides a device for enclosing at least part of an elongate object, which comprises a dimensionally-recoverable cover adapted to be positioned about the object and recovered thereon, the cover having corresponding closure portions preferably extending along or adjacent to the edges of the cover which are non-perforate and which can be retained together in a lap configuration by means of a mechanical closure arrangement which comprises a plurality of closure elements spaced apart along each closure portion, the closure elements of each closure portion being interlockable with the closure elements of the corresponding closure portion so that the closure portions can be retained together and adjacent pairs of engaged closure elements can move with respect to each other.
Preferably the adjacent pairs of engaged closure elements can move with respect to each other, if necessary, during recovery of the cover by changing their separation and/or their relative orientation.
The phase "lap configuration" as used herein includes any configuration in which one edge portion overlies another edge portion. Thus the phrase includes levelled lap, joggle lap, half lap and double lap joint configurations as described in the Adhesives Handbook (Skeist). In addition the phrase includes so called scarf joint configurations which are formed if the edge portions are tapered so that their thickness decreases in a direction toward their edges.
As stated above, the cover of the device is dimensionally-recoverable. Dimensionally-recoverable articles are articles, the dimensional configuration of which may be made substantially to change by the appropriate treatment. Thus, for example, the cover may comprise an elastomeric material which is bonded to a layer of material that holds the elastomeric material in an extended configuration, and which will contract when the bond is broken. Examples of such articles are disclosed in U.S. Pat. No. 4,070,746 and U.K. Specification No. 2,018,527A, the disclosures of which are incorporated herein by reference. Preferably the cover is dimensionally heat-recoverable. Heat-recoverable articles may, for example, be produced by deforming a dimensionally heat-stable configuration to a dimensionally heat-unstable configuration, in which case the article will assume, or tend to assume, the original heat-stable configuration on the application of heat alone.
According to one method of producing a heat-recoverable article, a polymeric material is first extruded or moulded into a desired shape. The polymeric material is then cross-linked or given the properties of a cross-linked material by means of chemical cross-linking initiators or by exposure to high energy radiation, for example a high energy electron beam or gamma radiation. The cross-linked polymeric material is heated and deformed and then locked in the deformed condition by quenching or other suitable cooling methods. The deformed material will retain its shape almost indefinitely until exposed to a temperature above its crystalline melting temperature, for example about 115° C. in the case of polyethylene. Examples of heat-recoverable articles may be found in U.S. Pat. No. 2,027,962 and UK Patent Specification No. 990,235, the disclosures of which are incorporated herein by reference. As is made clear in U.S. Pat. No. 2,027,962, however, the original dimensionally stable heat-stable configuration may be a transient form in a continuous process in which, for example an extruded tube is expanded, whilst hot, to a dimensionally heat unstable form.
Any polymeric material to which the property of dimensional recoverability may be imparted, may be used to form the cover. Preferably the cover comprises a polymeric material to which the property of dimensional recoverability has been imparted by crosslinking and deforming the material. Polymers which may be used to form the polymeric material include polyolefins such as polyethylene and ethylene copolymers for example with propylene, butene, vinyl acetate or ethyl acrylate, polyamides, polyurethanes, polyvinyl chloride, polyvinylidene flouride, elastomeric materials such as those described in UK Specification No. 1,010,064 and blends such as those disclosed in UK Specification Nos. 1,284,082 and 1,294,665, the disclosures of which are incorporated herein by reference. Preferably the cover is formed from a polyolefin or a blend of polyolefins, and especially it comprises polyethylene.
The closure arrangement preferably includes means for retaining the closure elements in engagement during recovery of the cover, which means will accommodate relative movement between adjacent pairs of engaged closure elements. The retaining means is arranged to retain the closure elements in engagement against any forces tending to separate them which may be caused by recovery of the cover. Thus, the retaining means should resist not only any shear forces on the edge portions which are arranged in the form of a lap joint, but also forces tending to lift the over-lying edge portion off the underlying edge portion. These latter forces are particularly pronounced in parts of the wrap-around device that are located in the crotch region or regions of `T's` and bends in the substrate or any other region of the substrate in which surfaces of the substrate meet at a dihedral angle (which may be acute, obtuse or, more usually, substantially a right-angle), and may be due to a number of reasons. These forces occur even if the region of the surfaces where they meet is rounded (as with a welded joint) so that there is no geometrically defined line of intersection, and the term "dihedral angle" is intended to include this arrangement. The forces may be caused by the fact that it is often not possible to cause all parts of the cover to recover simultaneously. Thus, for example, where the wrap-around device is arranged to enclose a "T", each leg of the wrap-around device being recoverable in a radial direction, recovery of any one leg will correspond to recovery in an axial direction with respect to a leg perpendicular thereto.
If one leg is recovered on to the substrate initially, subsequent recovery of a leg perpendicular to it will cause axial tension along the edge portions of the cover, tending to lift the overlying edge portion away from the underlying one in the crotch region. In addition, due to the relatively low thermal conductivity of the materials from which dimensionally-recoverable articles are formed, the overlying edge portion and parts of the cover adjacent to it may attempt to recover before the underlying edge portion and other parts of the cover can accommodate the recovery. Where this happens, the overlying edge portion and adjacent parts of the cover may attempt to contract in an axial direction and so lift the overlying edge portion from the underlying one.
As stated above the retaining means can accommodate relative movement between adjacent pairs of engaged closure elements on recovery of the cover. This is desirable in order to ensure that different parts of the cover in the region of the closure arrangement will recover satisfactorily onto the substrate and so prevent the formation of a path under the cover which may allow passage of fluid along the cover. If the retaining means does not allow the position or orientation of the closure elements, and especially their orientation, to change, it has been found that one part of the wrap-around device, e.g. one leg of a "T" configuration, may be recovered satisfactorily about the substrate, but that when another part of the wrap-around device is recovered, either it is prevented from recovering fully onto the substrate by the closure arrangement, or movement of the closure arrangement due to recovery of the other part of the wrap-around device causes the recovered part of the device to lift off the substrate to a small extent.
The closure elements may be formed in a number of configurations provided that the parts of the edge portions lying between the closure elements are sufficiently flexible to allow the position and/or orientation of the closure elements to change when the cover is recovered. For example the closure elements may be in the form of a row of protuberances extending along each edge portion each of which can be brought into abutment with a corresponding protuberance of the opposed edge portion and retained in abutment by the retaining means. The device not only has the advantage that it can be recovered satisfactorily onto a substrate of non-uniform profile but also that, since installation of the device does not require sliding a channel over the closure elements as with conventional devices, installation can be considerably facilitated, especially in confined spaces. Preferably, however the closure arrangement comprises a row of protuberances that extends along one closure portion and a row of corresponding protuberances that extends along the other closure portion, the protuberances being arranged so that a protuberance on one closure portion can be nested within a protuberance in the other closure portion. These forms of closure arrangement have the advantage that they do not require the provision of any holes in the cover. It has been found that, if the closure mechanism employs a row of apertures in the edge portion to receive closure elements of the other edge portion, there is the danger that the apertures will become elongated due to the recovery forces of the cover since the modulus of the polymeric material forming the edge portions is considerably reduced at the recovery temperature. Any elongation of the apertures would allow the closure elements of the underlying edge portion. to disengage themselves from the apertures of the overlying edge portion. A further advantage of the closure arrangements used in the device according to the invention is that the wrap-around devices may be formed from polymeric sheet, as described below, rather than by more expensive moulding processes.
Any of a number of forms of retaining means may be used with the device according to the invention, the particular form depending on the type of closure elements used in the closure arrangement. A number of individual retaining elements may be used, one for each pair of closure elements, or the retaining elements may be connected together for example in the form of a bandolier in which the retaining elements are supported on a carrier strip. The wrap-around device may be sold with the retaining elements in place or they may be provided separately and placed on the closure elements during installation of the wrap-around device. Where, however, the retaining elements are provided on a carrier strip which is intended to remain in place during recovery of the cover, it is desirable for the carrier strip to be sufficiently deformable to allow the position and/or orientation of the closure elements to change as the cover recovers onto the substrate. The retaining elements will usually be in the form of clips, caps, annular or split rings or the like, and are preferably either resiliently deformable to such an extent that they may be placed on one closure element before engagement with the other closure element, and by their deformation, allow the elements to be engaged, for example by a snap-fit action or are formed in such a manner that they can be twisted or crimped to grip the pair of engaged closure elements.
In the preferred form of device, each closure portion has a row of hollow protuberances extending along it, the protuberances of the underlying edge portion being nestable within those of the overlying edge portion, the protuberances of the underlying edge portion containing an internal hold-out member to retain the shape of the protuberance during recovery of the cover. The hold-out member will preferably also co-operate with the retaining elements to retain the protuberances together. In this form of device the internal hold-out member and the recess in the retaining element preferably have corresponding non-circular profiles when viewed from above so that the retaining means can accommodate the pair of engaged protuberances and can be twisted to a position in which the retaining element and internal hold-out member cooperate to lock the protuberances in engagement. The use of a cap has the advantage that it shields the protuberances from the flame of the torch and so prevents the possibility of them being scorched. In addition, the retaining elements used in the device according to the invention are capable of being formed from plastics materials such as thermosetting plastics, e.g., phenol-formaldehyde resins, and so it is possible to construct a wrap-around closure arrangement which uses no metal parts and further reduces the possibility of thermal damage to the heat-shrinkable polymeric material.
It is advantageous if at least one set of protuberances, and preferably all the protuberances, are dimensionally heat-recoverable in such a manner that, when the device is heated, they will become engaged more firmly. For example they may be formed so that, on recovery, their height decreases and their wall-thickness increases thereby causing the retaining elements to grip them more securely.
The wrap-around device according to the invention has the advantage over previously proposed wrap-around devices for enclosing "T's" and bends such as that described in German Offenlegungsschrift No. 1,947,057 in that it can be formed from polymeric sheet material that is dimensionally-recoverable or is capable of being rendered dimensionally-recoverable when deformed in an appropriate manner, for example by pressure or vacuum forming techniques. Thus, for example, a sheet of polymeric material which has been cross-linked and which has preferably also been expanded to render it heat-shrinkable, may simply be deformed, preferably vacuum formed, hot or cold, into the appropriate shape (for example a cruciform shape if it is to be used to enclose a "T") and the rows of protuberances or other closure elements may be formed along each closure edge portion during the same vacuum forming process. The edges of the wrap-around device may then be trimmed and, if desired, the retaining means and/or hold-out elements be provided on the closure elements. The device described in Offenlegungsschrift No. 1,947,057 has the further disadvantage that the closure mechanism is relatively inflexible and so suffers from defects described above.
In order to provide a completely fluid tight seal, it will often be desirable to provide at least the overlying edge portion with a coat of adhesive, preferably a hot-melt adhesive. Examples of hot-melt adhesives that may be used, include those based on polyamides, vinyl and acrylic homo- and copolymers, such as ethylene-vinyl acetate and ethylene-ethyl acrylate copolymers, polyesters and polyolefins.
In many cases it may be desirable to provide the surface of the cover that is intended to contact the object with a layer of sealant in order to fill voids between the cover and object and to provide a seal against contaminants such as moisture, dust, solvents and other fluids. The sealant may for example be an adhesive (preferably a hot-melt adhesive) or a "mastic", the term mastic as used herein including, amongst others, viscid, water-resistant macromolecular compositions which exhibit both viscous and elastic response to stress. Examples of suitable mastics are given in U.K. Patent Specification No. 2,023,021A, the disclosure of which is incorporated herein by reference. It will be appreciated from that specification that the sealant, whether it is a mastic or hot melt adhesive, preferably contains a corrosion inhibitor, and especially a water-soluble passivating corrosion inhibitor.
In most cases the devices will be in the form of a wrap-around article as described above, either an unbranched article for enclosing straight or bent objects, or a branched article, e.g. an article having a cruciform shape for enclosuring a "T" shaped object. It is also possible, however, for the cover to be adapted to be wrapped helically round the elongate object and the closure portions to extend along the length of the cover to retain adjacent windings of the cover together.
Accordingly to another aspect, the invention provides a dimensionally-recoverable device for enclosing at least part of an elongate object, the device having closure portions that can be retained together by means of a closure arrangement which comprises a closure element located on each closure portion, the closure element on each closure portion being engageable with the closure element on the other closure portion, and a retaining element for retaining the closure elements in engagement, the closure elements and retaining element being arranged so that the retaining element can be twisted about the closure elements to lock the closure elements together.
The device according to the invention may be produced by forming a cover from a polymeric material, the cover having non perforate closure portions, expanding the cover to render it dimensionally-recoverable, and forming a plurality of closure elements in each closure portion, the closure elements in each closure portions being engageable with the closure elements in the other closure portion.
The cover may be rendered heat-recoverable either by cross-linking the polymeric material from which it is formed and then expanding it or by forming the cover from polymeric material which has been stretched at a temperature below the crystalline melting point or softening point of the material and has been cross-linked after expansion. If the closure elements are formed by deformation of the cover, e.g. by a vacuum forming process, the cover itself may, if desired, be expanded or be further expanded in the same step.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a wrap-around device according to the invention before retaining elements have been placed thereon;
FIG. 2 is a perspective view of the wrap-around device of FIG. 1 when installed;
FIGS. 3 to 7 are schematic representations of part of a device according to the invention during installation on a substrate;
FIGS. 8 and 9 are schematic representations of a further form of device during installation on a substrate;
FIGS. 10 and 11 are sections through various different forms of closure elements and associated retaining elements of a wrap-around device;
FIG. 12 is a plan view of one form of retaining element;
FIG. 13 is a section through another pair of closure elements showing a section of the retaining element of FIG. 12 taken along line I--I;
FIG. 14 is a section through another pair of closure elements;
FIGS. 15 to 18 show further forms of retaining elements; and
FIG. 19 shows yet another form of device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the accompanying drawings, FIG. 1 shows a wrap-around device according to the invention that is suitable for enclosing a "T" section of a pipe. The device comprises a cover 1 formed in a cruciform shape having a main body 6 and two arms 4 and 5. One side of the main body 6 and one arm 4 has an edge portion 2 and the other side of the main body 6, with the other arm 5 has a corresponding edge portion 3. The body 6 has a flexible central portion 7 that allows the body and arms 4 and 5 to be folded around a substrate until the edge portions 2 and 3 are in overlying relationship. The edge portion has a row of hollow protuberances 8 and the edge portion 3 has a row of corresponding protuberances 9 which are of slightly smaller dimensions than the protuberances 8 and which, when the body 6 has been folded about its central portion 7 so that the edge portion 2 overlies the edge portion 3, can be nested within the hollow protuberances 8.
The main body 6 and the arms 4 and 5 of the cover 1 are heat-shrinkable in their radial direction, i.e. each part of the cover apart from the crux regions 10 is uniaxially shrinkable in a direction perpendicular to its edge region 2 or 3, and the crux regions are biaxially shrinkable. The wrap-around device may be formed by deforming a sheet of cross-linked polymeric material that may be, unexpanded or uni- or biaxially expanded, into the desired shape, the deformation preferably being performed by a vacuum forming process in which the protuberances 8 and 9 are formed at the same time.
Preferably the under surface of the cover is coated with a sealant, for example a mastic or a hot-melt adhesive. Preferably also, either the under surface of the edge portion 2 or the outer surface of each portion 3 is coated with a hot-melt adhesive in order to provide a seal between the edges of the installed device. The edge portions may, if desired, be provided with a flap (not-shown) that extends beyond the edge of the edge portion 3 and which, after installation of the device, lies under the part of the cover that is adjacent to the edge potion 2. The flap is preferably coated on its outer surface with a hot-melt adhesive in order to increase the path length for fluid ingress between the edge portions.
The device as shown in FIG. 1 may be positioned about a "T" section of a pipe by folding it about the flexible central portion 7 and engaging the protuberances 8 and 9 being retained together by retaining elements that are provided on the protuberances 8 or are provided separately. The device may then be recovered on to the pipe by heating it for example by means of a gas torch or hot-air gun. FIG. 2 is a perspective view of the device shown in FIG. 1 when installed on a substrate 11 (the retaining elements not being shown for the sake of clarity).
FIGS. 3 to 7, are schematic axial sections taken through the crotch region of a substrate and the edge portions of a wrap-around device at various stages during installation. The substrate 12 has a right angle bend and may, for example, be part of a "T" section as shown in FIG. 2. The wrap-around device comprises a cover having arms 13 and 14 that are heat-shrinkable in a radial direction, and edge portions 15 that are retained together by closure elements 16a, 16b, 16c and retaining elements (not shown).
FIG. 3 shows part of the wrap-around device after it has been positioned about the substrate and the edge portions joined together but before it has been recovered. Closure elements 16a are oriented with their axes parallel, as are closure elements 16c (but with their axes perpendicular to the axes of closure elements 16a), and closure element 16b is oriented with its axis at 45° to the axes of closure elements 16a and 16c. In order to continue installation of the device, arm 13 of the cover is heated until it has recovered radially onto the substrate. As can be seen from FIG. 4, when part of the arm 13 has been recovered, its closure elements 16a are no longer oriented parallel to each other, and the part of the edge portion between closure element 16b and its adjacent closure element 16a has opened out so that the angle between those closure elements is significantly less than 45°. If the arm 13 is heated further so that the part of the arm 13 supporting the closure element 16a adjacent to element 16b recovers onto the substrate, the relative orientation of elements will change so that the angle between their axes increases to a value of 45°, as shown in FIG. 7. Arm 14 of the device is then heated so that it recovers onto the substrate as shown in FIG. 5. At this stage the orientation of the elements 16c has changed in the same way as elements 16a so that the angle between closure element 16b and both its adjacent elements 16a and 16c is significantly reduced. Installation of the device is completed by heating the crux regions of the device so that it recovers onto the substrate as shown in FIG. 6.
FIG. 8 shows schematically part of a wrap-around device comprising a radially heat-shrinkable cover 20 that is in the form of a split sleeve and has edge portions 21 that have been joined together to close the sleeve by means of closure elements 22a, 22b and 22c and retaining elements (not shown). The wrap-around device is positioned over a tubular substrate 23 in the form of a transition from a part 24 that is of larger diameter to a part 25 that is of smaller diameter. When the device is recovered onto the substrate, the orientation of the closure elements will change as shown in FIG. 9, so the closure elements will change as shown in FIG. 9, so that the axis of the element 22b diverges from those of elements 22a by about 90° and converges to those of elements 22c. Whilst it is not usually possible for the device to recover fully on to any inwardly directed corner 26 of the substrate, the greater the flexibility of the edge portions (at least at the recovery temperature) and the less the resistance to the change of orientation of the closure elements, the less the distance will be separating the substrate and the edge portions at the corner 26.
FIG. 10 is a section through another pair of closure elements in which the closure element of the underlying edge portion 33 is in the form of a solid protuberance and the corresponding closure element 34 of the overlying edge portion is in the form of a hollow protuberance that can be positioned over the element 33 and retained thereon by a ring or resilient clip 34a.
Another pair of closure elements is shown in FIG. 11 in which the closure element 35 of the underlying edge portion is in the form of a hollow protuberance and has a rigid hold-out element 36 retained therein. A corresponding closure element 37 can be fitted over the element 35 and retained on it by a clip 37a. When the pair of closure elements is heated during recovery of the cover, both closure elements will attempt to recover with the result that their wall thickness in the region of the clip 37a will increase and the elements will be locked in position.
FIGS. 12 and 13 show a further form of retaining elements. The closure elements 38 and 39 are similar to those of FIG. 11, and the retaining element 40 is in the form of a planar member having an aperture 41 therein, the aperture being bounded by a number of leaf springs 42 directed into the aperture. The leaf springs 42 are bent away from the plane of the retaining element so that the element 40 may be forced over the outer closure element 38 either before or after the closure element 39 has been placed therein. The direction of the leaf springs is such that, when the closure elements and the retaining element have been placed in position, the closure elements cannot be pulled apart.
FIG. 14 shows yet another form of the closure elements after they have been engaged. The closure element of the underlying edge portion is in the form of a protuberance 50 and has a rigid hold-out member 51 retained therein. The corresponding closure element of the other edge portion is also in the form of a hollow protuberance 52 and contains a further rigid element 53 that is disc shaped. The protuberance 52 is provided with a metal cap 54 that has been positioned over the protuberance 52 and crimped so that two opposite sides 55 and 56 of the cap are deformed toward each other to form a neck that prevents the cap from being removed from the protuberance, while two other opposite sides 57 and 58 remain undeformed. The rigid hold-out member 51 of the protuberance 50 has a slightly elongate shape as seen in plan view with a minimum diameter that is smaller than the dimensions of the neck in the cap 54 and a maximum diameter that is larger than the dimensions of the neck. If the cap is twisted about the protuberance 52 so that the neck of the cap coincides with the minimum diameter of the member 51 and the undeformed sides 57 and 58 coincide with the maximum diameter of the hold-out member 51, the protuberance 50 can be inserted into the protuberance 52. The cap may then be twisted through an angle of 90° so that the neck coincides with the maximum diameter of the hold-out member 51, thereby locking the two protuberances together. When all the protuberances are locked together in this way, the wrap-around device may be recovered. Advantageously the cap contains means providing a clear visual indication that it has been twisted to an orientation in which the protuberances are locked. The neck need not necessarily be formed by crimping. It may, for example be formed by inserting an appropriately shaped spring within the cap. The maximum diameter of the rigid hold-out element 51 is preferably greater than the separation between walls 55 and 56 of the cap, and is especially from 1.3 to 1.6 times the wall separation.
The use of this arrangement not only has the advantage that the protuberance 52 is shielded from the flame of the gas torch used to recover the device, but also that the installed device may subsequently be removed by opening the engaged edge portions.
It is possible for the rigid element 53 also to be elongate so that the cap 54 may be entirely removed. It is also possible for the hold-out member 51 to be disc shaped and for the cap 54 to be crimped only when the protuberance 50 is nested within protuberance 52. In this case, the rigid element 53 could be dispensed with, although it is preferable for the element 53 to be present because the element 53 ensures that the hold-out member 51 does not slip out of its correct position and that the cap 54 is crimped below the hold-out member 51. FIGS. 15 and 17 show various forms of retaining elements that are suitable for retaining the closure elements together. FIG. 15 shows a clip formed from a wire that is bent into a serpentine shape and which is especially suitable for use with the closure elements shown in FIG. 11. The clip is preferably made from a metal and is resiliently deformable so that its jaws 43 and 44 can be opened to allow it to be positioned about the elements. The closure element shown in FIG. 16 is in the form of a planar element having a "keyhole" shaped aperture. The element may be placed about a hollow "female" protuberance that is elongate. The aperture has one region 45 of slightly larger dimensions than those of the other region 46 so that a "male" protuberance can be inserted into the part of the female protuberance located in the region 45 of the aperture, and then moved within the female protuberance to that part of it that is located in the region 46 of the aperture. Because the region 46 of the aperture is of smaller dimensions than the region 45, the male protuberance cannot be removed from the female protuberance except by being moved back again to region 45 of the aperture. When the protuberances are heated, the part of the female protuberance in the region 45 of the aperture will recover down and the male protuberance will be held within the female protuberance.
FIG. 17 shows another form of retaining element which is in the form of a short section of a split tube. The element may simply be placed over the closure elements so that edges 47 and 48 grip the elements and its apex 49 shields the closure elements from the heating tool, e.g. a gas torch.
FIG. 18 is a section through another form of cap which may be used with the closure arrangement shown in FIG. 14. The cap has a slightly tapering circular side wall 60, a top portion 61, and ridges 62 and 63 which extend along opposite sides of the wall 60. The inwardly facing edges of the ridges 62 and 63 are separated by a constant distance so that the ridges 62 and 63 together define an elongate recess corresponding to the recess defined by cap walls 55, 56, 57 and 58 in FIG. 14.
FIG. 19 shows another form of device comprising an elongate cover 65 which is adapted to be wrapped around a substrate 66 so that adjacent windings of the cover overlap. The cover is provided with a plurality of protuberances 67 extending along one edge portion and a plurality of protuberances 68 extending along or adjacent to the other edge, the protuberances 68 being nestable within the protuberances 67 to retain adjacent windings of the cover together. The protuberances 67 and 68 are shown schematically in the drawing and may have any of the forms described above but are preferably as described in FIG. 14. Retaining elements (not shown) may be positioned over the protuberances 67 either before or after the protuberances have been engaged. | A device for enclosing elongate objects comprises a dimensionally-recoverable cover which can be wrapped-around the object and closed by means of closure elements located on the cover. The closure elements are preferably in the form of a row of protuberances spaced apart along the edge portions of the cover the protuberances of one edge portion being nestable within the protuberances of the other edge portion. The protuberances are preferably provided with retaining elements which lock the nested protuberances together and will accommodate relative movement between adjacent pairs of nested protuberances to allow the device to be recovered onto objects of varying dimensions. | 1 |
This application is a continuation-in-part of U.S. patent application Ser. No. 07/875,748 filed Apr. 28, 1992 and entitled "Dual-Feed Single-Cam Compound Bow".
BACKGROUND OF THE INVENTION
In the past, most compound archery bows have used two cams, respectively mounted on the limb tips at opposite ends of the bow to provide the means to store more energy in the draw cycle and to reduce the force necessary to hold the bowstring in the full draw position. Examples of such compound bows are disclosed in the following U.S. patents.
______________________________________U.S. Pat. No. Issued To Date Issued______________________________________3,486,495 Allen June 23, 19663,890,951 Jennings, et al. June 24, 19754,060,066 Kudlacek Nov. 29, 19774,079,723 Darlington Mar. 21, 19784,112,909 Caldwell Sep. 12, 19784,300,521 Schmitt Nov. 17, 1981______________________________________
The early compound bows utilized cams consisting of eccentrically mounted circular shaped elements. As the desire for more stored energy and greater arrow velocities developed, special shaped cam elements were designed to provide these characteristics. These shaped cam elements, like the circular shaped elements, were mounted on the limb tips. It is well known in the art that to obtain the best bow performance, the cam elements at each end of the bow should be properly synchronized with each other. Patents disclosing various means to accomplish proper cam synchronization include the following:
______________________________________U.S. Pat. No. Issued To Date Issued______________________________________3,841,295 Hunter Oct. 15, 19743,958,551 Ketchum May 25, 19764,103,667 Shepley, Jr. Aug. 1, 19784,178,905 Groner Dec. 18, 1979______________________________________
The more modern compound bows have reverted back to the more simplistic design of the original U.S. Pat. No. 3,486,495 Allen patent, but the requirement for cam synchronization is still present as noted, for example, by the teachings of the following patents:
______________________________________U.S. Pat. No. Issued To Date Issued______________________________________4,372,285 Simonds Feb. 8, 19834,440,142 Simonds Apr. 3, 19844,909,231 Larson Mar. 20, 1990______________________________________
It is obvious, of course, that the use of a single cam avoids the problem of cam synchronization and, in fact, there are single cam bows known in the prior art. One such bow, popularly referred to as the "DynaBo"was invented by Len Subber. The original Dynabo design had one working limb located at the upper end of the bow handle. A single cam element was mounted on a rigid pylon at the lower end of the bow. The single cam element functioned in the same manner as the cam elements on the previously mentioned two cam bows. As the Dynabo was drawn, one track of the cam element payed out line to the bowstring which was fixed to the upper limb tip and the other track on the cam element acted as a take-up reel for a second line that was also anchored at the tip of the upper working limb.
Since there was only a single cam element, there was not a synchronization problem between two cams. There was, however, a problem in synchronizing the rate that the cam fed out cables to the bowstring at the lower end of the bow and the rate that the flexing of the upper limb feed out cable to the bowstring at the upper end as the bow was drawn. The result was a rather unpleasant feel to the bow as it was drawn and there was a drastic movement of the nocking point and the rear end of the arrow as the bow was drawn and released. This, in turn, made it very difficult to achieve good arrow flight from the bow under normal conditions. An early version of the DynaBo was described in the September 1976 edition of "Archery World" beginning at page 28.
The Dynabo single cam concept was offered in at least three different versions from as many manufacturers during the 1970's, and at least one manufacturer, Graham's Custom Bows, employed the Dynabo concept, with two working limbs. A description of the Graham bow is contained in the June/July edition of "Archery World" magazine. The Dynabo bow, however, never did become an acceptable alternative to the two cam bows and, in fact, appears to have lost whatever popularity it had achieved by the late 1970's.
Another known prior art device that had the capability of providing a solution to the previously mentioned problems of cam synchronization and synchronized bow string feed out (the latter being desirable to enable the nock end of the arrow to travel in a smooth, consistent path upon draw and release of the arrow) is set forth in U.S. Pat. No. 4,562,824 issued to Jennings. This patent teaches the use of a single multiple grooved cam mounted on a pylon attached to the bow handle. The cam had one string track feeding cable attached to an idler pulley mounted in the limb tip at one end of the bow and a second track feeding line to a second idler pulley mounted in the second limb tip at the other end of the bow. The cam also has two additional tracks, each of which are taking up line while the string tracks are feeding out line to the bow string. One take-up track is taking up a line which is anchored at one limb tip while the other take-up track is taking up a line which is anchored at the opposite limb tip. Thus, the '824 patent teaches a highly complicated system, as compared to the present invention, that is composed of considerably more parts resulting in a compound bow having greater mass weight than the more conventional two cam compound bow.
A single cam bow developed by Larry D. Miller in the late 1970's or early 1980's was the subject of a U.S. patent application titled "Archery Bow Assembly" (hereinafter referred to as the "Miller application"). The Miller application discloses the use of a single pulley, having two grooves thereon for feeding out line to the bow string. The primary groove is circular and concentric with the axle of the circular pulley. The secondary groove, also circular, may be slightly eccentric for the purpose of maintaining the nocking point of the bowstring perpendicular to the handle section of the bow. A third eccentric groove carries a take-up cable to provide the entire means of compounding (i.e. achieving the desired reduction in holding weight at full draw and storage of energy).
The Miller application, the serial number of which is not known, may be considered material to the examination of the subject application.
SUMMARY OF THE INVENTION
The present invention embodies a simple, lightweight compound bow construction which solves the cam synchronization problem of two cam bows and overcomes the problems of synchronously feeding out cable to the upper and lower ends of the bowstring. The resulting bow has a smooth, desirable nocking point travel path which enables ease in matching arrows to the bow and provides consistency in performance.
A cam is eccentrically journaled at one limb end of the bow and a pulley is journaled at the other limb end of the bow. A cable passes around the pulley to form a bowstring section and a second cable section, both sections forming a dual feed single cam compound bow. The amount of feed out to both ends of the bowstring is approximately the same. One embodiment of the drop-off cam provides a large periphery cam groove and a smaller periphery cam groove which are designed to synchronize the rate of cable feed-out at both ends of the bowstring section during the drawing operation. Other embodiments of the invention are also disclosed.
An anchor cable is provided to tie the two limbs of the bow together during the flexing of the bow. The anchor cable may be fixed at one end to the axle of the concentric pulley and at the other end fixed in a groove in the cam to synchronize the flexing action of the bow limbs.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view showing one embodiment of the invention;
FIG. 2 is a side elevational view of the cam shown in FIG. 1;
FIG. 3 is the opposite side elevational view of the cam shown in FIG. 2;
FIG. 4 is a top plan view of the cam taken along line 4--4 of FIG. 3;
FIG. 5 is a rear elevational view of the upper limb tip portion of the archery bow of the present invention showing the anchor cable mounting on the concentric pulley axle;
FIG. 6 is a view of the unassembled anchor cable of the present invention;
FIG. 7 is a side elevational view, similar to the view shown in FIG. 2, and showing an alternative embodiment of the cam of the present invention;
FIG. 8 is a side elevational view, similar to the view shown in FIG. 2, and showing another embodiment of the cam of the present invention;
FIG. 9 is a side elevational view, similar to the view shown in FIG. 2, and showing a still further embodiment of the cam of the present invention;
FIG. 10 is the opposite side elevational view of the cam shown in FIG. 9;
FIG. 11 is a top plan view taken along line 11--11 of the cam shown in FIG. 10;
FIG. 12 is a side elevational view similar to the view shown in FIG. 2, and showing a still further embodiment of the cam of the present invention;
FIG. 13 is the opposite side elevational view of the cam shown in FIG. 12;
FIG. 14 is a top plan view taken along line 14--14 of the cam shown in FIG. 13;
FIG. 15 is a side elevational view similar to the view shown in FIG. 2, and showing a still further embodiment of the cam of the present invention;
FIG. 16 is the opposite side elevational view of the cam shown in FIG. 15; and
FIG. 17 is a top plan view taken along line 17--17 of the cam shown in FIG. 16.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 of the accompanying drawings, an archery bow assembly B is illustrated which includes a central handle portion 10, having a pair of limbs 12 and 14, connected at their inner ends in fixed relation to the handle portion 10. The limbs 12 and 14 provide the desired resistance to bending which determines the draw weight of the bow and the force with which the arrow is discharged.
As shown in FIGS. 1-4, the outer ends of the bow limbs provide wheel receiving slots which define wheel mounting forks, respectively designated by the numbers 12aand 14a, for mounting axle pins 15 and 16. A pulley 17 is concentrically mounted on the axle pin 15. In this form of the invention, the pulley 17 is provided with a single groove. As shown in FIGS. 2-4, an eccentric drop-off cam 18 is mounted on axle pin 16 and has three eccentrically oriented grooves, 18a, 18b, and 18c formed in the outer periphery thereof to provide three separate cable groove paths.
A cable 22 has a medial portion trained around concentric pulley wheel 17 to form a main cable section or bowstring 22a and a secondary or return section 22b, both of which extend across the bow and terminate at the cam 18. The ends 22c and 22d of the two sections 22a and 22b are respectively received in grooves 18b and 18c of the cam 18. The end 22c and 22d of the sections 22a and 22b are anchored to the cam 18 as by the cable anchor pins 19a and 19b fixed in said cam 18, as best shown in FIG. 3. In the form shown, three anchor pins 19a are provided to permit adjustment of the effective length of cable 22 and bowstring 22a.
An anchor cable 25 is anchored at one end 25a to the axle 15 (see FIGS. 5 and 6) by loops 31 on sections 31a of anchor cable 25 encircling axle 15. It is seen that loops 31 extend on both sides of pulley 17 to provide load balancing and thus prevent twisting of upper limb 12. The other end of anchor cable 25 (as best shown in FIG. 2) passes around the cam groove 18a on the take-up side of the cam 18 and has a loop 33 thereon which is attached to anchor pin 19c and positively ties the ends of the bow limbs 12 and 14 together to form a direct connection between the limbs 12 and 14.
The operation of the archery bow having the eccentric cam illustrated in FIGS. 1-4 will next be described. When the archer draws the bowstring 22a, cam 18 is caused to rotate in the counterclockwise direction as viewed in FIG. 2 and bowstring 22a is fed out from cam 18 in the direction of the generally vertical arrow adjacent bowstring 22a in FIG. 1. Counterclockwise rotation of cam 18 likewise causes return section 22b to be fed out from cam 18 in the direction toward pulley 17. Return section 22b moves upwardly to the take-up side of concentric pulley 17, around and past the pulley 17 to become the second feed-out portion 22a of bowstring 22. At the same time that the bowstring section 22a is fed out, counterclockwise rotation of cam 18 causes anchor cable 25 to be taken up in groove 18a of cam 18 to cause the synchronized flexing of the bow limbs 12 and 14.
Alternative forms of the invention are illustrated in FIGS. 7 and 8, but in each case the dual-feed-out cable sections 22a and 22b operate and extend outwardly from a drop-off cam unit mounted on the limb 14 of the bow in the same manner, as described for the embodiment shown in FIGS. 1-4. In the FIG. 7 embodiment, an eccentric drop-off cam 27 is illustrated having the feed-out cable sections 22a and 22b extending outwardly therefrom toward the concentric pulley 17. The cam 27 has a single groove 27b extending all around its complete periphery with the cable sections 22a and 22b received in the groove 27b. The ends of the cable sections are anchored to an anchor pin 27a fixed to one side of the cam 27. The anchor cable 25 is also received in groove 27b and securely anchored to the anchor pin 27a, as shown in FIG. 7.
Another alternative form of the cam is illustrated in FIG. 8 which embodies eccentric drop-off cam 28 having a groove 28b thereon wherein cable sections 22a and 22b are received. A suitable anchor pin 28a is provided on the back side of the cam 28 as shown by dotted lines in FIG. 8 and both ends of cable sections 22a and 22b are secured thereto in the same manner as previously described. The anchor cable 25 is trained in groove 29 of cam 28 and secured to the anchor pin 29a of cam 28 as shown in FIG. 8. Cam 28 is eccentrically mounted on axle pin 16 connected to the limb 14 of the bow.
The embodiment of the cam shown in FIGS. 9 to 11 also operates in the manner as the eccentric cam illustrated in FIGS. 1 to 4. In this embodiment, the eccentric drop-off cam 30 has the feed out sections 22a and 22b extending outwardly therefrom toward the concentric pulley 17 (not shown). Feed out section 22a is received in a first groove 32 of cam 30 and feed out section 22b is received in a second groove 34 of smaller periphery of cam 30 which is located on one side of groove 32 of cam 30. Anchor cable 25, as best seen in FIGS. 9 and 11, is located in groove 36 of cam 30, which also is located on the side opposite of groove 32 from groove 34 of cam 30.
Feed out section 22a, as best seen in FIG. 10, may be attached to either anchor pin 37 (as shown) or anchor pin 38 on cam 30, and in this manner the effective length of feed out section 22a may be adjusted to change draw length. Feed out section 22b, also as best seen in FIG. 10, is attached to anchor pin 40 on cam 30. Anchor cable 25, as best seen in FIG. 9, is attached to anchor pin 42 which is located on the side of cam 30 opposite anchor pins 36, 38 and 40. As in the other embodiments, cam 30 is eccentrically mounted on the axle pin 16 connected to the limb 14 of the bow.
The embodiment of the cam shown in FIGS. 12 to 14 likewise operates in the manner as the eccentric cam illustrated in FIGS. 1 to 4. In this embodiment, the eccentric drop off cam 44 has the feed out sections 22a and 22b extending outwardly therefrom toward the concentric pulley 17 (not shown). Feed out section 22a is received in a first groove 46 of cam 44 and feed out section 22b is received in a second groove 48 of smaller periphery of cam 44 which is located outwardly of the center line of groove 46 of cam 44. Anchor cable 25, as best seen in FIG. 12, is located in groove 50 of cam 44, which also is located outwardly of the center line of groove 46 of cam 44.
Feed out section 22a, as best seen in FIG. 13, may be attached to either anchor pin 52 (as partially shown) or anchor pin 54 or anchor pin 56 on cam 44 and in this manner the effective length of the feed out section 22a may be adjusted. Feed out section 22b, also as best seen in FIG. 13, is attached to anchor pin 58 on cam 44. Anchor cable 25, as best seen in FIG. 12, is attached to anchor pin 60 which is located on the side of cam 44 opposite anchor pins 52, 54, 56 and 58. As in the other embodiments, cam 44 is eccentrically mounted on the axle pin 16 connected to the limb 14 of the bow.
The embodiment of the cam shown in FIGS. 15 to 17 operates in the manner as the eccentric cam illustrated in FIGS. 1 to 4. In this embodiment, the eccentric drop off cam 68 has the feed out sections 22a and 22b extending outwardly therefrom toward the concentric pulley 17 (not shown). Feed out section 22a is received in a first groove 70 of cam 68 and feed out section 22b is received in a second smaller periphery groove 72 of cam 68. Anchor cable 25, as best seen in FIG. 16, is located in groove 74 of cam 68, which is located intermediate of grooves 70 and 72 of cam 68.
Feed out section 22a, as best seen in FIG. 15, may be attached to either anchor pin 74 (as shown) or anchor pin 76 on cam 68 and in this manner the effective length of feed out section 22a may be adjusted. Feed out section 22b, as best seen in FIG. 16, is attached to anchor pin 78 on cam 68. Anchor cable 25, also as best seen in FIG. 16, is attached to anchor pin 80 which is located on cam 68. As in the other embodiments, cam 68 is eccentrically mounted on the axle pin 16 connected to the limb 14 of the bow.
It has been found that a desirable approach to designing the grooves in the cam is to initially have the groove which receives bowstring 22a (the "primary groove") be approximately twice the peripheral size of the groove which receives the bowstring 22b (the "secondary groove"). The size of the primary groove may, for example, be the peripheral size of a cam on a standard bow having two independent cams. A starting point for the design of the groove which receives anchor cable 25 (the "take up groove") for use on limbs having relatively low spring rates and relatively longer limb tip travel may be, for example, to have the size and shape of the take up groove be approximately the same size and shape as the primary groove. If, however, one desires limbs having a higher spring rate and desires to reduce limb tip travel, the take up cam size will be smaller than that of the primary feed cam for a given peak draw weight. Conversely, if one desires limbs having a lower spring rate and desires to increase limb tip travel, the take up cam size would be larger than that of the primary feed cam for a given peak draw weight. The final shape of the take up cam will depend on the energy storage characteristics that are desired. Adjustments of the peripheral size and shape will then be made to the secondary groove to assure that the nocking point travels in a smooth path during the draw cycle. To achieve this, the bowstring is drawn at discrete draw length intervals, for example, at draw length intervals of one inch and at each such interval the nocking point position and travel is analyzed and, if required, the secondary groove is made either peripherally larger or smaller to assure that the nocking point travels a smooth path between intervals. By continuing this process of modifying the size and shape of the secondary groove throughout the draw length, the resulting single cam compound bow will, among other desirable features, be provided with a smooth nocking point path of travel. It should be noted that the amount of stored energy will be directly related to the leverage ratios between the primary, secondary groove shapes and will depend on the combined effect of the two bowstring let off leverage arms as compared to the leverage arm of the bowstring take up side. | A cam is eccentrically journaled at one end of a compound archery bow and a pulley is journaled at the other end of the bow. A cable passes around the pulley to form a bowstring section and a second cable section, both sections forming a dual feed single cam compound bow. The amount of feed out to both ends of the bowstring is approximately the same. One embodiment of the cam provides a large radius cam groove and a smaller radius cam groove which are designed to synchronize the rate of cable feed out at both ends of the bowstring section during the drawing operation. An anchor cable is provided to tie the two limbs of the bow together during the flexing of the bow. | 8 |
This is a continuation of copending application Ser. No. 558,143, filed on Dec. 5, 1983 now abandoned.
BACKGROUND OF THE INVENTION
Most stub sill type rail vehicles employ a shear plate to transmit loads from a short center sill section to longitudinal members on the sides of the vehicle (side sills) for the purpose of transmitting longitudinal coupler loads through the car. A description of this shear plate is found in U.S. Pat. No. 3,339,499 hereby incorporated into the present application by this reference.
SUMMARY OF THE INVENTION
The present invention eliminates the shear plate, and a truss type system is located in the end structure.
The advantage of this truss arrangement is that a considerable weight savings is realized.
IN THE DRAWINGS
FIG. 1 is a side elevation view illustrating the present invention.
FIG. 2 is an end view looking in the direction of the arrows along the line 2--2 in FIG. 1.
FIG. 3 is a vertical sectional view looking in the direction of the arrows along the line 3--3 in FIG. 1.
FIG. 4 is a vertical sectional view looking in the direction of the arrows along the line 4--4 in FIG. 1.
FIG. 5 is a perspective view of the truss end structure of the present invention.
FIG. 6 is a vertical sectinal view looking in the direction of the arrows along the line 6--6 in FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENTS
The drawings show a covered hopper car 10 having end structure 11. Side sills 12, 12' run longitudinally down the lower sides of the car. These members carry the longitudinal train forces split approximately equally on each side. Side sheets 14, 14' extend from side sills 12, 12' to top chords 16, 16'. A roof 18 connects the top chords 16, 16'.
A coupler and conventional running gear are contained in stub sill 20 located along the longitudinal centerline of the car. Side sill extensions 30, 30' at each end of the car are a continuation of side sills 12, 12' on both sides of the vehicle. Side sill extension includes flange portions 31 and 32, inclined portions 33 and 34, and vertical web portion 35.
A transverse member 40 (FIGS. 1, 5 and 6) running horizontally from side sill to side sill reacts the horizontal component of side sill extensions 30, 30'. Transverse member or strut 40, conveniently an angle, aids in the transfer of loads from stub sill 20 to the side sills 12, 12'. Extensions 30, 30' and transverse member 40 at least in part replace the conventional shear plate described in U.S. Pat. No. 3,339,499.
Vertical loads and overturning moments are taken by truss 50 composed of members 60, 60', 70, 70' and 80, and by beams 90 and 90'. All of these members are conveniently angles or channels. Member 80 is a transverse cap extending across end sheet 94. Diagonals 60 are connected to cap 80 and extend inwardly and downwardly and engage extensions 22, 22' which extend outwardly from stub sill 20. Stub sill extensions 22, 22' each include closure plates 24, 24'.
Members 70 and 70' are inclined downwardly from transverse cap 80 and end slope sheet 94, and engage extensions 62, 62'. Members 70 primarily carry vertical loading of the structure including the "side bearing load."
Vertical beams 90, 90' extend from vertical end slope sheet 92 and top chords 16, 16' to the sides of stub sill 20.
The advantages of this design is it's light weight. Estimates show a considerable weight savings of about 3,000 pounds over the shear plate construction illustrated in U.S. Pat. No. 3,339,499, owing to a more efficient structure.
Because of the significant reduction in weight, a corresponding reduction in car cost is realized. | In a stub sill type railway hopper car the shear plate is eliminated and a truss arrangement is located in the end structure resulting in less weight. | 1 |
TECHNICAL FIELD
The present invention relates generally to product dispensers, and more particularly to liquid or fluid dispensers specially adapted to dispense cleansing, disinfecting or sterilizing products such as antiseptic soaps, hydroalcoholic solutions, disinfecting lotions, cleaning solutions and other antimicrobial liquids.
BACKGROUND
In food processing establishments, surgical centers, physician and dental offices, hospitals and other healthcare facilities, contamination of objects (e.g. hands) with infectious or other deleterious materials is a significant problem. The use of a contaminated object (e.g. a surgeon's hand) in such environments can be a serious problem.
To address the problems associated with the spread of bacteria and microorganisms, the art has developed a variety of dispensers adapted to provide products for cleaning, disinfecting and potentially even sterilizing objects. For example, antiseptic preparation of a surgeon's hands conventionally includes a prolonged hand and lower arm scrubbing with an antimicrobial soap. The antimicrobial soap is typically dispensed from a liquid soap dispenser mounted near a scrub sink. To resist contamination, antimicrobial soap dispensers are designed to be operated without hand contact by mechanical, pneumatic or electromechanical means.
The contamination problem extends not just to the objects to be cleaned but to the external and internal portions of dispensers themselves. Contamination accumulation over time is a problem to be addressed for each object left in a room over time. U.S. Pat. No. 3,203,597 discloses a surgical soap dispenser which includes a complex bracket/actuator assembly and a bottle/pump assembly. The entire fluid (soap) path is provided in the bottle/pump assembly. The bottle/pump assembly is disposable in order to resist contamination build up in the fluid path. However, the bracket/actuator assembly is intended to be reusable and must itself be cleaned and disinfected. The bracket/actuator assembly comprises a complex structure including keyways and cam surfaces. This complex structure may tend to collect debris and make it very difficult to clean.
Set up and maintenance of a dispenser are also affected by the contamination problem. Dispensers which require excessive handling during set up or maintenance increase the risk of contamination by the person preparing or maintaining the dispenser. For example, refillable bottles of soap with a threaded cap structure require personnel to rotate the cap relative to the rest of the dispenser for several revolutions. U.S. Pat. No.'s 4,667,854; 4,921,131; 4,946,070; 4,946,0721 and 5,156,300 disclose various dispensers which appear more difficult to set up and maintain than the present invention. Those patents disclose dispensers which include doors, flaps or covers which are opened and closed. Some of those dispensers include refill elements which are carefully placed in position to avoid dispenser malfunction. In U.S. Pat. No. 3,203,597, the entire refill bottle must be rotated ninety degrees so that a flange on a piston may be received in a slot in an actuator assembly. Dispensers which are complicated to set up or maintain increase the risk of improper set up due to operator error with the attendant risk of unsatisfactory dispenser performance or malfunction.
Problems are also associated with the storage, transportation, handling and shipping of prior art dispensers which include valve and pump means. For example, in U.S. Pat. No. 3,203,597, a pump mechanism projects from the end of a soap container. Care needs to be taken that the pump mechanism is not inadvertently actuated during storage, transportation, handling and shipping of the soap container. The art has developed articles such as caps and removable inserts which are designed to prevent inadvertent actuation of the dispenser prior to use by the intended user. However, these additional articles tend to complicate set up of the dispenser and may also add cost to the dispenser.
SUMMARY OF THE INVENTION
According to the present invention there is provided a container assembly for a product dispenser which (1) affords quick, convenient set up, refill and maintenance without requiring excessive user handling, (2) is easily cleaned, (3) reduces opportunities for contamination build up in its product path, (4) may optionally provide precise, repeatable metered amounts of product, regardless of the volume of product in a reservoir, (5) has a low profile, (6) optionally includes a novel nozzle for reducing dripping, waste, drying and clogging, (7) may be actuated without hand contact to avoid contamination due to actuation, and (8) includes container and bracket/actuator assemblies and an attachment mechanism which automatically aligns elements of the container and bracket/actuator assemblies without the need for excessive handling.
According to the present invention, there is provided a container assembly that is attachable to a bracket/actuator assembly. The bracket/actuator assembly has a movable actuator and a pair of mounting flanges. The actuator is movable between a retracted position which affords attachment of the container assembly to the bracket/actuator assembly and an extended position that is spaced from the retracted position. The container assembly comprises a reservoir for holding product to be dispensed, an outlet sized and shaped to afford passage of product to be dispensed, and a pump that is operatively associated with the actuator. The pump includes a driven surface for receiving the actuator. The driven surface is adapted to be driven by the actuator when the actuator moves from the retracted to the extended position.
The container assembly also includes a pair of channels which are sized and shaped to cooperatively receive the mounting flanges of the bracket/actuator assembly to attach the container assembly to the bracket/actuator assembly and to align the driven surface of the pump with the actuator when the container assembly is attached to the bracket/actuator assembly. The container assembly is attachable to the bracket/actuator assembly in a vertically downward direction. The channels of the bracket/actuator assembly are elongate and situated so that they taper toward each other in the direction of attachment so that the driven surface of the pump is guided into a predetermined orientation relative to the actuator upon attachment of the container assembly to the bracket/actuator assembly.
The container assembly includes a valve assembly having inner surfaces. The inner surfaces receive the pump and define a pump chamber. The valve assembly also has outer surfaces including sealing surfaces for sealing the reservoir, and grasping surfaces that are sized and shaped to be manually grasped. The valve assembly also includes the outlet. Surfaces extend between the inner and outer surfaces to define a fill hole for the pump chamber. The valve assembly is adapted to move between a sealed position with the sealing surfaces sealing the pump chamber from the reservoir, and a dispense position with the fill hole affording passage of the product from the reservoir to the pump chamber.
Alternatively, the present invention may be viewed as a unique method of dispensing product.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will be further described with reference to the accompanying drawing wherein like reference numerals refer to like parts in the several views, and wherein:
FIG. 1 is a perspective view of a container assembly attached to a bracket/actuator assembly, with a foot actuated pneumatic bladder pump shown in phantom lines;
FIG. 2 is a front view of the container and bracket/actuator assemblies of FIG. 1 with the foot actuated pneumatic bladder pump omitted and with a valve assembly shown in a sealed position;
FIG. 3 is a perspective view of the container assembly separated from the bracket/actuator assembly which illustrates the direction of attachment of the container assembly onto the bracket assembly;
FIG. 4 is a right side view of the container and bracket/actuator assemblies shown in FIG. 2, with the valve assembly shown in a dispense position;
FIG. 5 is a sectional view of the container assembly;
FIG. 6 is a right side view of FIG. 2, with the bracket/actuator assembly omitted to illustrate details of the container assembly;
FIG. 7 is a perspective view of a portion of the container assembly;
FIG. 8 is a bottom view of the container assembly;
FIG. 9 is a rear view of the container assembly;
FIG. 10 is a front view of a reservoir for holding product to be dispensed which forms a portion of the container assembly;
FIG. 11 is a side view of the reservoir of FIG. 10;
FIG. 12 is a top view of a cover which forms a portion of the container assembly;
FIG. 13 is a cross-section view of the cover taken substantially along section lines 13--13 in FIG. 12;
FIG. 14 is a cross-section view of the cover taken substantially along section lines 14--14 in FIG. 12;
FIG. 15 is a perspective view of a plug which forms a portion of the container assembly;
FIG. 16 is a cross-section view of the plug of FIG. 15 taken substantially along section lines 16--16 in FIG. 15, with an insert removed to illustrate other details of the plug;
FIG. 17 is a perspective view of a spool element for use in the container assembly;
FIG. 18 is a cross-section view of the spool element of FIG. 17 taken substantially along section lines 18--18 in FIG. 17;
FIG. 19 is a side view of a piston for use in a pump in the container assembly;
FIG. 20 is a cross-section view of the piston of FIG. 19 taken substantially along section lines 20--20 in FIG. 19;
FIG. 21 is a side view of a optional flexible, resilient member for use in the container assembly;
FIG. 22 is a perspective view of a retaining element for use in the container assembly;
FIG. 23 is a cross-section view of the retaining element of FIG. 22 taken along section lines 23--23 in FIG. 22;
FIG. 24 is a front view of the bracket/actuator assembly of FIG. 1 with the container assembly and foot actuated pneumatic bladder pump omitted;
FIG. 25 is a side view of the bracket/actuator assembly of FIG. 24 with portions broken away to schematically illustrate internal elements of the bracket/actuator assembly, and with an actuator shown in a retracted position with solid lines and in an extended position with phantom lines;
FIGS. 26 through 30 are cross-section views of portions of the container assembly which sequentially illustrate the operation of the container assembly, wherein:
FIG. 26 illustrates a piston in a return position and the optional flexible, resilient member in a relaxed position;
FIG. 27 illustrates the position of the piston just after the actuator moves the piston toward an actuated position (with the actuator omitted to emphasize other details) and a displaced sealing position of the flexible, resilient member, with the direction of the piston movement illustrated with an arrow;
FIG. 28 illustrates piston as it moves further toward the actuated position, and the flexible resilient member in a deflected, dispense position which affords dispensing of the product to be dispensed through an outlet in the valve assembly, with the direction of the piston movement illustrated with an arrow;
FIG. 29 illustrates the piston in the actuated position, and the flexible, resilient member returned to the displaced sealing position, with the flow of air into the reservoir illustrated with arrows; and
FIG. 30 illustrates the piston on a return stroke from the actuated position toward the return position, the flexible, resilient member returned to the relaxed position, and the ball of a ball valve displaced to afford flow of product from the reservoir into a pump chamber, with the flow of the product from the reservoir into pump chamber illustrated with arrows, and with the direction of the piston movement illustrated with an arrow.
DETAILED DESCRIPTION
Referring to FIG. 1, the present invention is directed to a dispenser 30 (or components thereof) for dispensing product. The dispenser 30 comprises a container assembly 32 (FIG. 3) which is removably attachable to a bracket/actuator assembly 34. The bracket/actuator assembly 34 includes an actuator 196 that is movable between a retracted position (see FIG. 3, FIG. 25, solid lines) which affords attachment of the container assembly 32 to the bracket/actuator assembly 34 and an extended position (FIG. 25, dashed lines). The bracket/actuator assembly 34 also includes a pair of inwardly directed mounting flanges 200 and 202 which will be described in greater detail below.
The container assembly 32 includes a reservoir for holding product to be dispensed. The dispenser 30 is particularly suitable for dispensing cleansing, disinfecting or sterilizing liquids, fluids, compositions or solutions, such as antiseptic soaps, hydroalcoholic solutions, disinfecting lotions, cleaning solutions and other antimicrobial liquids. For example, the product may comprise the compositions described in U.S. patent application Ser. No.'s 08/493,714 (filed Jun. 22, 1995 entitled, "Stable Hydroalcoholic Compositions") and 08/493,695 (filed Jun. 22, 1995 entitled, "Stable Hydroalcoholic Compositions"), the entire contents of each of which are herein incorporated by reference. While the dispenser 30 is particularly suitable for dispensing antimicrobial liquids that include volatile active ingredients, many other compositions may be dispensed from the dispenser 30. Preferably, the reservoir is provided by bottle 36 which is shown in FIGS. 10 and 11.
The actuator 196 of the bracket/actuator assembly 34 is preferably controlled without hand or arm contact with the dispenser 30 to reduce the risk of contamination due to actuation of the dispenser 30. For example, FIG. 1 illustrates a foot actuated pneumatic bladder pump 220 with an air hose 221 adapted to be connected to port 214. The bladder pump 220 may optionally be used to move the actuator 196 from the retracted position to the extended position by delivering pneumatic pressure to the bracket/actuator assembly 34 when depressed by the operator. Alternatively, a wide variety of structures may be used to operate the bracket/actuator assembly 34 without hand contact. To activate the dispenser 30, a wide variety of devices may be used which are designed to engage a user's foot, knee, elbow or even the user's hand. Optionally, an electronic eye may be used to activate the dispenser 30. Additionally, a wide variety of devices may be used to propel the actuator 196 between the retracted and extended position. For example, the actuator 196 may be propelled by a fluid (e.g. pneumatic or hydraulic), a mechanical device, an electromechanical device or an electro/fluid device. Examples of fluid driven devices include molded bulbs, bladders, bellows and cylinders. Examples of mechanical devices include linkages, cables and foot pedals. Electromechanical devices include motors and solenoids with and without mechanical linkages. An example of an electrofluid device includes an electric compressor.
The container assembly 32 includes a valve assembly (described in greater detail below) which includes an outlet 42 that is sized and shaped to afford passage of product to be dispensed (e.g. a circular opening with a diameter of about 0.094 inches), and a pump that is operatively associated with the actuator 196 to dispense product through the outlet 42.
Preferably, the pump for the dispenser 30 comprises a constant volume pump adapted to deliver reproducible, metered amounts of the product regardless of the product volume (e.g. fluid level) in the reservoir. The pump comprises a piston 98 which includes a driven means in the form of driven surfaces 164 for receiving the actuator 196. More preferably, the pump is capable of delivering a precise volume with each actuation. This feature is particularly preferred if the dispenser 30 is utilized to deliver a product whose efficacy, performance or effectiveness is dependent upon the volume delivered to the user. Controlling the volume of product delivered by the dispenser 30 also helps ensure that product is not wasted. Alternatively, the dispenser may function with a pump that varies the volume of product delivered.
The container assembly 32 includes a pair of channels 138 and 140 which are sized and shaped to cooperatively receive the mounting flanges 200 and 202 of the bracket/actuator assembly 34 to attach the container assembly 32 to the bracket/actuator assembly 34 and to align the driven surfaces 164 of the piston 98 with the actuator 196 when the container assembly 32 is attached to the bracket/actuator assembly 34. Engagement between the mounting flanges 200 and 202 and the channels 138 and 140 not only attaches the container assembly 32 to the bracket/actuator assembly 34, but also properly orients the actuator 196 and piston 98 to afford proper operation of the dispenser 30.
The container assembly 32 is quickly attachable to the bracket/actuator assembly 34 in a vertically downward direction (see arrows 10 in FIG. 3). Conveniently, to assembly the dispenser 30, the operator may simply drop the container assembly 32 into the bracket/actuator assembly so that the flanges 200 and 202 engage the channels 138 and 140. This relatively simple task does not require excessive handling with the attendant contamination risks. Set up, maintenance and refilling of the dispenser 30 may be rapidly accomplished without the need for complicated steps or excessive handling.
Preferably, the channels 138 and 140 are elongate and situated to taper toward each other in the direction of attachment 10 (FIG. 3) so that the driven surfaces 164 of the piston 98 are automatically guided into a predetermined orientation relative to the actuator 196 upon attachment of the container assembly 32 to the bracket/actuator assembly 34. Automatic orientation of the driven surfaces 164 and actuator 196 eliminates the need to carefully manipulate those elements into a proper orientation. As an example not intended to be limiting, the channels 138 and 140 may be situated to form an acute angle of about forty (40) degrees therebetween, and a vertical height of about 2.1 inches.
The container assembly 32 preferably includes a substantially planar rear wall 39 which is adapted to abut a substantially planar front housing 192 of the bracket/actuator assembly 34 when the dispenser 30 is assembled. Should the operator so desire, to assemble the dispenser 30, the rear wall 39 may be placed against the housing 192, and the container assembly 32 slid downwardly until the flanges 200 and 202 engage the channels 138 and 140.
The container assembly 32 includes a top wall 51, a front wall 53, a pair of side walls 45 and 47 which taper toward each other in the direction of attachment, and a bottom wall 49. Each of the side walls 45 and 47 include one of the channels 138 and 140. Referring to FIG. 7, there is shown a bottom, rear portion of the side wall 47. The channels (e.g. 140) are preferably located in the bottom, rear portion of a side wall (e.g. 47).
The dispenser 30 preferably has surfaces which are substantially free of sudden discontinuities to afford ease of cleaning and to reduce the potential for accumulation of contaminants on the dispenser 30. The top 51, front 53, side 45 and 47 and bottom 49 walls of the container assembly 32 have surfaces which are substantially free of sudden discontinuities to afford ease of cleaning. Further, the top, side and bottom walls of the bracket/actuator assembly 34 form a shape that is substantially identical to the shape of the container assembly 32 to provide a dispenser 30 which is substantially free of discontinuities. The shape of the dispenser 30 is not a complex geometry which contributes to the ease with which the dispenser 30 may be cleaned.
Preferably, the top 51 and front 53 walls have outer surfaces that are slightly curved while the side walls 45 and 47 are substantially flat. As an example not intended to be limiting, the front wall may have a radius of about six inches and the top wall 51 may have a radius of about six inches.
The dispenser 30 is preferably relatively flat so that it presents a low profile which reduces the chances of it being inadvertently bumped, dislodged, or knocked over. To this end, the container assembly 32 is preferably relatively flat. As an example not intended to be limiting, the thickness of the container assembly 32 (the distance between the rear wall 39 and the front wall 53) should be less than about two inches.
Also preferably, the flanges 200 and 202 project inwardly from support arms 201 and 203. The container assembly 32 includes recessed ledges 139 and 141 adjacent the channels 138 and 140. The ledges 139 and 141 are recessed from the rest of the side walls 45 and 47 by an amount that is substantially the thickness of the support arms 201 and 203 so that there is a substantially flush interface or junction between the container assembly 32 and the bracket actuator assembly 34 to reduce the surfaces which may collect contaminants or which may be difficult to keep clean.
The channels 138 and 140 each have first ends opening onto the bottom wall 49 and second ends defined by shoulder surfaces 143 and 145 which are adapted to engage stop surfaces S of the mounting flanges 200 and 202 and support arms 201 and 203. Engagement between the stop surfaces S and the shoulder surfaces 143 and 145 terminates the insertion of the container assembly 32 into the bracket/actuator assembly at the point where actuator 196 is properly oriented with the driven surfaces 164 of the piston 98.
The container assembly 32 has a product path between the reservoir and the outlet 42. Preferably, the container assembly 32 is disposable and the product path is located entirely within the container assembly 32 so that the entire product path is disposed of upon disposal of the container assembly 32. In this manner, the dispenser 30 avoids accumulation of contaminants within the product path. Alternatively, however, the container assembly 32 or portions thereof may be reusable.
Within the product path and between the outlet 42 and the reservoir, the container assembly 32 includes a valve assembly with inner surfaces which receive the piston 98 and define a pump chamber 90. The valve assembly includes outer surfaces 83 including sealing surfaces 84 for sealing the reservoir, grasping surfaces 40 (e.g. a knob) that are sized and shaped to be manually grasped, the outlet 42, and surfaces extending between the inner and outer surfaces 83 to define a fill hole 94. As described in greater detail below, the knob 40 can be turned to permit or prohibit flow of product (e.g. liquid) from the bottle 36 out through nozzle 42.
The valve assembly is mounted within the dispenser 30 for movement between a sealed position (FIG. 2) with the sealing surfaces 84 sealing reservoir from the pump chamber 90, and a dispense position (FIGS. 5 and 26-30) with the fill hole 94 affording passage of the product from the reservoir to the pump chamber 90. In the sealed position, the valve assembly provides a positive seal for the reservoir which is particularly convenient for shipping, handling or storage of the container assembly 32.
In the preferred embodiment of dispenser 30 shown in FIGS. 26-30, the pump is a constant volume pump. The piston 98 is mounted within the inner surfaces of the valve assembly for movement between a return position (FIG. 26) and an actuated position (FIG. 29). Movement of the actuator 196 from the retracted to the extended position causes the actuator 196 to engage the surfaces 164 of the piston 98 and drive the piston 98 from the return position to the actuated position. Preferably, a spring 100 is mounted within the inner surfaces of the valve assembly to bias the piston 98 toward the return position. The spring 100 also biases the actuator 196 toward the retracted position through the piston 98.
The container assembly 32 includes a cover 38 that is adapted to receive the reservoir. The cover 38 has surfaces defining a passageway 46. Preferably, the valve assembly comprises a spool element 52 (FIGS. 17 and 18) adapted to be received in the passageway 46 of the cover 38. The spool element 52 is mounted to rotate within the passageway 46 between the sealed and dispense positions.
The cover 38 includes a main opening 44 adapted to receive the bottle 36. The passageway 46 has a first end 48 and a second end 50 on opposite faces which receive the spool element 52. The axis of the passageway 46 in the cover 38 is conveniently oriented perpendicular to the main axis of the disposable container assembly 32. First 54 and second 56 hollow coaxial bosses project perpendicularly from the wall of the passageway 46 in the cover 38. The first hollow boss 54 includes a first opening 58 at the top and a second opening 60 into the passageway 46. The second hollow boss 56 includes an opening 62 at the top that is adapted to be connected to the bottle 36. The cover 38 may be constructed from any suitable material, such as, but not limited to high density polyethylene.
In addition to the product fill hole 94, the spool element 52 preferably includes a vent hole 96 which affords passage of replacement air into the reservoir. The vent hole 96 in the spool element 52 is a port for the aspiration of replacement air into the bottle 36.
The reservoir includes a plug 64 having first 76 and second 78 passageways. The first passageway 76 affords passage of product from the reservoir to the pump chamber 90, and the second passageway 78 affords passage of replacement air into the reservoir. Preferably, the plug 64 is constructed from an elastomeric material, but may include an insert 144 (FIG. 5). As an example not intended to be limiting, the majority of the plug 64 may be constructed from a thermoplastic elastomer such as Santoprene 271-64 available from Advanced Elastomer, and with the insert 144 constructed from high density polyethylene. In the sealed position, the sealing surfaces 84 seal the first and second passageways 76 and 78, and in the dispense position, the fill hole 94 is aligned with the first passageway 76 and the vent hole 96 is aligned with the second passageway 78.
The plug 64 is disposed between the bottle 36 and the cover 38. The plug 64 includes a conical top portion 66 that is adapted to seal against the inside surface of a neck portion 122 of the bottle 36, and a bottom portion 70 that is conveniently constructed to fit inside the first hollow boss 54 of the cover 38. The plug 64 also includes an intermediate flange 72 that is adapted to be compressed between the end of the bottle neck 122 and the top of the first hollow boss 54 in the cover 38. The bottom portion 70 of the plug 64 is constructed to include a cylindrical surface with a diameter substantially equal to that of the passageway 46 in the cover 38. When the plug 64 is compressed between the bottle 36 and the cover 38, the bottom surface 74 of the plug 64 projects slightly into the passageway 46 of the cover 38 and seals against spool element 52.
The passageways 76 and 78 communicate between the interior of the bottle 36 and the spool element 52. Preferably, the first passageway 76 includes a one-way valve 80 for preventing flow of product from the pump chamber 90 to the reservoir. The illustrated one-way valve 80 comprises a ball valve having a ball 146. The ball valve may be constructed from the insert mentioned above.
The ball 146 is movable between an open position (FIG. 30) which affords passage of product from the reservoir to the pump chamber 90, and a closed position (FIGS. 26-29) which prevents flow of product from the pump chamber 90 to the reservoir. In a preferred set up, the bottle 36 is situated above the outlet 42 when the dispenser 30 dispenses product, thus, gravity biases the ball 146 toward the closed position. The dispenser 30 is capable of completely dispensing substantially all of the product within the bottle 36, at least partly due to the location of the bottle 36 above the pump. Dispensing substantially all of the product within bottle 36 helps reduce wastage of product upon disposal of the container assembly 32.
The second passageway 78 is adapted to provide a vent 82 for the entrainment of replacement air into the bottle 36. The piston 98 includes first and second piston seals 104 and 106 which are situated to seal the vent hole 96 when the piston 98 is in the return position, and to afford passage of ambient air through the vent hole 96, the second passageway 78, vent tube 82 and into the reservoir when the piston 98 is in the actuated position.
The spool element 52 is adapted to closely fit in the passageway 46 of the cover 38 and includes a hollow cylindrical portion with a first end 86 that is adapted to connect to a retaining element 88 (FIGS. 22 and 23), a second end that comprises the knob 40, and the pumping chamber 90. The retaining element 88 axially holds the spool element 52 in the passageway 46 of the cover 38 but permits rotation thereof. In the sealed position of the valve assembly (particularly useful for shipping, handling and storage), a solid portion (the sealing surfaces 84) of the hollow cylindrical portion of the spool element 52 seals against the elastomeric plug 64 and blocks the first 76 and second 78 passageways that communicate with the liquid in the bottle 36. Notably, the driven surfaces 164 of the piston 98 preferably do not project out beyond the rear wall 39 of the container assembly which helps reduce the chances of inadvertent or undesirable actuation of the container assembly during shipping, storage or handling prior to use.
The inner cylindrical surface of the spool element 52 seals with piston 98. A boss 102 on the retaining element 88 holds the piston 98 in the spool element 52. In the return position of the piston 98, the vent hole 96 in the spool element 52 is closed between first 104 and second 106 piston seal surfaces. During movement of the piston 98 from the return to the actuated position, product (e.g. liquid) in the pump chamber 90 flows through a port 108 that connects with an outlet tube 110 which ends at outlet 42. At least at the end of the movement of the piston 98 to the actuated position, the vent hole 96 is open to the atmosphere.
The dispenser 30 preferably includes a drip resistant nozzle. The nozzle includes portions of the outlet tube 110 which includes the outlet 42, and a flexible, resilient member 112. The flexible, resilient member 112 has a seal portion 174 adapted to engage inner surfaces of the outlet tube 110 to seal the outlet 42 relative to the pump chamber 90.
The flexible, resilient member 112 prevents air aspiration into the pump chamber 90 when the pump chamber 90 is filled with product (e.g. a liquid) from the reservoir. The flexible, resilient member 112 also helps reduce the amount of unsealed liquid which is left adjacent the outlet 42 after a metered amount of the liquid is dispensed. This helps reduce contamination build up as there is less unsealed liquid adjacent the outlet 42 which may attract dirt, dust and other contaminants. Reducing the amount of unsealed liquid adjacent the outlet 42 diminishes the chance that dried liquid will clog or occlude the outlet 42 and also reduces the chance that any unsealed, undispensed liquid will drip from the outlet 42 at an inopportune time (e.g. between discharges of liquid).
Referring to FIGS. 26-30, the flexible, resilient member 112 is mounted within the inner surfaces of the nozzle for movement between a) a relaxed position FIGS. 26 and 30) with the seal portion 174 engaging a portion of the inner surfaces of the nozzle to seal the outlet 42 relative to the pump chamber 90, b) a displaced sealing position (FIGS. 27 and 29) in which the seal portion 174 is spaced from the relaxed position and in which the seal portion 174 engages a different portion of the inner surfaces of the nozzle to seal the outlet 42 relative to the pump chamber 90, and a deflected, dispense position (FIG. 28) with the seal portion 174 of the flexible, resilient member 112 spaced from engagement with the inner surfaces of the nozzle to afford flow of the product to be dispensed from the pump chamber 90 through the outlet 42. Movement of the flexible resilient member 112 from the deflected, dispense position (FIG. 28) toward said relaxed position (FIG. 29) tends to urge the unsealed, undispensed product from the outlet 42 back into the nozzle and away from the outlet 42.
A relaxed shape of the flexible, resilient member 112 is shown in FIGS. 21 and 26. The flexible, resilient member 112 is elongate in an axial direction and includes a seating portion having a first end 168 and retaining surfaces 172 spaced from the first end 168. Between the relaxed position (FIG. 26) and the displaced sealing position (FIG. 27), the flexible resilient member 112 is preferably physically displaced to a different location within the nozzle without being deformed or deflected from its relaxed shape. Between the displaced sealing position (FIG. 27) and the deflected, dispense position (FIG. 28), the flexible resilient member 112 preferably stretches axially to deform from its relaxed shape.
The inner surfaces of the nozzle include a base surface 173 for receiving the first end 168 of the flexible, resilient member 112 in the relaxed position (FIGS. 26 and 30), and a stop surface 175 which is spaced from the base surface 173 to afford displacement of the flexible resilient member 112 from the relaxed position to the displaced sealing position by pressure within the pump chamber 90. For example, the surfaces 173 and 175 may be spaced from each other about 0.19 inches. Alternatively, but not shown in the preferred embodiment, the seating portion of the member 112 may be fixed relative to the nozzle so that pressure within the pump chamber 90 deflects the flexible resilient member 112 from the relaxed position to the displaced sealing position.
Pressure within the pump chamber 90 and engagement between the retaining surface 172 and the stop surface 175 cause the flexible, resilient member 112 to deflect by stretching axially to afford movement of the flexible, resilient member 112 from the displaced, sealing position (FIG. 27) to the deflected, dispense position (FIG. 28). The flexible resilient member 112 is urged back from the deflected, dispense position (FIG. 28) toward the displaced, sealing position (FIG. 29) by the resiliency of its material.
As best seen in FIGS. 26-30, the inner surfaces of the outlet tube 110 of the nozzle are elongate in an axial direction and have a cross section along the axis. The cross section of the inner surface 118 of the outlet tube 110 which is immediately adjacent the sealing portion 174 of the flexible, resilient member 112 in the displaced, sealing position (FIG. 27) is smaller than the cross section of the inner surface 119 of the outlet tube 110 which is immediately adjacent the sealing portion 174 of the flexible, resilient member 112 in the deflected, dispense position (FIG. 28). Preferably the inner surface 118 comprises a cylindrical portion having a substantially constant cross-sectional diameter (e.g. about 0.25 inches). The cylindrical portion is adapted to engage the sealing portion 174 of the flexible, resilient member 112 in the relaxed position (FIGS. 26 and 30) and the displaced, sealing position (FIGS. 27 and 29). The inner surfaces 119 include an enlarged portion (e.g. tapering out to a diameter of about 0.29 inches) substantially adjacent the cylindrical portion 118.
The seating portion of the member 112 has a cross sectional area along its axis, and a central shaft portion 170 between the seating portion and the sealing portion 174. The central shaft portion 170 has a cross sectional area along the axis. The sealing portion 174 of the flexible resilient member 112 comprises a substantially cylindrical surface having a diameter defining a cross sectional area along the axis. Preferably, the cross sectional area of the central shaft portion 170 is substantially less than the cross sectional areas of both the seating portion and the sealing portion 174 to afford axial stretching of the flexible, resilient member 112. The seating portion of the member 112 is capable of being snapped through a partition in the outlet tube 110 during assembly of the container assembly 32. As an example not intended to be limiting, the seating portion may be cylindrical with a maximum outer diameter of about 0.22 inches and a thickness of about 0.12 inches; the central shaft portion may be cylindrical with a diameter of about 0.125 inches and a length of less than about 1 inch, and the sealing portion may be frusto-conical with a maximum diameter of about 0.26 inches with a taper of about forty five degrees relative to its longitudinal axis.
During movement of the piston 98 from the return to the actuated position, the flexible, resilient member 112 is first axially displaced and then stretched. In the deflected dispense position of the member 112, an annular flow path is opened between the seal portion 174 and the inner surface 119 of the outlet tube 110. At approximately the time when liquid stops flowing from the pump chamber 90 through the outlet 42, the member 112 relaxes from the deflected, dispense position to its relaxed shape in the displaced, sealing position and circumferentially seals. When the piston 98 moves from the actuated back toward the return position, the member 112 is axially retracted until the first end 168 of the seating portion abuts the base surface 173 of the inner surface of the nozzle. The axial retraction of the sealing portion 174 after it circumferentially seals against the inner surfaces of the nozzle causes any liquid remaining within the nozzle adjacent outlet 42 to be drawn back into the nozzle and away from the outlet 42.
When the piston 98 moves from the return to the actuated position, liquid in the pump chamber 90 flows through a port 108 into the outlet tube 110 in the knob 40. The member 112 controls the direction of flow and helps reduce the amount of unsealed liquid that remains adjacent the outlet 42 that could dry between uses and obstruct the outlet 42. The outlet 42 is preferably provided by an insert 41 that is connected to the distal end of the outlet tube 110 by means of a snap fit, although gluing, staking, or ultrasonic welding could also be used to make the connection.
Referring now to FIGS. 10 and 11, the bottle 36 includes a body portion 120 and neck portion 122 that is adapted to connect to the cover 38. The neck portion 122 of the bottle is adapted to connect to cover 38 by any convenient means; threads are one possibility, or as in the depicted embodiment, the neck portion 122 of the bottle 36 includes an externally projecting lip 124 that connects to cover 38 by means of a snap fit. In the preferred embodiment, the bottle 36 includes a non-circular region 126 that is recessed from the body portion 120. The recessed region 126 is adapted to extend into the cover 38 to prevent rotation of the bottle 36 after assembly with the cover 38. The bottle 36 can be fabricated from any material compatible with the product to be dispensed. In a preferred embodiment, the bottle 36 is fabricated from a blow molded thermoplastic such as, but not limited to high density polyethylene. Optionally, the entire bottle 36 or a portion thereof may be constructed from a transparent or semi-transparent material so that the user may visually determine the amount of product (liquid) that remains in the reservoir.
Referring to FIGS. 12 through 14, the cover 38 is seen in isolation. The cover 38 includes an exterior body portion with a main opening 44 adapted to receive bottle 36 (not shown in these views for clarity). In the preferred embodiment, the main opening 44 is sized and shaped to receive the recessed region 126 on the bottle 36 (FIG. 10) such that the junction between the bottle 36 and the cover 38 is essentially flush.
A passageway 46 runs substantially perpendicular to the main axis of the bottle 36, and there is an orifice 130 in the passageway 46 that is substantially parallel to the main axis of the bottle 36. The passageway 46 extends completely through the cover 38 and is bounded by a first end 48 on the front face and a second end 50 on the back face. Preferably, the first 48 and second 50 ends are surrounded by first 132 and second 134 countersunk regions. The first countersunk region 132 optionally includes projections 137 that function as a detent or to limit the rotation of the spool element 52. The second countersunk region 134 is adapted to receive retaining element 88.
The cover 38 includes first 54 and second 56 hollow coaxial bosses that project perpendicularly from the passageway 46. The first inner boss 54 surrounds the orifice 130 in the wall of the passageway 46 and is adapted to retain the bottom portion of the plug 64. The top of the first boss 54 is adapted to seat against a flange 72 on the plug 64 and control the distance that the bottom surface of the plug 64 projects into the passageway 46. The second boss 56 connects to the bottle 36 by any convenient means; in the depicted embodiment, the second boss 56 includes an inwardly projecting lip 136 that connects with the externally projecting lip 124 on the bottle 36 by means of a snap fit. The second boss 56 can be continuous or can be slotted so as to control the assembly force of the snap fit joint.
Referring now to FIGS. 15 and 16, the plug 64 is seen in isolation. The plug 64 includes a top conical portion 66 adapted to seal against the inside of the bottle neck 122, and a bottom portion 70 adapted to fit inside the first boss 54 in the cover 38. The bottom surface 74 is adapted to seal against the spool element 52, and an outwardly projecting flange 72 is adapted to seal between the end of the bottle neck 122 and the top of the first boss 54.
The plug 64 includes an outwardly projecting annular rib (FIGS. 15 and 16) that is intended to improve the seal between the top conical portion 66 and the inside of the bottle neck 122. The one-way valve 80 inserted within first passageway 76 can be of any of several well known types, including valves integrally molded in the elastomeric plug. As depicted in FIG. 5, the presently preferred valve 80 includes valve seat insert 144 and the valve includes a gravity-biased ball 146 or poppet. Alternatively the valve 80 could be a spring-biased ball or poppet sealing against an integral valve seat in the plug 64.
The second passageway 78 in the plug 64 retains a first end of a vent tube 82. The second end of the vent tube 82 is above the normal liquid level in the bottle when the disposable container assembly 32 is mounted in an inverted position on the bracket/actuator 34.
Portions of the plug 64 can be fabricated from any elastomeric material that is compatible with the product to be dispensed. This is can be accomplished by molding from a thermoset elastomer. The portions of the plug shown in FIG. 16 may be injection molded from thermoplastic elastomers (e.g. Santoprene 271-64) with a hardness of 40 to 90 Shore A.
At first end 86, the spool element 52 is adapted to connect to a retaining element 88. Referring now to FIGS. 17 and 18, the second end of the spool element 52 is shaped as a knob 40 that integrally includes outlet tube 110. The spool 52 includes two externally projecting ribs 148 and 150 that seal with the passageway 46 in the cover 38 by means of an interference fit. The first end 86 of the spool element 52 is adapted to be axially retained in the cover 38 by any convenient means. In the depicted embodiment, the first end 86 of the spool element 52 includes an externally projecting lip 152 that engages a snap fit joint on retaining element 88, but other expedients such as a threaded retainer or a split ring retainer could be used.
The pump chamber 90 is open at first end 86 and is in part defined by the inner surfaces of the knob 40 at the other end. The pump chamber 90 contains the piston 98 and the piston return spring 100. A shoulder 154 in the pump chamber 90 acts as a piston stop. The knob 40 includes a flange 156 adapted for grasping by the hand of a user. The flange 156 of the knob 40 can include projections 158 adapted to limit the rotation of the spool element 52 in the cover 38. Preferably, the valve assembly rotates approximately one-hundred twenty (120) degrees between the sealed and dispense positions.
Referring now to FIGS. 19 and 20, the piston 98 is seen in isolation. The piston 98 slidably seals in the pump chamber 90 and includes a rod portion 162. The piston 98 preferably includes multiple piston seals 104 and 106 but could optionally include a single sealing surface. The vent hole 96 in the spool element 52 is blocked between the two piston surfaces 104 and 106 in the return position of the piston 98. The two piston surfaces 104 and 106 are supported from the rod portion by any convenient structure. The driven surface 164 transmits the force from an actuator 196 in the bracket/actuator assembly 34 as will be explained with more particularity below. The second end 166 of the rod portion 162 retains the piston return spring 100. The piston 98 can be fabricated from any material compatible with the liquid to be dispensed; in the presently preferred embodiment, the piston 98 is injection molded from a thermoplastic material, such as, but not limited to high density polyethylene (HDPE).
Referring now to FIGS. 5, 22 and 23, the retaining element 88 connects to the spool element 52 to axially hold the spool element 52 in the cover 38 and to retain the piston 98 in the spool element 52 in the normal spring-biased (return) position. A number of expedients for retaining the spool element 52 may be used, such as a threaded retainer or a split ring retainer.
The retaining element 88 includes three concentric bosses projecting from a cylindrical disc portion 176. The first central boss 178 fits inside the spool element 52. The top surface 180 of the first boss 178 retains the piston 98 in the return position. An axial bore 182 in the first boss 178 functions as a bushing for the piston 98 and the reciprocating actuator 196 of the bracket/actuator assembly 34. The second middle boss 184 includes projections 186 that connect to the first end 86 of the spool element 52 by means of a snap fit. The third outer boss 188 includes multiple, inwardly projecting, cantilevered beams 190 that axially bias the spool element 52 against the cover 38. In the presently preferred embodiment, the retaining element 88 is injection molded from a thermoplastic material, such as high density polyethylene.
Referring now to FIGS. 24 and 25, the bracket/actuator assembly 34 includes a housing 191 including a front housing 192 and a rear housing 194. Mounted within the two housings are the actuator 196 and a means 198 to drive the actuator 196. The front and rear housings 192 and 194 can be fabricated in any convenient shape, although it is desirable to provide an exterior surface with simple planar projections as depicted so as to make the bracket/actuator assembly 34 easy to clean. Preferably, the bracket/actuator assembly 34 is formed from a plastic material in a shape visually similar to the disposable container assembly 32.
The front housing 192 includes a passageway 208 that serves as a bushing for the actuator 196. The means 198 for moving the actuator 196 conveniently includes a cavity 210 in the rear housing 194 in which the actuator can slide forwards and back. An air chamber 212 disposed behind the cavity 210 is in fluid communication with the hose 221 which allows the air chamber to be pressurized. When the air chamber is pressurized, the actuator 196 is moved forward and against the driven surface 164 of the piston 98. The piston return spring 100 in the container assembly 32 helps return the actuator when the air chamber 212 is depressurized. An actuator seal 216 is provided to prevent leakage of air from the air cavity past the actuator 196. The seal 216 can include any well known devices such as o-rings, v-rings, u-seals, diaphragms, and rolling diaphragms.
While the depicted embodiment shows the actuator 196 being moved pneumatically, the actuator can be reciprocated by any of several well known means including mechanically, for example a mechanical linkage to a user operated lever; electromechanically, for example a motor and a lead screw; or hydraulically, for example a fluid actuator.
The various parts of the container assembly 32 may be injection molded from a thermoplastic material. The spool element 52 can be fabricated from any material compatible with the liquid to be dispensed. In a preferred embodiment, the spool element 52 is injection molded from a thermoplastic material, such as, but not limited to high density polyethylene. The flexible, resilient member 112 can be fabricated from any elastomeric material compatible with the product to be dispensed. In a preferred embodiment, the flexible, resilient member 112 is molded from a compatible elastomer by well known processes; conveniently, the member 112 is injection molded from a thermoplastic elastomer. As an example not intended to be limiting, the member 112 may be constructed from a thermoplastic elastomer, such as, but not limited to Santoprene 271-64 available from Advanced Elastomer Systems.
OPERATION
Set up of the dispenser 30 may begin with attaching the bracket/actuator assembly 34 in a convenient location, such as on the wall by a sink or on a wheel mounted vertical pole (not shown). The foot actuated pneumatic bladder pump 220 is coupled to the bracket/actuator assembly 34 with the air hose 221 through port 214.
The container assembly 32 may then be attached to the bracket/actuator assembly 34 in the manner shown in FIG. 3, except that typically the valve assembly will be in the sealed position (as opposed to the dispense position shown in FIG. 3) during attachment of the container assembly 32 to the bracket/actuator assembly 34. The rear wall 39 of the container assembly 32 is placed opposite the front housing 192 of the bracket/actuator assembly 34 and the container assembly is moved in a substantially vertically downward direction 10 until the flanges 200 and 202 engage the channels 138 and 140. The flanges 200 and 202 and channels 138 and 140 are situated to automatically guide the driven surfaces 164 of the piston 98 to a position opposite the actuator 196. Engagement between the stop surfaces S and the shoulder surfaces 143 and 145 limits the insertion of the container assembly 32 into the bracket/actuator assembly 34 at the point where the piston 98 is properly oriented relative to the actuator 196.
Once the container assembly 32 is attached to the bracket assembly, the valve assembly should be moved from the sealed position (FIG. 2) to the dispense position (FIG. 1). Preferably, in the dispense position, the outlet 42 opens substantially vertically downward.
To dispense the product from the dispenser 30, the user now steps on the foot actuated pneumatic bladder 220 which causes the actuator 196 to move from the retracted (FIG. 25 solid lines) position to the extended position (FIG. 25 dashed lines). Movement of the actuator from the retracted to the extended position causes the distal end of the actuator 196 to engage the driven surfaces 164 of the piston 98 and drives the piston from the return position to the actuated position.
FIGS. 26 through 30 sequentially illustrate movement of the piston 98 from the return to actuated position and back to the return position. The actuator 198 is omitted from these views to emphasize other details.
In FIG. 26, the piston 98 is biased to the return position by spring 100. The vent tube 82 and hole 96 are sealed from atmospheric air by piston seal surface 106. After the pump is primed, the pump chamber 90 is full of a precise, metered amount of product to be dispensed, regardless of the amount of product in the reservoir. The pump chamber 90 is sealed by the piston seal surfaces 104 and 106 and the flexible, resilient member 112 in the relaxed position. Because the ball 146 of the ball valve is in a down, closed position, product from the pump chamber 90 cannot travel from the pump chamber 90 back into the reservoir via first passageway 76.
The arrow in FIG. 27 illustrates the direction of movement of the piston 98. The piston 98 is shown just as it moves from the return toward the actuated position. As the piston 98 moves, pressure within the pump chamber 90 increases and causes the flexible, resilient member 112 to be initially displaced from its relaxed position in FIG. 26 to a displaced, sealing position (FIG. 27). While the flexible resilient member 112 still seals the pump chamber 90 when it is in the displaced, sealing position, it seals with a different portion of the inner surface 118 than it does when it is in the relaxed position. At this point, the dispenser has not yet dispensed product.
FIG. 28 illustrates the piston 98 after it has moved further along its stroke toward the actuated position. After sufficient pressure builds up in the pump chamber 90, the flexible, resilient member 112 stretches axially to a deflected, dispense position which affords dispensing of the product from pump chamber 90 through the outlet 42. The axial stretching of the member 112 opens an annular path for the product to flow from the pump chamber 90, past the sealing portion 174 of the member 112 and past the inner surface 119 which is just adjacent the sealing portion 174 when the member 112 is in the deflected, dispense position.
FIG. 29 illustrates the piston 98 in the actuated position. Once the pressure within the pump chamber 90 dissipates sufficiently, the internal resilience of the flexible, resilient member 112 causes the member 112 to retract from the deflected, dispense position (FIG. 28) back to the displaced sealing position (FIG. 29). In this position, the piston seal 106 no longer seals vent hole 96 and vent tube 82 from ambient, and air is allowed to flow from ambient, through vent tube 82 and into the reservoir. Note the arrows in FIG. 29 which show the ingress of air into the reservoir.
FIG. 30 illustrates the piston 98 as it is being spring biased from the actuated position back to the return position. As the piston 98 moves back to the return position, a partial vacuum is created in the pump chamber. Vacuum in the pump chamber 90 causes the flexible, resilient member 112 to move from the displaced sealing position (FIG. 29) back to the relaxed position (FIG. 30). The movement of the member 112 from the displaced sealing position (FIG. 29) back to the relaxed position (FIG. 30) changes the unsealed volume within tube 110 that is substantially adjacent the outlet 42. The unsealed volume adjacent outlet 42 is increased which tends to draw product from the outlet 42 back within outlet tube 110 which helps reduce the chance that the outlet 42 will drip at an inopportune time. Preferably, the outlet 42 is formed by insert 41 which provides a restriction substantially adjacent the outlet 41 to enhance the effectiveness of the flexible, resilient member 112 at preventing drips.
The vacuum also causes the ball 146 of the ball valve to move upward to an open position which affords flow of product from the reservoir, through first passageway 76 and into the pump chamber 90. Note the arrows in FIG. 30 which illustrate the flow of product from the reservoir and into the pump chamber 90. The direction of the piston 98 is also illustrated in FIG. 30 with an arrow. Piston seal 106 has already sealed vent hole 96 and vent tube 82. Once the spring 100 moves the piston to the return position, the elements of the container assembly 32 are back to their position shown in FIG. 26 and the dispenser 30 is ready to be actuated again until product within the reservoir is depleted.
When the product within the reservoir is depleted, the entire container assembly 32 may be disposed of which reduces the chance of contaminant build up within the dispenser 30. A refill container assembly may be attached to bracket/actuated assembly 34 and the process repeated. Optionally, but not preferably, product with the reservoir may be simply be replenished (or a new, full bottle 36 may be supplied for the container assembly 32) and the other elements of the container assembly (e.g. the pump and valve assembly) may be reused.
The present invention has now been described with reference to several embodiments thereof It will be apparent to those skilled in the art that many changes or additions can be made in the embodiments described without departing from the scope of the present invention. | A dispenser for dispensing products such as liquid antimicrobials is described. The dispenser includes a bracket/actuator assembly and a container assembly. The dispenser includes a novel mechanism for attaching the container assembly to the bracket/actuator assembly and also includes a novel valve assembly. | 0 |
RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 10/662,132, filed Sep. 13, 2003, entitled, “MODULAR MULTI-CONFIGURABLE DISPLAY SYSTEM”, which is now abandoned which in turn is a continuation-in-part application of U.S. patent application Ser. No. 09/953,113, filed Sep. 13, 2001, entitled, “MODULAR MULTI-CONFIGURABLE DISPLAY SYSTEM”, which is now abandoned, hereby fully incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The present invention relates to displays, and in particular, to a modular display system for the multi-configurable assembly of a display stand at a trade show or other exhibition.
BACKGROUND OF THE INVENTION
Trade shows have been common for some time as a means for companies to significantly expand their client base. Generally, a trade show exhibitor is allocated a specific limited space within a large hall in which to set up a booth or display. It has been common practice for these exhibitors to purchase specially designed displays to showcase their products or services.
These conventional displays usually include a “back wall.” This back wall is set as the focal point for the exhibition. However, while these back walls have generally been readily available and portable, they are often very limited in their use and can be quite expensive. For the most part, the currently available back walls come in limited configurations, with the display manufacturer designing a back wall specifically for the exhibitor. Consequently, conventional back walls are truly customized and are only capable of a limited number of configurations. Rectangular paneled back walls are often the only real configuration option and the exhibitor is only able to modify the look of the wall through the addition of furniture and shelves at predetermined locations.
The lack of configuration flexibility is problematic. First, trade show facilities can vary greatly. The overall size and shape of the exhibit space is an important consideration. A small space may require a reduction in the size of the back wall, while a larger space may present opportunities for the exhibitor to expand the wall and the draw or appeal of the exhibited products or services. In addition, a uniquely shaped booth space may present a problem for those exhibitors utilizing conventional back wall displays since the wall cannot be configured to conform with the space.
Second, exhibitors may wish to periodically change the configuration of the back wall for non-functional reasons. An exhibitor may simply wish to have options available to vary the look of the back wall in order to highlight specific products, influence a particular trade show audience, or for many other creative and aesthetic reasons. However, conventional back wall display systems are generally limited in this respect.
Limited component shapes, such as those used in rectangular panel systems, restrict the ability of an exhibitor to creatively configure the wall. Consequently, there is a need for a display booth back wall system that includes various components of convenient interchangeable shapes and sizes that permit an exhibitor to assemble the wall in a myriad of modular configurations. In addition, the back wall system must be designed for ease of disassembly and portability to accommodate the demands of trade show exhibitors.
SUMMARY OF THE INVENTION
The modular multi-configurable display system of the present invention includes multiple interchangeable components. Namely, the system includes a plurality of vertical columns, a plurality of horizontal truss members, including arcuate members, and a plurality of linear member. The columns are capable of fixedly removably receiving the horizontal arcuate and linear members at each end of the columns. Each column may be formed of one or typically two elongated box frames that are removably stackable and connectable with respect to each other. Each box frame has elongate frame members secured and braced with webbing only at the ends. Whereby appurtenant components can be attached at various positioning locations to a columns. Similarly, in a preferred embodiment, the trusses have only end webbing, no intermediate webbing, thereby providing substantially the entire length of the truss for attachment positions for appurtenances. A myriad of modular configuration combinations are available to an exhibitor.
A significant advantage and feature of the modular multi-configurable display system of the present invention is that configuration options are increased to accommodate an exhibitor's specific needs or creative desires.
Another significant advantage and feature of the present invention is its modular interchangeability and connectability. Each modular component (i.e., the arcuate and linear members) is in connectable communication with other components of identical or different design through an intermediary connection with a frame assembly. Common connectability with a frame assembly permits flexibility in defining the overall shape and size of the display wall. In addition, a specific component is not directed or limited to a particular connection position, or to an individually designated frame assembly. This significantly increases the ease of assembly and decreases the time associated with assembly and disassembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a display in accordance with the invention herein.
FIG. 2 is a front perspective view of a framework for a display.
FIG. 3 is an exploded view of a column in accordance with the invention herein.
FIG. 4 is an exploded view of the connection between an elongate box frame and a truss.
FIG. 5 is a plan view of a stamping for forming an end webbing.
FIG. 5 b is a perspective view of a formed webbing.
FIG. 6 is a perspective view of an elongate box frame, a truss and a graphic screen.
FIG. 7 is a perspective view of an elongate box frame and appurtenance attachment means.
FIG. 8 is a perspective view of a table adjustably mounted on an elongate box frame.
FIG. 9 a is a plan view of one configuration of the modular multi-configurable display wall system of the present invention.
FIG. 9 b is a plan view of another configuration of the modular multi-configurable display wall system of the present invention.
FIG. 9 c is a plan view of yet another configuration of the modular multi-configurable display wall system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 , a display 20 suitable back wall of trade show exhibits is illustrated. FIG. 2 illustrates the framework 22 for the display and is generally comprised of a plurality of vertical columns 24 and a plurality of trusses 26 that are combined to form a series of graphical screen window frames 30 defining a plurality of graphical screen windows or openings 32 . The window frames are generally laid out in a sequential manner to form a structurally stable display due to the serpentine shape.
Referring to FIG. 3 , a portion of a vertical column 24 is illustrated. The column is composed of two elongated box frames 40 , each presenting a longitudinal axis a. Each box frame in a preferred embodiment is comprised of four frame tubing segments 42 formed from square steel tubing. Each framed segment 42 has a first end 46 and a second end 48 . Each of the respective first ends 46 of the four framed segments 42 is joined together by an end webbing 50 as well as are the second ends 48 . The ends 46 , 48 of the frame tubing segments 42 are opened defining a socket 56 , which facilitates connection to another elongated box frame 40 or to a truss 26 . Said connections are facilitated by in line connectors 60 as illustrated in FIG. 3 , or right angle connectors 62 as illustrated in FIG. 4 . In line connectors 60 have a portion 57 , which is sized so as to be received in socket 56 of the frame tubing segments 42 . The ends of the elongate box frames 46 , 48 also have threaded portions 64 configured as nuts 66 welded onto the ends 48 of the steel tubing frame segments 42 . Set screws 70 are threaded through threaded portions 64 to frictionally contact and thereby attach the connectors 60 , 62 . The connectors will preferably have indentations 74 at the set screw location points. Similarly, the right angle connectors 62 have a portion 58 sized so as to be received in socket 56 . Right angle connectors 62 may also have body portion 59 , which is sized slightly larger than socket 56 as depicted in FIG. 4 . The right angle connectors may also have threaded bores 78 for attachment of feet 80 or other appurtenances.
A piece of sheet steel 81 is illustrated in FIG. 5 and 5 b , which is suitable for forming the end webbing 50 . Sheet steel piece 81 has notches 84 which conform in shape and dimension to the exterior of tubular frame segments 42 . Perpendicular portions 85 as depicted in FIG. 5 b are formed by bending sheet steel piece 81 along folding lined 83 . To lighten the assembly, end webbing 50 may have one or more apertures 86 formed therein. The end webbing 50 is welded onto each of the four tubular frame segments 42 at welds 43 to form an optimally strong and light structure. Although the end webbing as illustrated is formed of a single unitary piece, it is also contemplated that the webbing could be formed of individual strips bridging individual frame segments. Thus webbing is defined as the structure securing segments together, whether a single unitary piece or multiple pieces.
Significantly, the elongated box frames 40 have an intermediate portion 89 positioned intermediate the end webbing 50 ; said intermediate portion 89 does not have any webbing or bracing. This facilitates four “clean” frame segments for variable positioning of appurtenances as illustrated in FIGS. 7 and 8 , for providing an aesthetically pleasing and uncluttered look. In an ideal embodiment the clean intermediate portion 89 without webbing will constitute 70 percent or more of the length of the box frame 40 .
As depicted in FIGS. 7 and 8 , various appurtenances may be positioned along intermediate portion 89 of box frame 40 . In FIG. 7 , for example, a shelving support apparatus 120 is depicted. The apparatus generally includes a frame attachment portion 121 and a shelf support member 122 . Shelf support member 122 may be a typical shelf support commonly used with adjustable shelving systems. As depicted in FIG. 7 , the member 122 typically has a proximal end 126 with a plurality of downwardly directed hooks 128 . Frame attachment portion 121 is u-shaped so as to fit over and secure to frame segments 42 . A plurality of vertically aligned slots 124 , each sized to receive a hook 128 , are provided in frame attachment portion 121 . Each shelf support member 122 may be attached to a frame attachment portion 121 by inserting hooks 128 into corresponding slots 124 , and moving the shelf support downwardly, thereby hooking the hooks 128 into the slots 124 . Another exemplary embodiment of a shelf support is depicted in FIG. 8 . In this embodiment, shelf 90 has projecting portion 92 confronting frame segments 42 . Threaded knob 95 extends through clamping portion 94 , and threads into projecting portion 92 . If threaded knob 95 is tightened, frame segments 42 are trapped and frictionally secured between projecting portion 92 and clamping portion 94 , thereby providing a support for shelf 90 . Shelf 90 may be positioned in any desired position along frame segments 42 by loosening threaded knob 95 , sliding the shelf 90 along the frame segments 42 as depicted by the arrow until the desired position is reached, and retightening threaded knob 95 .
Referring to FIGS. 2 , 4 and 6 , details of the horizontal trusses 26 are illustrated. These trusses 26 may be linear in configuration as illustrated in FIG. 4 and 1 or may be arcuate as illustrated in FIG. 6 and 1 . In either case, the trusses have parallel frame segments 102 , which may be joined by webbing members 104 proximate the ends, or alternatively by conventional webbing 106 as depicted in FIG. 4 .
As illustrated in FIG. 6 , the horizontal trusses 26 are utilized for connection of the graphic screen panels 108 which due to the positioning of the unshaped webbing 104 on the bottom of the bottom truss and the top of the top truss, allows positioning of the screens 108 in four positions as identified by the arrows labeled as A, B, C and D in FIG. 6 . This provides an extraordinary amount of flexibility in mounting the graphical screen. The horizontal trusses, in an alternate embodiment of the display may utilize conventional webbing 106 as illustrated by the dashed lines of FIG. 4 .
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. | The modular multi-configurable display has a series of box frames and provides variable positioning for appurtenances. The display can include a plurality of vertical columns, and generally horizontal trusses. The columns are capable of receiving the trusses at each end of the columns. Each box frame can be stackable with another box frame such that the vertical span of the display is adjustable. Appurtenance can be attached at various positioning locations to the display such that a myriad of modular configuration combinations are available to an exhibitor. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for filtering, dehydrating and drying particularly suspension material, powder material and the like, and to a method for filtering, dehydrating and drying same.
Conventional operations for filtering, dehydrating and drying suspension material, powder material and the like require several processes and apparatus, and the apparatus used in the conventional operations are very complicated in construction; thus, it costs much and takes much time to treat the material, and good working efficiency can hardly be obtained. Furthermore, when the treated material is carried from one process to another process, manual operations are required; thus, operators expose themselves to danger when treating hazardous material.
SUMMARY OF THE INVENTION
In accordance with the present invention, an apparatus and a method for filtering, dehydrating and drying suspension material, powder material and the like are provided. The material to be treated is filtered through a filter mesh disposed on a valve plate arranged rotatably in a vertical type filter cylinder of the apparatus to collect a filter cake on the filter mesh. Then the filter cake is dried and dropped from the filter mesh through an opening at the lower portion of the cylinder by tilting the valve plate together with the filter mesh. The apparatus may have an auxiliary filter means engagable with the filter mesh, and this means is constructed of a mounting plate and a plurality of rods of predetermined length suspended from the bottom of the mounting plate. The auxiliary filter means serves to provide advantages of increasing filtering area and of improving filtering efficiency. When the auxiliary filter means is moved upwardly from the filter mesh in course of making deposition of the filter material on the filter mesh by means of an actuator to withdraw the rods from the deposition layer, a lot of holes are formed in the deposition layer, thus filtering area is increased. Furthermore, filtering efficiency is improved in such a way that particles of material deposited on the upper surface flow into the holes to allow the deposition layer of the material to get thinner. Furthermore, a system for providing the filter mesh with vibration in the vertical and/or horizontal direction may be additionally applied to the apparatus according to the present invention.
Accordingly, an object of the present invention is to provide an apparatus for filtering, dehydrating and drying efficiently suspension material, powder material and the like.
Another object of the present invention is to provide an apparatus for filtering, dehydrating and drying suspension material, power material and the like automatically and mechanically in one process.
Another object of the present invention is to provide an apparatus for filtering, dehydrating and drying suspension material, powder material and the like which has a very simple construction.
Another object of the present invention is to provide an apparatus for filtering, dehydrating and drying suspension material, powder material and the like safely without requiring manual operations.
A further object of the present invention is to provide a method for filtering, dehydrating and drying efficiently suspension material, powder material and the like.
A further object of the present invention is to provide a method for filtering, dehydrating and drying suspension material, powder material automatically and mechanically in one process.
Still a further object of the present invention is to provide a method for filtering, dehydrating and drying suspension material, powder material safely without requiring manual operation.
Other objects and advantages of the present invention will become apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the present invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIGS. 1A to 1F are schematical illustrations of working steps of an apparatus for filtering, dehydrating and drying material according to one embodiment of the present invention;
FIG. 2 is a vertically sectional view of an apparatus according to another embodiment of the present invention;
FIG. 3 is a plan view of an auxiliary filtering means for the apparatus as shown in FIG. 2;
FIG. 4 is a partial sectional view showing particularly an actuator for the auxiliary filtering means; and
FIG. 5 is a partial sectional view of another actuator similar to that of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An apparatus of filtering, dehydrating and drying material according to one embodiment of the present invention, as shown in FIG. 1, is constructed of a vertically extending filter cylinder A having a full opening at the lower side thereof, a filtering zone B located around the center of the filter cylinder A, a hollow valve plate D bearing the filtering zone B thereon and disposed rotatably within the filter cylinder A so that material to be treated is deposited on the valve plate D when it is in the horizontal position and treated material is dumped from the valve plate B when it is rotated from the horizontal position to the vertical position, and a hollow valve stem C which is communicated with the filter zone B.
Material to be treated E such as liquid of suspension is fed through an inlet pipe F into the filter cylinder A of which the center portion is closed by the valve plate (see FIG. 1A). Then the material E is filtered through the filtering zone B on the valve plate D under pressurized air supplied through an air inlet pipe G and the filtered liquid E' is removed through the hollow valve stem C (see FIG. 1B) and dehydrated material E" is collected on the filtering zone (see FIG. 1C). Then hot air supplied through an inlet pipe H is blown upon the material E" to dry the material (E"), so that a dried filter cake E'" is obtained (see FIG. 1D). Thereafter the valve plate D is tilted by rotating the hollow valve stem C (see FIG. E) so as to allow the filter cake E'" on the filtering zone B of the valve plate D to be dumped down the filter cylinder A (see FIG. 1F). Thus the filtered cake E'" is taken out of the filter apparatus efficiently in one process.
The filter apparatus may be provided with a vibration means to prevent the filter cake E'" from being adhered to the filtering zone B and the screen mesh from getting clogged. Vibration is applied to the apparatus in course of filtering the liquid of suspension E in such a way as to vibrate laterally and/or vertically the filtering zone B of the valve plate D to prevent the filtering zone B from getting clogged. However, in this apparatus, as deposition layer of the material E" becomes thicker or gets more dense, filtering efficience on the filtering zone B is also gradually reduced. To eliminate such drawbacks, an auxiliary filter means may be provided with the filter apparatus, as shown in FIGS. 2 to 5.
Referring to FIG. 2, on a mounting base 1 is mounted a vertically extending filter cylinder 7 which has a top cover 2 arranged thereon and has a full opening 6 on the bottom portion thereof, said top cover 2 being provided with an inlet pipe 3 for feeding liquid of suspension. An inlet pipe 4 for pressurized air and an inlet pipe 5 for hot air may be provided. On the center portion of the filter cylinder 7 is horizontally arranged a hollow valve plate 8, of which filter side is connected to a hollow valve stem 10 with a discharge valve 9, said valve plate 8 being rotated around the hollow valve stem 10 between the horizontal and vertical positions thereof within the filter cylinder 7 by means of an actuator 24 such as an air cylinder, so that material to be treated is deposited on the valve plate 8 when it is in the horizontal position, and treated material is dumped from the valve plate 8 when it is rotated from the horizontal position to the vertical position. The rotating angle of the valve plate 8 is preferably about 90 degrees. On the filter side of the valve plate 8 is arranged laterally and/or vertically movably a filter mesh 12 integral with a perforation plate 11 therebelow, from which a connection rod 13 is suspended to be engaged with a vibration rod 15 which extends through the hollow valve stem 10 and is supported at its free end within a support ring 14 set fast to the valve stem 10. In the upper portion of the filter cylinder 7 is housed an auxiliary filter means 18 comprising a mounting plate 16 of which diameter is smaller than of the inner wall of the filter cylinder 7, and a large number of suspension rods 17 of predetermined length set fast to the mounting plate 16 so that the rods 17 is suspended from the plate 16. At the center of the mounting plate 16 of the auxiliary filter means 18 is securely provided an actuator of a rod, a cord or the like 19 which extends upward through a hole 20 on the top cover 2.
As shown in FIG. 2, the vibrating rod 15 comprises a long reciprocal rod connected to a crank piece 23 on an output end 22 of electric motor 21.
FIG. 3 is a plan view of the auxiliary filter means 18, wherein reference numeral 16 denotes a circular mounting plate, numeral 25 does a large number of perforated holes for liquid passage, the numerals 26 and 27 do stopper means for prevention of rotation, and numeral 28 does slide piece of plastics material e.g. Tephlon protruded from the side portion of the mounting plate 16.
FIG. 4 illustrates by way of a partial cross sectional view an example of actuator for lifting and lowering the auxiliary filter means 18, that is, pneumatic cylinder means, wherein numeral 30 denotes an air cylinder, numeral 29 does a grand packing arranged between the air cylinder 30 and the upper portion of the filter cylinder 7, and numeral 31 does an air inlet or outlet.
FIG. 5 is another example of actuator for the auxiliary filter means by which said pneumatic cylinder arrangement is replaced, wherein a connection of worm and worm wheel is employed in stead of pneumatic piston and cylinder means. In FIG. 5, numeral 32 denotes a worm wheel having an inner thread at a center thereof, numeral 33 a hand wheel for rotating a worm shaft 35, and numeral 34 does a threaded portion of the actuator rod 19, which is allowed to move up and down by means of rotation of the worm wheel 32.
The filter apparatus as constructed according to the present invention as described above is operated in the following manner.
At first the valve plate 8 is rotated to shut down the center portion of the filter cylinder 7 and a plurality of suspension rods 17 of the auxiliary filter means 18 are lowered to abut against the upper surface of the valve plate 8 and then liquid of suspension to be filtered is fed through the inlet pipe 3 into the interior of the filter cylinder 7. Then pressurized air is blown through the air inlet pipe 4 thereinto, as desired, so that the liquid is allowed to be put in forcible filtration through the filter mesh 12 on the valve plate 8. Then the filtered liquid is removed from the mesh plate 12 through the valve plate 8 by opening the discharge valve 9 of the hollow valve stem 10, while the residual solid material is left deposited on the mesh plate 12. In course of making deposition of the solid material on the mesh plate 12, the auxiliary filter means 18 supported on the mesh plate 12 at its lower end is moved up toward the hole 20 by means of the actuator rod 19, resulting in a lot of residuary recesses corresponding to the suspension rods 17 of the auxiliary filter means 18. A group of said residuary recesses or holes serves to increase effective filtering area for liquid of suspension and to improve filtering efficience in such a manner that fine grain of material on the upper portion of the deposition flows into said residuary recesses thus making additional deposition of the material on the side and bottom thereof to cause the deposition layer of fine grain of material to get thinner. The filtered material is then dried either by hot air supplied through the air inlet pipe 5 or in a natural way, so that filter cake is produced in a shorter period of time.
In case of certain kind of suspension material the above mentioned steps of filtration may be accomplished just by the weight of material itself to be filtered without pressurized air. Thus the air inlet pipe 4 is eliminated. Further in case drying by hot air isn't required, the hot air inlet pipe 5 is also eliminated.
When the vibrating rod 15 supported at one end thereof with the support ring 14 is vibratorily actuated through the crank piece of the output shaft 23 by the motor 21 during filtering and dehydrating the filter mesh 12 is vibrated together with the perforation plate 11, because the former is connected to the latter through the connecting rod 13 fastened to the lower side of the latter. This contributes to preventing the filter mesh from getting clogged with solid material and to allowing the filter cake to be floated up.
Accordingly, the filter cake on the filter mesh 12 is completely dumped through the opening 6 of the filter cylinder 7 by tilting the valve plate 8 with the hollow valve stem 10 as vibrating is applied. Moreover such removal of filter cake is carried out smoothly and in shorter time by way of dumping activity under vibration.
As mentioned above, the present invention improves remarkably filtering efficience by means of a group of recesses or holes, corresponding to the suspension rods 17, which are brought about on the deposition layer after removing upward the auxiliary filter means 18 which is located on the filter mesh 12. So the apparatus according to the present invention provides excellent performance of filtering, dehydrating and drying. | A filter apparatus for treating material comprises a filter cylinder, a hollow valve plate mounted rotatably in the center portion of the filter cylinder and having a filter mesh provided thereon, and a hollow shaft connected to the valve plate to cause the valve plate to rotate and discharging a filtrate therethrough. The filter apparatus is preferably provided with a vibrator to cause the filter mesh to be vibrated and an auxiliary filter equipment to improve filtering efficiency. The material is filtered, dehydrated and dried on the filter mesh in one process, and then is dropped from the filter mesh by rotating the filter mesh, thus the treated material is obtained. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation under 35 U.S.C. § 365(c) and 35 U.S.C. § 120 of international application PCT/EP2004/006166, filed Jun. 8, 2004. This application also claims priority under 35 U.S.C. § 119 of DE 103 27 127.9, filed Jun. 13, 2003, and of DE 103 61 081.2, filed Dec. 22, 2003, each of which is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] (1) Field of the Invention
[0005] The present invention relates to a process for stabilizing percarboxylic acids, particularly imidopercarboxylic acids, which are solid at room temperature, in dispersions containing surfactants, preferably aqueous dispersions, as well as the dispersions containing surfactants that are obtained in this way and their use in washing and cleaning agents, tooth-care products, hair colorants and decolorizing or bleaching agent compositions for technical uses. Furthermore, the present invention relates to washing and cleaning agents, tooth-care products, hair colorants and decolorizing or bleaching agent compositions particularly for technical uses, which comprise the stabilized surfactant-containing dispersions of percarboxylic acids.
[0006] For liquid, particularly aqueous washing and cleaning agents that are enjoying an increased popularity due to their positive product properties such as a better and faster solubility and practicality, the addition to the formulation or incorporation of bleaching (agent) components is problematic for numerous reasons. Due to their decomposition reactions or hydrolysis and incompatibilities towards other constituents of the washing agent formulation, such as, e.g., enzymes or surfactants, the added bleaching agents often lose their activity already on storage or even during product utilization. An adverse consequence resulting from this is that the washing performance—particularly the bleaching power—of the washing agent formulation noticeably deteriorates, such that bleachable stains in particular can no longer be satisfactorily removed.
[0007] Bleaching agents, such as, for example, perborates or percarbonates, which are usually used in solid washing agent formulations, are moisture sensitive, with the result that they often lose their bleaching power within a few days in a liquid and particularly aqueous washing or cleaning agent, due to the loss of active oxygen.
[0008] On the other hand, percarboxylic acids, especially imidopercarboxylic acids, the most important representative of which is phthalimidopercaproic acid (PAP), are more efficient and less sensitive to hydrolysis and are known in the prior art as bleaching agents for washing and cleaning agents. Nevertheless, their storage stability is by far insufficient to guarantee a long-term use of the corresponding washing and cleaning agent without the consequent loss in activity. The addition of percarboxylic acids, particularly imidopercarboxylic acids, in liquid washing and cleaning agents is therefore particularly problematic.
[0009] Because of the disadvantages that result from a modification of the washing and cleaning agent formulation as a consequence of the decomposition of imidopercarboxylic acids, particularly PAP, attempts have been made in the prior art to modify the washing and cleaning agents that contain imidopercarboxylic acids (e.g., PAP), such that the imidopercarboxylic acid in these formulations has a greater stability or storage stability.
[0010] (2) Description of Related Art including Information Disclosed under 37 C.F.R. §§ 1.97 and 1.98
[0011] Therefore, an aim of the prior art has been to stabilize these percarboxylic acids by putting a protective shell layer onto the percarboxylic acids in order to prevent any contact with the aqueous dispersion. However, the layered shell systems, known from the prior art, are often not sufficiently compatible with the dispersion medium and do not always provide the necessary stabilization. For example, certain shell materials can be dissolved over time by the dispersion medium. Other shell layer materials, particularly waxes having high melting points, (see EP 0 510 761 B1 and U.S. Pat. No. 5,230,822) have the disadvantage that they only release the enveloped or encapsulated percarboxylic acids at relatively high temperatures—and mostly without a delay—and in addition leave insoluble residues behind.
[0012] On the other hand, in the prior art, attempts have been made to adjust the dispersion medium for the percarboxylic acids so as to stabilize the percarboxylic acids. The measures known from the prior art, however, are not sufficient to adequately stabilize the percarboxylic acids in the presence of surfactants.
[0013] Thus, EP 0 334 405 B1 describes aqueous bleaching agent compositions containing solid, particulate, essentially water-insoluble, organic percarboxylic acids, wherein 1 to 30 wt. % of a secondary C 8 -C 22 alkane sulfonate and 0.5 to 10 wt. % of a fatty acid are added to stabilize the percarboxylic acid against phase separation from the aqueous liquid. Due to the very specific composition of the additives, such a bleaching agent composition is not generally applicable. Moreover, the resulting stabilizing effect is not always adequate.
[0014] In a similar way, it was also attempted in EP 0334404 B1 to stabilize the percarboxylic acid against phase separation from the aqueous liquid. However, the percarboxylic acids could not be sufficiently stabilized against decomposition.
[0015] Overall, no efficient measures are disclosed in the prior art for an adequate stabilization of percarboxylic acids in aqueous dispersions.
BRIEF SUMMARY OF THE INVENTION
[0016] Against this background, an object of the present invention therefore consists in providing surfactant-containing dispersions of percarboxylic acids, particularly imidopercarboxylic acids, such as phthalimidopercaproic acid (PAP), which possess a high storage stability, as well as to specify an appropriate manufacturing process for these dispersions.
[0017] A further object consists in providing storage stable, surfactant-containing dispersions of percarboxylic acids, particularly imidopercarboxylic acids, such as phthalimidopercaproic acid (PAP), with improved properties compared with the prior art, as well as an appropriate manufacturing process for these dispersions.
[0018] Another further object of the present invention is the provision of surfactant-containing dispersions that comprise solid, particulate percarboxylic acids and which lead to a good stabilization of the percarboxylic acid and hence to an improved storage stability. In particular, in the scope of the present invention, it is intended to provide dispersions that, inter alia, can be used for washing or cleaning agents, tooth-care products, hair colorants and decolorizing or bleaching agent compositions, particularly for technical uses or the like, or can be incorporated inter alia in washing or cleaning agents, tooth-care products, hair colorants and decolorizing or bleaching agent compositions, particularly for technical uses or the like. For this, the percarboxylic acids present in the dispersions should possess firstly, a high storage stability in the state of the concentrated dispersion, and secondly, on use of the product, particularly when diluted with water (e.g., during the washing process), possess a high active power or develop the entire bleach activity.
[0019] In this context, it can be frequently observed that percarboxylic acids, particularly PAP, when added in liquid, particularly aqueous media in the presence of surfactants, such as, for example, in washing and cleaning agent compositions, often in large amounts e.g., from 0.5 to 30 wt. %, particularly 5 to 30 wt. %, are rapidly decomposed, such that their use in surfactant-containing liquids, particularly aqueous media is of only very limited possibility.
[0020] Applicants have now surprisingly found that organic percarboxylic acids, particularly imidopercarboxylic acids (e.g., PAP), can be incorporated into surfactant-containing media or dispersions with a long storage stability, if they possess specific stabilizing properties, such as will be mentioned below in detail.
[0021] The object of the present invention, according to a first aspect, is therefore a process for stabilizing solid percarboxylic acids, particularly imidopercarboxylic acids, in a dispersion containing surfactants, preferably an aqueous dispersion, wherein the surfactant-containing dispersion is adjusted in such a way that a decomposition of the percarboxylic acid present in the surfactant-containing dispersion is prevented or at least reduced or retarded in the dispersion or the solubility of the percarboxylic acid in the dispersion is reduced.
[0022] According to the invention, the term “surfactant-containing dispersion” is particularly understood to mean a liquid, particularly aqueous system or medium that has a significant surfactant content (e.g., from 0.5 to 30 wt. %, particularly 5 to 30 wt. %, based on the dispersion or the continuous dispersion phase), as is required in e.g., washing and cleaning agents. In particular, the term “surfactant-containing dispersion” is understood to mean such a composition that in the context of its end-use disposes of an adequate surfactant content such that, e.g., the composition provides a washing or cleaning agent action.
[0023] The inventive process enables percarboxylic acids (e.g., PAP) in liquid, particularly aqueous dispersions or media to be efficiently stabilized in the presence of surfactants or their decomposition in such media to be efficiently minimized; this permits their use in such systems. Without these appropriate measures, percarboxylic acids (e.g., PAP) are unstable in liquid, particularly aqueous dispersions or media and are rapidly decomposed, such that their use in surfactant-containing liquid, particularly aqueous media was not possible up to now or was at the most of very limited possibility.
[0024] The percarboxylic acids, particularly imidopercarboxylic acids, used in the context of the present invention are those that are in the form of solid grains or particles at room temperature (20° C.) and normal or atmospheric pressure (101 325 Pa), i.e. are particulate.
[0025] For the purposes of the present invention, the term “decomposition” is understood to mean particularly chemical and/or physical decomposition processes or decomposition reactions of the percarboxylic acid, particularly chemical decomposition processes or decomposition reactions, such as hydrolysis, reduction, oxidation, disintegration etc. Such reactions lead to an irreversible decomposition or to a disintegration of the percarboxylic acids and hence to an impairment of their applicability, particularly an impairment of the bleaching performance of dispersions of such percarboxylic acids.
[0026] Applicants have now surprisingly found that a decomposition of percarboxylic acids, particularly imidopercarboxylic acids (e.g., PAP), in surfactant-containing dispersions, particularly surfactant-containing, aqueous dispersions, can be efficiently impeded or at least significantly minimized or reduced when the halide content of these dispersions is minimized, in particular when these dispersions are essentially free of or at least poor in halides, particularly chloride and/or bromide.
[0027] Applicants have surprisingly found that a high halide, especially chloride or bromide ion concentration, as is commonly found in conventional washing and cleaning agents, leads to an increased decomposition of percarboxylic acids. Therefore, a reduction in the halide, especially chloride or bromide ion concentration, can lead to a reduced decomposition of the percarboxylic acid in the (concentrated) dispersion. Consequently, a reduction or minimization of the halide ion concentration leads to a drastic decrease in decomposition or a significant stabilization of the solid particulate percarboxylic acids present in the dispersion.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0028] Not Applicable
DETAILED DESCRIPTION OF THE INVENTION
[0029] The percarboxylic acids in the dispersion are particularly well stabilized when the total content of halide ions, particularly chloride and/or bromide, based on the continuous dispersion phase, does not exceed 100 ppm, particularly 50 ppm, preferably 30 ppm, particularly preferably 15 ppm (i.e. the total quantity of halides by weight in the continuous phase of the dispersion C halide(total) is ≦100 ppm, particularly ≦50 ppm, preferably ≦30 ppm, particularly preferably ≦15 ppm). According to the invention, the abovementioned amounts are understood to mean essentially halide-free or halide-poor ranges or amounts. According to the invention, the term “continuous phase of the dispersion” is understood to mean the dispersion agent with the components or ingredients (e.g., salts, surfactants etc.) dissolved therein. According to the invention, the preferred dispersion agent is water.
[0030] The minimization of the halide ion content carried out in the context of the present invention, particularly the chloride and bromide content, in the inventive dispersion can be achieved by choosing or avoiding certain ingredients, components etc. (e.g., the use of essentially halide-free components, thus halide-free surfactants, halide-free phosphonates etc.). According to the invention, a low halide, particularly chloride ion concentration can be achieved, for example, by the addition of halide-free cationic surfactants, e.g., in the form of compounds of methyl sulfate, phosphate, tosylate or cumene sulfonate. On the other hand, many technical components of detergents contain sometimes non-negligible concentrations of chloride or bromide, in particular technical qualities of anionic surfactants may be cited. Therefore, according to the invention preferably only those detergent components—particularly surfactants—should be selected that have at least essentially no halide or chloride ions and only those raw materials with a particularly low halide or chloride content.
[0031] In general, the additional components, which are used in the inventive process for manufacturing the dispersions, should be chosen with the proviso that they are firstly essentially halide-free or at least halide-poor and secondly that they are at least largely compatible with respect to the percarboxylic acids, i.e. there should be no unwanted chemical reactions, such as degradation, in particular reduction or oxidation and/or hydrolytic reactions between these components and the percarboxylic acid and none induced by the additional components on the percarboxylic acid that would lead to its loss in activity, in particular to its decomposition.
[0032] Applicants have now surprisingly found that the stabilizing effect, achieved by minimizing the halides, can even be increased with respect to the percarboxylic acids present in the surfactant-containing dispersion by adjusting the surfactant-containing dispersion to acidic, preferably weakly to slightly acidic or if need be neutral. Preferably the dispersion is adjusted to a pH of maximum 7, particularly a pH of 3.5 to 7, preferably from 4.0 to 6.5, particularly preferably from 4.5 to 6, quite particularly preferably of about 5.
[0033] Surprisingly, bleaching agents based on percarboxylic acids, such as PAP, can be efficiently stabilized in an acidic surfactant-containing environment, as the percarboxylic acids are only slightly soluble in the dispersion agent, particularly water, at such a pH and are present as crystal dispersions, whereas at neutral or alkaline pH a relatively rapid decomposition of the percarboxylic acids like PAP, takes place due to the increased solubility. Nevertheless, the pH of the dispersion, particularly of the washing or cleaning agent, should not be made too acidic in order to avoid a degradation or inactivation of any enzymes optionally present in the dispersion. Consequently, the pH value cited in the context of the present invention illustrates one of the optimized areas of this background.
[0034] The adjustment, particularly the reduction or shift of the pH of the dispersion into the acidic region, can be carried out in the context of the present invention with acids or acidic salts. Exemplary inventively suitable acids or acidic salts for adjusting the pH are e.g., organic polycarboxylic acids, bisulfates and biphosphates. Moreover, phosphonates used as chelating agents, can be incorporated as phosphonic acids and subsequently adjusted to the desired pH by the addition of alkalis (Process for adjusting the pH).
[0035] In addition, Applicants could surprisingly demonstrate that the stabilizing effect with respect to the percarboxylic acids present in the dispersion and obtained by use of the cited measures, can be further increased when the surfactants, present in the dispersion—as is the case for instance for washing and cleaning agents—are converted into an inactivated form, i.e. the dispersion should at least essentially comprise no surfactants in active form. The total active surfactant content in the dispersion or the continuous phase of the dispersion should be less than 5%, particularly less than 2.5%, preferably less than 1%, based on the dispersion or the continuous dispersion phase. In other words, the total inactivated surfactant content in the dispersion is more than 95%, particularly more than 97.5%, preferably more than 99%, based on the total surfactant.
[0036] In this context, Applicants were able to show that organic percarboxylic acids, particularly PAP, are rapidly decomposed in the presence of active surfactants (i.e. surfactants, present in free and/or micellar form in the washing or cleaning agent formulation), as the percarboxylic acids, due to the surfactants, are better dissolved and are extremely unstable in this dissolved state. In this context, non-ionic surfactants or niosurfactants, e.g., based on alkyl polyglycol ethers, lead to an accelerated decomposition of the percarboxylic acids. In the inventive process, the dispersion should therefore have an optimized, preferably a low non-ionic surfactant (niosurfactant)/charged surfactant ratio. Here, the alkyl polyglycol ether content should be as low as possible.
[0037] The surfactants can be inactivated by adding sulfates, particularly preferably sodium sulfate. This produces in particular, a salting out of the surfactants i.e. a phase separation is induced to form a surfactant-poor, continuous phase and a preferably lamellar, generally high viscosity crystalline or liquid-crystalline surfactant-rich phase) the surfactants being transported out of the particularly micellar, active form into a preferably lamellar, crystalline or liquid-crystalline form (crystal formation or liquid crystal formation) that is dispersed in an almost surfactant-free continuous phase. The dispersed surfactant liquid crystal, itself, which can be separated by centrifugation, for example, should be as highly viscous as possible. A particularly good stabilization of the percarboxylic acid can be obtained when the content of free surfactants in the inventive washing and cleaning formulations in the continuous phase is particularly preferably not more than 1%, based on the dispersion or the continuous phase of the dispersion.
[0038] Preferably, the surfactants can be inactivated by incorporating sodium sulfate into the continuous phase of the dispersion. For this, the sodium sulfate can be incorporated into the dispersion in amounts of 5 to 30 wt. %, particularly 15 to 30 wt. %, preferably 20 to 30 wt. %. According to the invention, the term “incorporate” is particularly understood to mean to dissolve the sodium sulfate incorporated into the dispersion, by dissociation or solubilization, for example.
[0039] Applicants have now unexpectedly found that a particularly good stabilization of the percarboxylic acid present in the dispersion is then obtained when all of the abovementioned measures are realized in the dispersion (i.e. minimization of the halide content, lowering the pH, inactivating the surfactants, optimized or minimized niosurfactant content). Surprisingly, the abovementioned measures act synergistically, resulting in a particularly efficient stabilization of the dispersed, solid particulate percarboxylic acids and consequently a good storage stability of such dispersions.
[0040] The inventive process for stabilizing percarboxylic acids, particularly imidopercarboxylic acids, which are solid at room temperature, in dispersions containing surfactants, preferably aqueous dispersions, can also, all in all, be carried out so as to adjust the dispersions in such a way,
that the total content of halide ions, particularly chloride and/or bromide, based on the continuous dispersion phase, does not exceed 100 ppm, particularly 50 ppm, preferably 30 ppm, particularly preferably 15 ppm; and/or that the dispersion has a pH of maximum 7, particularly a pH of 3.5 to 7, preferably from 4.0 to 6.5, particularly preferably from 4.5 to 6, quite particularly preferably of about 5; and/or that the dispersion, at least essentially, comprises no surfactants in active form, in particular wherein the total active surfactant content in the continuous phase of the dispersion is less than 5%, particularly less than 2.5%, preferably less than 1%, based on the continuous dispersion phase.
[0044] As Applicants have unexpectedly discovered, the stabilization of the percarboxylic acid in the inventive dispersions can be further increased when at least one chelating agent is added to the aqueous dispersion, preferably in amounts of 0 to 10 wt. %. The chelating agent, can be selected from the group of quinoline and/or its salts, alkali metal polyphosphonates, picolinic acid and dipicolinic acid, mono- or polyphosphonic acids, particularly 1-hydroxyethylidene-1,1-diphosphonic acid (HEDP), ethylene diamine tetraacetic acid (EDTA), diethylene triamine penta(methylenephosphonic acid) (DTPMP), azacycloheptane diphosphonate (AHP), nitrilotriacetic acid (NTA), citrate and/or short chain dicarboxylic acids. According to the invention, these chelating agents are particularly added to complex the heavy metal ions that act as catalysts for oxidation processes and can thereby lead to a decomposition of percarboxylic acids, such as PAP and which can be incorporated, for example, from water pipes or metallic components of the production units or from raw materials or ingredients into the inventive washing or cleaning agents.
[0045] In addition, in the scope of the inventive process, at least one catalase can be added to further increase the stabilization of the percarboxylic acids of the aqueous dispersion. Here, the catalase is used in particular to remove any hydrogen peroxide present or formed in the dispersion. Hydrogen peroxide may possibly form from the reaction of the percarboxylic acid with water; the addition of a catalase efficiently diminishes the hydrogen peroxide content in the dispersion, and thus any additional oxidation-sensitive ingredients, for example, enzymes are efficiently protected. With this objective, at least one peroxidase and/or at least one antioxidant, optionally in addition to the at least one catalase, can similarly be added to the inventive washing or cleaning agents. According to the invention, preferred antioxidants are e.g., ascorbic acid, tocopherol, gallic acid or their derivatives.
[0046] Moreover, Applicants have surprisingly discovered that the stability of the percarboxylic acids in the inventive surfactant-containing dispersions can be increased if in particular a water-miscible solvent (e.g., glycerin) is added to the dispersion or even the water-miscible solvent is the dispersion agent or the dispersion. The solvent should be a poor solvent for the organic percarboxylic acids, particularly imidopercarboxylic acids. This solvent is preferably glycerin. Preferably, the quantity of solvent (e.g., glycerin) can be more than 20 wt. %, particularly preferably more than 30 wt. %, based on the dispersion. For these solvent-based variants, the water content of the washing or cleaning formulations should be about 5 wt. % based on the dispersion, wherein the glycerin content can exceed 70 wt. %. Glycerin is a poor solvent for organic percarboxylic acids, particularly imidopercarboxylic acids and this can lead to a stabilization of the percarboxylic acid in the inventive dispersions. Consequently, the quantity of optionally added glycerin should be such that it does not negatively influence the additional ingredients, particularly concerning their solubility in the dispersion. Overall, water is the preferred dispersion agent, however.
[0047] To further increase the stability, in particular the storage stability of the percarboxylic acids in the inventive dispersions, the percarboxylic acids—in so far as is desired or required from the process or application points of view—can be additionally provided with at least one shell or be incorporated into at least one matrix, such that e.g., a capsule system results, having a capsule core based on at least one percarboxylic acid. For this inventive embodiment, the storage stability of the percarboxylic acids is increased by at least essentially preventing or at least diminishing a direct contact of the percarboxylic acid with the surroundings, in particular with the dispersion or the dispersion agent and the dissolved or dispersed substances therein.
[0048] For example, the shell or matrix can include or consist of at least one inorganic salt, preferably an inorganic sulfate, particularly preferably sodium sulfate. For a capsule system of this type, the inventive dispersion should be formed in such a way that during storage the sulfate shell is at least essentially not disintegrated, in particular dissolved away or dissolved, which can be accomplished particularly by adding a salt to influence the solubility of the shell, for example, an inorganic sulfate, particularly preferably sodium sulfate. A release of the percarboxylic acid should then occur during use, particularly in a washing liquor by corresponding dilution effects accompanied by disintegration of the shell.
[0049] Advantageously, the coating of the shell or matrix onto the percarboxylic acid occurs prior to incorporation into the dispersion. The shell or matrix, for example, can be a gel, based, for example, on an oil phase that was hardened or gelled by a stabilizer, particularly gel-formers. Moreover, in the scope of the inventive process, the shell can be a multi-layered polyelectrolyte capsule shell, for example. In addition, the shell or matrix can comprise, for example, inorganic salts, particularly sulfates and/or phosphates, inorganic oxides, organic polymers, particularly cellulose ethers, polyvinyl alcohols (PVA) and polyvinyl pyrrolidones (PVP).
[0050] By coating the percarboxylic acid with at least one shell or matrix, capsule systems are obtained that besides the capsule core based on percarboxylic acid, have a capsule shell based on the shell materials—as described below. In this way, both the capsule core as well as the capsule shell can possess additional substances for the adjustment of the capsule system properties, in the case that this is required or desired from process or application reasons. Thus, the organic percarboxylic acid can be coated with a substance that can undergo endothermic reactions with itself, in particular elimination of water of crystallization or decomposition reactions at a temperature below 80° C., particularly below 70° C. However, this substance can also be blended or mixed with the percarboxylic acid. For example, the substance can be boric acid. Moreover, the shell or matrix can comprise at least one chelating agent, particularly as defined above.
[0051] In addition, the rate of dissolution of the capsule system and therefore the release of the percarboxylic acids during usage, particularly in a washing liquor, can be adjusted as required, by coating a shell or matrix onto the percarboxylic acid. In this way, a “controlled release effect” with respect to the percarboxylic acids contained in the inventive capsule system can be achieved. A “controlled release effect” is particularly understood to mean a slightly delayed, preferably between 1 and 15 minutes, dissolution of the capsule system during usage, for example, on dilution in a washing or cleaning liquor, or a release of the percarboxylic acid from the capsule system.
[0052] The decomposition, particularly the dissolving away or the dissolution of the capsule shells during use of the dispersion (for example, in a washing liquor) generally results due to physical or chemical interactions or reactions, for example, solubilization or dissociation processes, particularly as a result of dilution effects in the wash liquor.
[0053] In the inventive process, the particle size of the organic percarboxylic acids incorporated into the dispersion can be ≦3000 μm, particularly ≦2500 μm, advantageously ≦2250 μm, preferably ≦2000 μm, particularly preferably 1500 μm. In this context, the particle size of the organic percarboxylic acids should be 10 to 3000 μm, particularly 50 to 2500 μm, preferably 100 to 1500 μm.
[0054] In the inventive process, the content of organic percarboxylic acids, particularly imidopercarboxylic acid, based on the dispersion, is 0.1 to 30 wt. %, particularly 0.5 to 25 wt. %, advantageously 1 to 20 wt. %, preferably 1 to 15 wt. %. According to the invention, the particle size of the solid percarboxylic acid particles can be adjusted before incorporating the percarboxylic acid particles into the dispersion using processes known to the expert, for example, by shearing, vibration and/or ultrasound, milling, grinding etc., such that a targeted match of particle size, corresponding to their later use, is possible.
[0055] A controlled adjustment or matching to the required product properties can be undertaken by selecting the particle size as well as the inorganic percarboxylic acid content in the dispersions.
[0056] In the inventive process, as in the inventive dispersion, organic percarboxylic acids are employed as the substances to be stabilized. The percarboxylic acids may be selected from organic mono or di percarboxylic acids. Particular examples are dodecanebis(peroxoic) acid or preferably imidopercarboxylic acids, particularly preferably 6-phthalimidopercaproic acid (6-phthalimidoperhexanoic acid, PAP). Advantageously the percarboxylic acid should have a melting point at atmospheric pressure (101 325 Pa) above 20° C., particularly above 25° C., in preference above 35° C., preferably above 45° C., particularly preferably above 50° C., quite particularly preferably above 100° C.; in this way it is assured that the percarboxylic acid used is mainly present as solid particles, such that a degradation of the percarboxylic acid in the inventive dispersion is at least reduced.
[0057] A further subject—according to a second aspect of the present invention—concerns the storage stable, surfactant-containing dispersions, particularly surfactant-containing aqueous dispersions of percarboxylic acids, particularly imidopercarboxylic acids that are solid at room temperature and manufacturable according to the inventive process. The inventive surfactant-containing dispersion is adjusted in such a way that a decomposition of the percarboxylic acid present in the state of the surfactant-containing dispersion is prevented or at least reduced or retarded or the solubility of the percarboxylic acid in the surfactant-containing dispersion is reduced.
[0058] An inventive, storage stable surfactant-containing dispersion can thus be adjusted in such a way
that the content of halide ions, particularly chloride and/or bromide, based on the continuous dispersion phase of the dispersion, does not exceed 100 ppm, particularly 50 ppm, preferably 30 ppm, particularly preferably 15 ppm; and/or that the dispersion has a pH of maximum 7, particularly a pH of 3.5 to 7, preferably from 4.0 to 6.5, particularly preferably from 4.5 to 6, quite particularly preferably of about 5; and/or that the dispersion, at least essentially, comprises no surfactants in active form, in particular wherein the total active surfactant content in the continuous phase of the dispersion is less than 5%, particularly less than 2.5%, preferably less than 1%, based on the continuous dispersion phase.
[0062] For further details concerning the inventive dispersions, reference can be made to the above statements on the inventive process, which are correspondingly valid for the inventive dispersions.
[0063] The inventive dispersions possess numerous application possibilities, thus—according to a further aspect of the present invention—they can be added into or as washing and cleaning agents, particularly liquid washing and cleaning agent compositions, tooth-care products, hair colorants or decolorizing or bleaching agent compositions for technical uses.
[0064] In this respect, the cited formulations or compositions exhibit a high storage stability with respect to the percarboxylic acids and thus dispose of a high activity, particularly bleaching activity, even after longer periods.
[0065] A further subject of the present invention—according to a further aspect of the present invention—are washing and cleaning agents, tooth-care products, hair colorants or decolorizing or bleaching agent compositions for technical uses, which comprise the inventive dispersions.
[0066] The inventive washing and cleaning agents can be used for cleaning hard surfaces and/or soft, especially textile surfaces. The inventive washing and cleaning agents can be used especially as dishwasher agents, general purpose cleaners, bath cleaners, floor cleaners, automobile cleaners, glass cleaners, furniture care agents or cleaners, facade cleaners, detergents or the like, particularly preferably as detergents. In addition, the inventive washing and cleaning agents are advantageously suited for cleaning fibers, textiles, carpets and the like.
[0067] The inventive washing and cleaning agents comprise, in addition to the inventive dispersions, usual ingredients or constituents known to the expert (e.g., surfactants, fragrances, colorants, enzymes, enzyme stabilizers, olfactory materials or olfactory builders, pH-adjusters, other bleaching agents, bleach activators, silver protection agents, soil repellents, optical brighteners, graying inhibitors, disintegration auxiliaries, thickeners, defoamers, chelating agents for heavy metals, soil repellents, color transfer inhibitors, solvents, optical brighteners and/or optional further usual ingredients), wherein in the context of the present invention, care should be taken concerning the compatibility of the individual ingredients or components, both among themselves as well as in regard to the inventive dispersions or the percarboxylic acids contained therein, and can be realized by judicious choices of ingredients or components and/or their relative proportions. In this manner, an unwanted interaction of the ingredients or components with the percarboxylic acids incorporated in the inventive dispersions can be avoided.
[0068] An inventive washing or cleaning agent, especially a liquid washing or cleaning agent, includes, for example, the following ingredients:
(i) at least one solid, particulate organic percarboxylic acid, particularly imidopercarboxylic acid, in amounts of 0.1 to 30 wt. %, particularly 0.5 to 25 wt. %, advantageously 1 to 20 wt. %, preferably 1 to 15 wt. %; and/or (ii) surfactants, advantageously in inactivated form, particularly cationic and/or anionic surfactants, advantageously in amounts of 0 to 30 wt. %, and/or non-ionic surfactants, preferably in amounts of 0 to 30 wt. %; and/or (iii) optional electrolytes, particularly inorganic and/or organic salts, particularly phosphate, citrate and/or sulfate, particularly preferably sodium sulfate, preferably in amounts of 5 to 30 wt. %; and/or (iv) optional chelating agents, particularly selected from the group of quinoline and/or its salts, alkali metal polyphosphonates, picolinic acid and dipicolinic acid, mono- or polyphosphonic acids, particularly 1-hydroxyethylidene-1,1-diphosphonic acid (HEDP), ethylene diamine tetraacetic acid (EDTA), diethylene triamine penta(methylenephosphonic acid) (DTPMP), azacycloheptane diphosphonate (AHP), nitrilotriacetic acid (NTA), citrate and/or short chain dicarboxylic acids, preferably in amounts of 0 to 10 wt. %; and/or (v) optional enzymes, such as proteases, amylases, cellulases and/or lipases, and/or enzyme stabilizers, preferably in amounts of 0 to 10 wt.%; and/or (vi) optional builders, particularly fatty acids, preferably saturated and/or branched fatty acids, particularly with a melting point below 30° C., and/or citric acid and/or citrate, preferably in amounts of 0 to 15 wt. %; and/or (vii) optional fragrances, preferably in amounts of 0 to 5 wt. %; and/or (viii) optional auxiliaries, such as defoamers, pH regulators, rheology modifiers (thickeners), solvents, colorants; and/or (ix) optional additional usual ingredients, such as brighteners etc.; and/or (x) water;
wherein all the specified weights are based on the washing or cleaning agent.
[0079] In general, the inventive washing or cleaning agent formulation should be designed in such a way that the stability of the percarboxylic acids, at least essentially, is not reduced. Thus, the components, which are used in the inventive washing or cleaning agent, should be chosen with the proviso that they are at least largely compatible with respect to the percarboxylic acids, i.e. particularly in the washing or cleaning agent itself, particularly in the period before its utilization (storage time), there should be no unwanted chemical reactions, such as in particular degradation, oxidation or reduction and/or hydrolytic reactions between these components and the gel capsules, which would lead to a premature decomposition and a loss in activity of the percarboxylic acids.
[0080] In the inventive washing and cleaning agents, particularly in liquid washing and cleaning agents, the surfactants in the washing and cleaning agent formulations should be inactivated, particularly by salting out, i.e. the induction of a phase separation into a surfactant-poor, continuous phase and a preferably lamellar, generally high-viscosity, crystalline or liquid-crystalline surfactant-rich phase, preferably by incorporating a sulfate compound, particularly preferably sodium sulfate, into the washing or cleaning agent formulation.
[0081] As illustrated above, the inactivation of the surfactants leads to an effective protection or to an increased stability of the percarboxylic acids. The free surfactant content in the inventive washing and cleaning agent formulations should be preferably not more than 1% in the continuous phase. In this context, an optimized or smallest possible niosurfactant/charged surfactant ratio should also be present in the inventive washing or cleaning agents—corresponding to the explanations of the inventive dispersion or the manufacturing process. Here, the alkyl polyglycol ether content should be as low as possible.
[0082] In addition, the content of inorganic salt, particularly preferably sodium sulfate in the washing or cleaning agent, should be chosen such that the surfactants in the washing or cleaning agent are at least essentially inactivated, particularly by salting out, advantageously by the introduction of a sulfate compound, particularly preferably sodium sulfate. The sulfate concentration in the inventive washing or cleaning agents should be chosen such that on using the washing or cleaning agent in the washing liquor, the surfactants are once more present in active form, which can be achieved, for example, through a dilution effect when the washing or cleaning agent is incorporated into the washing liquor. In particular, the concentration should be chosen such that—as previously mentioned—less than 1% of active surfactant is present in the continuous phase of the washing or cleaning agent and no sulfate crystallizes out on lowering the temperature, particularly down to 0° C.
[0083] The inventive washing and cleaning agent should have, at least essentially, no increased chloride or bromide ion content; this can be achieved by the addition of compounds of methyl sulfate, phosphate, tosylate or cumene sulfonate. Moreover, raw materials should be selected, which have a particularly low chloride or bromide content.
[0084] The inventive washing or cleaning agents can comprise at least one fatty acid. According to the invention, saturated and/or branched fatty acids, particularly with a melting point below 30° C., are preferred. In the context of the present invention, Isocarb-16® from the Sasol company, for example, can be used in the inventive washing or cleaning agents.
[0085] For further details concerning the inventive washing or cleaning agents, reference can be made to the above statements on the inventive process and the inventive dispersions.
[0086] In order to obtain an adequate bleaching power in the washing liquor, the inventive washing or cleaning agent or the inventive dispersions should be converted in such a way that the percarboxylic acids are activated or released sufficiently quickly. The activation or release of the percarboxylic acids results particularly from physical or physico-chemical or chemical processes. Thus, as the inorganic salt, particularly sodium sulfate, is diluted in the washing liquor, the surfactants are converted from their inactivated form (for example, surfactants present as liquid crystals) into the active, micellar form, such that the surfactants, activated in this way, can dissolve or solubilize the solid percarboxylic acids. The dilution in the washing liquor simultaneously causes a marked jump in the pH of the washing and cleaning agent that had been adjusted to be generally acidic, with the result that the solubility of the percarboxylic acid also markedly increases.
[0087] In addition, the washing or cleaning agent should be composed in such a way that it ensures a disintegration, in particular a dissolution or solubilization of an optional shell or matrix coated onto the percarboxylic acids—in particular as previously illustrated—during the application, particularly in the washing liquor. Thus, for example, dissolution of the optionally present sulfate shell can be achieved by means of the dilution effect addressed previously. Furthermore, an optionally present gel matrix can be dissolved or solubilized by activating the surfactants in the washing liquor. In this context, dissolution, particularly solubilization of an optional polyelectrolyte shell can also be supported or provoked by the activated surfactants. Mechanical forces also contribute here.
[0088] Compared with the prior art, the present invention exhibits a series of advantages:
[0089] The inventive dispersions lead to a significant increase in the storage stability of the percarboxylic acids incorporated therein—particularly in combination with a low chloride or bromide content—such that the efficiency of the percarboxylic acids, particularly the bleaching power, is also guaranteed over a prolonged period or after a lengthy storage time. In this way, in line with a synergistic effect, each of the measures or adjustments of the dispersion lead to a significant increase in storage stability of the percarboxylic acid in the dispersion.
[0090] The inventive process for manufacturing the dispersions is simple and well manageable, resulting in the avoidance of any addition of difficultly manufacturable and therefore expensive substances. Therefore the process is extremely suitable for use on a large industrial scale.
[0091] Due to the targeted adjustment of each property of the dispersion, in particular the chloride content, the inactivation of the surfactants, pH adjustment etc., firstly an exceptionally good stabilization of the percarboxylic acids is achieved, particularly in that an increased stability can be achieved due to the synergy resulting from the combination of these measures. Secondly, the inventive dispersions or washing and cleaning agents permit the percarboxylic acids to be released or activated on use, particularly in a washing liquor and therefore provide an outstanding washing power, particularly bleaching power to the appropriate formulation.
[0092] In addition, the composition and active substance content of the dispersions can be widely varied or tailor made such that particularly for washing and cleaning agents, an individual match to each requirement can be obtained. Due its specific formation, the dispersion can be almost universally used for various compositions over a wide field.
[0093] In addition, percarboxylic acids, which are equipped with a shell or matrix for additional stability, can also be incorporated into the inventive dispersions, i.e. the inventive dispersion is also compatible with such capsule systems.
[0094] Due to their adjusted and synergistically acting modifications on each other listed above, i.e. in particular a lower halide ion content, optimization of the pH, addition of chelating agents, inactivation of surfactants, use of specific solvents or enzymes, such as catalases or peroxidases, addition of antioxidants, the inventive washing and cleaning agent formulations possess substantial advantages compared with the prior art, as a decomposition of the sensitive bleaching agent based on percarboxylic acid is significantly reduced.
[0095] Further developments, modifications and variations as well as advantages of the present invention are directly recognizable and realizable by the expert on reading the description, without him thereby leaving the scope of the present invention.
[0096] The present invention is clarified by means of the following exemplary embodiments, which in no way, however, limit the invention.
EXAMPLES
Example 1
[0097] In this exemplary embodiment it is shown how the stability of PAP is impaired by chloride: A 3% aqueous dispersion of PAP (Eureco® W in distilled water) was treated with various concentrations of NaCl and stored at 40° C. The remaining fraction of PAP (in %) was determined after different times. This is depicted in the following TABLE:
c(NaCl) (wt. %) 0 0.03 0.1 0.3 1 3 10 1 day 100 98 97.7 93 86 75.7 48 4 days 97.7 94 86.8 76.7 51.7 12.5 7.3
[0098] An increased degradation with increasing chloride content is observed.
Example 2
[0099] In this EXAMPLE it is shown that by adding raw materials—here technical surfactants—with inventive chloride levels, the stability of PAP can be significantly increased.
[0100] Solutions of the following composition were prepared:
1. Comparative EXAMPLE:
[0102] 3% PAP
[0103] 15% SDS, Texapon® K-12 (Cognis), chloride content ˜0.4% remainder water
2. Inventive
[0105] 3% PAP
[0106] 15% SDS, recrystallized, chloride content <1 ppm remainder water
[0107] The samples were stored at room temperature. The residual proportions of PAP are given in the following TABLE:
3 days 1 week Comparative EXAMPLE: — 57.1 Inventive — 93.3 | A method for stabilizing particulate peroxycarboxylic acids, in particular imidoperoxycarboxylic acids, (such as, e.g., PAP), which are solid at an ambient temperature in a preferably aqueous dispersion containing surfactants. The dispersion is established in such a way that in the dispersed state a degradation of the peroxycarboxylic acids in the dispersion is prevented or at least reduced or retarded, or that the solubility of the peroxycarboxylic acids in the dispersion is diminished, in particular by minimizing the halide ion content, reducing the pH value to pH values ≦7, minimizing the content of free or active surfactants, minimizing the content of non-ionic surfactants, adding complexers, adding catalases or adding a solvent with a low solubility capability for peroxycarboxylic acids etc. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the production of a layer of polyurethane of high optical quality, which can be used in the production of laminated safety windows, in particular for the production of a layer of thermohardening polyurethane having the properties of resistance to scratching and abrasion, which can be used as a cover layer of a solid or laminated rigid support made of glass and/or a rigid plastic material such as polycarbonate, methyl polymethacrylate, or as a cover layer for a more flexible layer, for example a layer of polyurethane with energy absorption properties, a layer of polyester, these layers themselves being in contact with the rigid support.
2. Description of the Background
A cover layer of the type described above is discussed, for example, in the publications of French Patents 2,187,719; 2,251,608 and 2,574,396 (U.S. Pat. No. 4,657,796). This said layer, which is also self-cicatrizing, is based on thermohardening polyurethane and has a high capacity for elastic deformation, a low modulus of elasticity, less than 2000 DaN/cm 2 , and an elongation to rupture of more than 60% with less than 2% plastic deformation, under normal temperature conditions. A thermohardening polyurethane which is especially preferred is the one described in the publication of the French Patent 2,251,608.
In order to produce a layer of this type, a process with reactive flow is generally used, which is a process in which the layer of thermohardening polyurethane is formed starting with a homogeneous mixture of the reaction components, which are allowed to flow continuously on a support, generally a flat support made of glass, which is located below the flow apparatus. A process of reactive flow is described, for example, in French Patent 2,442,128. The components which form the reaction mixture for flow are, on the one hand, a polyol component which is generally a polyether polyol or a polyester polyol with a functionality greater than 2, generally 3 or between 2 and 3, and, on the other hand, an isocyanate component which can be chosen from among 1,6-hexane diisocyanate biurets or triisocyanurates, this component having a functionality of 3.
This process with reactive flow of the mixture of the two components described above results in a layer with excellent optical quality, which also presents the desired properties such as resistance to scratching, to abrasion, to outside agents, to solvents and the like. However, this reactive flow is not entirely satisfactory except at layer thicknesses generally above 200 μm. For lesser thicknesses, on the order of 100 μm and less, although the mechanical properties are generally suitable, the optical quality of the layer obtained is not always satisfactory.
To produce layers of thermohardening polyurethane with low thicknesses, particularly below 300 μm, a process of reactive pulverization has been proposed. In this case, the reaction mixture is no longer allowed to flow using a flow head, but rather pulverized, for example using a device with a bowl rotating at high speed, such as described, for example, in European Patent 0,161,184 (U.S. Pat. No. 4,749,586). But here again, the optical quality obtained is not always satisfactory for layers with a thickness on the order of 100 μm and less.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a process for the production of a layer of polyurethane by reactive flow or reactive pulverization, which eliminates the disadvantages discussed above, and in particular allows the production of a layer of thermohardening self-cicatrizing polyurethane which has good optical quality, even for thicknesses less than 100 μm.
Briefly, this object and other objects of the present invention as hereinafter will become more readily apparent can be attained in a process for the preparation of a layer of thermohardening polyurethane by preparing a reactive mixture of an isocyanate component which is a diisocyanate or a mixture of diisocyanate monomers capable of forming an isocyanate trimer, a polyol monomer having a functionality of at least 2, and a trimerization catalyst, placing the reactive mixture onto a support for formation of said layer, heating the reactive mixture to a temperature sufficient to initiate trimerization, and then further heating the reactive mixture to initiate and conduct polymerization thereby forming said polyurethane layer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Trimerization of the isocyanate reactant in situ, in the invention, makes it possible, in surprising manner, to obtain a polyurethane layer having all the qualities required for use in safety windows. It is submitted that from a knowledge of the difficulties of producing a layer with high optical quality from a reaction mixture which is very homogeneous, consisting of components with adapted functionality, in other words, a functionality of 3 for the isocyanate component, in order to obtain the desired thermohardening polyurethane final product, it would not be possible for one of skill in the art to envisage providing a supplemental reaction, a source of heterogeneity of the layer, which could result in irreparable optical defects, within a process for production of a layer with high optical quality by reactive flow.
Trimerization of the isocyanate reactant in situ by the process of the invention can be cyclotrimerization with the resultant formation of a triisocyanurate as shown in the following schematic employing 1,6-hexamethylene diisocyanate monomer: ##STR1##
In addition to 1,6-hexamethylene diisocyanate shown above, other monomer diisocyanates can also be used in the present process. These are diisocyanates which are capable of forming isocyanate triisocyanurates or isocyanate biurets as indicated below, starting with a single type of monomer or a mixture of monomers. Suitable diisocyanates include 3-isocyanatomethyl-3,5,5-trimethyl cyclohexyl diisocyanate (IPDI), m-tetramethyl xylylene diisocyanate (m-TMXDI), and 2,2,4-trimethyl-6-hexane diisocyanate (TMDI).
In order to cyclotrimerize 1,6-hexamethylene diisocyanate in situ, known catalysts for the cyclotrimerization reaction in a reactor can be used such as, for example, organometallic catalysts, quaternary ammonium hydroxides and organic acid salts, strong bases such as potassium acetate and potassium octoate.
The quantities of catalysts employed can vary, depending on the type of catalyst. Generally, an amount of catalyst between 0.01 and 5% by weight relative to the weight of diisocyanate in the reaction mixture is chosen.
A catalyst that is particularly suitable for trimerization of 1,6-hexamethylene diisocyanate in situ is a quaternary ammonium salt, for example the product sold commercially under the name of Dabco TMR.
In an embodiment of the invention, trimerization in situ can be performed in a biuret forming reaction involving diisocyanate monomer, particularly 1,6-hexamethylene diisocyanate, in the presence of biuret promoting agent, such as a primary, secondary or tertiary aliphatic amine, which produces isocyanate biurets with low viscosity.
The polyol component used in the process of the invention can be any known one which is used for the production of layers of thermohardening polyurethane described in the publications of the patents already cited such as FR 2,187,719 (U.S. Pat. No. 4,232,080), 2,251,608 (U.S. Pat. No. 3,979,548) and 2,574,396.
The polyol component can be chosen from among polyether polyols, polyester polyols obtained by reaction of polyfunctional alcohols such as 1,2,3-propanetriol (glycerol), 2,2-bis(hydroxymethyl)-1-propanol (trimethylol ethane) 2,2-bis(hydroxymethyl)-1-butanol (trimethylol propane), 1,2,4-butanetriol, 1,2,6-hexanetriol, 2,2-bis(hydroxymethyl)-1,3-propanediol (pentaerythritol) and 1,2,3,4,5,6-hexanehexol (sorbitol) with aliphatic diacids such as malonic acid, succinic acid, glutaric acid, adipic acid, suberic acid and sebacic acid, or with cyclic ethers such as ethylene oxide, 1,2-propylene oxide and tetrahydrofuran oxide or even poly(ε-caprolactone) polyols. The molecular weight of the branched polyols is advantageously approximately 250 to 4000 and preferably approximately 450 to 2000.
The preferred polyol component is selected from among the polyether polyols having a molecular weight of approximately 450 obtained by condensation of 1,2-propylene oxide with 2,2-bis(hydroxymethyl)-1-butanol and having a content of free hydroxyl groups of approximately 10.5 to 12% by weight, a slightly branched polyester polyol based on trimethylol propane, 1,6-hexanediol, adipic acid and o- and i-phthalic acid, having a content of OH radicals of 3 to 5% by weight, a trifunctional lactone polyester polyol based on trimethylol propane or glycerol, and ε-caprolactone having a content of OH groups of approximately 8 to 12% by weight.
Other than the catalyst for the trimerization reaction in situ, the reaction mixture advantageously contains a second catalyst, which specifically promotes the formation of polyurethane by the condensation of the triisocyanate formed in situ and the polyol component. The catalyst is an organometallic compound, for example, particularly an organic tin compound such as dibutylstannous dilaurate.
In order to assure trimerization of the diisocyanate prior to the reaction with the polyol, the quantity of the catalyst which is employed to specifically promote trimerization is greater than the quantity of the catalyst employed for the polyurethane formation reaction. Thus, the quantity of the trimerization catalyst employed can be advantageously more than 10 times greater than the quantity of the catalyst.
The quantities of diisocyanate, on the one hand, and polyol on the other hand, in the reaction mixture, are preferably calculated to have a final ratio of NCO/OH between 0.7 and 1.2.
Another advantage of the present process is that the trimerization reaction utilizes the temperature conditions employed in the production of a polyurethane layer by reactive flow of the reaction mixture of components with a functionality greater than 2. In other words, the reaction mixture is allowed to flow at a temperature which is generally below 80° C., on a support which itself is brought to a temperature below 80° C., the layer formed on the flow support then being increased to a temperature on the order of 100° to 150° C. for polymerization.
Because of the low viscosity of the reaction mixture which is allowed to flow or is pulverized according to the invention, it is possible to obtain layers of self-cicatrizing polyurethane by this process which have good optical qualities, with a thickness of only several tens of microns, but also up to thicknesses which can be as high as several hundred microns.
The support for formation of the layer on which trimerization is carried out simultaneously with or just before polymerization is advantageously a continuous support of glass, or a continuous metallic band, or even a flexible ribbon such as those described in the publications of the European Patents 0038760 and 0131483 (U.S. Pat. No. 4,605,528), mentioned above, if applicable, with a separation agent such as described in French Patent 2383000, for example.
Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLE 1
On a mobile support of glass passing by in a continuous manner, covered with a separation agent which can be a material such as one described in French Patent 2383000, for example, i.e., a modified addition product of ethylene oxide, a homogeneous mixture of the following components is allowed to flow:
1000 g of a polyether with a molecular weight of approximately 450 obtained by condensation of 1,2-propylene oxide with 2,2-bis-(hydroxymethyl)-1-butanol having a content of free hydroxyl groups of approximately 10.5 to 12%, containing 0.5% by weight of a stabilizer, 0.75% by weight of a quaternary ammonium salt as a catalyst for the trimerization of the diisocyanate, 0.025% by weight of a catalyst for the polyurethane polymerization reaction, specifically dibutyl stannous dilaurate, and 0.05% by weight of a sheeting agent; and
880 g of 1,6-hexamethylene diisocyanate.
The theoretical final ratio of NCO/OH is 0.8.
To apply the mixture, a flow head such as described in French Patent 2347170 is used. A uniform layer with a thickness of 0.1 mm is formed on the flow support, which is at a temperature of about 40° C. when the flow is applied. The temperature of the layer is then raised to about 80° C. to achieve trimerization of the isocyanate component, for about 5 minutes, followed by another increase in temperature to 120° C. for about 15 minutes, for polymerization of the polyurethane layer. The thermal treatment lasts for a total of approximately 20 minutes. The layer obtained is transparent and presents good optical quality. This layer demonstrates the properties of resistance to scratching and to abrasion, as well as characteristics of mechanical strength such as resistance to scratching and elongation to rupture, as indicated below, comparable to the characteristics of a layer produced as described in French Patent 2251608, by flow of the mixture of trifunctional components, for example.
EXAMPLE 2
The procedure of Example 1 is followed in which the following homogeneous mixture is allowed to flow:
942 g of a trifunctional polycaprolactone based on trimethylolpropane and e-caprolactone having a content of free hydroxyl groups of approximately 9.3% by weight, containing 0.5% by weight of a stabilizer, 0.75% by weight of a quaternary ammonium salt as a catalyst for the trimerization, 0.025% by weight of a catalyst for the polymerization reaction, specifically dibutyl stannous dilaurate, and 0.05% by weight of a sheeting agent; and
1000 g of 1,6-hexamethylene diisocyanate.
The theoretical final ratio of NCO/OH is 1.
A layer with a thickness of 0.1 mm is formed. The layer is brought to a temperature of 120° C. for 20 minutes. The layer obtained presents good optical quality and mechanical properties, as indicated below, making it suitable for use as a coating layer for safety glass.
EXAMPLE 3
The procedure of Example 2 is repeated except that the layer formed is 0.3 mm thick.
After polymerization, the layer obtained exhibits good optical quality.
COMPARATIVE EXAMPLE
A reaction mixture is prepared by mixing 1000 g of a trifunctional polyisocyanate formed from isocyanurate based on 1,6-hexamethylene diisocyanate having a content of free NCO groups of 21.5% by weight, with 942 g of a trifunctional polycaprolactone having a content of free OH groups of 9.3% by weight. The ratio of NCO/OH is therefore 1. First, 0.015% by weight relative to the weight of the polycaprolactone, dibutyl- stannous dilaurate is added to the polycaprolactone as a catalyst.
The reaction mixture is deposited on the flow support as in Example 1, to form a layer with a thickness of 0.1 mm.
The temperature is raised to 120° C. for 15 minutes, to achieve polymerization of the polyurethane layer.
The layer obtained is of poorer optical quality than in the preceding examples.
Stripes are observed (which is not the case when the layer is thicker). The abrasion test is therefore not significant.
After polymerization of the coating layers prepared above, and after having removed the formation support, their mechanical properties are determined by measuring the traction resistance of the sheets, and the traction elongation according to the standard of DIN 53455. Furthermore, the abrasion resistance is determined according to the European standard ECE R-43, and the scratching resistance according to the Erichsen method, using layers of polyurethane adhering to sheets of glass. During the determination of scratching resistance according to Erichsen, an experimental set-up such as that described in the standard DIN 53799 is used, except that the conical scratching diamond used has a conic angle of 50 degrees and a radius of curvature of 15 μm at the tip of the cone. For an evaluation of the scratching resistance, the greatest application weight of the scratching diamond for which no permanent visible damage on the surface is identifiable is indicated.
The evaluation of the surface condition of the polyurethane layers is conducted by visual examination.
The results of mechanical measurements are summarized in Table 1 below. Table 1 also indicates the intervals in which the measured values must be located for the polyurethane layer to have self-cicatrizing properties and to be able to meet the utilization requirements for safety windows, for the various mechanical properties.
The coating layer obtained by the process of the invention can be used in safety windows, alone or in combination with a layer of polyurethane which has energy absorption properties, to form a sheet of two layers as described, for example, in European Patents 0,132,198 and 0,133,090 (U.S. Pat. Nos. 4,652,494 and 4,671,838).
TABLE 1______________________________________ rupture traction scratching resistance elongation abrasion resistance N/mm.sup.2 % % (g)______________________________________Required interval 5-40 >60 <4 >10limit valuesExample 1 15.7 90 3.8 30Example 2 13.7 85 2.4 35Example 3 14.1 85 2.3 34Comparative 24 115 24Example______________________________________
Having now fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein: | A coating layer of a thermohardening polyurethane having self-cicatrization properties is prepared by preparing a reactive mixture of an isocyanate component which is a diisocyanate or a mixture of diisocyanate monomers capable of forming an isocyanate trimer, a polyol monomer having a functionality of at least 2 and a trimerization catalyst; placing the reactive mixture onto a support for formation of said layer; heating the reactive mixture to a temperature sufficient to initiate trimerization; and then further heating the reactive mixture to initiate and conduct polymerization thereby forming said polyurethane layer. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims benefit under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 60/684,576 filed May 26, 2005.
TECHNICAL FIELD
[0002] The present invention relates to a method for epoxidizing diolefin to obtain a bifunctional epoxy monomer having an epoxy group and a double bond in the molecule. The present invention particularly relates to a novel method for producing a bifunctional epoxy monomer which comprises reacting diolefin with a hydrogen peroxide aqueous solution in the presence of an oxide of molybdenum or tungsten as a catalyst to selectively epoxidize a double bond at a specific position. The bifunctional epoxy monomers provided by the present invention are useful materials which can be widely used in various industrial fields such as chemical industry, as materials for resist materials (particularly solder resist materials), intermediates of agrochemicals and medicines, and various polymers such as plasticizers, adhesives and coating resins.
BACKGROUND ART
[0003] The technique for selectively epoxidizing one double bond at a specific position of diolefin is of low productivity (low reactivity, low selectivity), and application thereof is often limited to those with structures of some kinds.
[0004] Peracids have been conventionally used as selective epoxidizing agents for diolefin (see, for example, Chem. Ber., 1985, 118, 1267-1270). However, in the technique, a large amount of diepoxides are produced as by-products, and equivalent amounts of acids derived from the oxidizing agents are produced, which cause problems such as corrosion of apparatuses.
[0005] A selective epoxidizing method of a diolefin using oxone as an oxidizing agent in the presence of a ketone catalyst (for example, see J. Org. Chem., 1998, 63, 2948-2953) has been known. In this reaction, there are problems that a large amount (20 to 30 mol % relative to diolefin) of ketones of catalysts are required, and the reaction conditions such as a pH and a reaction temperature must be strictly controlled in order to prevent reacting oxon from being decomposed.
[0006] On the other hand, a hydrogen peroxide solution is cheep, non-corrosive, and environmentally friendly because any by-product is not produced or the by-product is water. It is an excellent oxidizing agent to be used in industry.
[0007] As the methods for producing an epoxy compound from an olefin using a hydrogen peroxide solution as an epoxidizing agent, (1) an epoxidizing method with hydrogen peroxide in the presence of quaternary ammonium chloride, phosphoric acids, and a tungsten metal salt {see Kokai (Jpn. Unexamined Patent Publication) 2003-192679 (Patent Publication 1 hereinafter)}; (2) an epoxidizing method with hydrogen peroxide using organic oxorhenium as a catalyst {see Kokai 2001-25665 (Patent Publication 2 hereinafter)}; (3) an epoxidizing method with titanium silicate and hydrogen peroxide (see, for example, Journal of Catalysis, 1993, 140, 71-83); and (4) an epoxidizing method with hydrogen peroxide in the presence of a fluoroalkyl ketone catalyst (see, for example, Chem. Commun., 1999, 263-264) have been known. These methods basically relate to epoxidizing of a monoolefin having sole double bond, and do not indicate selective epoxidizing of diolefin.
[0008] With respect to selective epoxidizing of diolefin using a hydrogen peroxide solution as an epoxidizing agent, there are (5) a method for epoxidizing diolefin with hydrogen peroxide in the presence of a catalyst represented by the formula Q 3 XW 4 O 24 (in the formula, Q represents a quaternary ammonium cation having carbon atoms up to 70, X represents P or As) (see, for example, Kokai 4-275281); (6) a method for epoxidizing diolefin having a methacrylic acid unit with hydrogen peroxide in the presence of quaternary ammonium chloride, phosphoric acid, and a tungsten compound (see, for example, Tetrahedron, 1992, 48 (24), 5099-5110); (7) a method for epoxidizing diolefin with hydrogen peroxide in the presence of a tungsten and molybdenum polyoxometalate complex {see, for example, Kokai 2002-155066 (Patent Publication 3 hereinafter)}; and (8) a method for epoxidizing diolefin using organic oxorhenium as a catalyst (Angew. Chem. Int. Ed. Engl., 1991, 30(12), 1638-1641). However, in the above method (5), the amount of hydrogen peroxide is less than one equivalent amount relative to one equivalent amount of diolefin, the reaction yields are very poor (32 to 48% relative to the used diolefin), it takes much time and it costs much money for performing separation and purification steps which result in poor productivity. As the catalyst has a surfactant property and a halogenated hydrocarbon such as methylene chloride is required for phase separation after the reaction is complete, it is not environmentally friendly. The above methods (6) and (7) have strict substrate specificity, the substrates in the methods (6) and (7) are limited to diolefins having a methacrylic acid unit and large cycle diolefins having 8 to 20 rings, respectively. Especially in the above method (8), substrate conversion ratio of diolefin is very high, but a large amount of a diol compound of a hydrolysis product from a bifunctional epoxy monomer is produced as a by-product, and the yield of the monoepoxy compound is low. Organic oxorhenium is very expensive, and they are industrially cost ineffective.
[0009] Accordingly, a method for selectively producing a bifunctional epoxy monomer in high yield at a low cost from diolefin, under a mild condition, without any use of an organic solvent, by easy operation, has been strongly desired.
[0010] [Patent Publication 1] Kokai 2003-192679
[0011] [Patent Publication 2] Kokai 2001-25665
[0012] [Patent Publication 3] Kokai 2002-155066
SUMMARY OF THE INVENTION
[0013] The present invention is directed to providing a novel safe and easy production method of a bifunctional epoxy monomer comprising reacting diolefin with a hydrogen peroxide aqueous solution, under a mild condition, without any use of an organic solvent.
[0014] The inventors studied hard to solve the problems, and discovered that if diolefin is reacted with a hydrogen peroxide aqueous solution without any use of an organic solvent, using quaternary ammonium hydrogen sulfate and a Group VI metal compound (molybdenum, tungsten) as a catalyst, a bifunctional epoxy monomer having an epoxy group and a double bond in the molecule is selectively produced in high yield, and completed the present invention.
[0015] The present invention relates to a method for producing a bifunctional epoxy monomer comprising reacting diolefin with a hydrogen peroxide aqueous solution in the presence of quaternary ammonium hydrogen sulfate and a catalytic amount of a Group VI metal compound (molybdenum, tungsten), without any use of an organic solvent.
[0016] The present invention specifically relates to a method for producing a bifunctional epoxy monomer represented by the following formula (2):
[0000]
[0017] Wherein n represents an integer of 0 to 2, R 1 to R 8 each is independently identical or different, and represents a hydrogen atom, a hydroxy group, a halogen atom, a carboxyl group, an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cycloalkyl group having 3 to 7 carbon atoms, an aryl group, an aralkyl group, an acyl group, an acyloxy group, or R 1 and R 2 ; R 1 and R 3 ; R 1 and R 4 ; R 1 and R 5 ; R 2 and R 3 ; R 2 and R 4 ; R 2 and R 5 ; R 3 and R 4 ; R 3 and R 5 ; or R 4 and R 5 represent a carbon chain bridge having 1 to 3 carbon atoms, and these groups may be independently substituted with an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cycloalkyl group having 3 to 7 carbon atoms, an aryl group, an aralkyl group, a carboxyl group or a halogen atom, the method comprising selectively oxidizing a diolefin compound represented by the following formula (1):
[0000]
[0018] wherein n represents an integer of 0 to 2, R 1 to R 8 each is independently identical or different, and represents a hydrogen atom, a hydroxy group, a halogen atom, a carboxyl group, an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cycloalkyl group having 3 to 7 carbon atoms, an aryl group, an aralkyl group, an acyl group, an acyloxy group, or R 1 and R 2 ; R 1 and R 3 ; R 1 and R 4 ; R 1 and R 5 ; R 2 and R 3 ; R 2 and R 4 ; R 2 and R 5 ; R 3 and R 4 ; R 3 and R 5 ; or R 4 and R 5 represent a carbon chain bridge having 1 to 3 carbon atoms, and these groups may be independently substituted with an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cycloalkyl group having 3 to 7 carbon atoms, an aryl group, an aralkyl group, a carboxyl group or a halogen atom, using an oxidizing agent.
[0019] The above-described oxidizing agent may be a hydrogen peroxide aqueous solution.
[0020] A Group VI metal compound (molybdenum, tungsten) and quaternary ammonium hydrogen sulfate can be used as a catalyst.
EFFECT OF THE INVENTION
[0021] According to the method of the present invention, a bifunctional epoxy monomer, which is useful substance widely used in various industrial fields, such as chemical industry, as materials for resist materials (particularly solder resist materials), intermediates of agrochemicals and medicines, and various polymer materials for plasticizers, adhesives, coating resins, can be produced by reaction of the corresponding diolefin with a hydrogen peroxide solution by easy and safe operation, in high yield, at low cost. The present invention brings great influences to industry. In the method of the present invention, any organic solvent, acids and bases are not used, and the method has an environmentally friendly effect.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The diolefin compound of the substrate in the present invention is represented, for example, by the following formula (1):
[0000]
[0023] wherein n represents an integer of 0 to 2, R 1 to R 8 each is independently identical or different, and represents a hydrogen atom, a hydroxy group, a halogen atom, a carboxyl group, an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cycloalkyl group having 3 to 7 carbon atoms, an aryl group, an aralkyl group, an acyl group, an acyloxy group, or R 1 and R 2 ; R 1 and R 3 ; R 1 and R 4 ; R 1 and R 5 ; R 2 and R 3 ; R 2 and R 4 ; R 2 and R 5 ; R 3 and R 4 ; R 3 and R 5 ; or R 4 and R 5 represent a carbon chain bridge having 1 to 3 carbon atoms, and these groups may be independently substituted with an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cycloalkyl group having 3 to 7 carbon atoms, an aryl group, an aralkyl group, a carboxyl group or a halogen atom.
[0024] More specifically, the diolefin compound of a substrate in the present invention includes 3-cyclopenten-1-carboxylic acid allyl ester, 1-methyl-3-cyclopenten-1-carboxylic acid allyl ester, 3-methyl-3-cyclopenten-1-carboxylic acid allyl ester, 3,4-dimethyl-3-cyclopenten-1-carboxylic acid allyl ester, 3-cyclopenten-1-carboxylic acid-2′-methyl-2′-propenyl ester, 3-cyclopenten-1-carboxylic acid 2′-chloro-2′-propenyl ester, 3-cyclopenten-1-carboxylic acid 2′-bromo-2′-propenyl ester, 3-cyclopenten-1-carboxylic acid 1′-methyl-2′-propenyl ester, 3-cyclopenten-1-carboxylic acid 1′-ethyl-2′-propenyl ester, 3-cyclopenten-1-carboxylic acid 1′-phenyl-2′-propenyl ester, 3-cyclohexen-1-carboxylic acid allyl ester, 1-methyl-3-cyclohexen-1-carboxylic allyl ester, bicyclo[2.2.1]-5-hepten-2-methyl-2-carboxylic acid allyl ester, 3-cyclohexen-1-carboxylic acid 2′-methyl-2′-propenyl ester, 3-cyclohexen-1-carboxylic acid 2′-chloro-2′-propenyl ester, 3-cyclohexen-1-carboxylic acid 2′-bromo-2′-propenyl ester, 3-cyclohexen-1-carboxylic acid 1′-methyl-2′-propenyl ester, 3-cyclohexen-1-carboxylic acid 1′-ethyl-2′-propenyl ester, 3-cyclohexen-1-carboxylic acid 1′-phenyl-2′-propenyl ester, 3-cyclohepten-1-carboxylic acid allyl ester, 1-methyl-3-cyclohepten-1-carboxylic acid allyl ester, 3-methyl-3-cyclohepten-1-carboxylic acid allyl ester, 3,4-dimethyl-3-cyclohepten-1-carboxylic acid allyl ester, 3-cyclohepten-1-carboxylic acid 2′-methyl-2′-propenyl ester, 3-cyclohepten-1-carboxylic acid 2′-chloro-2-propenyl ester, 3-cyclohepten-1-carboxylic acid 2′-bromo-2′-propenyl ester, 3-cyclohepten-1-carboxylic acid 1′-methyl-2′-propenyl ester, 3-cyclohepten-1-carboxylic acid 1′-ethyl-2′-propenyl ester, and 3-cyclohepten-1-carboxylic acid 1′-phenyl-2′-propenyl ester.
[0025] The diolefin compound of a substrate in the present invention preferably includes 3-cyclohexen-1-carboxylic acid allyl ester, 1-methyl-3-cyclohexen-1-carboxylic acid allyl ester, bicyclo[2.2.1]-5-hepten-2-methyl-2-carboxylic acid allyl ester, and 3-cyclohexen-1-carboxylic acid 2′-methyl-2′-propenyl ester.
[0026] The concentration of a hydrogen peroxide solution used in the method of the present invention is not particularly limited, and reaction proceeds, resulting in diolefin production. The concentration is usually selected from the range of 1 to 80%, preferably 20 to 60%.
[0027] The amount of hydrogen peroxide aqueous solution is not limited and reaction proceeds, resulting in diolefin production, depending on the amount. The amount is usually selected from the range of 0.8 to 10.0 equivalent amounts, preferably 1.0 to 3.0 equivalent amounts.
[0028] The quaternary ammonium hydrogen sulfate includes tetrahexylammonium hydrogen sulfate, tetraoctylammonium hydrogen sulfate, methyltrioctylammonium hydrogen sulfate, tetrabutylammonium hydrogen sulfate, ethyltrioctylammonium hydrogen sulfate, and cetylpyridinium hydrogen sulfate. Tetrahexyammonium hydrogen sulfate, tetraoctylammonium hydrogen sulfate, and methyltrioctylammonium hydrogen sulfate are preferable. These quaternary ammonium hydrogen sulfates can be used alone or in combination of two or more thereof. The amount thereof is selected from the range 0.0001 to 10 mol %, preferably 0.01 to 5 mol %, relative to diolefin of a substrate.
[0029] The Group VI metal compound which is molybdenum, for example, produces molybdic acid anions in water, and includes molybdic acid, molybdenum trioxide, molybdenum trisulfide, molybdenum hexachloride, phosphomolybdic acid, ammonium molybdate, potassium molybdate dihydrate, and sodium molybdate dihydrate. Molybdic acid, molybdenum trioxide, and phosphomolybdic acid are preferable. If it is tungsten, it produces tungsten acid anions in water, and includes tungsten acid, tungsten trioxide, tungsten trisulfide, tungsten hexachloride, phosphotungstic acid, ammonium tungstate, potassium tungstate dihydrate, and sodium tungstate dihydrate. Tungsten acid, tungsten trioxide, phosphotungstic acid and sodium tungstate dihydrate are preferable. These Group VI compounds can be used alone or in combination of two or more compounds. The amount thereof is 0.0001 to 20 mol %, preferably 0.01 to 10 mol %, relative to a diolefin of a substrate. The catalyst of the kind can be modified using an additive such as phosphoric acid, polyphosphoric acid, aminomethylphosphonic acid, or sodium phosphate.
[0030] In the production method of the present invention, reaction is usually performed at temperature of 30 to 100° C., preferably 50 to 90° C.
[0031] Thus-obtained bifunctional epoxy monomers are compounds represented by the formula (2):
[0000]
[0032] wherein n represents an integer of 0 to 2, R 1 to R 8 each is independently identical or different, and represents a hydrogen atom, a hydroxy group, a halogen atom, a carboxyl group, an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cycloalkyl group having 3 to 7 carbon atoms, an aryl group, an aralkyl group, an acyl group, an acyloxy group, or R 1 and R 2 ; R 1 and R 3 ; R 1 and R 4 ; R 1 and R 5 ; R 2 and R 3 ; R 2 and R 4 ; R 2 and R 5 ; R 3 and R 4 ; R 3 and R 5 ; or R 4 and R 5 represent a carbon chain bridge having 1 to 3 carbon atoms, and these groups may be independently substituted with an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cycloalkyl group having 3 to 7 carbon atoms, an aryl group, an aralkyl group, a carboxyl group or a halogen atom.
[0033] Examples of the obtained bifunctional epoxy monomers include 3,4-epoxycyclopentan-1-carboxylic acid allyl ester, 1-methyl-3,4-epoxycyclopentan-1-carboxylic acid allyl ester, 3-methyl-3,4-epoxycyclopentan-1-carboxylic acid allyl ester, 3,4-dimethyl-3,4-epoxycyclopentan-1-carboxylic acid allyl ester, 3,4-epoxycyclopentan-1-carboxylic acid 2′-methyl-2′-propenyl ester, 3,4-epoxycyclopentan-1-carboxylic acid 2′-chloro-2′-propenyl ester, 3,4-epoxycyclopentan-1-carboxylic acid 2′-bromo-2′-propenyl ester, 3,4-epoxycyclopentan-1-carboxylic acid 1′-methyl-2′-propenyl, 3,4-epoxycyclopentan-1-carboxylic acid 1′-ethyl-2′-propenyl ester, 3,4-epoxycyclopentan-1-carboxylic acid 1′-phenyl-2′-propenyl ester, 3,4-epoxycyclohexan-1-carboxylic acid allyl ester, 1-methyl-3,4-epoxycyclohexan-1-carboxylic acid allyl ester, 3-oxa[3.2.1.0 2,4 ]octan-6-methyl-6-carboxylic acid allyl ester, 3,4-epoxycyclohexan-1-carboxylic acid 2′-methyl-2′-propenyl ester, 3,4-epoxycyclohexan-1-carboxylic acid 2′-chloro-2′-propenyl ester, 3,4-epoxycyclohexan-1-carboxylic acid 2′-bromo-2′-propenyl ester, 3,4-epoxycyclohexan-1-carboxylic acid 1′-methyl-2′-propeyl ester, 3,4-epoxycyclohexan-1-carboxylic acid 1′-ethyl-2′-propenyl ester, 3,4-epoxycyclohexan-1-carboxylic acid 1′-phenyl-2′-propenyl ester, 3,4-epoxycycloheptan-1-carboxylic acid allyl ester, 1-methyl-3,4-epoxycycloheptan-1-carboxylic acid allyl ester, 3-methyl-3,4-epoxycycloheptan-1-carboxylic acid allyl ester, 3,4-dimethyl-3,4-epoxycycloheptan-1-carboxylic acid allyl ester, 3,4-epoxycycloheptan-1-carboxylic acid 2′-methyl-2′-propenyl ester, 3,4-epoxycycloheptan-1-carboxylic acid 2′-chloro-2′-propenyl ester, 3,4-epoxycycloheptan-1-carboxylic acid 2′-bromo-2′-propenyl ester, 3,4-epoxycycloheptan-1-carboyxlic acid 1′-methyl-2′-propenyl ester, 3,4-epoxycycloheptan-1-carboxylic acid 1′-ethyl-2′-propenyl ester, and 3,4-epoxycycloheptan-1-carboyxlic acid 1′-phenyl-2′-propenyl ester. Preferable examples include 3,4-epoxycyclohexan-1-carboxylic acid allyl ester, 1-methyl-3,4-epoxycyclohexan-1-carboxylic acid allyl ester, 3-oxa[3.2.1.0 2,4 ]octan-6-methyl-6-carboyxlic acid allyl ester, and 3,4-epoxycyclohexan-1-carboxylic acid 2′-methyl-2′-propenyl ester.
[0034] Thus-formed desired bifunctional epoxy monomer can be isolated after the mixture solution has been concentrated, by a general step such as recrystallization, distillation and sublimation.
[0035] The present invention will be further specifically explained with the following examples, but it is not limited thereto.
EXAMPLES
Example 1
[0036] After Na 2 WO 4 .2H 2 O (500 mg, 1.5 mmol), 40% hydrogen peroxide aqueous solution (7.65 g, 90 mmol), methyltrioctylammonium hydrogen sulfate (260 mg, 0.56 mmol) and 3-cyclohexen-1-carboxylic acid allyl ester (12.5 g, 75 mmol) were mixed, and were reacted at 25° C. for 15 min., the temperature was raised to 70° C., and the mixture was stirred for 3.5 hours. After the reaction was complete, the mixture was cooled to room temperature. Aftertreatment was performed with a sodium thiosulfate saturated aqueous solution, an organic layer was taken out. The obtained solution was determined by gas chromatography, and it was confirmed that the conversion rate of 3-cyclohexen-1-carboxylic acid allyl ester of a starting material was 79%, and the yield of 3,4-epoxycyclohexan-1-carboxylic acid allyl ester of a bifunctional epoxy monomer was 69%. The result that no diepoxides were formed, and monoepoxy selectivity was 100% was obtained.
Example 2
[0037] After Na 2 WO 4 .2H 2 O (39.6 mg, 0.12 mmol), 36% hydrogen peroxide aqueous solution (600 mg, 6.3 mmol), methyltrioctylammonium hydrogen sulfate (23.4 mg, 0.05 mmol), aminomethylphosphonic acid (4.5 mg, 0.04 mmol) and 3-cyclohexen-1-carboxylic acid allyl ester (1.00 g, 6 mmol) were mixed, and were reacted at 25° C. for 15 min., the temperature was raised to 70° C., and the mixture was stirred for 3 hours. The same steps as in Example 1 were repeated. It was confirmed that the conversion rate of 3-cyclohexen-1-carboxylic acid allyl ester of a starting material was 89%, and the yield of 3,4-epoxycyclohexan-1-carboxylic acid allyl ester of a bifunctional epoxy monomer was 80%. The result that no diepoxides were formed, and monoepoxy selectivity was 100% was obtained.
Example 3
[0038] After Na 2 WO 4 .2H 2 O (26.4 mg, 0.08 mmol), 36% hydrogen peroxide aqueous solution (400 mg, 4.2 mmol), methyltrioctylammonium hydrogen sulfate (15.6 mg, 0.033 mmol), aminomethylphosphonic acid (3.0 mg, 0.027 mmol), and bicycle[2.2.1]-5-hepten-2-methyl-2-carboxylic acid allyl ester (0.79 g, 4 mmol) were mixed, and were reacted at 25° C. for 15 min., the temperature was raised to 70° C., and the mixture was stirred for 3 hours. The same steps as in Example 1 were repeated. It was confirmed that the conversion rate of bicycle[2.2.1]-5-hepten-2-methyl-2-carboxylic acid allyl ester of a starting material was 74%, and the yield of 3-oxa[3.2.1.0 2,4 ]octan-6-methyl-6-carboxylic acid allyl ester of a bifunctional epoxy monomer was 70%. The result that no diepoxides were formed, and monoepoxy selectivity was 100% was obtained.
Comparative Example 1
[0039] After Na 2 WO 4 .2H 2 O (13.2 mg, 0.04 mmol), 36% hydrogen peroxide aqueous solution (290 mg, 3.0 mmol), methyltrioctylammonium chloride (8.1 mg, 0.02 mmol), and 3-cyclohexen-1-carboxylic acid allyl ester (333 mg, 2 mmol) were mixed, and were reacted at 25° C. for 15 min., the temperature was raised to 70° C., and the mixture was stirred for 2.5 hours. The same steps as in Example 1 were repeated. It was confirmed that the conversion rate of 3-cyclohexen-1-carboxylic acid allyl ester of a starting material was 0%, and the presence of 3,4-epoxycyclohexan-1-carboxylic acid allyl ester of a bifunctional epoxy monomer was not determined.
Comparative Example 2
[0040] After 36% hydrogen peroxide aqueous solution (400 mg, 4.2 mmol), methyltrioctylammonium hydrogen sulfate (15.6 mg, 0.033 mmol), and 3-cyclohexen-1-carboxylic acid allyl ester (670 mg, 4 mmol) were mixed, and were reacted at 25° C. for 15 min., the temperature was raised to 70° C., and the mixture was stirred for 3 hours. The same steps as in Example 1 were repeated. It was confirmed that the conversion rate of 3-cyclohexen-1-carboxylic acid allyl ester of a starting material was 0%, and the presence of 3,4-epoxycyclohexan-1-carboxylic acid allyl ester of a bifunctional epoxy monomer was not determined.
Comparative Example 3
[0041] After Na 2 WO 4 .2H 2 O (26.4 mg, 0.08 mmol), 36% hydrogen peroxide aqueous solution (400 mg, 4.2 mmol), and 3-cyclohexen-1-carboxylic acid allyl ester (670 mg, 4 mmol) were mixed, and were reacted at 25° C. for 15 min., the temperature was raised to 70° C., and the mixture was stirred for 3 hours. The same steps as in Example 1 were repeated. It was confirmed that the conversion rate of 3-cyclohexen-1-carboxylic acid allyl ester of a starting material was about 0%, and the presence of 3,4-epoxycyclohexan-1-carboxylic acid allyl ester of a bifunctional epoxy monomer was hardly determined. | There is provided a novel method for producing a bifunctional epoxy monomer which comprises reacting diolefin with a hydrogen peroxide aqueous solution, in the presence of molybdenum or tungsten oxide as a catalyst to selectively epoxidize a double bound at a specific position. The bifunctional epoxy monomers provided by the present invention are substances widely used in various industrial fields such as chemical industry, as materials for resist materials (particularly solder resist materials), and intermediates of agrochemicals and medicines, and various polymers such as plasticizers, adhesives and coating resins. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to and the benefit of Korean Patent Application Nos. 10-2013-0168182 filed on Dec. 31, 2013 and 10-2014-0063997, filed on May 27, 2014, the disclosures of which are incorporated herein by reference in their entirety.
BACKGROUND
1. Field
The present disclosure relates to a film target for laser-induced particle acceleration and a method of manufacturing the same, and more particularly, to a film target in which an ion layer is inserted and a method of manufacturing the same.
2. Discussion of Related Art
Conventionally, research and development of laser-induced particle acceleration using an ultra-short intense laser have been actively conducted.
When the ultra-short intense laser is focused on a thin layer, high energy ion beams are generated. The biggest issue is improving the energy characteristic of the ion beam, that is, to increase energy and reduce the energy width in the laser accelerated ion beam generation techniques.
Currently, the most remarkable technique is to use a very thin film of tens of nanometers thickness. However, the technique for substantially reducing a preceding pulse of the laser is additionally required, and the energy characteristic of the ion beam resulting from a very thin film are also not continuously improved when the intensity of the laser is increased due to non-uniform transverse spatial distribution of the laser intensity.
SUMMARY
One aspect of the present invention is directed to a film target for laser-induced particle acceleration in which energy characteristic of an ion bean is improved, and a method of manufacturing the same.
Another aspect of the present invention is directed to a film target for laser-induced particle acceleration in which manufacturing thereof is easy and handling thereof is convenient, and a method of manufacturing the same.
A further aspect of the present invention is directed to a film target for laser-induced particle acceleration in which the energy characteristic of an accelerated ion beam may be adjusted, and a method of manufacturing the same.
One aspect of the present invention provides a film target 100 for laser-induced particle acceleration, including: a first target layer 300 on which a laser 200 is incident; an intermediate layer 400 located behind the first target layer 300 along a propagating direction of the laser 200 , and in which an intended ion beam 600 is generated; and a second target layer 500 located opposite to the first target layer 300 with the intermediate layer 400 interposed therebetween.
Another aspect of the present invention provides a method of manufacturing a film target for laser-induced particle acceleration, including: preparing a first target layer 300 on which a laser is incident; forming an intermediate layer 400 behind the first target layer 300 along a propagating direction of the laser to generate an intended ion beam; and forming a second target layer 500 opposite to the first target layer 300 with the intermediate layer 400 interposed therebetween.
Another aspect of the invention provides a film target for laser-induced ion beam acceleration, the film target comprising: a first metallic layer comprising a laser-incident surface to which a laser is to be incident; a second metallic layer; and an intermediate layer interposed between the first and second metallic layers, the intermediate layer being of a non-metallic material comprising one or more source elements for ion beams.
In the foregoing film target, the first metallic layer may have a thickness measured in a direction perpendicular to the laser-incident surface and greater than that of the second metallic layer. The intermediate layer may contact the first metallic layer on one side, the intermediate layer contacting the second metallic layer on the other side. The non-metallic material may comprise a plastic material. The non-metallic material may comprise either or both of hydrogen (H) and carbon (C).
Still another aspect of the invention provides a laser-induced particle acceleration device comprising: a laser source configured to generate a laser beam; and the foregoing film target arranged such that the laser beam is to be incident to the laser-incident surface of the first metallic layer.
A further aspect of the invention provides a method of manufacturing a film target for laser-induced ion beam acceleration, the method comprising: providing a first metallic layer; forming an intermediate layer of a non-metallic material over the first metallic layer, the non-metallic material comprising one or more source elements for ion beams; and forming a second metallic layer over the intermediate layer such that the intermediate layer is interposed between the first and second metallic layers, thereby making the foregoing film target.
In the foregoing method, the first metallic layer may have a thickness measured in a direction perpendicular to the laser-incident surface and greater than that of the second metallic layer. The intermediate layer may contact the first metallic layer on one side, the intermediate layer contacting the second metallic layer on the other side. The non-metallic material may comprise a plastic material. The non-metallic material may comprise either or both of hydrogen (H) and carbon (C).
A further aspect of the invention provides a method of manufacturing the foregoing film target, the method comprising: providing a metallic layer for the second metallic layer of the film target; forming an intermediate layer of a non-metallic material over the metallic layer, the non-metallic material comprising one or more source elements for ion beams; and forming another metallic layer for the first target layer of the film target over the intermediate layer such that the intermediate layer is interposed between the two metallic layers, thereby making the foregoing film target.
In the foregoing method, the first metallic layer may have a thickness measured in a direction perpendicular to the laser-incident surface and greater than that of the second metallic layer. The intermediate layer may contact the first metallic layer on one side, the intermediate layer contacting the second metallic layer on the other side. The non-metallic material may comprise a plastic material. The non-metallic material may comprise either or both of hydrogen (H) and carbon (C).
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the present invention will become more apparent to those of ordinary skill in the art by describing in detail example embodiments thereof with reference to the accompanying drawings, in which:
FIG. 1 is a view showing a double-layer target including a vacuum layer for laser-induced particle acceleration according to a conventional technique;
FIG. 2 is a view showing a film target for laser-induced particle acceleration according to an embodiment of the present invention;
FIG. 3 is a view showing a film target for laser-induced particle acceleration according to another embodiment of the present invention;
FIGS. 4A and 4B are graphs showing a gradient in a spatial distribution of an electric field inside the film target and a phase distribution of an ion beam according to changes in a thickness T1 of a first target layer and a thickness T2 of a second target layer;
FIG. 5 is a graph showing an energy distribution of the ion beam according to the changes in the thickness T1 of the first target layer and the thickness T2 of the second target layer;
FIG. 6 is a graph showing an energy distribution of a proton beam when a single thin film is used; and
FIGS. 7A-7C are schematic cross-sectional views showing a method of manufacturing the film target for laser-induced particle acceleration according to the embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
Hereinafter, example embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
In one example, a double-layer target includes a vacuum layer for laser-induced particle generation, as described in FIG. 1 . A double-layer target 10 includes a first target layer 30 configured to react with a preceding pulse of a laser 20 and generate plasma. The double-layer target 10 further includes a second target layer 50 configured to generate an ion beam 60 by a main pulse of the laser 20 , and a vacuum layer 40 formed between the first target layer 30 and the second target layer 50 to prevent a shock wave by the plasma from being transferred to the second target layer 50 .
The double-layer target has an advantage in that the ion beam, of which the energy is high and at the same time the energy width is small, may be generated, even though a high quality laser, in which a preceding pulse required in the existing target is small, is not required.
Film Target for Laser-Induced Particle Acceleration
FIG. 2 is a view showing a film target for laser-induced particle acceleration according to an embodiment of the present invention.
As shown in FIG. 2 , a film target 100 for laser-induced particle acceleration according to the embodiment of the present invention includes a first target layer 300 configured to react with a laser 200 and adjust energy characteristic of an accelerated ion beam 600 , a second target layer 500 , and an intermediate layer 400 located between the first target layer 300 and the second target layer 500 , and comprising an intended ion species.
The laser 200 radiates from left to right in FIG. 2 , and is focused on a surface of the first target layer 300 .
The first target layer 300 and the second target layer 500 may include metal materials of several micrometers thickness, for example, Al, Cu, Ti, Ta, etc. Specifically, it advantageously serves to increase the energy of the ion beam 600 when a material having a higher atomic number is used for the first target layer 300 and the second target layer 500 .
The first target layer 300 and the second target layer 500 may be configured to have different thicknesses T1 and T2. Specifically, the thickness T1 of the first target layer 300 may be greater than the thickness T2 of the second target layer 500 in order that the ion beam 600 is smoothly accelerated to the right in FIG. 2 .
The intermediate layer 400 may be a very thin layer of which a thickness T is tens of nanometers, and may be configured of an intended accelerated particle, for example, a material including H, C, etc. Specifically, the intermediate layer 400 may be configured of a plastic-based material.
As described above, the film target 100 for laser-induced particle acceleration according to the embodiment of the present invention is insensitive to the influence by the preceding pulse, since the thickness T1 of the first target layer is several micrometers or more, and at the same time the intended ion beam 600 is formed on a center of the entire film target 100 . Therefore, the additional technique for reducing the preceding pulse of the laser 200 is not required compared to the conventional technique.
Therefore, the film target for laser-induced particle acceleration according to the embodiment of the present invention may innovatively improve the energy characteristic of the ion beam among laser accelerated ion beam generation techniques. That is, the film target may adjust the energy characteristic of the ion beam and be insensitive to the preceding pulse of the laser as described above, and may be easy to manufacture, as described below. As these effects are difficult to implement by the conventional technique, utilization of the laser accelerated ion beam may be considerably increased in many areas of basic science, nuclear physics, health care, and the like, such as high-speed plasma diagnostics, nuclear reactions, cancer treatment, etc.
FIG. 3 is a view showing a film target for laser-induced particle acceleration according to another embodiment of the present invention. FIGS. 4A and 4B are graphs showing a gradient in a spatial distribution of an electric field inside the film target and a phase distribution of an ion beam according to changes of a thickness T1 of a first target layer and a thickness T2 of a second target layer, which are generated by focusing an ultra-intense laser pulse. Specifically, FIG. 4A is a graph showing a film target configured of copper (Cu) in which the thickness T1 of the first target layer is 1.6 μm, and the thickness T2 of the second target layer is 0.8 μm, and FIG. 4B is a graph showing a film target configured of copper (Cu) in which the thickness T1 of the first target layer is 2.0 μm, and the thickness T2 of the second target layer is 0.4 μm. FIG. 5 is a graph showing an energy distribution of the ion beam according to the changes in the thickness T1 of the first target layer and the thickness T2 of the second target layer. Further, FIG. 6 is a graph showing an energy distribution of a proton beam when a single thin film is used.
A film target for laser-induced particle acceleration according to another embodiment of the present invention is similar to the film target for laser-induced particle acceleration according to an embodiment of the present invention described above except for the thickness T1 of the first target layer and the thickness T2 of a second target layer. Thus, like reference numerals in the drawings denote like elements, and thus the description thereof will not be repeated.
As shown in FIG. 3 , the film target for laser-induced particle acceleration according to another embodiment of the present invention includes a first target layer 300 , a second target layer 500 , and an intermediate layer 400 .
In embodiments of the present invention, energy characteristic of an accelerated ion beam 600 may be adjusted by controlling a ratio of a thickness T1 of the first target layer to a thickness T2 of the second target layer.
Referring to FIG. 4A and FIG. 5 , in the case where the intermediate layer 400 , in which an intended ion beam 600 is generated, is closely located to a center of the first target layer 300 and the second target layer 500 (T1=1.6 μm, and T2=0.8 μm), when the ion beam 600 is accelerated by an electric field E formed inside a plasma by a laser, since a gradient in the spatial distribution of the electric field E is larger and an acceleration length is longer, an energy width of the ion beam 600 is greater, however, a maximum energy thereof is increased. As shown in FIG. 4A , the gradient in the spatial distribution of the electric field E is larger in a center area of an X-axis, however, the gradient therein is reduced toward the right. Therefore, since an initial location of the ion beam 600 is concentrated in the middle of the X-axis, and the ion beam 600 is accelerated by an entire electric field E having a positive (+) value, the acceleration length is longer.
Referring to FIG. 4B and FIG. 5 , and to the contrary of FIG. 4A , since the gradient in the spatial distribution of the electric field E is smaller when the intermediate layer 400 is located close to a surface of the second target layer 500 (T1=2.0 μm, and T2=0.4 μm), the maximum energy of the ion beam 600 is smaller, however, the energy width thereof is reduced. As shown in FIG. 4B , the gradient in the spatial distribution of the electric field E is similar to that of in FIG. 4A . However, FIG. 4B shows that the initial location of the ion beam 600 is more biased to the right on the X-axis. Therefore, since the ion beam 600 is accelerated by a right part of the entire electric field E having a positive (+) value, the acceleration length is reduced.
Referring to FIGS. 5 and 6 , when the intermediate layer 400 is located too close to the surface of the second target layer 500 , rather, the energy characteristic of the generated ion beam 600 becomes the energy characteristic of the ion beam generated in the existing thin film.
A Method of Manufacturing the Film Target for Laser-Induced Particle Acceleration
FIGS. 7A , 7 B, and 7 C are schematic cross-sectional views of the process showing a method of manufacturing the film target for laser-induced particle acceleration according to the embodiment of the present invention, and show a process of manufacturing the film target for laser-induced particle acceleration shown in FIGS. 2 and 3 .
As shown in FIG. 7A , a first target layer 300 having a predetermined thickness T1 is prepared using an easily obtainable metal film.
As shown in FIG. 7B , an intermediate layer 400 is formed by coating the first target layer 300 with a plastic-based material to have a thickness T of tens of nanometers.
As shown in FIG. 7C , a second target layer 500 is formed by coating the intermediate layer 400 , which is formed on the first target layer 300 , to have a thickness T2 of several micrometers, again, using a metal film.
According to embodiments of the present invention as described above, there are the following advantages.
According to embodiments of the present invention, as different materials are used for the first target layer and the second target layer, the energy characteristic of the accelerated ion beam can be improved.
According to embodiments of the present invention, as the first target layer and the second target layer have different thicknesses from each other, the energy characteristic of the accelerated ion beam can be adjusted.
According to embodiments of the present invention, as the intended ion beam is generated between the first target layer and the second target layer, it is insensitive to an influence by a preceding pulse of the laser, and it does not require an additional technique for reducing the preceding pulse of the laser.
According to embodiments of the present invention, as easily obtainable materials are used, manufacturing thereof is easy.
Further, according to embodiments of the present invention, as a target is formed in a film shape, handling thereof is convenient.
While the present invention has been particularly described with reference to example embodiments, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention. Therefore, the example embodiments should be considered in a descriptive sense only and not for purposes of limitation. The scope of the invention is defined not by the detailed description of the invention but by the appended claims, and encompasses all modifications and equivalents that fall within the scope of the appended claims. | A film target for laser-induced particle acceleration includes a first target layer on which a laser is incident; an intermediate layer located behind the first target layer along a propagating direction of the laser, and in which an intended ion beam is generated; and a second target layer located opposite to the first target layer with the intermediate layer interposed therebetween. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/379,423 filed Apr. 20, 2006, which is a continuation of U.S. patent application Ser. No. 10/247,765 filed Sep. 18, 2002, now U.S. Pat. No. 7,148,211, both of which are incorporated herein by reference in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] This invention relates to pharmaceutical formulations of lipophilic therapeutic agents in which such agents are solubilized in largely aqueous vehicles, and uses for such formulations. The formulations are stable in aqueous-based vehicles, and have therapeutically and commercially useful concentrations of active ingredient.
[0004] Many pharmacologically active substances are lipophilic, i.e., only sparingly or negligibly water-soluble. Lipophilic therapeutic agents span the entire range of biologically and/or pharmacologically active substances. For example, they include certain analgesics and anti-inflammatory agents, anti-asthma agents, anti-bacterial agents, anti-viral agents, anti-coagulants, anti-depressants, anti-neoplastic agents and immunosuppressants, β-blockers, corticosteroids, opioid analgesics, lipid regulating agents, anxiolytics, sedatives, hypnotics and neuroleptics.
[0005] The poor water-solubility of these lipophilic agents often results in major difficulties in formulation, particularly when easily sterilizable and administrable homogeneous aqueous solutions are needed. Efficacious aqueous-based formulations are particularly problematic for systemic administration, in particular parenteral administration (i.e., injectable solutions) and for certain liquid preparations for, e.g., topical gynecologic, dermatologic ophthalmic, etc. use, and for use on the oral mucous membranes.
[0006] A number of approaches for obtaining aqueous compositions of sparingly water-soluble drugs are known. Such approaches seek to increase the solubility, and accordingly, increase the ease of formulation and the bioavailability of the sparingly soluble or lipophilic active agents. One such approach involves chemical modification of the lipophilic drug by introduction of a ionic or ionizable group or a group that lowers the melting point. The former generally depends upon the lipophilic drug having a hydroxyl or carboxy group which can be used to form various kinds of esters. The latter is based on the concept that, to be solubilized, the molecules have to leave the crystal lattice. Any modification of the molecule that lowers the melting point, and thus reduces the energy of the crystal lattice, tends to increase the solubility thereof in any solvent.
[0007] Another method involves physico-chemical solubilization techniques such as micellar solubilization by means of surface-active agents, i.e., the use of surfactant micelles to solubilize and transport the therapeutic agent. Micelles are agglomerates of colloidal dimensions formed by amphiphilic compounds under certain conditions. Micelles, and pharmaceutical compositions containing micelles, have been extensively studied and are described in detail in the literature. In aqueous solution, micelles can incorporate lipophilic therapeutic agents in the hydrocarbon core of the micelle, or can entangle the agents at various positions within the micelle walls. Although micellar formulations can solubilize a variety of lipophilic therapeutic agents, the loading capacity of conventional micelle formulations is limited by the solubility of the therapeutic agent in the micelle surfactant. For many lipophilic therapeutic agents, such solubility is too low to offer formulations that can deliver therapeutically effective doses.
[0008] The formation of complexes, solid solutions and solid dispersions by means of the use of suitable polymers is another approach for increasing the water-solubility of pharmaceutically active substances. In such a case, the active ingredient is incorporated in a suitable hydrophilic carrier, which increases the solubility and the bioavailability thereof without any formal covalent bonds originating between the drug and the polymer matrix. The difference between a solid solution and a solid dispersion is typically in the form of the active ingredient. In a solid solution, the active is present in the amorphous molecular form, while in a dispersion the active is present in a crystalline form, as fine as possible.
[0009] Even more widespread and studied is the use of the interaction between a polymer and a drug to give rise to a true complex, wherein chemical bonds of a noncovalent nature are involved. Complexing polymers employed in the pharmaceutical field include, e.g., polyethylene glycols, polypropylene glycols, cyclodextrins, carboxymethylcellulose, polyvinylpyrrolidone (PVP)
[0010] Co-precipitation is yet another widespread method for the preparation of complexes with increased solubility. In this method, the substance and the polymer are dissolved in an organic solvent in which they are both soluble, and the solution is then evaporated at atmospheric pressure, under vacuum, by spray-drying or by lyophilization, to yield a dry product actually made of the complex of the treated drug. Such complexes can also be obtained by applying other methods, such as grinding and mixing the ingredients in a mill, or by extrusion of a paste containing the two products together with a minor amount of water, etc. In comparison with the starting drug, the complex typically shows an appreciably enhanced water-solubility.
[0011] In devising a working method for solubilizing drugs by complexation, it is necessary to take into account the molecular weight of the polymer, since the solubility of the active ingredient directly depends thereon. In general, low molecular weights are more suitable than medium to high molecular weights.
[0012] Still another method involves use of various co-solvent systems, i.e., compositions using a solvent mixture containing water and one or more organic solvents. One approach to solubilizing lipophilic drug agents in aqueous systems is to employ some combination of alcohols and glycols (PDA J. Pharm. Sci. Technol. 50(5) 1996; U.S. Pat. Nos. 6,136,799; 6,361,758 and 5,858,999) Organic contents as high as 50% or more are often required to ensure solubility during manufacturing, storage and administration. Although organic levels while high will still be below the LD 50 for a low volume parenteral dosage, the amounts are still typically undesirable. High levels of organic solvent can cause pain on injection and tissue necrosis.
[0013] Other methods involve the formation of complexes by the addition of chelating agents such as citric acid, tartaric acid, amino acids, thioglycolic acid and edetate disodium. Others use buffering agents such as acetate, citrate, glutamate and phosphate salts. However, buffers and chelating agents have been implicated in imparting aluminum levels in products to in excess of 3.5 parts per million leading to adverse side effects. (International Patent Application Publication WO 96/36340) Moreover, certain chelating agents such as EDTA have be implicated in adverse effects such nephrotoxicity and renal tubular necrosis. (U.S. Pat. No. 6,361,758)
[0014] Each of these foregoing methods has its inherent limitations. For many of the pharmaceutical substances, the solubility levels that can be achieved with one or another of the methods discussed above are still insufficient to make their use in aqueous-based commercial products viable.
[0015] An exemplary and important class of lipophilic drug agents are the vitamin D compounds. Properly metabolized vitamin D compounds are necessary for the maintenance of healthy bones and have been found to display more other biological activities. The lipophilicity of the natural forms of vitamin D and of the many known synthetic analogs of vitamin D makes it difficult to manufacture an efficacious formulation, particularly, a parenteral formulation which is preferred for, e.g., renal dialysis patients.
[0016] Additionally, vitamin D compounds, among other lipophilic compounds, are known to be oxygen sensitive, being oxidized when exposed to air, and thus, losing integrity. One approach to circumventing this problem is to add an antioxidant directly to a formulation of the drug. However, certain antioxidants, such as ascorbic acid and sodium ascorbate, which are highly water soluble, will discolor in the course of performing their intended function. Buffers and/or chelating agents have also been added to decrease oxygen sensitivity thus maintaining active drug potency (U.S. Pat. Nos. 4,308,264; 4,948,788 and 5,182,274.) However, as noted above, buffers and chelating agents are known to introduce undesirable levels of aluminum into the product.
[0017] Thus, there is a need for pharmaceutical formulations of lipophilic therapeutic agents that overcome the limitations of the many known approaches.
BRIEF SUMMARY OF THE INVENTION
[0018] The present invention provides a pharmaceutical formulation that overcomes the problems associated with parenteral formulations of lipophilic drugs. The present invention provides a formulation that can be terminally sterilized, and contains little or no organic solvent such as alcohol. It has also been surprisingly discovered that the novel formulations of the present invention provide a synergistic solubilizing and antioxidative effect. Additionally, the present invention allows for the inclusion or occlusion of aseptic agents, depending on the intended use and/or handling.
[0019] The present invention provides a pharmaceutical formulation comprising a therapeutically effective amount of (1) a lipophilic therapeutic agent, (4) a non-ionic solubilizer, (3) a lipophilic antioxidant, and (4) optionally, an agent that is an organic solvent, or a preservative (e.g., antimicrobial), or both, in an aqueous vehicle. Lipophilic therapeutic agents suitable for use in the formulations of the present invention are not particularly limited. Agents of particular interest include vitamin D compounds and analogs. By employing a lipophilic, i.e., fat-soluble, antioxidant, smaller amounts of antioxidant may be used compared to known formulations utilizing water soluble antioxidants.
[0020] The formulations of the present invention preclude the need for high organic solvent contents, which can cause irritations in some patients. In addition, formulations of the present invention omit buffers and chelating agents. The use of buffers and chelating agents in, e.g., some prior vitamin D formulations, has been linked to the introduction of undesirable aluminum levels into the product and eventually into the patient.
[0021] The invention also relates to methods for the treatment and/or prophylaxis of certain diseases and disorders comprising administering, e.g., parenterally, to a patient in need thereof a formulation in accordance with the present invention. For example, for formulations containing vitamin D compounds or analogs, these diseases include hyperparathyroidism, e.g., secondary hyperparathyroidsim, neoplastic diseases, such as cancers of the pancreas, breast, colon or prostate as well as other diseases of abnormal cell differentiation and/or cell proliferation such as psoriasis, and disorders of calcium metabolism such as osteomalacia.
[0022] Other advantages and a fuller appreciation of the specific attributes of this invention will be gained upon an examination of the following detailed description of the invention, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Not applicable.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention provides a stable, self-preserved pharmaceutical formulation of a lipophilic therapeutic agent in aqueous vehicle utilizing a non-ionic solubilizer and lipophilic antioxidant. The formulation is suitable for parenteral administration.
[0025] As used herein, “lipophilic” in reference to a therapeutic agent or drug is intended to mean a sparingly (or poorly, slightly, scarcely) soluble biologically active or pharmaceutically active substance or antigen-comprising material, which has a therapeutic or prophylactic effect, and has utility in the treatment or prevention of diseases or disorders affecting mammals, including humans, or in the regulation of an animal or human physiological condition. The water-solubility of lipophilic drugs, at room temperature, is typically too low to make commercially proposable, sufficiently active or advantageous any aqueous preparations containing the compound as an active ingredient. Lipophilic therapeutic agents include substances, typically compounds, with little or no water solubility. Intrinsic water solubilities (i.e., water solubility of the unionized form) for lipophilic therapeutic agents usable in the present invention include, for example, those with a solubility of less than about 1% by weight, and typically less than about 0.1% or 0.01% by weight, or, e.g., less than about 10 μg/mL.
[0026] Lipophilic therapeutic agents suitable for use in the formulations of the present invention are not particularly limited, as the method of the present invention is surprisingly capable of solubilizing and delivering a wide variety of lipophilic therapeutic agents. Therapeutic agents that can be utilized with the formulations of the present invention may be selected from a wide range of biologically and/or pharmacologically active substances which lack adequate solubility in aqueous systems without a solubilizing agent. Such therapeutic agents include any agents having therapeutic or other value when administered to an animal, particularly to a mammal, such as drugs, prodrugs (i.e., agents than transform into active substances), nutrients (nutraceuticals), and cosmetics (cosmeceuticals). Such therapeutic agents can be utilized in formulations in accordance with the present invention so as to yield an effective therapeutic dose, e.g., for parenteral administration. The precise biological and/or pharmacological activity of the substance is immaterial, so long as the substance can be solubilized in the present formulations.
[0027] Specific non-limiting examples of lipophilic therapeutic agents that can be used in the formulations of the present invention include the following representative compounds, as well as their pharmaceutically acceptable salts, isomers, esters, ethers and other derivatives. These include:
[0028] analgesics and anti-inflammatory agents, such as aloxiprin, auranofin, azapropazone, benorylate, capsaicin, celecoxib, diclofenac, diflunisal, etodolac, fenbufen, fenoprofen calcium, flurbiprofen, ibuprofen, indomethacin, ketoprofen, ketorolac, leflunomide, meclofenaminc acid, mefenamic acid, nabumetone, naproxen, oxaprozin, oxyphenbutazone, phenylbutazone, piroxicam, rofecoxib, sulindac, tetrahydrocannabinol, tramadol and tromethamine;
[0029] anthelmintics, such as albendazole, bephenium hydroxynaphthoate, cambendazole, dichlorophen, ivermectin, mebendazole, oxamniquine, oxfendazole, oxantel embonate, praziquantel, pyrantel embonate and thiabendazole;
[0030] anti-arrhythmic agents, such as amiodarone HCl, disopyramide, flecamide acetate and quinidine sulfate;
[0031] anti-asthma agents, such as zileuton, zafirlukast, terbutaline sulfate, montelukast, and albuterol;
[0032] anti-bacterial agents, such as alatrofloxacin, azithromycin, baclofen, benzathine penicillin, cinoxacin, ciprofloxacin HCl, clarithromycin, clofazimine, cloxacillin, demeclocycline, dirithromycin, doxycycline, erythromycin, ethionamide, furazolidone, grepafloxacin, imipenem, levofloxacin, lorefloxacin, moxifloxacin HCl, nalidixic acid, nitrofurantoin, norfloxacin, ofloxacin, rifampicin, rifabutine, rifapentine, sparfloxacin, spiramycin, sulphabenzamide, sulphadoxine, sulphamerazine, sulphacetamide, sulphadiazine, sulphafurazole, sulphamethoxazole, sulphapyridine, tetracycline, trimethoprim, trovafloxacin, and vancomycin;
[0033] anti-viral agents, such as abacavir, amprenavir, delavirdine, efavirenz, indinavir, lamivudine, nelfinavir, nevirapine, ritonavir, saquinavir, and stavudine;
[0034] anti-coagulants, such as cilostazol, clopidogrel, dicumarol, dipyridamole, nicoumalone, oprelvekin, phenindione, ticlopidine, and tirofiban;
[0035] anti-depressants, such as amoxapine, bupropion, citalopram, clomipramine, fluoxetine HCl, maprotiline HCl, mianserin HCl, nortriptyline HCl, paroxetine HCl, sertraline HCl, trazodone HCl, trimipramine maleate, and venlafaxine HCl;
[0036] anti-diabetic agents, such as acetohexamide, chlorpropamide, glibenclamide, gliclazide, glipizide, glimepiride, miglitol, pioglitazone, repaglinide, rosiglitazone, tolazamide, tolbutamide and troglitazone;
[0037] anti-epileptic agents, such as beclamide, carbamazepine, clonazepam, thotoin, felbamate, fosphenyloin sodium, lamotrigine, methoin, methsuximide, methylphenobarbitone, oxcarbazepine, paramethadione, phenacemide, phenobarbitone, phenyloin, phensuximide, primidone, sulthiame, tiagabine HCl, topiramate, valproic acid, and vigabatrin;
[0038] anti-fungal agents, such as amphotericin, butenafine HCl, butoconazole nitrate, clotrimazole, econazole nitrate, fluconazole, flucytosine, griseofulvin, itraconazole, ketoconazole, miconazole, natamycin, nystatin, sulconazole nitrate, oxiconazole, terbinafine HCl, terconazole, tioconazole and undecenoic acid;
[0039] anti-gout agents, such as allopurinol, probenecid and sulphinpyrazone;
[0040] anti-hypertensive agents, such as amlodipine, benidipine, benezepril, candesartan, captopril, darodipine, dilitazem HCl, diazoxide, doxazosin HCl, enalapril, eposartan, losartan mesylate, felodipine, fenoldopam, fosenopril, guanabenz acetate, irbesartan, isradipine, lisinopril, minoxidil, nicardipine HCl, nifedipine, nimodipine, nisoldipine, phenoxybenzamine HCl, prazosin HCl, quinapril, reserpine, terazosin HCl, telmisartan, and valsartan;
[0041] anti-malarial agents, such as amodiaquine, chloroquine, chlorproguanil HCl, halofantrine HCl, mefloquine HCl, proguanil HCl, pyrimethamine and quinine sulfate;
[0042] anti-migraine agents, such as dihydroergotamine mesylate, ergotamine tartrate, frovatriptan, methysergide maleate, naratriptan HCl, pizotifen maleate, rizatriptan benzoate, sumatriptan succinate, and zolmitriptan;
[0043] anti-muscarinic agents, such as atropine, benzhexyl HCl, biperiden, ethopropazine HCl, hyoscyamine, mepenzolate bromide, oxyphencyclimine HCl and tropicamide;
[0044] anti-neoplastic agents and immunosuppressants, such as aminoglutethimide, amsacrine, azathioprine, bicalutamide, bisantrene, busulfan, camptothecin, capecitabine, chlorambucil, cyclosporin, dacarbazine, ellipticine, estramustine, etoposide, irinotecan, lomustine, melphalan, mercaptopurine, methotrexate, mitomycin, mitotane, mitoxantrone, mofetil mycophenolate, nilutamide, paclitaxel, procarbazine HCl, sirolimus, tacrolimus, tamoxifen citrate, teniposide, testolactone, topotecan HCl, and toremifene citrate;
[0045] anti-protozoal agents, such as atovaquone, benznidazole, clioquinol, decoquinate, diiodohydroxyquinoline, diloxanide furoate, dinitolmide, furazolidone, metronidazole, nimorazole, nitrofurazone, ornidazole and tinidazole;
[0046] anti-thyroid agents, such as carbimazole and propylthiouracil;
[0047] anti-tussives, such as benzonatate;
[0048] anxiolytics, sedatives, hypnotics and neuroleptics, such as alprazolam, amylobarbitone, barbitone, bentazepam, bromazepam, bromperidol, brotizolam, butobarbitone, carbromal, chlordiazepoxide, chlormethiazole, chlorpromazine, chlorprothixene, clonazepam, clobazam, clotiazepam, clozapine, diazepam, droperidol, ethinamate, flunanisone, flunitrazepam, triflupromazine, flupenthixol decanoate, fluphenthixol decanoate, flurazepam, gabapentin, haloperidol, lorazepam, lormetazepam, medazepam, meprobamate, mesoridazine, methaqualone, methylphenidate, midazolam, molindone, nitrazepam, olanzapine, oxazepam, pentobarbitone, perphenazine pimozide, prochlorperazine, pseudoephedrine, quetiapine, risperidone, sertindole, sulpiride, temazepam, thioridazine, triazolam, zolpidem, and zopiclone;
[0049] β-blockers, such as acebutolol, alprenolol, atenolol, labetalol, metoprolol, nadolol, oxprenolol, pindolol and propranolol;
[0050] cardiac inotropic agents, such as aminone, digitoxin, digoxin, enoximone, lanatoside C and medigoxin;
[0051] corticosteroids, such as beclomethasone, betamethasone, budesonide, cortisone acetate, desoxymethasone, dexamethasone, fludrocortisone acetate, flunisolide, fluocortolone, fluticasone propionate, hydrocortisone, methylprednisolone, prednisolone, prednisone and triamcinolone;
[0052] diuretics, such as acetazolamide, amiloride, bendroflumethiazide, bumetanide, chlorothiazide, chlorthalidone, ethacrynic acid, frusemide, metolazone, spironolactone and triamterene;
[0053] anti-parkinsonian agents, such as bromocriptine mesylate, lysuride maleate, pramipexole, ropinirole HCl, and tolcapone;
[0054] gastrointestinal agents, such as bisacodyl, cimetidine, cisapride, diphenoxylate HCl, domperidone, famotidine, lanosprazole, loperamide, mesalazine, nizatidine, omeprazole, ondansetron HCL, rabeprazole sodium, ranitidine HCl and sulphasalazine;
[0055] histamine H 1 and H 2 -receptor antagonists, such as acrivastine, astemizole, chlorpheniramine, cinnarizine, cetrizine, clemastine fumarate, cyclizine, cyproheptadine HCl, dexchlorpheniramine, dimenhydrinate, fexofenadine, flunarizine HCl, loratadine, meclizine HCl, oxatomide, and terfenadine;
[0056] keratolytics, such as acetretin, calciprotriene, calcifediol, calcitriol, cholecalciferol, ergocalciferol, etretinate, retinoids, targretin, and tazarotene;
[0057] lipid regulating agents, such as atorvastatin, bezafibrate, cerivastatin, ciprofibrate, clofibrate, fenofibrate, fluvastatin, gemfibrozil, pravastatin, probucol, and simvastatin;
[0058] muscle relaxants, such as dantrolene sodium and tizanidine HCl;
[0059] nitrates and other anti-anginal agents, such as amyl nitrate, glyceryl trinitrate, isosorbide dinitrate, isosorbide mononitrate and pentaerythritol tetranitrate;
[0060] nutritional agents and fat-soluble vitamins, such as calcitriol, carotenes, dihydrotachysterol, essential fatty acids, non-essential fatty acids, phytonadiol, vitamin A, vitamin B 2 , vitamin D, vitamin E and vitamin K;
[0061] opioid analgesics, such as codeine, dextropropoxyphene, diamorphine, dihydrocodeine, fentanyl, meptazinol, methadone, morphine, nalbuphine and pentazocine;
[0062] sex hormones, such as clomiphene citrate, cortisone acetate, danazol, dehydroepiandrosterone, ethynyl estradiol, finasteride, fludrocortisone, fluoxymesterone, medroxyprogesterone acetate, megestrol acetate, mestranol, methyltestosterone, norethisterone, norgestrel, oestradiol, conjugated estrogens, progesterone, rimexolone, stanozolol, stilbestrol, testosterone and tibolone;
[0063] stimulants, such as amphetamine, dexamphetamine, dexfenfluramine, fenfluramine and mazindol;
[0064] and others, e.g., erectile dysfunction improvement agents, anti-osteoporosis agents, anti-obesity agents, cognition enhancers, anti-urinary incontinence agents, anti-benign prostate hypertrophy agents, such as becaplermin, donepezil HCl, L-thryroxine, methoxsalen, verteporfin, physostigmine, pyridostigmine, raloxifene HCl, sibutramine HCl, sildenafil citrate, tacrine, tamsulosin HCl, and tolterodine.
[0065] It should be appreciated that this listing of lipophilic therapeutic agents and their therapeutic classes is merely illustrative. Indeed, a particular feature, and surprising advantage, of the formulations of the present invention is the ability of the present formulations to solubilize and deliver a broad range of lipophilic therapeutic agents, regardless of functional class. Of course, mixtures of lipophilic therapeutic agents may also be used where desired.
[0066] Examples of lipophilic agents of particular interest include active vitamin D compounds. As used herein, the term “activated vitamin D” or “active vitamin D” is intended to include any biologically active vitamin D compound, including a pro-drug (or pro-hormone), a precursor, a metabolite or an analog, in any stage of its metabolism. It is known that vitamin D compounds display a variety of biological activities, e.g., in calcium and phosphate metabolism (see, e.g., U.S. Pat. No. 5,104,864), as an antineoplastic agent (see, e.g., U.S. Pat. No. 5,763,429), and as an anti-hyperparthyroid agent (see, e.g., U.S. Pat. No. 5,602,116), and it is contemplated that any of the biologically active forms of vitamin D can be used in the formulations in accordance with the present invention. Generally, an active vitamin D compound or analog is hydroxylated in at least the C-1, C-24 or C-25 position of the molecule, and either the compound itself or its metabolite binds to the vitamin D receptor (VDR). Pro-drugs, for example, include vitamin D compounds that are hydroxylated in the C-1. Such compounds undergo further hydroxylation in vivo and their metabolites bind the VDR.
[0067] Precursors include previtamins, such as 1α-hydroxyprevitamin D 2 , 1α,24-dihydroxyprevitamin D 2 , 1α,25-dihydroxyprevitamin D 2 , 24-hydroxyprevitamin D 2 , 1α-hydroxyprevitamin D 3 and 1α,25-dihydroxyprevitamin D 3 , which are thermal isomeric forms of the vitamin forms. Metabolites generally include compounds or analogs that have undergone further metabolic processing, e.g., hydroxylation.
[0068] Examples of vitamin D compounds suitable for formulations of the present invention include, without limitation, 1α,24-dihydroxyvitamin D 2 , 1α,2-dihydroxyvitamin D 4 , 1α,24-dihydroxyvitamin D 2 , 1α,25-dihydroxyvitamin D 3 (calcitriol), 1α hydroxyvitamin D 3 (α-calcidol) 1α,25-dihydroxyvitamin D 2 , 1α,25-dihydroxyvitamin D 4 , and 1α,24,25-dihydroxyvitamin D 2 , seocalcitol (EB-1089), calcipotriol, 22-oxacalcitriol (maxacalcitol), fluorinated compounds such as falecalcitriol, and 19-nor compounds such as paricalcitol. Among those compounds having a chiral center, e.g., in the sidechain, such as at C-24, it is understood that both epimers (e.g., R and S) and the epimeric mixture are within the scope of the present invention.
[0069] It also is understood that any numerical value recited herein includes all values from the lower value to the upper value. For example, if a concentration range is stated as 1% to 50%, it is intended that values such as 2% to 40%, 10% to 30%, or 1% to 3%, etc., are expressly enumerated in this specification. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application.
[0070] The amount of selected therapeutic is not critical to the present invention and may be varied to achieve the desired therapeutic response for a particular patient. The amount of active therapeutic agent in the formulations of the invention will be dependent, in part, on the solubility of the specific surfactant used and its intended use. Those skilled in the arts can adjust the ratios without undue experimentation. The selected dosage also will depend on the activity of the specific therapeutic, the route of administration, the severity of the condition being treated and the condition and history of the specific patient. For example, a therapeutic dose for vitamin D-type compounds may range between about 2 μg and about 100 μg/dose.
[0071] Suitable solubilizing agents for the formulations of the present invention include nonionic solubilizers. A non-ionic solubilizer is one where the hydrophilic part of the solubilizer carries no charge but derives its water solubility from highly polar groups such as hydroxyl or polyoxyethylene groups. Some surfactants known for use in the pharmaceutical field also have a solubilizing function.
[0072] Solubilizers generally include, but are not limited to, the polyoxyalkylenes dextrans, fatty acid esters of saccharose, fatty alcohol ethers of oligoglucosides (e.g., the alkylpolyglucosides such as TRITON™), fatty acid esters of glycerol (e.g., glycerol mono/distearate or glycerol monolaurate), and polyoxyethylene type compounds (e.g., POE, PEG, PEO, SOLUTOL™ CREOMOPHOR™S, MACROGOL, CARBOWAX, POLYOXYL). The latter also include polyethoxylated fatty acid esters of sorbitan (e.g., polysorbates, such as TWEEN™s, SPAN™s), fatty acid esters of poly(ethylene oxide) (e.g., polyoxyethylene stearates), fatty alcohol ethers of poly(ethylene oxide) (e.g., polyoxyethylated lauryl ether), alkylphenol ethers of poty(ethylene oxide) (e.g., polyethoxylated octylphenol), polyoxyethylene-polyoxypropylene block copolymers (also known as poloxamers, such as “Pluronic”), and ethoxylated fats and oils (e.g., ethoxylated castor oil, or polyoxyethylated castor oil, also known as polyethylene glycol-glyceryl triricinoleate). Mixtures of solublilizers are also within the scope of the invention. Such mixtures are readily available from standard commercial sources. Solubilizers of particular interest include polysorbates, e.g. TWEEN™. Amounts of such solubilizer present in the formulations of the present invention include from about 0.05% to about 5% w/w.
[0073] Suitable lipophilic antioxidants include, but are not limited to, butylated hydroxytoluene (BHT), lipoic acid, lycopene, lutein, lycophyll, xanthophyll, carotene, zeaxanthin or vitamin E and/or esters thereof. The lipophilic antioxidants are present in very small but effective amounts, e.g., about 20 to about 2000 ppm.
[0074] If desired, formulations of the present invention can optionally include additional agents to enhance the solubility of the lipophilic therapeutic agent in the carrier system. Examples of such optional agents include organics solvents, preservatives or both. Such agents include alcohols and polyols, such as ethanol, benzyl alcohol, chlorobutanol, isopropanol, butanol, ethylene glycol, propylene glycol, butanediols, glycerol, pentaerythritol, sorbitol, mannitol, transcutol, dimethyl isosorbide, polyethylene glycol, polypropylene glycol, polyvinylalcohol, hydroxypropyl methylcellulose and other cellulose derivatives, cyclodextrins and cyclodextrin derivatives. Amounts of optional agents include 0% to about 30% w/w, e.g., organic solvent. A useful range is 0% to about 10% w/w, and a particularly useful range is about 1% to about 3%.
[0075] Accordingly, a formulation in accordance with the present invention includes a lipophilic drug agent (e.g., a drug agent with a solubility in water of <10 μg/mL), about 0.05% to about 5% w/w of a non-ionic solubilizer, about 20 to about 2000 ppm lipophilic antioxidant, and 0% to about 30% w/w optional agent. A particular formulation for treating secondary hyperparathyroidism includes 2-6 μg/mL 1α-hydroxyvitamin D 2 (doxercalciferol), 2.5% w/w benzyl alcohol, 0.5%-2.5% w/w TWEEN™-20, and 20 ppm BHT. The amount of optional agent, e.g., benzyl alcohol or ethanol, may range from 0 to 30% w/w; a highly useful range comprises 1% to 3% w/w. With a vitamin D formulation (e.g., a doxercalciferol formulation), a most useful amount of optional agent comprises 2.5% w/w.
[0076] A pharmaceutical formulation in accordance with the present invention comprises an aqueous vehicle. The aqueous vehicle contains, of course, water, but it may furthermore also contain pH adjusting agents, stabilizing agents, solubilizing agent (see, hereinabove), isotonic adjusting agents, and solvents (e.g. organic solvents; as discussed above). A formulation in accordance with the present invention precludes the need for high organic solvent which can cause irritation in some patients. In some cases, however, it may be appropriate to include an organic solvent or co-solvents. The amount of water in a formulation in accordance with the present invention is normally at least about from about 50% to about 99% w/w.
[0077] For the pharmaceutical formulations of the present invention, the intended route of administration is suitably parenteral, i.e., for use by injection into, e.g., an animal or human body. Such route includes intravenous, intramuscular and subcutaneous administration, the intravenous route being especially suitable for the formulations of the present invention for use in connection with, e.g., secondary hyperparathyroidism or neoplastic disorders.
[0078] However, whenever relevant, formulations in accordance with the present invention may also be suitable for use by other administration routes such as, e.g., the oral route, the topical route or the nasal route. In such cases, a person skilled in the art can make any necessary adjustments with respect to the concentration of the active substance and with respect to the other ingredients included in the formulation.
[0079] A formulation in accordance with the present invention is normally presented as an aqueous solution. However, in certain cases such as, e.g., in connection with the administration of a formulation by the topical or oral route, a formulation in accordance with the present invention may include a liquid composition which may be presented in the form of a solution or a gel.
[0080] Pharmaceutical formulations may be readily prepared by using pharmacopoeia grade reagents in which the reagents are made up in stock solutions from which the resulting solutions at the appropriate concentrations can be made. Once the appropriate amounts of stock solution and combined, it is often desirable to stir the reagents for several minutes under nitrogen gas gently blown over the top of the mixture, i.e., a nitrogen gas overlay. Degassed Water for Injection is then added to bring the desired final volume, and stirring under nitrogen gas continued for another several minutes.
[0081] A pharmaceutical formulation in accordance with the present invention containing a vitamin D compound or a vitamin D analogue like those substances described above, is suitable for use in the treatment and/or prophylaxis of (i) diseases or conditions characterized by abnormal cell differentiation and/or cell hyperproliferation such as, e.g., psoriasis and other disturbances of keratinisation, neoplastic diseases and cancers, such as pancreas, breast, colon and prostate cancers as well as skin cancer; (ii) diseases of, or imbalance in, the immune system, such as host-versus-graft and graft-versus-host reaction and transplant rejection, and auto-immune diseases such as discoid and systemic lupus erythematosus, diabetes mellitus and chronic dermatoses of auto-immune type, e.g., scleroderma and pemphigus vulgaris; (iii) inflammatory diseases such as rheumatoid arthritis as well as in the treatment and/or prophylaxis of a number of (iv) other diseases or disease states, including hyperparathyroidism, particularly secondary hyperparathyroidism associated with renal failure, and in promoting (v) osteogenesis and treating/preventing bone loss as in osteoporosis and osteosmalacia. (For use of vitamin D compounds for treatment and prophylaxis, see, e.g., U.S. Pat. Nos. 5,9722,917; 5,798,345; 5,763,428; 5,602,116; 5,869,386; 5,104,864; 5,403,831; 5,880,114; 5,561,123. The vitamin D formulations in accordance with the present invention are especially suited for treatment of cell hyperproliferative disorders; disorders of the calcium metabolism, such as osteomalacia; or neoplastic diseases, such as cancers of the pancreas, breast, colon or prostate. The method of treatment comprises treating the cells and/or administering to a patient in need thereof a formulation in accordance with the present invention in an amount that is effective to amelariate or prevent the disease or disorder. For example, in the treatment of hyperproliferative or neoplastic diseases, an effective amount is, e.g., a growth-inhibiting amount. Daily dosages as well as episodic doses, e.g., once per week to three times per week, are contemplated.
[0082] Additionally, as described hereinabove, vitamin D compounds in accordance with the present invention include prodrugs, i.e., drugs that require further metabolic processing in vivo, e.g., additional hydroxlation. Such prodrugs of vitamin D compounds that have been found to be effective therapeutic agents are generally less reactive than, e.g., the dihydroxy natural hormone, 1α,25-dihydroxyvitamin D 3 . These compounds may offer further advantage for use in formulations.
[0083] In addition, formulations of the current invention may be terminally sterilized by means of e.g., autoclaving.
[0084] The present invention is further explained by the following examples which should not be construed by way of limiting the scope of the present invention.
Preparation of Stock Solutions
Example 1
Doxercalciferol (1α-hydroxyvitamin D 2 ) Stock Solution
[0085] 12.558 mg of doxercalciferol was weighed and transferred to a 10-mL volumetric flask. The solid was diluted to volume with ethanol and the flask was vigorously shaken to dissolve the solid.
Example 2
Butylated Hydroxytoluene (BHT) Stock Solution
[0086] 2.22 g BHT was transferred to a 100-mL volumetric flask. The solid was diluted to volume with ethanol and the flask was vigorously shaken to dissolve the solid.
Example 3
10% TWEEN™-20
[0087] 100 g TWEEN™-20KR was transferred to a 1-L volumetric flask and diluted to volume with degassed Water for Injection. A magnetic stir bar was added and the mixture stirred to mix.
Formulations
Example 4
Doxercalciferol Formulations
[0088] The general procedure for preparing doxercalciferol formulations was as follows. To a glass formulation vessel was added Doxercalciferol Stock Solution, 10% TWEEN™-20, BHT Stock Solution, and ethanol, in the order listed. Nitrogen gas was gently blown over the top of the mixture. A stir bar was added to the mixture and stirred for not less than 20 minutes while continuing the nitrogen gas overlay. Degassed Water for Injection was added to bring the final volume to one liter. The mixture was stirred for not less than 20 minutes while continuing the nitrogen gas overlay. The volumes of each component used in preparing the formulations are listed in the Table 1 below.
[0000]
TABLE 1
Preparation of Doxercalciferol Formulations
Doxercalciferol
Tween ™-20
BHT Stock
Ethanol
Water for
Stock (mL)
Stock (mL)
(mL)
(mL)
Injection (mL)
2.0
50
1.0
27
920
6.0
250
1.0
23
720
Use of Formulations
Example 5
Double-blind Study in End Stage Renal Disease (ESRD) Patients Exhibiting Secondary Hyperparathyroidism
[0089] Up to 120 ESRD (End Stage Renal Disease) patients undergoing chronic hemodialysis are studied in a multicenter, double-blind, placebo-controlled study based in two major U.S. metropolitan areas. The selected patients reside in two major metropolitan areas within the continental U.S., have ages between 20 and 75 years and have a history of secondary hyperparathyroidism. They have been on hemodialysis for at least four months, have a normal (or near normal) serum albumin, and have controlled serum phosphorus (often by using oral calcium phosphate binders).
[0090] On admission to the study, each patient is assigned at random to one of two treatment groups. One of these groups receives two consecutive 12-week courses of therapy with 1α-OH-vitamin D 2 (doxercalciferol); the other receives a 12-week course of therapy with 1α-OH-vitamin D 2 followed, without interruption, by a 12-week course of placebo therapy. Each patient discontinues any 1α,25-(OH) 2 -vitamin D 3 therapy for eight weeks prior to initiating 1α-OH-vitamin D 2 therapy (daily dose of 4 μg doxercalciferol, formulated with 2.5% w/w benzyl alcohol, 0.5%-2.5% w/w TWEEN™-20, and 20 ppm BHT). Throughout this eight-week washout (or control) period and the two subsequent 12-week treatment periods, patients are monitored weekly for serum calcium and phosphorus. Serum intact PTH is monitored weekly or biweekly, and bone-specific serum markers, serum vitamin D metabolites, serum albumin, blood chemistries, hemoglobin and hematocrit are monitored at selected intervals.
[0091] During the study, patients undergo routine hemodialysis (three times per week) using a 1.24 mM calcium dialysate and ingest calcium phosphate binders (such as calcium carbonate or calcium acetate) in an amount sufficient to keep serum phosphate controlled (6.9 mg/dL). Patients who develop persistent mild hypercalcemia or mild hyperphosphatemia during the treatment periods reduce their 1α-OH-vitamin D 2 to 4 μg three times per week (or lower). Patients who develop marked hypercalcemia or marked hyperphosphatemia immediately suspend treatment. Such patients are monitored at twice weekly intervals until the serum calcium or phosphorus is normalized, and resume 1α-OH-vitamin D 2 dosing at a rate which is 4 μg three times per week (or lower).
[0092] During the eight-week washout period, the mean serum level of PTH increases progressively and significantly. After initiation of 1α-OH-vitamin D 2 dosing, mean serum PTH decreases significantly to less than 50% of pretreatment levels. Due to this drop in serum PTH, some patients need to reduce their dosage of 1α-OH-vitamin D 2 to 4 μg three times per week (or to even lower levels) to prevent excessive suppression of serum PTH. In such patients, exhibiting excessive suppression of serum PTH, transient mild hypercalcemia is observed, which is corrected by appropriate reductions in 1α-OH-vitamin D 2 dosages.
[0093] At the end of the first 12-week treatment period, mean serum PTH is in the desired range of 130 to 240 pg/mL and serum levels of calcium and phosphorus are normal or near normal for end stage renal disease patients. At the end of the second 12-week treatment period (during which time 1α-OH-vitamin D 2 treatment is suspended and replaced by placebo therapy), mean serum PTH values markedly increase, reaching pretreatment levels. This study demonstrates that: (1) 1α-OH-vitamin D 2 is effective in reducing serum PTH levels, and (2) 1α-OH-vitamin D 2 is safer than currently used therapies, despite its higher dosages and concurrent use of high levels of oral calcium phosphate binder.
Example 6
Open Label Study of Elderly Subjects with Elevated Blood PTH from Secondary Hyperparathyroidism
[0094] Thirty elderly subjects with secondary hyperparathyroidism are enrolled in an open label study. The selected subjects have ages between 60 and 100 years and have elevated serum PTH levels (greater than the upper limit of young normal range). Subjects also have femoral neck osteopenia (femoral neck bone mineral density of 0.70 μg/cm 2 ).
[0095] Subjects are requested to keep a diet providing approximately 500 mg calcium per day without the use of calcium supplements. For a twelve week treatment period, subjects self-administer orally 2.5 μg/day 1α-OH-vitamin D 2 . (i.e., 2.5 μg doxercalciferol, 2.5% w/w benzyl alcohol, 0.5%-2.5% w/w TWEEN™-20, and 20 ppm BHT) At regular intervals throughout the treatment period, subjects are monitored for serum PTH levels, serum calcium and phosphorus, and urine calcium and phosphorus levels. Efficacy is evaluated by pre- and post-treatment comparisons of serum PTH levels. Safety is evaluated by serum and urine calcium and phosphorus values.
[0096] The administration of 1α-OH-vitamin D 2 is shown to significantly reduce PTH levels with an insignificant incidence of hypercalcemia, hyperphosphatemia, hypercalciuria and hyperphosphaturia.
Example 7
Clinical Studies of 1α,24-(OH) 2 D 2 in Treatment of Prostate Cancer
[0097] Patients with advanced androgen-independent prostate cancer participate in an open-labeled study of 1α,24-(OH) 2 D 2 . Qualified patients are at least 40 years old, exhibit histologic evidence of adenocarcinoma of the prostate, and present with progressive disease which had previously responded to hormonal intervention(s). On admission to the study, patients begin a course of therapy with intravenous 1α,24-(OH) 2 D 2 lasting 26 weeks, while discontinuing any previous use of calcium supplements, vitamin D supplements, and vitamin D hormone replacement therapies. During treatment, the patients are monitored at regular intervals for: (1) hypercalcemia, hyperphosphatemia, hypercalciuria, hyperphosphaturia and other toxicity; (2) evidence of changes in the progression of metastatic disease; and (3) compliance with the prescribed test drug dosage.
[0098] The study is conducted in two phases. During the first phase, the maximal tolerated dosage (MTD) of daily 1α,24-(OH) 2 D 2 is determined by administering progressively higher dosages to successive groups of patients. All doses are administered in the morning before breakfast. The first group of patients is treated with 25.0 μg of 1α,24-(OH) 2 D 2 (formulated with 2.5% w/w benzyl alcohol, 0.5%-2.5% w/w TWEEN™-20, and 20 ppm BHT). Subsequent groups of patients are treated with 50.0, 75.0 and 100.0 μg/day. Dosing is continued uninterrupted for the duration of the study unless serum calcium exceeds 11.6 mg/dL, or other toxicity of grade 3 or 4 is observed, in which case dosing is held in abeyance until resolution of the observed toxic effect(s) and then resumed at a level which has been decreased by 10.0 μg.
[0099] Results from the first phase of the study show that the MTD for 1α,24-(OH) 2 D 2 is above 20.0 μg/day, a level which is 10- to 40-fold higher than can be achieved with 1α,25-(OH) 2 D 2 . Analysis of blood samples collected at regular intervals from the participating patients reveal that the levels of circulating 1α,24-(OH) 2 D 2 increase proportionately with the dosage administered, rising to maximum levels well above 100 pg/mL at the highest dosages, and that circulating levels of 1α,25-(OH) 2 D 2 are suppressed, often to undetectable levels. Serum and urine calcium are elevated in a dose responsive manner. Patients treated with the MTD of 1α,24-(OH) 2 D 2 for at least six months report that bone pain associated with metastatic disease is significantly diminished.
[0100] During the second phase, patients are treated with 1α,24-(OH) 2 D 2 for 24 months at 0.5 and 1.0 times the MTD. After one and two years of treatment, CAT scans, X-rays and bone scans used for evaluating the progression of metastatic disease show stable disease or partial remission in many patients treated at the lower dosage, and stable disease and partial or complete remission in many patients treated at the higher dosage.
Example 8
1α-(OH)D 2
[0101] The study of Example 7 is repeated for the active vitamin D compound, 1α-(OH)D 2 (formulated with 2.5% w/w benzyl alcohol, 0.5%-2.5% w/w TWEEN™-20, and 20 ppm BHT). The results of the phase one study indicate that patients treated with the MTD of 1α-(OH)D 2 for at least six months report that bone pain associated with metastatic disease is significantly diminished. The results of the phase two study indicate that after two years, CAT scans, X-rays and bone scans used for evaluating the progression of metastatic disease show stable disease or partial remission in many patients treated at the lower dosage, and stable disease and partial or complete remission in many patients treated at the higher dosage. In summary, the present invention provides an improved formulation for lipophilic drug agents that are only slightly soluble in an aqueous vehicle. The formulation in addition to the lipophilic drug agent includes a lipophilic antioxidant, a non-ionic solubilizer or surfactant, and optionally, an agent which is an organic solvent/preservative.
[0102] All patents, publications and references cited herein are hereby fully incorporated by reference. In the case of conflict between the present disclosure and the incorporated patents, publications and references, the present disclosure should control.
[0103] While the present invention has now been described and exemplified with some specificity, those skilled in the art will appreciate the various modifications, including variations, additions, and omissions that may be made in what has been described. Accordingly, it is intended that these modifications also be encompassed by the present invention and that the scope of the present invention be limited solely by the broadest interpretation that lawfully can be accorded the appended claims. | The invention relates to pharmaceutical formulations of lipophilic therapeutic agents in which such agents are solubilized in largely aqueous vehicles, and processes for preparing and using the same. | 0 |
TECHNICAL FIELD
The invention is concerned with analytical technology and, more specifically, with the detection of a fluorescent species or fluorophore in a sample. This application is a division of application Ser. No. 09/186,248, filed 4 Nov. 1998, now U.S. Pat. No. 6,528,801.
BACKGROUND OF THE INVENTION
Fluorescent species or fluorophores emit fluorescent radiation when suitably stimulated by stimulating radiation. The emitted radiation can be used for chemical/biological analytic purposes, e.g. in determining whether a fluorophore of interest is present in a sample and in quantifying its concentration. One analytic technique of this type is disclosed in U.S. Pat. No. 5,171,534 to Smith et al. wherein DNA fragments produced in DNA sequencing are characterized on the basis of fluorescence of chromophores tagged to the fragments. Stimulating electromagnetic radiation may be monochromatic, or may include significant energy in a plurality of energy bands, e.g. as disclosed in U.S. Pat. No. 5,784,157 to Gorfinkel et al.
The stimulating radiation usually varies in time, either stochastically or regularly. Regular variation of the radiation intensity can be introduced artificially by modulating the intensity of the radiation source or the transmittance or reflectance of a filter element in the optical path. Regularly modulated radiation may be termed as encoded radiation if the temporal variation of the radiation is used as a carrier of information. Associated with such encoded radiation is a temporal code, i.e. a time-domain function which corresponds to the temporal evolution of the intensity of modulated radiation. A time-domain function can be formed as a linear combination of several suitable functions whose respective contributions to the linear combination can be quantified reliably. Suitable in this respect are sinusoidal functions of time, for example, oscillating at distinct frequencies.
In prior-art techniques, the encoded radiation is considered as continuous, with the time dependence of detected radiation intensity regarded as a continuous time-domain function.
Further background includes several known single-photon detection techniques for which W. R. McCluney, Introduction to Radiometry and Photometry , Artech House, 1996, pp. 114-122 provides a general introduction. Such techniques are designed for measuring modulated radiation, and they can be classified into two groups: (a) asynchronous photon counting and (b) synchronous detection. As described in Alan Smith, Selected Papers on Photon Counting Detectors, SPIE, Vol. MS 413, 1998, methods (a) of asynchronous photon counting involve the detection of a number of photons during a fixed time interval, e.g. one second, called the registration interval. These methods allow the determination of an average frequency of photon arrival. This frequency varies in time, either stochastically or regularly, and synchronous counting can be employed to measure the time variation. An essential limitation of this method is associated with the impossibility of measuring frequencies of modulation that are higher than the repetition rate of registration intervals. This difficulty is inherent in the principle of asynchronous counting, which is to keep track of the total number of photons received during the registration interval rather than register their times of arrival. A difficulty arises when the highest frequency f mod in the modulation spectrum of modulation radiation is comparable to or higher than the average frequency f phot of single-photon detection. In this case, if the frequency limit is increased by reducing the time interval chosen for counting, the technique becomes increasingly inefficient because the counter will count nothing during most registration intervals.
Methods (b) of synchronous detection involve measurement of the time of arrival of incident single photons. This time may be referenced to an “absolute” clock, or may be measured relative to or “synchronously with” a triggering excitation signal. The triggering signal may be associated with the arrival of the first of detected photons, for example. Such methods are particularly valuable for application to fast processes, e.g. the fluorescent decay of a single excited dye molecule as described, e.g., by D. Y. Chen et al., “Single Molecule Detection in Capillary Electrophoresis: Molecular Shot Noise as a Fundamental Limit to Chemical Analysis”, Analytical Chemistry, Vol. 68 (1996), pp. 690-696, typically requiring special electronics for handling fast temporal variations. An essential limitation of these methods is associated with the difficulty of maintaining records of high temporal resolution for a relatively long time. Thus, detecting photon arrivals at the temporal resolution corresponding to nanosecond time intervals over a one-second period requires acquisition of a billion data records. This makes methods of synchronous detection difficult to apply to the photometry of relatively slowly varying modulated single-photon fluxes.
SUMMARY OF THE INVENTION
We have recognized that, in detecting a fluorescent species in a sample, single-photon counting can be used to advantage, especially at low levels of fluorescent signal energy. Preferred detection techniques include methods in which (i) fluorescence-stimulating radiation is intensity-modulated in accordance with a preselected code, (ii) wherein it is the fluorescent radiation which is intensity-modulated with the preselected code, and (iii) wherein modulation with a preselected code is applied to a sample to influence a property, e.g. temperature, pressure, or an electric or magnetic field strength or frequency which functionally affects emitted fluorescent radiation.
Preferably, for registration of the signals from a sensing element of a single-photon detector, time of arrival is recorded, optionally in conjunction with registration of time intervals. Advantageously, in the interest of minimizing the number of pulses missed due to close temporal spacing of pulses, D-triggers can be included in counting circuitry.
The preferred techniques are generally applicable to photometry of time-encoded single-photon or particle fluxes. They involve measurement of time intervals between single-photon/particle arrivals combined with data analysis that permits decoding of the encoded radiation, i.e., discrimination between alternative possible codes and quantification of different combinations of mixtures of the codes. The techniques provide for the time intervals between successive pulses to be measured asynchronously, without requiring an external clock reference or special triggering signal. They provide for efficient measurement and decoding of time-encoded single-photon or particle fluxes.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic of a preferred first technique in accordance with the invention, using a modulated light source.
FIG. 2 is a schematic of a preferred second technique in accordance with the invention, using a dispersive element.
FIG. 3 is a schematic of a preferred third technique in accordance with the invention, involving temporal encoding of different spectral components of a fluorescent signal.
FIG. 4 is a schematic of a preferred fourth technique in accordance with the invention, for registration of temporal parameters of a stochastic sequence of pulses of constant or similar shape.
FIG. 5 is a schematic of a preferred fifth technique in accordance with the invention, wherein the fourth technique is integrated with the measurement of time intervals.
FIG. 6 is a schematic of a preferred sixth technique in accordance with the invention, wherein the fourth technique is augmented for further minimization of pulses lost to registration.
DETAILED DESCRIPTION
For purposes of the present description, no distinction need be made between “photon” and “quantum”, as each can result in a detector signal, typically an electrical signal or pulse for electronic processing in accordance with techniques of the invention. Use of other types of signal processing is not precluded, e.g. by opto-electronic or purely optical means. It is understood that, in alternative processing means, a detector signal or a pulse being processed can be other than an electric signal or pulse.
A. Single-Photon Detection in Methods for Fluorophore Identification
A special illumination technique is used, with a plurality of modulated narrow-band sources, each modulated according to its own distinguishable time-domain function. The narrow-band sources excite different fluorophores differently, so that the emitted fluorescent radiation is encoded with information about the nature and composition of illuminated fluorescent species. Photons are detected individually.
In a preferred first embodiment as illustrated by FIG. 1 , a modulated multi-band light source producing encoded radiation of excitation of fluorescence is combined with single-photon detection of encoded fluorescence signal.
FIG. 1 shows the light source 11 producing a radiation flux 12 which, via an optical illumination system 13 , is incident on the container 14 holding a fluorescent sample. The radiation flux 12 comprises a plurality of spectral bands, each modulated according to its own distinguishable time-domain function. Fluorescent radiation 15 emitted by the fluorescent sample is received by an optical receiver system, e.g. an objective 16 , and is directed to the optical input of a single-photon detector 17 . The output of the detector 17 is a stochastic stream 18 of electric pulses of similar shape, and information about the intensity of the received fluorescent radiation in a set time interval is contained in the average frequency of the pulses arriving in the interval. The temporal characteristics of the stream 18 of electric pulses are registered in a suitable form by the recorder 19 which is described below in further detail, in connection with FIGS. 4 and 5 . In a preferred embodiment, the stochastic stream of pulses is characterized in terms of the spacing in time between arrivals of successive pulses. The detection system may be complemented by communication means 120 for transferring the recorded information at an appropriate rate from the recorder 19 to a signal processor unit 121 .
A preferred second embodiment as illustrated by FIG. 2 can be viewed as an improvement over a known method for multicolor fluorescent detection, e.g. as disclosed in the above-referenced patent to Smith et al. In this technique, the fluorescent radiation emitted by an excited molecule is optically analyzed into distinct wavelength channels, e.g. by a prism or a diffraction grating. The intensity of fluorescent radiation in each of the wavelength channels is then determined by photometric means. In the preferred second embodiment, sensitivity is enhanced by the use of single-photon detection.
FIG. 2 shows radiation 22 from a modulated optical source 21 being focused by a lens 23 onto a fluorescent sample 24 . The modulated optical source 21 may produce one or several spectral bands that are modulated either together or independently with distinct time domain functions. Fluorescence 25 emitted by the sample 24 in response to the incident radiation 22 is directed by an objective 26 to an optical processor which comprises a dispersive element 27 , e.g. a prism or a diffraction grating, and a set 29 of single photon detectors (SPD). The dispersive element 27 effects spectral analysis of the fluorescent signal.
Each of the SPD's produces at its output a stochastic stream of electrical pulses of similar shape, and information about the intensity of the received fluorescent radiation is contained in the temporal characteristics of the stochastic stream. With reference to FIG. 2 , the temporal characteristics 210 from each SPD are registered by a recorder 211 whose structure is described below in further detail in connection with FIGS. 4 and 5 . In a preferred embodiment, also described below in further detail in connection with FIGS. 4 and 5 , the description of the stochastic stream of pulses is specified in terms of the time separations between arrivals of successive pulses. The detection system further comprises a signal processor unit 212 and means for transferring the recorded information at an appropriate rate from the recorder 211 to the signal processor unit 212 .
FIG. 2 illustrates combination of a modulated light source for excitation of fluorescence with a dispersive element for analyzing the fluorescent response into distinct spectral bands, and single-photon detection of modulated fluorescence in each of the spectral bands. Additionally, as in FIG. 1 , the modulated light source can be multi-band also, so that the radiation flux 22 comprises a plurality of spectral bands, each modulated according to its own distinct time domain function. In this case, a preferred technique is advantageous further in that different fluorescent species are distinguished both by their fluorescence emission spectrum and their fluorescence excitation spectrum. This enhances the fidelity of fluorophore identification.
A preferred third embodiment of the invention, illustrated by FIG. 3 , can be viewed as an improvement over a known technique for multicolor fluorescent detection, e.g. as applied according to the above-referenced patent to Smith et al. The known technique is combined with single-photon detection, using a modulation technique disclosed in U.S. patent application Ser. No. 08/946,414, filed Oct. 7, 1997 now abandoned, by Gorfinkel et al. In accordance with the latter technique, radiation reflected, transmitted, or fluorescently emitted by an object is encoded in such a way that the encoded radiation carries information about properties of the object, e.g. its color as characterized by reflected wavelengths, or the identity and quantitative content of fluorescent species present in the object. In the present embodiment of the invention, temporal encoding of different spectral components of a fluorescent signal is combined with single-photon detection of the encoded spectral components, for enhanced sensitivity.
FIG. 3 shows radiation 32 from optical source 31 being focused by an objective 33 onto a fluorescent sample 34 . In contrast to the embodiments illustrated by FIGS. 1 and 2 , the optical source 31 need not be modulated, and the radiation 32 may or may not be encoded. Fluorescence 35 emitted by the sample 34 in response to incident radiation 32 is directed by an objective 36 onto an optical processor which comprises a dispersive element 37 , e.g. a prism or a diffraction grating, and a set of optical modulators 38 . The dispersive element 37 effects spectral analysis of the fluorescence 35 . The spectral components are directed onto a set of optical modulators 38 which modulate in time the resolved spectral components in such a way that each different resolved spectral component is coded by a distinct function of time. The modulated components 39 of the fluorescent spectrum are combined by an optical element 310 into an optical flux 311 focused onto the optical input of the single-photon detector 312 . The output of the detector 312 represents a stochastic stream 313 of electrical pulses of similar shape, whose temporal characteristics are registered by the recorder 314 which is described below in further in connection with FIGS. 4 and 5 . In a preferred embodiment, also described below in further detail, the description of the stochastic stream of pulses is specified in terms of the temporal separation between arrivals of successive pulses. The detection system further comprises means 315 for transferring the recorded information at an appropriate rate to a signal processor unit 316 .
B. Single Photon Detection of Modulated Photon Fluxes
A preferred fourth embodiment of the invention is illustrated by FIG. 4 , of a method for registration of temporal parameters of a stochastic sequence of pulses of constant or similar shape.
The recorder of FIG. 4 operates with a controlled time resolution, controlled by a clock 45 which provides a regular sequence 46 of electrical pulses of constant shape which define the recording time intervals. A stochastic stream 41 of electric input pulses may originate from a sensing element of a single-photon detector which is typically a photo-multiplying tube (PMT) or an avalanche photo diode (APD).
The input pulses are not required to be of the same shape. With an APD, a special avalanche quenching circuit is used, either passive or active. Typically, the APD is pre-biased into its avalanche regime, for the first photon to initiate the avalanche. To prepare for the next photon arrival, the avalanche has to be quenched. It may be advantageous to use a so-called forced-quenching circuit which regularly quenches the avalanche condition, irrespective of whether an avalanche had actually been initiated, so that the arrival of photons and the time of quenching are not correlated. As a result, the avalanche-pulse duration will be stochastic also, depending on the time of photon arrival relative to subsequent quenching.
The stream of pulses 41 is directed to an n-state cyclic state-shift device or register 42 . Such a device has n successive stable states which may be numbered 0, 1, 2, . . . , n−1, with a change from a state k to its successor state k+1 being triggered by an input pulse, and with state n- 1 having state 0 as its successor state. Between input pulses, the n-state cyclic state-shift device 42 retains its state. For example, for a 2-state cyclic state-shift device a flip-flop can be used, having a sequence of stable states 0, 1, 0, 1, . . . , with each input pulse causing a transition from 0 to 1 or from 1 to 0. It is not necessary that the cyclic state-shift device return to its initial state when its state is read. This is in contrast to conventional photon counters where each reading of the counter data is accompanied by resetting the state of the counter back to the initial state.
For the sake of specificity, without limiting the invention, a flip-flop will be assumed in the following further description of FIG. 4 . The output from the flip-flop represents a stochastic sequence 43 of rectangular pulses of variable length. The sequence 43 is directed to a recording device 44 , which can be realized as an analog or digital signal recorder. The output signal 47 is transferred from the recording device 44 to a signal processor (not shown).
The recorder of FIG. 4 operates essentially in an asynchronous mode. But, in contrast to asynchronous photon counters which record the total number of photons arriving in a particular time interval, the preferred recorder records their times of arrival. Accuracy of recording of the arrival time is controlled by the clock 45 .
Time intervals are recorded without measuring the duration of the intervals. This function can be performed by one of a number of devices known to those skilled in the art, placed in an electrical circuit serially with the recorder and using its output signal 47 . For example, a general-purpose computer can be used to process the array of data acquired by the recording device 44 .
In some applications it may be advantageous to integrate in a single device the functions of registering the time intervals between successive single photon detections and measurement of the time intervals. Such an integrated preferred fifth embodiment of the invention is illustrated by FIG. 5 , for a stochastic stream of electric pulses 51 to which the shape and APD-quenching considerations concerning pulses 41 of FIG. 4 are applicable also.
As shown in FIG. 5 , a stochastic stream of electric pulses 51 is directed onto a flip-flop 52 . Its output represents a stochastic sequence 53 of rectangular input pulses of variable length. The sequence 53 is split three ways between counters 56 and 56 ′ and the controlled delay line 531 . The counter 56 receives the signal from the flip-flop directly, and the counter 56 ′ receives its signal through an inverter 521 . Thus, the counters 56 and 56 ′ are controlled by opposite-phase signals. Instead of a flip-flop, 52 , an n-state cyclic state-shift device can be used, as described with reference to FIG. 4 . Advantageously in this case, instead of two counters, 56 and 56 ′, up to n counters can be used.
A clock 54 provides a regular sequence 55 of electric pulses of constant shape which are counted by the counter 56 . Exemplarily, counter 56 is that counter whose input signal equals 1 at the time of clock pulse arrival. Advantageously, if the pulses 51 originate from and APD, the external quenching circuit which periodically forces the APD out of its avalanche regime can be synchronized by the clock 54 . There is no advantage in increasing the quenching frequency beyond the clock frequency which provides the basic discretization of time in the technique.
When a photon is detected and an electric pulse 51 enters the flip-flop 52 , one of the counters 56 and 56 ′ stops counting and the other begins counting. The one counter that has just stopped counting then contains the record 57 of how long the interval between two successive pulses has lasted, measured in terms of the number of clock cycles counted. The record 57 is transferred to the recording device 510 through a commutator 58 which serves to provide successive recording at intervals of time so that, while one time interval is being recorded, the next one is being measured. The commutator 58 is controlled by a switch signal which is derived by input signals 53 delayed by a characteristic time τ 1 corresponding to the response time of the counter 56 . The output of the commutator 58 represents a sequence of codes 59 describing the measured time intervals between detected photons. The codes 59 appear at the output of the commutator 58 in stochastic fashion corresponding to the detection of incoming photons and delayed by the time interval which is the sum of τ 1 and the response time τ 2 of the commutator itself. It is advantageous, therefore, to control the recording device 510 by switch signals which are derived from the input signals 53 , delayed from the moment of flip-flop switching by the time τ 1 +τ 2 . The output 514 of the recording device 510 represents the same sequence 59 of codes describing the measured time intervals between detected photons. In contrast to the sequence 59 , which is accumulated in time stochastically, the sequence 514 can be transmitted in a regular fashion, e.g. at a constant rate, for further processing.
Further to the technique illustrated by FIG. 4 , FIG. 6 illustrates inclusion of D-triggers for minimizing the number of pulses uncounted due their close spacing in time. Electric pulses from a single-photon detector output are directed through a fast switch 61 to the input C of a synchronous 8-bit binary counter 62 . The result of the count is passed to the storage register 63 as an 8-bit word or byte. To avoid changing the state of the counter 62 during storage, the synchronous pulse generator 65 shuts off the switch 61 simultaneously with sending a short record pulse to the input Wr of the storage register 63 . The output from the storage register 63 goes through the buffer 64 directly to the parallel port of a computer. Operational control error indicator is facilitate by a logic comparator 66 equipped with an LED (light emitting diode) 67 . The parallel computer port is synchronized by a synchronous pulse through a delay line 68 with a suitable delay τ. The same delayed pulse synchronizes the logic comparator 66 .
For an exemplary embodiment of the the technique illustrated by FIG. 6 , the following may be specified and realized: a discretization frequency of 125 KHz, a maximum number of pulses per discretization interval of 256, a minimum time between registered pulses of 20 ns, a maximum average frequency of registered pulses of 32 MHz, and a maximum fraction of missed photons of 0.25%.
Techniques of the invention can be used to advantage in a variety of applications involving encoded electromagnetic radiation, including multicolor luminescent detection based on fluorescence spectroscopy and fluorescence excitation spectroscopy. They can be used in general sensor applications with other modulated luminescence signals, e.g., those based on various spectroscopic techniques such as transmission, absorption, reflection, or Raman spectra, as well as electro-luminescence, chemiluminescence and the like. The techniques are especially useful for detecting weak signals, e.g. those prevalent in optical communication links where signals are transmitted over long optical fibers. | In analyzing radiation from a communication link, single-photon counting can be used to advantage especially at low levels of radiation energy, e.g. in the detection of optical radiation. Preferred detection techniques include methods in which (i) received optical radiation is intensity-modulated in accordance with a preselected code, (ii) wherein it is the optical radiation which is intensity-modulated with the preselected code, and (iii) wherein the radiation modulated with a preselected code is received. For registration of the signals received by a sensing element of a single-photon detector, time of arrival is recorded, optionally in conjunction with registration of time intervals. Advantageously, in the interest of minimizing the number of pulses missed due to close temporal spacing of pulses, D-triggers can be included in counting circuitry. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of co-pending U.S. Provisional Patent Application Ser. No. 62/297,470 filed Feb. 19, 2016, which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present disclosure is related to the field of sucker rod engineering and design, in particular, composite sucker rod assemblies for use in down-hole vertical lift oil extraction.
BACKGROUND
[0003] Sucker rods for use with vertical lift rod pumps, actuated by surface units (also referred to as surface units, rocking horse or pump jacks), are traditionally made from individual lengths of steel rod sections that are connected together by threaded couplings. The individual sucker rods are typically 25 feet, 30 feet or 37.5 feet in length and are connected together with couplings to form a sucker rod string. A typical sucker rod string is from 700 to 10,000 feet or more in length. The sucker rod string connects the vertical lift surface device to the down-hole pump unit. The design length of the traditional sucker rod is for service convenience. Work-over derrick rigs are brought into position above the well to pull the string and access the down-hole pump for service. The height of the work-over rig derrick determines the individual segment length of a sucker rod that can be pulled one at a time until the entire sucker rod string is pulled out of the well. The process to incrementally pull each sucker rod in order to access the down-hole pump for service requires noteworthy time, manpower and expense.
[0004] Fiberglass sucker rods the same lengths as steel sucker rods have also been used. Carbon fiber sucker rods as described in U.S. Provisional Application No. 62/003,437 and U.S. Provisional Application No. 61/903,194 (both of these applications are incorporated by reference in their entirety into this application) describe light-weight, low-stretch and corrosion resistance properties compared to steel and fiberglass rods.
[0005] Continuous steel sucker rod strings in a variety of forms have also been developed. One perceived advantage of continuous steel sucker rods is the elimination of the many threaded coupling joints that can fatigue and break on conventional sucker rod strings. Another advantage of continuous sucker rods is rapid deployment and removal from the well bore. However, continuous steel sucker rod strings are still heavy, subject to stress corrosion cracking and require large specialized spools and techniques to coil the product for transport, installation and service. A continuous carbon fiber sucker rod would be attractive to the user because of its lightweight, high strength, low stretch and corrosion resistance provided it could be reasonably coiled without damage. To be practical, a continuous length of sucker rod must be coiled to a diameter that can be easily transported over highways and narrow roads to deliver it to the well site.
[0006] A simple round monolithic pultruded carbon fiber rod could be made in a suitably long length from 1,000 to 10,000 feet for vertical lift oil well applications as a continuous length rod. The challenges to make a practical and effective continuous sucker are associated with the terminations and coiling. A continuous length carbon fiber rod for the application would need to be made in various sizes from ½ inch diameter to ¾ inch diameter to be suitable to be used in the top 60% or more of the sucker rod string. Monolithic pultruded carbon fiber rods in these diameters are very stiff in terms of bending. Considerable stress must be applied to coil such a product and the resultant strain can cause failure in the unidirectional composite due to the low inter-laminar strength associated with these materials. The end result is the coiled diameter must be unreasonably large (hence not easily transported) to manage the stress and strain energy and not cause damage to the carbon fiber rod. One early attempt at a continuous carbon fiber sucker rod utilized a pultruded rectangular strap configuration (approximately 3/16 inch thick by 1 and ¼ inch wide in cross section) that could be coiled in a reasonably small diameter. While convenient to coil, this product did not gain wide acceptance for other reasons primarily the strength of the terminations. Other attempts at a continuous carbon fiber sucker rod have utilized an oval cross section for the pultruded rod such that it can be coiled in a slightly smaller diameter than a round rod. Even an oval cross section suitable for the sucker rod application has considerable strain when coiled at a reasonable diameter that can be damaging to the composite. A secondary related but still important criterion for a continuous carbon fiber sucker rod is the termination required at each end. The termination must be as close to the strength of the mid-span of the rod as possible to be usable. A strong and reliable termination is difficult to make on a monolithic round or oval pultruded carbon fiber rod because the adhesively bonded terminus is only attached to the outer surface of the monolithic cross section rod and not to the individual fibers or strands that make up the carbon fiber rod.
[0007] It is, therefore, desirable to provide a continuous carbon fiber sucker rod that overcomes the shortcomings of the prior art.
SUMMARY
[0008] A continuous carbon fiber sucker rod assembly and its method of manufacture are provided.
[0009] Broadly stated, in some embodiments, a method can be provided for manufacturing a length of rod, the method comprising: drawing a plurality of pultruded carbon fiber rods through a collector die to organize the plurality of pultruded carbon fiber rods into a predetermined cross-section shape; drawing the plurality of pultruded carbon fiber rods through an extrusion die; and encapsulating the plurality of pultruded carbon fiber rods in a jacket of heated thermoplastic polymer by extruding the heated thermoplastic polymer about the plurality of pultruded carbon fiber rods through the extrusion die.
[0010] Broadly stated, in some embodiments, the method can further comprise spooling the encapsulated plurality of pultruded carbon fiber rods.
[0011] Broadly stated, in some embodiments, the method can further comprise cooling the encapsulated plurality of rods after exiting the extrusion die.
[0012] Broadly stated, in some embodiments, the method can further comprise fitting an end fitting cone onto at least one end of the length of rod, the end fitting cone further comprising a coupling pin.
[0013] Broadly stated, in some embodiments, a system can be provided for manufacturing a length of rod, the system comprising: at least one spools for providing a supply of a plurality of pultruded carbon fiber rods; a collector die for organizing the plurality of pultruded carbon fiber rods into a predetermined cross-section shape; an extrusion die configured for encapsulating the organized plurality of pultruded carbon fiber rods with heated thermoplastic polymer to form the length of rod; and a puller unit configured for pulling the encapsulated plurality of pultruded carbon fiber rods from the at least one spool through the collector die and the extrusion die.
[0014] Broadly stated, in some embodiments, the system can further comprise a take-up spool for spooling the length of rod.
[0015] Broadly stated, in some embodiments, the system can further comprise a cooling trough configured for cooling the length of rod after exiting the extrusion die.
[0016] Broadly stated, in some embodiments, the system can further comprise means for fitting an end fitting cone onto at least one end of the length of rod, the end fitting cone further comprising a coupling pin.
[0017] Broadly stated, in some embodiments, a length of rod can be manufactured using the method or the system as set forth above.
[0018] Broadly stated, in some embodiments, the length of rod can further comprise an end fitting cone fitted onto at least one end of the length of rod, the end fitting cone further comprising a coupling pin.
[0019] Broadly stated, in some embodiments, one or more of the pultruded carbon fiber rods can comprise a composition of carbon fiber and epoxy.
[0020] Broadly stated, in some embodiments, the composition can further comprise one or more from a group comprising of fiberglass, phenolic resin, vinyl ester resin, polyester resin, benzoxyzene resin and cyanurate ester resin.
[0021] Broadly stated, in some embodiments, the thermoplastic polymer can comprise one or more of a group comprising of high density polyethylene, polyetherimide, polyphenylenesulfide and polyetheretherketone.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1A is a side elevation cross-section view depicting a round carbon fiber sucker rod jacketed by an extruded polymer jacket and comprising 37 each 3.3 mm pultruded fiber rods.
[0023] FIG. 1B is a side elevation cross-section view depicting a round carbon fiber sucker rod jacketed by an extruded polymer jacket and comprising 30 each 3.3 mm pultruded fiber rods.
[0024] FIG. 1C is a side elevation cross-section view depicting an oval carbon fiber sucker rod jacketed by an extruded polymer jacket and comprising 29 each 3.3 mm pultruded fiber rods.
[0025] FIG. 1D is a side elevation cross-section view depicting a polygonal carbon fiber sucker rod jacketed by an extruded polymer jacket and comprising 37 each 3.3 mm pultruded fiber rods.
[0026] FIG. 1E is a side elevation cross-section view depicting a polygonal carbon fiber sucker rod jacketed by an extruded polymer tube drawn down onto 37 each 3.3 mm pultruded fiber rods.
[0027] FIG. 2 is a side elevation view depicting a system carrying out a continuous extrusion process, comprising strand spools, collector plate, cross head extruder, water chill trough downstream of the hot extrusion die, a caterpillar puller device and take up spool.
[0028] FIG. 3 is a side elevation view depicting one embodiment of a terminus end fitting and a short length of rod exiting the end fitting.
DETAILED DESCRIPTION OF EMBODIMENTS
[0029] In some embodiments, a continuous sucker rod assembly can be provided, comprising of a plurality of parallel carbon fiber and epoxy composite strength elements, referred to as “strands” to create a light weight, corrosion and fatigue resistant sucker rod assembly. While carbon fiber/epoxy composite strands are uniquely suited for the sucker rod application, other high strength fibers and matrix resins can be also used in the manner described herein. The individual pultruded strands, in some embodiments, can be 2 to 3 millimeters (“mm”) in cross-section when made from carbon fiber and epoxy resin although smaller and larger diameter strands can be employed depending on the application. The number of strands bundled together can determine the strength and stiffness of the continuous sucker rod. The individual strands can be held together by encapsulating the strands in a thermoplastic polymer, such as High Density Polyethylene (“HDPE”), Polyetherimide (“PEI”), Polyphenylenesulfide (“PPS”), Polyetheretherketone (“PEEK”) or any other suitable thermoplastic polymers for down-hole use, as well known to those skilled in the art.
[0030] In some embodiments, a method to encapsulate the bundle of pultruded carbon fiber strands can comprise the steps of running the bundle of strands through a cross-head extruder to form a polymer jacket over and around the bundled strands. By this method, long lengths of bundled rod on the order of 1,000 to 12,000 feet in length can be practically encapsulated to be handle-able and coil-able.
[0031] In some embodiments, the function of the thermoplastic encapsulation can be three-fold. First, it can provide a means of holding the bundle of parallel composite strands together. Second, it can allow the composite strands to twist a small amount when the sucker rod is coiled. Third, it can provide a wear-resistant encapsulation of the strength elements when they rub against the inner wall of the oil well tubing as the surface unit moves the rod up and down to actuate the down-hole pump.
[0032] When a carbon fiber sucker rod made in this manner is coiled, the bundled high modulus strands, which are parallel when encapsulated, can progressively twist since the thermoplastic encapsulation is an unreinforced and lower modulus material. The amount of twist can be very small at any specific location along the length of the sucker rod. However, the twist over a long length of sucker rod can be significant because it progressively develops as the sucker rod is coiled. The twist can be automatically and naturally removed as the sucker rod is deployed off the spool due to the elastic properties of the encapsulation polymer. This is in contrast to a monolithic pultruded composite rod wherein the outer fibers are put in extreme tension and the inner fibers are put in extreme compression when the rod is coiled and the resin matrix is too stiff to allow twist when coiling. Additionally, there is significant inter-laminar shear stress when a monolithic composite rod is coiled. This results in significant strain energy and potential damage to the composite.
[0033] In some embodiments, a carbon fiber rod can be manufactured in the following manner. The carbon fiber/epoxy composite strands can first be pultruded. Carbon fiber and epoxy can be used in some embodiments, but other high-strength fibers such as fiberglass and matrix resins such as phenolic, vinyl ester, polyester resin, benzoxyzene, cyanurate ester, amongst others well known to those skilled in the art, can be used in combination with the fiber to make the strands. In some embodiments, the strands can be pultruded in multiple streams at lengths of 2,000 to 12,000 feet, the length dependent only on the length of the carbon fiber spool and coiled on individual spools after pultrusion. Because of the small size of the individual strands, they can be coiled on conventional cable spools as small as 18 inches in diameter when the rods are in the 2 to 3 mm diameter range.
[0034] After pultrusion, the strands can be individually unspooled and brought together into a parallel bundle using collector plates. There can be a generally round natural nesting geometry to the bundle since it is made of a plurality of parallel strands that are typically round. For example, a bundle of 37 pultruded rods ( 12 ) of 3.3 mm diameter can form sucker rod ( 10 ) having a polygon cross-section shape approximately ¾ inches round, as shown in FIG. 1A , wherein pultruded rods ( 12 ) can be encapsulated in extruded HDPE jacket ( 14 ). Other naturally generally round bundles, meeting the strength and stiffness requirements of typical oil wells, can use 14, 19 or 30 strands of pultruded rods ( 12 ) to form sucker rod ( 10 ) encapsulated in jacket ( 14 ), although other combinations can be used. FIG. 1 B shows a bundle comprising 30 pultruded rods ( 12 ) encapsulated in jacket ( 14 ) to form sucker rod ( 10 ). The bundled configuration can also be tailored to create a generally oval cross section that is more easily coiled. FIG. 1C shows an oval bundle comprising 29 pultruded rods ( 12 ) encapsulated in jacket ( 14 ) to form sucker rod ( 10 ). In some embodiments, sucker rod ( 10 ) can be formed as a bundle with a polygonal cross-section shape. As an example, FIG. 1D shows a polygonal bundle comprising 37 pultruded rods ( 12 ) encapsulated in jacket ( 14 ) to form sucker rod ( 10 ). In this example, sucker rod ( 10 ) comprises a 6-sided polygonal cross-section shape although it is obvious to those skilled in the art that sucker rod ( 10 ) can comprise a polygonal cross-section shape of any number of sides.
[0035] In some embodiments, the composite strands can be run through a cross-head screw extrusion machine die. Referring to FIG. 2 , in some embodiments, a plurality of pultruded rods ( 12 ) can be drawn from spool ( 16 ) (which can include up to 37 separate 4 foot diameter spools, each containing up to 10,000 feet of 3.3 mm diameter pultruded carbon rod), and drawn through die ( 18 ). In some embodiments, die ( 18 ) can be perfectly round in cross section even though the bundle of strands may be a polygon. Thermoplastic polymers such as HDPE, PEI, PPS or PEEK can be introduced to extrusion die machine ( 20 ) in pellet form, which can be stored in pellet hopper ( 22 ) for feeding into die machine ( 20 ). In some embodiments, extrusion die machine ( 20 ) can melt and pressure the thermoplastic pellets into extrusion die machine ( 20 ) as rods ( 12 ) are pulled by traction unit ( 26 ) just downstream of extrusion die machine ( 20 ). In some embodiments, extrusion die machine ( 20 ) can be configured to form a sucker rod having a round cross-section shape, as shown in FIGS. 1A and 1B . In some embodiments, extrusion die machine ( 20 ) can be configured to form a sucker rod having an oval cross-section shape, as shown in FIG. 1C . In some embodiments, die ( 20 ) can be configured to form a sucker rod having a polygonal cross-section shape, as shown in FIG. 1D .
[0036] In other embodiments, an HDPE tube can be co-extruded and continuously drawn down onto the outside of rods ( 12 ) as HDPE tube ( 15 ) cools (as well known to those skilled in the art), wherein the drawn down HDPE tube ( 15 ) can comprise a “leather-like” outer surface once it has been drawn down onto rods ( 12 ) to form sucker rod ( 10 ), as shown in FIG. 1E .
[0037] In some embodiments, traction unit ( 26 ) can comprise a dual caterpillar tractor belt mechanism. In other embodiments, traction unit ( 26 ) can comprise reciprocating gripper pullers as used in pultrusion machines. The feed rate of thermoplastic polymer to fully encapsulate the bundle of carbon fiber strands can be proportional to the speed in which the strands are pulled through the extrusion die. Composite strands can be drawn from their respective supply spools as the product is pulled through the collector plates and the extrusion die in a continuous manner. In some embodiments, water chill bath ( 24 ) can be placed between hot extrusion die machine ( 20 ) and puller system ( 26 ) to cool finished sucker rod ( 10 ) product exiting die machine ( 20 ), to be spooled onto take up spool ( 28 ) for transport to a well site.
[0038] A short length of exposed strands (with no extruded jacket) can be left at the beginning and the end of the continuous length of sucker rod to facilitate affixing the terminus as described in U.S. Provisional Application No. 62/003,437 and U.S. Provisional Application No. 61/903,194, which are incorporated into this application by reference in their entirety. Referring to FIG. 3 , as an example, sucker rod ( 10 ) can be fitted with end fitting cone ( 30 ) using the techniques as described in these applications, wherein cone ( 30 ) can further comprise wrench flats ( 32 ) and threaded coupling pin ( 34 ). Wrench flats ( 32 ) enable the use of a wrench to engage flats ( 32 ) for threading coupling pin ( 34 ) into an adjoining coupler as well known to those skilled in the art (not shown) for coupling to another length of sucker rod ( 10 ) (not shown). The resultant product can then be a continuous long length of carbon fiber sucker rod ( 10 ) on the order of 1,000 to 12,000 feet in length, or more.
[0039] While the assemblies and methods described herein can be used as a continuous composite sucker rod, one skilled in the art will immediately recognize that such assemblies and methods can be used for making any long length of composite cable that needs to be stored in a reasonable diameter without damage due to coiling.
[0040] Although a few embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications can be made to these embodiments without changing or departing from their scope, intent or functionality. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the invention is defined and limited only by the claims that follow. | A continuous length composite sucker rod assembly is provided for use in down-hole wells. The assembly can include a plurality of parallel composite strands forming an elongate rod. The strands can be encapsulated with a thermoplastic polymer by co-extrusion. A terminus can be affixed to both ends of the length of sucker rod by splaying the strands out into a conical cavity within the terminus and casting a polymer wedge plug. The resulting sucker rod assembly can be readily coiled in a transportable diameter by virtue of the composite strands being able to twist when the rod is coiled and untwist when the rod is un-coiled. | 4 |
FIELD OF THE INVENTION
This invention relates to the field of heat sinks and in particular to heat sinks for use in small electronic devices or devices in which there is little clearance for heat sinks.
BACKGROUND OF THE INVENTION
A great deal of effort in the electronics industry today is devoted to trying to produce the electronic product in the smallest possible package, while at the same time enhancing the product's performance. Nowhere is this trend more evident than in the computer field, where personal computers have become increasingly smaller over the last few years. At the same time, the manufacturers have also tried to make the smaller computers as fast and as powerful as possible. This creates a problem in terms of heat dissipation.
In general, the more powerful the electronic semiconductor, the more heat it generates. Unless the heat is dissipated, the semiconductor may fail. There are a variety of well known devices for dissipating such heat. These include various finned heat sinks, which dissipate heat through the surface area of metal fins, and which may be and often are in connection with computers used in conjunction with electric fans, which drive air through the fins to enhance their cooling effect. Other types of heat sinks are also used, as well as other cooling devices such as cooling tubes, which extend around the devices and which carry a flow of some cooling medium. The problem with these existing devices is that they tend to take up a good deal of space. In fact, in many applications, the heat sinks, fans or other cooling devices take up more space than the semiconductors they are designed to cool. Moreover, these heat sinks and other related devices tend to take up "vertical" space. That is they tend to have a significant height, so that it becomes difficult to put them in a thin electronics package, at least without so severely downsizing them as to make them generally ineffective. By the same token, the effort to minimize the package for electronic devices such as portable computers by making them as thin and small as possible, while not sacrificing speed and power, makes the need for such heat dissipation means in these packages all the more acute.
Accordingly, an object of the invention is to provide a heat sink, which provides a significant amount of heat dissipation, while taking up very little space, particularly very little vertical space.
SUMMARY OF THE INVENTION
The invention here is a heat sink which comprises a thin plate made of a heat conducting material, which plate includes a series of small chimneys extending therethrough. The plate is adapted to fit over an entire circuit board, contacting the electronic semiconductors on the board, with the chimneys being spaced inbetween. The chimneys are designed to facilitate natural or forced airflow through the plate by reducing the pressure drop associated with such openings. When in use, the heat sink of this invention takes up virtually no vertical space, while providing effective heat dissipation for a variety of electronic components on a board.
In the preferred embodiment, a heat sink according to the invention comprises a flat copper plate coated with an electrically insulating, black epoxy paint. The plate is sized in relation to the board on which it will be used, but six inches by 9 inches would be a common size. The plate is 20 thousandths inches thick. The heat sink includes a series of holes interspaced over its surface. The location of the holes depends upon the configuration of the electronic elements on the board to which the heat sink is intended to be applied. In general, however, the holes are disposed so as to be located above the pathways between the electronic devices on the board, once the heat sink is in place. The holes are not cylindrical. Instead, they have a wide bottom and curved, tapering sides extending upwardly to a narrower open top disposed about a tenth of an inch above the rest of the plate of the heat sink. The heat sink of the preferred embodiment also includes alignment holes to assure proper placement of the heat sink on the board over the electronic devices. Proper placement is also aided by a series of indents on the underside of the heat sink, which indents serve to help properly align the heat sink with the electronic devices over which the heat sink is to be placed. The heat sink is held to the board by connectors at its corners, and double-faced, heat conductive tape attaches the semiconductive devices on the board to the underside of the heat sink of this invention. In operation, the heat sink dissipates heat from all the electronic devices on the board to which the heat sink is attached, and the holes or chimneys provide airflow passages with low pressure drops to facilitate cooling airflow around the electronic devices to further dissipate the heat they generate. At the same time, the heat sink of this invention takes up very little vertical space on the board.
DESCRIPTION OF THE PREFERRED EMBODIMENT
I turn now to a complete description of the preferred embodiment, after first briefly describing the drawings.
FIG. 1 is a perspective view of a heat sink according to this invention mounted on a printed circuit board;
FIG. 2 is a top view of the heat sink of FIG. 1;
FIG. 3 is an expanded view of a portion of the side of the heat sink of FIG. 1;
FIG. 4 is an expanded view of one of the chimneys of the heat sink of FIG. 1; and
FIG. 5 is an expanded view of an edge of the heat sink of FIG. 1.
STRUCTURE
Referring to FIG. 1, a heat sink according to the invention is shown at 10. The heat sink 10 generally comprises a plate 20 having a top surface 22 and a bottom surface 24, with a series of chimneys 30 extending therethrough. The heat sink 10 is shown in FIG. 1 attached to a printed circuit board 40, upon which is mounted a number of semiconductor devices 50 (only partially shown in FIG. 1).
Referring to FIGS. 1 and 2, the plate 20 is rectangular and has approximately the same length and width as the printed circuit board 40. In the preferred embodiment, these dimensions are six inches by nine inches. Other sizes and shapes are possible without departing from the invention herein, and it is not always necessary for the heat sink 10 to cover the entire printed circuit board 40. The plate 20 is made of copper in the preferred embodiment and is about 0.020 inches thick. Other materials may, of course, be used. For example, aluminum may be used for applications where the heat needed to be dissipated is not as great, or where a lighter material is needed. Other metals may also be used. The plate 20 is coated with a black epoxy paint which provides electrical but not thermal insulation. Such a paint is CC3-341 from Cast Coat, Inc. of West Bridgewater, Mass. The paint covers the entire plate 20 including both the top surface 22 and the bottom surface 24.
As shown in FIGS. 3 and 4, all the chimneys 30 on the plate 20 are identical and generally conical in cross section. Each such chimney 30 has a bottom opening 32 disposed on the bottom surface 24 of the plate. In the preferred embodiment, the diameter of the bottom opening is 0.400 inches for each chimney, although other dimensions are possible. As best shown in FIG. 4, each chimney 30 has an inwardly curved sidewall 34 which extends from the bottom opening 32 to a top opening 36. The top opening has a diameter of 0.200 inches in the preferred embodiment, and the sidewall 34 extends 0.100 inches above the top surface 22. Other dimensions are possible here. With these dimensions, however, the chimney 30 has an internal area several times greater than that of a hole with a 0.200 inch diameter through the plate 20. In the preferred embodiment, the chimneys 30 are created by a conventional extrusion process.
As best shown in FIG. 2, the placement of the chimneys 30 is not random. In FIG. 2, there is shown in dotted display beneath the plate 20, the location of the semiconductor devices 50 to be cooled by the heat sink 10. Also shown in dotted display is the location of other electronic components 60 mounted on the particular printed circuit board 40 shown in the Figures. This configuration of semiconductors 50 and other electronic components 60 depends upon the printed circuit board 40 with which the heat sink 10 is to be used. The arrangement shown here is for illustrative purposes only. As is typical of many printed circuit boards, the semiconductors 50 and other electronic components 60 are arranged more or less in rows so that open, air-flow passageways 62 exist between components. In general, as shown in FIG. 2, the chimneys 30 are disposed in the plate 20 above the intersection of such passageways 62 on the board 40 and above otherwise open areas on the board 40.
As also shown in FIG. 2, the plate 20 has a series of location holes 26 therethrough. The location holes 26 are disposed over opposite corners of the semiconductors 50 when the heat sink 10 is properly aligned over the board 40. The holes 26 allow a visual means by which this alignment can be determined. The location of the hole 26 depends, of course, on the location of the semiconductors 50 on the particular board 40 and thus may vary from board to board. In addition, for key semiconductors, such as microprocessors, a triangular inspection hole 28 is provided so that a visual inspection of pin number one of the microprocessor may be made when the heat sink 10 is in place so that it can be determined whether or not pin one on the device is properly positioned.
As shown in FIG. 3, another alignment means is provided in the form of ridges 29 which extend from the bottom surface 24 of the plate 20. The ridges, which are about 0.030 inches high in the preferred embodiment, are disposed to be adjacent to each semiconductor 50. As a result, when the heat sink 10 is put in place, the ridges 29 provide a guide for correct positioning over the semiconductors 50.
As shown in FIGS. 1 and 5, the heat sink 10 has a pair of sides 12, 14. The sides 12, 14 extend down the lengthwise sides of the plate 20. As shown in FIG. 5, the sides 12, 14 are formed by folding over the edges of the plate 20, although other means could be used. Connectors 16 are attached to the sides 12, 14 at their ends, and the connectors 16 are used to attach the heat sink 10 to the printed circuit board 40. Any standard type of connector may be used. The connectors used in the preferred embodiment are of the type covered by U.S. patent application Ser. No. 804,804, filed on Dec. 9, 1991. As a result of this configuration with the sides 12, 14, the heat sink 10 is open at each widthwise end.
It is also possible to have the sides 12, 14 extend completely around the plate 20 so as to partially close off the ends. While this restricts airflow somewhat, it is useful in situations where the board needs to be shielded from electro-magnetic radiation (EMR) or radio frequency interference (RFI).
OPERATION
In operation, the heat sink 10 is made so that the chimneys 30, inspection holes 26, 28 and ridges 29 correspond, as indicated previously, to the configuration of the printed circuit board 40 on which the heat sink 10 is to be used. The semiconductors 50, which are to be attached directly to the heat sink 10, each have a piece of double-sided, heat conductive tape 52 placed on its exposed upper surface. The heat sink 10 is then lined up with the semiconductors 50 using the ridges 29 and inspection holes 26, 28. When properly aligned, the connectors 16 are attached to the board 40 by inserting them into holes (not shown) in the board, and the heat sink 10 is then attached to the board 40. The tape 52 thermally connects the semiconductors 50 to the bottom surface 24 of the plate 20 of the heat sink 10. In operation, heat from the semiconductors 50 is dissipated by the heat sink, which has a significant amount of surface area compared to the semiconductors 50. In addition, to aid in the cooling, the configuration of the chimneys 30 creates a low pressure drop between the air adjacent to the bottom surface 24 and the top surface 22 of the plate 20. As a result, air flows easily up through the chimneys 30 from the underside of the plate 10 to the upper side, by means of natural convection, without the need for forced air blowing. Of course, forced air blowing may be used with the heat sink 10 of this invention, and applied at one of the open ends not covered by a side 12, 14.
Other embodiments will occur to those skilled in the art. | A heat sink comprising a thin plate made of a heat conducting material, which plate includes a series of small tapered chimneys extending therethrough, the plate being adapted to fit over and parallel to an entire circuit board, thermally connecting with the semiconductors on the board, the chimneys being spaced inbetween the semiconductors and facilitating natural or forced airflow from the area between the plate and the printed circuit board to the area outside by means of the low pressure drop created by their tapering, the heat sink taking very little vertical space in the electronics package including the printed circuit board while providing effective heat dissipation and shielding from electro-magnetic radiation and/or radio frequency interference for the semiconductors on the board. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under the Paris Convention on Australia Patent Application No. 2015904166 filed on Oct. 13, 2015, the entire content of which is herein incorporated by reference
TECHNICAL FIELD
[0002] The present invention relates to recreational vehicles such as caravans and to awnings for recreational vehicles. Particular applications of the invention include awning assemblies for camper trailers typically of the wind up type.
BACKGROUND OF THE INVENTION
[0003] It is known to provide a canopy or rollout awning for a recreational vehicle such as a caravan. The awning may be supported at its outer edges by arms that are pivotally mounted to the side of the recreational vehicle and which can be pivoted out to support the outer edges of the awning.
[0004] When the recreational vehicle is parked the awning can be extended laterally from a side of the recreational vehicle to provide shade and an undercover outside area adjacent the recreational vehicle. Whilst the recreational vehicle is travelling the awning is retracted and the arms are brought against the side of the recreational vehicle.
[0005] A problem that arises with canopy support arms is that they are presently not well suited for use with camper trailers. Camper trailers, or as they are sometimes called, expandable caravans have a lower rigid base and wall section and an upper, flexible wall and roof section. During towing of a camper trailer the upper section is collapsed down upon the lower base section. In the collapsed configuration towing of the camper trailer is straightforward due to its low profile. Once the camper trailer is parked the top section is erected so that there is sufficient headroom within the camper trailer for occupants.
[0006] To date it has not been convenient to affix a rollout awning to a side of a camper trailer because arms have not been known which are suitable for locating vertically to the side of the camper trailer in the collapsed configuration and which are able to support an outer edge of the awning once the camper trailer is in the erected configuration.
[0007] It is an object of the present invention to provide an arm that is suitable for supporting the rollout awning of a camper trailer.
SUMMARY OF THE INVENTION
[0008] According to a first aspect of the present invention there is provided an awning support arm for a camper trailer including:
[0009] an outer member formed with an elongated opening;
[0010] an intermediate member slidable relative to the outer member;
[0011] an inner member slidable relative to the intermediate member;
[0012] an outer fastening assembly arranged to hold the outer member fast with the intermediate member; and
[0013] an inner fastening assembly arranged to hold the intermediate member fast with the inner member the inner fastening assembly including a user operation portion that extends through the elongated opening of the outer member;
[0000] wherein the members may be slid relative to each other to assume an extended configuration or a retracted configuration and maintained in either configuration by means of said fastening assemblies.
[0014] In a preferred embodiment of the present invention the outer fastening assembly is mounted to the outer member and includes a pin that penetrates a first hole formed through the intermediate member to fasten the intermediate member in an extended configuration relative to the outer member.
[0015] It is preferred that a second hole be formed through the intermediate member at a distance from the first hole whereby the pin of the outer fastening assembly penetrates the second hole in the retracted configuration.
[0016] In a preferred embodiment of the invention the outer fastening assembly includes a spring loaded plunger which is biased to urge the pin toward the intermediate member.
[0017] Preferably the inner fastening assembly includes at least one threaded member to which a user operation handle is attached wherein the threaded member engages a clamping member disposed within the inner member, whereby tightening of the threaded member urges opposed surfaces of the inner member and the intermediate member into abutment to thereby fix the inner member in a desired position relative to the outer member.
[0018] The inner fastening assembly may include two threaded members disposed toward opposite ends of the clamping member and threadedly engaged therewith.
[0019] In a preferred embodiment of the invention each of the inner member, the outer member and the intermediate member is formed with elongate openings to accommodate sliding motion of members protruding from adjacent of said arms.
[0020] According to a further aspect of the present invention there is provided a camper trailer awning assembly including:
[0021] a pair of support arms pivotally attached at lower ends thereof to a side of the camper trailer, each of the support arms being of the previously described type;
[0022] a member for supporting an edge of an awning disposed between upper ends of the support arms; and
[0023] a pair of awning support struts extending from above the lower ends of the support arms and arranged to brace each of the support arms in their extended configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:
[0025] FIG. 1A is a front view of a camper trailer with the arms and the roof of the camper trailer retracted.
[0026] FIG. 1B is a side view of a camper trailer h the arms and the roof of the camper trailer retracted.
[0027] FIG. 1C is a front view of a camper trailer with the roof expanded and the arms in an extended configuration supporting an outer edge of the awning.
[0028] FIG. 2A is a plan view of an arm in an extended configuration.
[0029] FIG. 2B is a plan view of an arm in a retracted configuration.
[0030] FIG. 3 depicts an intermediate member of the arm.
[0031] FIG. 4 is a partially cutaway and cross sectional view of the arm.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring now to FIGS. 1A and 1B , there is shown a camper trailer or “expandable” caravan 100 in front and side view respectively.
[0033] As shown in FIGS. 1A and 1B the camper trailer 100 is in a retracted configuration wherein its pop-top roof 107 is pulled down for storage or travel. Telescopic awning support arms 1 , each according to a preferred embodiment of the present invention, are mounted to the side of the camper trailer 100 toward its forward and rear ends.
[0034] An awning roller tube 102 is attached between upper ends of the left and right arms 1 for supporting an outer edge of awning canopy 42 (shown in FIG. 1C ).
[0035] FIG. 1C is a front view of the camper trailer 100 in use with the pop-top roof 107 extended upwardly. In this configuration the left and right arms 1 are extended, in a manner that will be explained, with their upper ends supporting an outer edge of awning canopy 42 . The awning canopy 42 extends from an awning track 104 to the awning roller tube 102 and tilts downwardly to allow water to runoff and away from the side of the caravan 100 . Left and right tension struts 3 attach proximally towards an upper edge of the camper trailer pop-top roof and distally to the remote ends of the left and right arms 1 . The triangulation of the caravan side wall, tension struts 3 and arms 1 provides support to the awning canopy 42 in the extended configuration shown in FIG. 1C .
[0036] The arms 1 may also be unhinged from the lower support bracket 113 fastened to the chassis or lower portion of the camper trailer to stand the arms 1 on the ground in an upright vertical position if desired.
[0037] It may be observed from FIG. 1C that the arm 1 includes three members, an outer member 5 , to the free end of which the awning roller tube 102 is attached, an intermediate member 7 which slides within the outer member 5 and an inner member 9 , which slides within the intermediate member 7 . The lower end of the inner member 9 is pivotally attached to the side of the caravan via bracket 113 .
[0038] Referring to FIGS. 2A and 4 the three members are each provided in the form of a U shaped channel with medially directed returns defining an elongated opening or slot therebetween, e.g. opening 109 of the outer member 5 as shown in FIG. 2A .
[0039] FIGS. 2A and 2B are plan views of arm 1 in erected and retracted configurations respectively. The outer member 5 is formed with a plunger pin opening formed through one side toward its bottom end. An outer fastening assembly 23 in the form of a spring loaded plunger is mounted to the outer member 5 so that a plunger pin 25 of the plunger locates coaxially with the plunger pin opening. In the extended configuration shown in FIG. 2A the plunger pin 25 penetrates through the plunger pin opening in the side of the outer member 5 and thence through a hole 22 that is formed through the side of intermediate member 7 toward the intermediate member's upper end. Accordingly, in the configuration shown in FIG. 2A the plunger pin 25 retains the intermediate member 7 and the outer member 5 so that they are non-sliding and extended with respect to each other. A support bracket 11 is located at the upper end of the outer member 5 . The support bracket is in the form of a U channel having triangular sides with a pin 15 therebetween. The tension strut 3 connects to the arm 1 by means of pin 15 to thereby provide support for the awning in the extended configuration as shown in FIG. 1C .
[0040] The tension strut 3 may typically consist of a central pivot folding arm 1 with an air ram tensioning strut within a box profile member pivoting inside a U channel with a locking pin.
[0041] Referring again to FIG. 2A , an inner fastening assembly in the form of clamp or clamping assembly 120 (shown in cross section in FIG. 4 ) is provided to clamp the intermediate member 7 and the inner member 9 together at a desired position relative to each other. The clamp 120 includes of two fasteners 13 a, 13 b, (generally referred to as “ 13 ”). Each fastener 13 has an operator handle 122 that is concentrically mounted to a threaded shaft 124 . The shaft proceeds through openings 20 in the intermediate member 7 and threadedly attaches to clamp plate 17 . Clamp plate 17 is located inside the inner member 9 so that rotating the operator handle 122 in turn rotates the threaded shaft 124 thereby bringing the clamping plate 17 toward the inner member 9 and causing it to be clamped against the intermediate member 7 . Consequently the inner member and the outer member may be clamped together at a desired position.
[0042] Referring now to FIG. 2B , the arm 1 is shown in a collapsed or retracted configuration. To bring the arm 1 from the extended configuration of FIG. 2A to the retracted configuration of FIG. 2B a user firstly withdraws the handle of plunger assembly 23 in order that the plunger pin 25 is brought clear from the hole 22 of the intermediate member 7 . Once that is done the outer member 5 is free to slide and is then slid downwards until the plunger pin 25 registers with a second hole 24 that is formed through the side of intermediate member 7 towards its lower end. As the plunger pin 25 registers with the second hole it penetrates therethrough and so locks the outer member 5 in a retracted configuration relative to the intermediate member 7 . The handles 122 a and 122 b of the clamping assembly 120 are then rotated to loosen the clamping plate 17 and so remove the clamping force holding the intermediate member 7 fast with the inner member 9 . The intermediate member, along with the outer member that is locked to it, is then slid down the inner member 9 to the retracted position shown in FIG. 2B . In the retracted position the clamp handles 122 a and 122 b are tightened to clamp the intermediate member 7 to the inner member 9 .
[0043] It will therefore be realized that the arm 1 constitutes an effective and convenient awning arm for a rollout awning fitted to a camper trailer. The arm can be quickly extended in an initial operation by means of the outer fastening assembly, e.g. plunger 23 , wherein the outer member is extended from the retracted configuration (relative to intermediate member 7 ) that is defined by second hole 24 , to the extended configuration that is defined by hole 22 . A fine extension adjustment can then be made by use of the inner fastening assembly, e.g. clamp 120 , which allows for the intermediate member and the inner member to be clamped together at a desired position relative to each other. Consequently, the arm is convenient to use and may be readily extended for supporting the awning as shown in FIG. 1C and also readily retracted when it is time to move the camper trailer as shown in FIGS. 1A and 1B .
[0044] Furthermore, by virtue of the arm composed of three sliding members it has, in its extended configuration, an overall length that is sufficient to support the outer edge of the awning whilst the camper trailer is at its full height. Nevertheless, in its retracted configuration the arm is able to assume a reduced length that falls within the height of the side of the camper trailer when the caravan is retracted as shown in FIGS. 1A and 1B . Consequently, the arm is highly suitable for use with camper trailers.
[0045] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and; “includes” and its variations, are used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described includes preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art. | An awning support arm for a camper trailer including: an outer member formed with an elongated opening; an intermediate member slidable relative to the outer member; an inner member slidable relative to the intermediate member; an outer fastening assembly arranged to hold the outer member fast with the intermediate member; and an inner fastening assembly arranged to hold the intermediate member fast with the inner member the inner fastening assembly including a user operation portion that extends through the elongated opening of the outer member; wherein the members may be slid relative to each other to assume an extended configuration or a retracted configuration and maintained in either configuration by means of said fastening assemblies. | 4 |
BACKGROUND OF THE INVENTION
[0001] This application relates to an electrical generation system and method where a constant frequency generator is associated with a gas turbine engine and is capable of operating in both a start mode (as a starter) and a generate mode (as a generator).
[0002] Aircraft typically utilize gas turbine engines, which include turbine rotors that rotate to provide power. Generators are connected to each turbine engine in order to produce electrical energy, which is then utilized to power onboard electronic systems, as well as for other uses on the aircraft.
[0003] A system using a variable frequency generator and a constant frequency generator is described in U.S. patent application Ser. No. 12/406,992 to LeGros, and is hereby incorporated by reference. Typical systems constructed with the combined generator types described in the LeGros application utilize the variable frequency generator in a start mode where the generator acts as a motor and provides an initial motive force to rotate (start) the gas turbine engine. The variable frequency generator is also used in a generate mode, once the gas turbine engine has been started, to generate electrical power. The frequency of the generated electrical power varies depending on the speed of a rotor within the gas turbine engine.
[0004] The system described in the LeGros application also uses a constant frequency generator which functions only in generate mode, and is switched off during start mode. A constant frequency generator generates power having a constant frequency regardless of the rotor speed. One example constant frequency generator can be found in U.S. Pat. No. 6,838,778 to Kandil, et al., which is hereby incorporated by reference.
[0005] In order for a constant frequency generator, such as the one described in U.S. Pat. No. 6,838,778 to operate in a start mode, a torque converter, pony motor, and a two overrunning (start) clutches are included within the generator. In addition, a pony motor controller is required to power the pony motor which is within the constant frequency generator. The pony motor is used to get the constant frequency generator to synchronous speed, which then is transferred to an AC (main) bus. The torque converter is then allowed to fill with oil which allows the synchronous motor torque to provide a motive force to start the turbine engine. Many practical applications, such as an aircraft power generation system, require the minimization of the size and weight of each component. The addition of a torque converter and a pony motor runs contrary to this concept.
SUMMARY OF THE INVENTION
[0006] A generation system and method utilizes a constant frequency generator to generate electrical power. The generation system has a motor controller which controls the constant frequency generator while operating in a start mode. The motor controller is used to generate various controlled frequencies during generate mode. Also disclosed and claimed is an aircraft electrical architecture incorporating the above electrical generation system and method.
[0007] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 schematically illustrates an aircraft incorporating the present invention, operating in a generate mode.
[0009] FIG. 2 schematically illustrates an aircraft incorporating the present invention, operating in a start mode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] An aircraft 20 operating in a generate mode is schematically illustrated in FIG. 1 , incorporating a pair of gas turbine engines 22 and 24 . As known, the gas turbine engines 22 , 24 include a turbine rotor that is driven to rotate by products of combustion. The rotation of the turbine rotor drives a shaft 27 which is connected to a gear box 129 . The gear box 129 translates the rotational movement of the rotor to each of two different shafts which are connected to a variable frequency (and/or constant frequency) generator 28 and a constant frequency generator 26 .
[0011] The variable frequency generator 28 is connected to two motor controllers 32 , 34 via a power bus 29 . The motor controllers 32 , 34 provide control signals and power conversion necessary for the operation of the variable frequency generator 28 through the power bus 29 . The power bus 29 additionally provides variable frequency power to electrical components of the aircraft, which do not need power to be maintained at a set frequency. Techniques for controlling a variable output frequency generator in a generate mode using multiple motor controllers are known in the art.
[0012] The constant frequency generator 26 is connected to electrical components 36 which require a constant frequency power source via power bus 25 . As is known in the art, no control signals from the motor controllers 32 , 34 are necessary for constant frequency generator 26 to operate as a generator during a generate mode.
[0013] When a turbine engine 22 , 24 is initially starting, it is known to provide a motive force from the connected generators 28 , and 26 (which act as motors during a start mode) to produce the force required to start the engine. FIG. 2 schematically illustrates an aircraft in a startup mode which utilizes both the variable frequency generator 28 and the constant frequency generator 26 to provide a motive force to the turbine engine 22 , 24 without the additional inclusion of a torque converter. According to previously known techniques, a constant frequency generator 26 can only operate in a starter mode with the assistance of an additional torque converter acting in conjunction with a pony motor and two start clutches.
[0014] In order for the example illustrated in FIG. 2 to operate in the start mode, the constant frequency generator 26 includes a single overrunning (start) clutch 42 which is operable to bypass the constant speed device (CSD), which is used during generation mode. When a line contactor is energized, and electrical power thru the motor controller 34 is provided to the constant frequency generator 26 , the constant frequency generator 26 will operate as a motor and provide a motive force to the shaft. The motor torque will be engaged through the overriding (start) clutch 42 to the input shaft. Once the engine is started, the line contactor 40 will be opened which will reconfigure the aircraft electrical bus to the generation mode as shown in FIG. 1 .
[0015] The schematic of FIG. 2 illustrates one of the motor controllers 34 , which is used to control the output frequency of the variable frequency generator 28 during generate mode, being connected to the constant frequency generator 26 during the start mode. One method of switching the motor controller's 34 connections, illustrated schematically in FIGS. 1 and 2 , utilizes a mechanical switch (contactor) 40 to change the electrical bus connections. Other methods and systems for switching a motor controller's 34 connections are known in the art, and require minimal components. By connecting the already existing motor controller 34 to the constant frequency generator 26 , the motor controller 34 can act in place of the torque converter, pony motor and pony motor controller configuration, which is required in all prior art systems, thereby eliminating components and reducing size and weight.
[0016] The second motor controller 34 is capable of acting as a start motor controller for item 26 during a start mode since it is otherwise idle during the start mode of the variable frequency generator 28 . This allows for the elimination of the torque converter, one of the two over running (start) clutches, the pony motor and the pony motor controller from the electrical generation system, without requiring the torque converter or the pony motor to be replaced by new components, thereby reducing size and weight and improving efficiency of the overall system.
[0017] While an example utilizing a second variable frequency generator 28 motor controller 34 which is idle during a start mode has been disclosed above, it is known that alternate motor controllers which are present in the system and idle during a start mode could be used to control the constant frequency generator 26 during a start mode and fall within the above disclosure.
[0018] Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. | A power generation system and method uses a constant frequency generator to generate electrical power in a generate mode. When operating in a start mode, the constant frequency generator is controlled by a motor controller which at least partially controls another component while the system is in a generate mode. The power generation system and method can be implemented in, for example, an aircraft electrical architecture. | 5 |
NOTICE OF COPYRIGHT
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to any reproduction by anyone of the patent disclosure, as it appears in the United States Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE PRESENT INVENTION
Field of Invention
The present invention relates to a heater.
Description of Related Arts
Currently, most outdoor heaters use standing columns to prop up burners, for example, patent CN 20052000535 U discloses an infrared remote control heating stove, which uses a standing column to prop up its burner; by arranging a reflecting cover above the burner to reflect the heat; that infrared remote control heating stove has some drawbacks such as low thermal efficiency and small heating space; the heat is circumferentially radiated, resulting in most of the heating area not being utilized; and using a standing column for connecting parts can easily cause the head part of the heater to become askew.
SUMMARY OF THE PRESENT INVENTION
The main object of the present invention is to provide a balanced high efficiency outdoor heater. The technical problem of the conventional heater to be solved is to increase the heating radiation area and improve the structural stability.
To solve the above mentioned problem, the present invention utilizes the following technical improvement: a balanced high efficiency outdoor heater includes a burner, and the burner is set at the upper end of a standing column, and the lower end of the standing column is provided with a bottom base, and the burner is an infrared burner, and a beam is set between the burner and the standing column, wherein the beam and the to standing column are connected by pipe fittings, and the rear end of the beam is provided with a base, and an ignition control device is equipped inside the base, and the burner is mounted on the front end of the beam, and the heating surface of the burner is facing downwards, and an electrode rod and a thermocoupler are connected to the ignition control device under the burner; a first reflector is fixedly connected to the lower end of the burner, and a gas valve is equipped in the bottom base, wherein an inlet and an outlet of the ignition control unit are connected to the burner by a gas pipe in the beam and a gas valve in the bottom base separately.
The present invention comprises a burner which further comprises a furnace cover with an opening facing downwards and a combustion chamber, and a furnace cover bracket is set on the upper end of the furnace cover being fixedly connected to the beam; an ejector pipe is transversely arranged inside the combustion chamber, and the ejector pipe is connected to the outlet of the ignition control device by gas pipes; a spoiler is upwardly bent arranged at the front end of the ejector pipe; the first reflector is arranged at the lower end of the furnace cover, and a sintered mat is fixedly set between the furnace cover and the first reflector which can cover the opening of the furnace cover.
The ignition control device of the present invention is a gas stove ignition switch, and the ignition switch shaft of the gas stove ignition switch extends from the rear end of the base, and a rotary knob is set on the ignition switch shaft.
The ignition control device of the present invention comprises an automatic gas control, a solenoid valve, a battery box, a valve dead plate, and an anti-dumping switch, and the automatic gas control, the solenoid valve, the battery box, and the anti-dumping switch are mounted on the valve dead plate by screws respectively, and the automatic gas control is connected to the battery box, the solenoid valve and the thermocouple respectively, and a first ejector pipe is connected to an outlet of the solenoid valve by gas pipes, and an inlet of the solenoid valve is connected to the gas valve; a key-press pad is fixedly connected to the rear end of the base, and the key-press pad is connected to a control wire end of the automatic gas control, and the key-press pad is provided a faceplate which is bonded to the key-press pad.
A second reflector is arranged between the sintered mat and the first reflector, and the reflector surface of the second reflector is smaller than the reflector surface of the first reflector; the second reflector, the first reflector and the sintered mat are fixedly connected to the furnace cover by screws successively.
The second reflector further comprises a gas-collecting hood which has a cavity inside; the upper end of the gas-collecting hood extends from the upper end of the second reflector, and the electrode and the thermocouple are arranged inside the cavity of the gas-collecting hood, and louvers are arranged on the lower end surface of the gas-collecting hood for wind shutter purposes.
The lower end of the second reflector is connected to a meshed shield cover.
Each of the pipe fittings are Tee pipe fittings.
The upper end of the burner is provided with a rain cover.
The present invention, compared with prior art, utilizes an infrared burner with a sintered mat, and the heating surface of the infrared burner faces downwards, in that case, the thermal efficiency is increased without an open flame; by utilizing the beam to increase the heating area, the whole heating area can be utilized; and the standing column is connected to the beam by pipe fittings, using such a balanced arrangement which can improve the structural stability.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a structure schematic view of the present invention.
FIG. 2 is a perspective view illustrating the structure of a burner of the present invention.
FIG. 3 is a first structure schematic view of a base of the present invention.
FIG. 4 is a second structure schematic view of a base of the present invention.
FIG. 5 is a schematic view illustrating the connecting part between the beam and the standing column.
FIG. 6 is a structure schematic view illustrating a first preferred embodiment of the ignition control device of the present invention.
FIG. 7 is a structure schematic view illustrating a second preferred embodiment of the ignition control device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description is disclosed to enable any person skilled in the art to make and use the present invention. Preferred embodiments are provided in the following description only as examples and modifications will be apparent to those skilled in the art. The general principles defined in the following description would be applied to other embodiments, alternatives, modifications, equivalents, and applications without departing from the spirit and scope of the present invention.
Referring to FIG. 1 of the drawings, a balanced high efficiency outdoor heater comprises a bottom base 3 , and a standing column 2 is connected to the bottom base 3 , and a curved beam 4 is connected to the upper end of the standing column 2 by pipe fittings, and a furnace cover bracket 13 is arranged at the front end of the beam 4 connecting by screws, and an ignition control device 6 is connected to the rear end of the beam 4 ; a burner 1 is mounted at the lower end of the furnace bracket 13 with the heating surface facing downwards, and the burner 1 is an infrared burner; the standing column 2 and the beam 4 both have a hollow tube structure, and two gas pipes are arranged inside the standing column 2 and the beam 4 , wherein one gas pipe is connecting the burner 1 and an outlet of the ignition control device 6 , and the another gas pipe is connected to a gas valve 10 and an inlet of the ignition control device 6 , and on the upper end of the burner 1 is provided a rain cover 48 .
The beam 4 has a two-section structure, which is a first beam 27 and a second beam 28 with the same outer diameters, and the length of the second beam 28 is less than the length of the first beam 27 . The pipe fitting 5 is a tee pipe fitting. By connecting the pipe fitting 5 with the first beam 27 , the second beam 28 and the standing column 2 by bolts, the interior of the first beam 27 , the second beam 28 and the standing column 2 can communicate with each other, so that the gas pipes can be arranged therein.
A base 15 is set at the rear end of the second beam 28 , and the base 15 is provided with a base cover 43 which can be opened, and the gas ignition device 6 is fixed in the base 15 , and the burner 1 is connected to the front end of the first beam 27 .
Referring to FIG. 2 , the burner 1 comprises a furnace cover 12 which is a cuboid, wherein the furnace cover 12 has an opening at the lower end, and the furnace cover 12 comprises a combustion chamber 11 , and the upper end of the furnace cover 12 is connected to a furnace cover bracket 13 by screws; a furnace cover hole 29 is set on the rear end of the furnace cover 12 , and an outer edge 30 is set on the opening of the furnace 12 for connecting other parts like a sintered mat which is extended outwardly, and an ejector pipe 14 is transversely mounted inside of the combustion chamber 11 , and the rear end of the ejector pipe 14 is extended through the furnace cover hole 29 to the outside of the furnace cover 12 , and the rear end of the ejector pipe 14 is hermetically connected to an outlet of the ignition control device 6 by gas pipes; a spoiler 23 being bent upwardly is fixedly connected to the lower end of the pipe orifice at the front end of the ejector pipe 14 , and some small holes are evenly distributed on the spoiler 23 ; the upwardly bent part of the spoiler 23 blocks the front pipe orifice of the ejector pipe 14 , so that exhaust gas from the ejector pipe 14 is guided to the upper end of the inner wall of the furnace cover 12 and be reflected to the front inner wall of the furnace cover 12 , and the gas is exhausted downward; beneath the combustion chamber 11 is provided with an electrode 7 and a thermocouple 22 , and at the lower end opening of the furnace cover 12 is provided with a sintered mat 8 which can completely cover the opening, and the gas is finally discharged to the upper end surface of the sintered mat 8 and burned there, and at the lower end of the sintered mat 8 is successively equipped a first reflector 9 and a second reflector 52 by screws, and the first reflector 9 is in a flared shape, and the shape and the size of the upper end opening of the first reflector 9 is adapted with that of the sintered mat 8 , and the opening diameter of the upper end opening of the first reflector 9 is smaller than the opening diameter of the lower end opening; and the reflect surface of the second reflector 52 is smaller than that of the first reflector 9 , and the second reflector 52 is also in a flared shape, and the shape and the size of the upper end opening of the second reflector 52 is adapted with that of the sintered mat 8 , and the lower end opening diameter is larger than that of the upper end opening; at the rear side of the upper opening of the second reflector 52 is equipped with a gas-collecting hood 24 , and a cavity is set inside the gas-collecting hood 24 , and after the gas-collecting hood being mounted in the second reflector 52 , the upper end of the gas-collecting hood 24 is extended through the upper end opening of the second reflector 52 , and on the lower end surface of the gas-collecting hood 24 is provided with some gas-collecting hood holes 25 .
A shield cover 26 is mounted at the lower end of the second reflector 52 , wherein the shield cover 26 is a strip meshed cover, and the shield cover can be connected to the second reflector 52 by screws, and can also be connected to the second reflector 52 by providing some holes on the second reflector 52 , and by using some column which can fit with the holes to fix the shield cover 26 .
Furthermore, the thermocouple 22 and the electrode 7 are arranged inside the cavity of the gas-collecting hood 24 . The electrode 7 and the thermocouple 22 are connected by screws on the dead plate of the second reflector 52 .
Furthermore, the ejector pipe 14 can be set into two sections, which is a first ejector pipe 31 and a second ejector pipe 32 , and the first ejector pipe 31 is connected by screws to the rear end of the furnace cover hole 29 and outside of the furnace cover 12 , and the front end of the first ejector pipe 31 is plugged into the furnace cover hole 29 , and the second ejector pipe 32 is muff-coupled to the front end of the first ejector pipe 31 , and the second ejector pipe 32 is thread connected to the first ejector pipe 31 ; the second ejector pipe is set inside the combustion chamber 11 , and the spoiler 23 is mounted at the front end orifice of the second ejector pipe 32 ; at the connection part of the first ejector pipe 31 and the second ejector pipe 32 is provided with a gasket 33 , when the ejector pipe is set into two sections, the outlet of the ignition control device 6 is connected to the first ejector pipe 31 by gas pipes, and the first ejector pipe 31 is connected to the gas pipes by thread connection.
Referring to FIG. 3 and FIG. 4 , the bottom base 3 has an internal hollow barrel structure, which comprises an upper and a lower circular surface referred to as a bottom surface 39 and a top surface 40 respectively, two pieces of semi-circular cross-sectional shaped shells 38 and a framework 46 , and the two shells 38 are hinged on one side, and the other side of the two shells 38 are connected by a snap joint, after the two shells 38 are combined together, they form a cylindrical barrel body, and a gas cylinder can be placed inside the bottom base 3 ; after the gas cylinder is connected to the gas valve 10 , the gas cylinder can supply air for the burner 1 ; wheels 34 are provided on the rear side peripheral wall of the bottom surface 39 , and a column hole 35 is provided on the top surface 40 for column inserting purpose, and the column hole 35 is set at the front side of the top surface 40 ; a hollow column holder 37 is arranged in the column hole 35 , and the column holder 37 is fixed within the column hole 35 ; the peripheral wall of the column holder 37 is provided with grooves 44 along the axial direction, and an adjustable pipe clamp 36 is set at the lower end of the column holder 37 and inside the bottom base 3 which is extended to the lower end of the bottom base 3 , and after the standing column 2 is plugged into the column hole 35 , screws can be locked into the standing column 2 from the grooves 44 , and by tightening nuts on the pipe clamp 36 , the standing column 2 is fixed within the column holder 37 .
Furthermore, a chain 45 is set in the bottom base 3 for fixing the gas cylinder, and two ends of the chain 45 are connected to the framework 46 by buckles which are detachable.
Referring to FIG. 5 , the pipe fittings 5 are tee pipe fittings, and the pipe fittings 5 comprise a left and a right pipe pieces 47 which are symmetrical to each other, and the pipe pieces 47 further comprise a column fixing part 41 for connecting with the standing column 2 and a beam fixing part 42 for connecting with the two beams, and the beam fixing part 42 is arranged on the front and rear sides of the column fixing part 41 , and cross-sectional shape of the column fixing part 41 and the beam fixing part 41 are both semi-circle; and the inner diameter of the column fixing part 41 is equal to the outer diameter of the standing column 2 ; and the inner diameter of the beam fixing part 42 is equal to the outer diameter of the beam, and after combing the two pipe pieces 47 together, the cross-section of the column fixing part 41 forms a circle, and the cross-section of the beam fixing part 42 forms a circle. Two first screw holes 49 are provided on the column fixing part 41 along the axial direction, and two second screw holes 50 are provided on the two beam fixing parts 42 with one on each side respectively, and a third screw hole 51 is provided on the standing column 2 at the corresponding position to that of the first screw hold 49 on the lower end of the column fixing part 41 , and the two pipe pieces 47 can hold the column and the beam by inserting bolts into the first screw hole 49 , the second screw hole 50 and the third screw hole 51 and using nuts to tighten the bolts, so that the column, the beam and the pipe pieces are fixedly connected.
Referring to FIG. 6 , the first embodiment of the ignition control device 6 can utilizes a manual type gas stove ignition switch 16 of the prior art, and an ignition switch shaft of the gas stove ignition switch 16 extends to the rear end of the base 15 , and a rotary nob 17 is provided on the ignition switch shaft of the gas stove ignition switch 16 , and the rotary nob 17 is set at outside of the rear end of the base 15 , and the electrode 7 is connected to the ignition wire of the gas stove ignition switch 16 , and the thermocoupler 22 is connected to a signal wire of the gas stove ignition switch 16 , and an outlet of the gas stove ignition switch 16 is connected to the first ejector pipe 31 by pipes, and an inlet of the gas stove ignition switch 16 is connected to the gas valve 10 by pipes.
The manual type gas stove ignition switch 16 can also utilize the SRSV03 gas ignition device which is produced by SHINERICH INDUSTRIAL Co., Ltd. (the burner in China Patent No. CN 20052000535 U).
Referring to FIG. 7 , the ignition control device 6 comprises an automatic gas control 18 , a solenoid valve 19 , a battery box 54 , a valve dead plate 53 and an anti-dumping switch 55 , and the power line of the automatic gas control 18 is connected to the battery box 44 which provides power for the ignition control device 6 . The solenoid valve wire end of the automatic gas control 18 is connected to the solenoid valve 19 . The anti-dumping switch 55 and the thermocouple 22 are connected to a signal sensing wire end of the automatic gas control 18 respectively. The first ejector pipe 31 is connected to an outlet of the solenoid valve 19 by gas pipes, and an inlet of the solenoid valve 19 is connected to the gas valve 10 by gas pipes, and an ignition wire of the automatic gas control 18 is connected to the electrode 7 ; a key-press pad 20 is fixedly connected to the rear end of the base 15 , and the key-press pad 20 is connected to a control wire end of the automatic gas control 18 , and a faceplate 21 is provided on the key-press pad 20 , and the faceplate is bolted on the key-press pad 20 . The ignition control device 6 can also be connected following the wire connecting arrangement of the ignition control device in China Patent No. CN 20052000535 U.
When in use, by rotating the rotary nob 17 or pressing the ignition key on the key-press pad 20 , gas goes into the combustion chamber 11 via gas pipes and the ejector pipe 14 , which the electrode 7 discharges to ignite, so that the gas is burned on the upper end surface of the sintered mat 8 . Because the gas is burned on the sintered mat 8 , an infrared effect can be achieved. When heat is reflected downward by the second reflector 52 and the first reflector 9 , an effect of efficiently radiated heat can be achieved.
As a result of no open flame being used in the present invention, the thermal efficiency is increased over 30%, and even in a windy environment, the function of the burner is not effected, and the ignition control device uses a module design, which makes the maintenance more convenient.
One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
It will thus be seen that the objects of the present invention have been fully and effectively accomplished. The embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims. | A balanced high efficiency outdoor heater is provided to increase the heat radiation area, and to improve the stability of the structure. The heater includes a burner provided at an upper end of a standing column, a bottom base provided at a lower end of the standing column, and a beam is set between the burner and the standing column. The beam and the standing column are connected by pipe fittings. An ignition control device is equipped inside the base and is connected to the burner. An electrode rod and a thermocoupler are connected to the ignition control device under the burner. A first reflector is fixedly connected to the lower end of the burner and a gas valve is equipped in the bottom base. Compared with the prior art, the burner uses sintered felt and a heating surface of the burner faces upside down to improve thermal efficiency. | 5 |
FIELD OF THE INVENTION
[0001] This invention relates to the retardation of crystallization of a composition containing an arylene-bridged oligomeric phosphate flame retardant. Such a composition can be used as a flame retardant additive, for example, in engineering resins.
BACKGROUND OF THE INVENTION
[0002] Arylene-bridged oligomeric phosphate compositions, such as bisphenol A bis(diphenyl phosphate), have the tendency, when stored, to crystallize as described at Col. 2, lines 1-5 of U.S. Pat. No. 6,319,432 to W. B. Harrod et al. It is known to use such oligomeric phosphate esters as flame retardants in engineering resins, such as polycarbonate-containing polymer compositions. It is also known to employ blends of alkylene-bridged compositions and arylene-bridged compositions (see, for example, PCT Patent Publication No. WO 96/11977, which does not show or suggest the retardation of the crystallization of arylene-bridged oligomeric phosphate compositions by adding to such a composition an alkylene-bridged oligomeric phosphate, as will be further described below).
DESCRIPTION OF THE INVENTION
[0003] The present invention relates to the retardation of crystallization that would normally take place over time for such arylene-bridged oligomeric phosphate compositions by adding a sufficient amount of an alkylene-bridged oligomeric phosphate to such an arylene-bridged oligomeric phosphate composition to effect such retardation of crystallization.
[0004] The arylene-bridged oligomeric phosphate compositions that can be improved in regard to their crystallization behavior are of the following formula:
where R 1 , R 2 , R 3 , R 4 are each aryl or substituted aryl, X is a bridging group derived from a diol that comprises an arylene moiety, and n preferably ranges from about 1 to about 5. The grouping —O—X—O— in the above-depicted formula can be derived from such diols as hydroquinone, resorcinol, and bisphenol A.
[0005] The foregoing type of phosphate compositions can have their crystallization retarded, upon being stored, by the incorporation therein of an effective amount (from about 10% to about 80%, by weight) of the arylene-bridged oligomeric phosphate composition of the formula
where R 1 , R 2 , R 3 , R 4 are each aryl or substituted aryl, X is a bridging group derived from a diol that comprises an alkylene moiety, and n preferably is 1. The grouping —O—X—O— in the above-depicted formula can be derived from a diol such as neopentyl glycol.
[0006] This effect for the alkylene-bridged bisphosphate is unexpected despite the fact that mixtures of it and arylene-bridged oligomeric phosphate compositions have been described before in PCT WO 96/11996 for improvement of the viscosity of oligomeric phosphate ester flame retardants. This PCT patent application does not discuss the effect that the alkylene-bridged bisphosphate has when the blend of it and the arylene-bridged oligomeric phosphate composition is stored for a period of time that would normally cause crystallization, for example, in a neat arylene-bridged oligomeric phosphate composition.
[0007] As indicated above, a preferred alkylene-bridged bisphosphate for use herein is neopentylglycol bis(diphenyl phosphate) of the following formula:
This product is most preferably a liquid product containing more than 80 wt. % of the bisphosphate depicted immediately above, less than 5 wt. % of the cyclic product
and less than 8 wt. % of triphenyl phosphate.
[0008] The present invention is further illustrated by the Examples that follow.
EXAMPLES 1-6
[0009] Bisphenol A bis(diphenyl phosphate), “BDP”, and neopentylglycol bis(diphenyl phosphate), “NDP”, were mixed at different ratios as shown in Table 1. The viscosities of plain aromatic bisphosphates and their blends were measured at 55° C. and 70° C. using a Brookfield viscometer. The mixtures of BDP/NDP were poured in the 50 ml test tubes, caped and placed in the laboratory freezer at −15° C. Plain BDP and plain NDP (Examples 1 and 2, which are presented for comparative purposes, were treated in the similar way as the BDP/NDP mixtures. The results of viscosity measurements as well as freezing measurements are shown in Table 1:
TABLE 1 Aromatic Viscosity, centipoise Time to freeze # bisphosphate 55° C. 70° C. day 1 BDP 420 181 1 day 2 NDP 50 26 >300 3 BDP/NDP = 4:1 229 97 >300 4 BDP/NDP = 3:2 178 71 >300 5 BDP/NDP = 2:3 98 47 >300 6 BDP/NDP = 1:4 71 36 >300 BDP: Bisphenol A bis(diphenyl phosphate) NDP: Neopentylglycol bis(diphenyl phosphate)
[0010] NDP also helps significantly decrease viscosity of BDP which is beneficial for handling of aromatic bisphosphates, particularly for pumping aromatic bisphosphates into extruder during compounding.
[0011] BDP/NDP mixtures do not freeze at prolonged storage at low temperatures therefore these mixtures do not require heated tank for their storage and heat-traced lines for their transfer.
[0012] The foregoing Examples should not be construed in a limiting sense since they are being presented only to illustrate certain embodiments of the present invention. The scope of protection is set forth in the claims that follow. | Storing, for a period of time, of a blend comprising an arylene-bridged oligomeric phosphate composition and an effective amount of an alkylene-bridged bisphosphate results in a retardation of crystallization as compared to storage of a composition comprising the arylene-bridged oligomeric phosphate composition without also containing the alkylenebridged bisphosphate. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an expandable and crosslinkable elastomeric material with improved fire retardant properties and low smoke generation, the process for manufacturing of such material and the use of such material.
[0003] 2. Description of the Background Art
[0004] Fire retardancy and the issues conjugated herewith play an important role in the field of elastomer development. Many efforts have been taken to select and produce fire retardant rubber bases, with prominent examples, such as PVC or chloroprene (CR). The latter has often been used as fire retardant adhesive (e.g. JP 11346416), coating (e.g. DE 2453238) or as impregnation for the same purpose (e.g. JP 62167334). An extraordinary challenge is to render elastomeric foams fire retardant or at least less flammable as the air included in the foam cells and the thin cell walls will accelerate flame spread. Chloroprene has been used also here to reduce flammability, such as impregnation of existing foams (e.g. GB 977929) or as foamed CR latices, emulsions and such (e.g. JP 61272248, JP 10060151, the latter also said to be suitable for thermal insulation). These methods, however, will lead to non-flexible materials and/or mechanically weak compounds. Foamed pure rubbers with better mechanical and general properties in CR are quite rare; in some cases the CR (among other polymers and fillers) is just used as a massive rubber base and the foam is only formed in contact with flame (so-called intumescences, as in DE 4135678, UA 61419, UA 78131), in other cases the manufacturing of the foam is very complicated and costly, as it is done using polymerization (JP 6041341, however, flame retardant properties are not even mentioned) or by using both a complicated formulation and expansion method (JP 60186543 and JP 60186544; based on critical chemicals such as isocyanate).
[0005] It is known from the above stated patent literature that chloroprene containing formulations can be used to improve flame resistance properties, but those formulations generate high levels of smoke which is seen as the most severe threat for humans in case of fire. Even less works have been done on flame retardant insulating materials, especially thermal insulation compounds: JP 10077478 mentions a compound (where CR is a possible ingredient) which will give an insulation effect against flame spread during fire by formation of water vapour, whereas JP 1182030 mentions a foamed CR for wetsuits achieving the insulation properties by low-conductive filler. However, a suitable flame retardant flexible foam material for industrial as well as for general (e.g. building) insulation and shielding/damping purposes can not be obtained by any of the above mentioned state of the art technologies, especially in regard to the fact that flame retardant and protective properties are required and get more severe in all public sectors: new challenges have come up such as the harmonization of European standards concerning building and construction insulation (EN 13823, “Euroclasses”); these standards do not only require a general flame retardancy, but include severe testing conditions (“SBI round corner test”) and add additional obstacles for norm fulfillment by introducing parameters such as flame and smoke generation and smoke density.
SUMMARY OF THE INVENTION
[0006] In accordance with one embodiment, an expandable and crosslinkable elastomeric material contains 50 to 100 percent by weight of polychloroprene based on the total polymer content and more than 25 percent by weight of chloroparaffin based on the total polymer content.
DETAILED DESCRIPTION OF THE INVENTION
[0007] A major object of the present invention thus is to provide a foamed rubber material not showing the above mentioned deficiencies but exhibiting both easy, i.e. economic and ecologic, manufacturing and handling (e.g. in mounting), showing excellent insulation properties and fulfilling the modern regulations in the respective application fields by a high level of immanent flame retardancy, low flame spread and low smoke density levels.
[0008] Surprisingly, it is found that such a versatile elastomeric foam material not showing the above mentioned disadvantages can be made directly from chloroprene rubber in a very limited number of steps by compounding it with chloroparaffin and different kinds and levels of fillers, and by expanding and crosslinking it.
[0009] The claimed material contains compound (A), which is a chloroprene rubber (polychloroprene, CR), and which can be present in the formulation to a minimum level of 50 weight percent, based on the total polymer content.
[0010] The polychloropene rubber can be chosen from the group of sulphur-, xanthogen- or mercaptan-modified types, especially preferred are mercaptan modified types. The polychloroprene can be used with Mooney-viscosities (ML1+4 at 100° C.) from 25 to 125 Mooney units, especially preferred from 35 to 45 Mooney units.
[0011] The claimed material furthermore contains compound (B) which is chloroparaffin (chlorinated paraffin) of all possible chain lengths and molecular weight of a level of more than 25 weight %, calculated based on 100 weight % of the total polymer content. A preferred chain length is from C 8 -C 50 . Especially preferred are chain lengths from C 17 -C 27 . The chloroparaffin can exhibit chlorine levels from 10 to 80%, preferably from 48 to 72%.
[0012] The claimed material includes one or more fillers (C), which may be chosen from the classes of both active and inactive fillers, such as metal and non metal oxides, carbon black, metal hydroxides, silica, carbonates, and so on and mixtures thereof. Especially preferred are fillers of the class of metal hydroxides, metal carbonates, and metal oxides. The filler(s) (C) may be contained to an extent of 50-800 weight %, preferably 100-500 weight %, especially preferred 200-400 weight %, calculated based on 100 weight % of the total polymer content.
[0013] The claimed material contains a suitable crosslinking system (D), such as sulphur-based systems, irradiation, peroxides, or mixtures thereof. Preferred are sulphur based crosslinking systems containing sulphur and all kind of organic accelerators used in rubber industry. Especially preferred are mixtures of sulphur, pipentamethylenethiuram tetrasulfide, zinc-N-dibenzyl-dithiocarbamate, N,N′-diphenyl thiourea, ethylene thiourea and dibenzothiazyl disulfide.
[0014] The claimed material furthermore contains a suitable foaming system (E), which can lead to the formation of open and closed-cell as well as mixed-cell structures. Preferred are closed-cell structures forming additives. The foaming system (E) can either consist of chemicals forming gases at defined temperatures or can be a physical foaming system which will bring the gases (such as nitrogen, carbon dioxide, vapours) into the compound by mechanical methods, e.g. pressure, as well as of mixtures of both methods. Chemicals (E) for the expansion may be CO 2 releasing chemicals (e.g. carbonates, carbamates, carbonamides etc.), water or water releasing compounds (including crystalline and interchalate water), nitrogen releasing chemicals (e.g. azo compounds, azides, hydrazides), expanding microspheres and hollow spheres in general, containing expandable gases or liquids, expanding clays and graphites and similar particles, and so on, and any mixtures thereof.
[0015] The claimed material furthermore may contain flame retardant agents (F) and mixtures thereof, as used in the rubber and plastics industry, such as halogen compounds, metal oxides and hydroxides, metal sulfides, phosphor and phosphor based compounds, melamine based compounds and mixtures thereof. A preferred class of flame retardant agents would be brominated organics which can be combined with synergists like antimony trioxide.
[0016] The claimed material may contain plasticizers (G) to improve its compounding and manufacturing properties in a range of 0-200 weight %, calculated based on 100 weight % of the total polymer content.
[0017] The elastomeric compositions useful in the present invention may be prepared by any conventional procedure such as for example, by mixing the ingredients in an internal mixer or on a mill.
[0018] The claimed material furthermore may contain any additive (H) for improving its manufacturing, application, aspect and performance properties, such as inhibitors, retarders, accelerators, stabilizers (e.g. heat, UV), colours etc. Additives (H) can also be chosen of the class of intumescence additives, such as expanding graphite, vermiculite, perlite etc., to render the material self-intumescent in case of fire to close and protect e.g. wall and bulkhead penetrations. Additives (H) can also consist of substances that will lead to a self-ceramifying effect to protect cables, pipes, wall penetrations etc. in case of fire, such as boron compounds, silicon containing compounds etc.
[0019] The claimed material may contain additional polymers or polymer compounds (I) that can be mixed with the rubber compound to obtain a rubber or rubber/plastics blend, such as organic rubbers, silicones, thermoplastic elastomers, thermoplasts and thermosets, and mixtures thereof.
[0020] The claimed material may furthermore contain fibres or chopped fibres or pulp as both filler material (C) and reinforcing agent (J), such as glass fibres, polyaramid fibres, polyester fibres and so on, and mixtures thereof,
[0021] A major advantage of the claimed material is its suitability for “Euroclass” applications where low flame spread and low smoke generation are required (see Table 3, FIGRA/SMOGRA), and that this suitability is immanent to the material, means, it is not achieved by external means, but is generated by the formulation itself.
[0022] A further advantage of the claimed material is that no brominated flame retardants are needed to achieve demanded flame resistance. Brominated flame retardants are critical for environmental issues and can generate toxic fumes in case of fire. For that reasons brominated flame retardants are already partially prohibited.
[0023] A basic advantage of the claimed material is the fact that in its preferred compositions it is free of both fibres and PVC, both of them being under survey and being discussed for environmental and health issues.
[0024] A further advantage of the claimed material is that phthalates are not needed as plasticizers, which are partially under discussion and partially prohibited already for the same reason.
[0025] A further advantage of the claimed material is the possibility to adapt its properties to the desired property profile (concerning mechanics, damping, insulation etc.) by expanding it to an appropriate foam cell structure from totally open-cell to totally closed-cell. This can be achieved by modifying the crosslinking system(s), the foaming agent(s) and the base matrix.
[0026] A further advantage of the claimed material is the fact that it can be crosslinked by widespread and economic methods like both sulphur and peroxide curing due to the fact that with chloroprene an appropriate polymer has been chosen.
[0027] It is a prominent advantage of the claimed material that it can be produced in an economic way in a one-step mixing and a one-step shaping process, e.g. by moulding, extrusion and other shaping methods. It shows versatility in possibilities of manufacturing and application. It can be extruded, co-extruded, laminated, moulded, co-moulded etc. as single item or multilayer and thus it can be applied in unrestricted shaping onto various surfaces in automotive, transport, aeronautics, building and construction, furniture, machinery engineering and many other industries.
[0028] It is a further advantage of the claimed material that it can be transformed and given shape by standard methods being widespread in the industry and that it does not require specialized equipment.
[0029] A further advantage of the claimed material is the fact that it is easily colourable in contrast to e.g. existing insulation materials that are mainly black.
[0030] An important advantage of the claimed material is the fact that it is low gassing, which is both important for e.g. automotive applications, but also for flame retardancy in general.
[0031] Another advantage of the material is the fact that it can be blended or filled with or contain scrapped or recycled material of the same kind to a very high extent not losing its fire retardant or other relevant properties significantly.
[0032] A further advantage of the claimed material is its suitability for thermal insulation applications, ranging from very low (−100° C.) to very high (150° C.) temperatures by choosing the proper compound.
[0033] An important advantage of the claimed material for its application is the fact that it can be glued, coated etc. easily and even with polychloroprene rubber and/or latex based glues/coating that show flame retardancy themselves and thus would not render the applied material's fire protection properties worse.
[0034] A major advantage of the claimed material is the fact that its fire retardancy is immanent, thus contained in the material itself and not brought to the material by any other means. This will facilitate both modification, adaptation and variation of the material without losing important properties.
[0035] A resulting major advantage of the claimed material is the fact that it can be surface treated, e.g. coated, welded, braided etc. with various agents and by various means. By these means the fire retardancy can be pushed to even higher levels if properly applied.
Examples
[0036] In the following examples and comparative examples, elastomer processing was carried out in the following manner: processing was done in an internal mixer having an inner volume of 5000 cubic centimetres; kneading was carried out at approximately 30 rpm. The batches were processed as two pass mixes. In the first pass, all ingredients except the sulphur, accelerators and activator were added to the internal mixer and mixed to a temperature of about 135° C., dumped, milled and cooled to ambient temperature. In the second pass, the master batch compound was mixed together with sulphur, accelerators and activator to 105° C., dumped, milled and cooled to ambient temperature.
[0037] The final process was carried out on a laboratory extruder with screw diameter of 37.25 mm and screw length of 25 D. The extruder was equipped with vacuum port and tube die. The extruded tube was cut directly after extrusion and spread to a sheet before to be transferred into the oven line.
[0038] The expansion and vulcanisation of the extruded compound was carried out on a continuous oven line starting from 120° C. and step-by-step increasing to 180° C. Table 1 illustrates the elastomeric composition formulations for test samples for Examples 4, 5 and 6 of the present invention, and for Comparative Examples 1, 2 and 3.
[0000] TABLE 1 Chemical composition: declaration of ingredients are calculated based on 100 weight % of total polymer content Comparative Comparative Comparative Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Polychloroprene 83.30 95.00 79.20 83.40 83.40 Polynitril-butadiene-rubber 47.60 Poly-vinyl-chloride 52.40 16.70 Polybutadien 5.00 4.20 Silicone resin 16.60 8.30 Copolyester 8.30 Ethylene-Vinylacetate 16.60 Aluminium Trihydroxide 63.80 41.70 150.00 156.60 166.60 166.60 CarbonBlack 11.00 25.00 30.00 Calciumcarbonate 56.20 41.70 Chloroparaffin 56.20 45.80 45.80 45.80 45.80 Antimony trioxide 6.20 5.70 12.00 3.30 1.70 1.70 Di-isononylphthalate 11.40 Diphenyl-kresylphosphate 42.00 Dekabromo-diphenylether 12.40 21.60 Zinc borate 11.70 Azodicarbonamide 43.30 33.30 38.00 33.30 39.20 39.20 Zinc oxide 2.40 0.42 0.50 0.42 0.42 0.42 Sulphur 0.20 0.42 0.50 0.42 0.42 0.42 Dipentamethylenethiuram 0.26 tetrasulfid Zinc 0.14 0.17 0.14 0.14 0.14 dibutyldithiocarbamate Ethylene thiourea 0.16 0.19 0.16 0.16 0.16 Zinc dimethyldithiocarbamate 0.46
Table 2 describes used raw materials and sources thereof
[0000]
TABLE 2
Used chemicals
Chemical
Trade name
Supplier
Polychloroprene
Denka M-30
Denki Kagaku Kogyo
Kabushiki Kaischa
Polynitril-butadien-rubber
Nipol DN 300 W 80
Zeon Chemicals
Poly-vinyl-chloride
Evipol SH 5730
Ineos
Polybutadiene
BR 9000
NGS Elastomer GmbH
Silicon resin
Resin Modifier
Dow Corning
4-7081
Copolyester
Griltex P-1533 EP
EMS-Griltech
Ethylen-Vinylacetat
Elvax 250
DuPont Elastomers
Aluminium Trihydroxide
Martinal 107 LE
Martinswerk GmbH
Carbon Black
Nhumo N 660
NHumo
Calciumcarbonate
Omya BSH
Omya
Chloroparaffin
Chlorparaffin 137
Leuna Tenside GmbH
Antimony Trioxide
Antimontrioxid
GMS-Chemie
Handelsgesellschaft
m.b.H.
Di-Isononylphthalate
Palatinol N
BASF
Diphenyl-kresylphosphate
Disflamoll DPK
Lanxess
Dekabromo-diphenylether
Saytex 102 E
Albemarle
Zinc borate
ZB 467
Great Lakes
Manufaturing Ltd
Azodicarbonamide
Tracel K 3/95
Tramaco
Sulfur
Rubersul 700
Nasika Products S.A.
Dipentamethylenethiuram
Nasika DPTT-70
Nasika Products S.A.
Tetrasulfide
Zinc-
Nasika ZDBC-75
Nasika Products S.A.
Dibutyldithiocarbamate
EthyleneThiourea
Nasika ETU-75
Nasika Products S.A.
Zinc diethyldithiocarbamate
nasika ZDEC-70
Nasika Products S.A.
[0039] Physical tests were conducted for all compounds after processing, expansion and vulcanisation. Properties of the resulting foams (sheets) were measured according to the following test protocols:
[0000] Density by ISO 845; LOI by ISO 4589; Thermal Conductivity by EN 12667; Flammability and determination of Total Heat Release (THR), Fire Growth Rate (FIGRA), Smoke Growth Rate (SMOGRA) and Total Smoke Production (TSP) by EN 13823; Flammability Classification in accordance with EN 13501. Table 3 illustrates analytical data, especially from fire testing.
[0000]
TABLE 3
Physical data
Comparative
Comparative
Comparative
Example 1
Example 2
Example 3
Example 4
Example 5
Example 6
Wall Thickness
25 mm
25 mm
25 mm
25 mm
25 mm
25 mm
(Sheets)
Density [kg/m3]
46
82
80
75
76
73
LOI
39.2
53.7
39.9
59.0
59.3
59.2
Thermal
0.034
0.038
0.038
0.037
0.035
0.036
Conductivity
at 0° C. [W/mK]
THR [MJ]
3.7
2.5
1.9
2.1
1.4
1.2
FIGRA [W/s]
221
55
179
107
96
85
SMOGRA [m2/s]
1980
1300
615
172
164
142
TSP [m2]
316
260
199
85
111
83
Classification
C-S3-d0
B-S3-d0
C-S3-d0
B-S2-d0
B-S2-d0
B-S2-d0 | The present invention relates to an expandable and crosslinkable elastomeric material with improved fire retardant properties and low smoke generation, the manufacturing and use of the material. The material includes polychloroprene as a main polymeric ingredient and chloroparaffin and which is expanded to a final density of less than 200 kg/m 3 . | 2 |
FIELD OF THE INVENTION
The present invention relates to a monitor bracket, and more particularly to a wall mounting monitor bracket that firmly and easily adjusts a monitor to different angles by adjusting a movable arm means and a connection means.
BACKGROUND OF THE INVENTION
The commercial monitor bracket is generally composed of two parts including a base disposed on the table and an angle-adjustable movable arm coupled with the base, wherein a monitor is fixed on one end of the movable arm such that the monitor can be disposed stably and the monitor's angle is adjustable.
However, the drawbacks existing in angle adjustment and integral assembly of the conventional monitor bracket are listed as follows:
1. In the process of coupling a plug of a computer machine with the monitor, the monitor or the movable arm must be detached first since the elevational angle of the monitor is not adjustable, causing the inconvenience to the user.
2. An accidental fall of the bracket including the monitor fixed thereon from the table may be caused easily by shifting the bracket or impacting the bracket incautiously, so it is unsteady and not safe enough.
3. The adjustment of the movable arm is confined to specific angles so the adjustable angle is incomplete, causing the inconvenience to the user.
SUMMARY OF THE INVENTION
It is a main object of the present invention to provide a wall mounting monitor bracket for firmly and easily adjusting the monitor to different angles.
In order to achieve the above object, a wall mounting monitor bracket comprises a sliding base means, at least a movable arm means, and at least a connection means. The movable arm means is hung on the sliding base means via one end, and connected to the connection means via the other end. The other end of the connection means is attached to a first monitor. By adjusting the movable arm means and the connection means, the first monitor can be firmly and easily adjusted to different angles.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a first preferred embodiment of the present invention.
FIG. 2 is elevational, exploded view of the first preferred embodiment of present invention.
FIG. 3 is elevational, exploded view of the movable arm means of the first preferred embodiment of present invention.
FIG. 4 is elevational, exploded view of the connection means of the first preferred embodiment of present invention.
FIG. 5 is partial, cross-sectional view of the first preferred embodiment of present invention.
FIG. 6 is schematic view showing the operation of the first preferred embodiment of present invention.
FIG. 7 is schematic view showing another operation of the first preferred embodiment of present invention.
FIG. 8 is an elevational view of a second preferred embodiment of the present invention.
FIG. 9 is schematic view showing the operation of the second preferred embodiment of present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 through 5 , a first preferred embodiment of a wall mounting monitor bracket of the present invention comprising a sliding base means 1 , a movable arm means 2 , and a connection means 3 is shown.
The sliding base means 1 comprises several fixing bases 11 and several sliding rods 12 . The fixing bases 11 are fixed on the wall, and each fixing base 11 comprises several holding parts 111 , wherein each holding part 111 has a holding trench 112 on one side. Each aforesaid sliding rod 12 has two ends held in the holding trenches 112 , respectively.
The movable arm means 2 is movably hung on the aforesaid sliding rods 12 , and the movable arm means 2 comprises a first movable arm 21 , a second movable arm 22 , a third movable arm 23 , several rotating shafts 24 , several decorative devices 25 , several axial connecting bases 26 , several sliding bushings 27 , and at least a wedging device 28 .
The first movable arm 21 has a first shaft sleeve 211 and a second shaft sleeve 212 on both ends, respectively. The first shaft sleeve 211 and the second shaft sleeve 212 have a through hole 213 and a first circular hole 214 respectively axially penetrating through the center regions. The second movable arm 22 has a third shaft sleeve 221 on one end, wherein the third shaft sleeve 221 has a first square hole 222 axially penetrating through the center region thereof.
The second movable arm 22 further has a fourth shaft sleeve 223 on the other end, wherein the fourth shaft sleeve 223 has a second circular hole 224 axially penetrating through the center region.
The third movable arm 23 has a fifth shaft sleeve 231 on one end, wherein the fifth shaft sleeve 231 has a second square hole 232 axially penetrating through the center region. The third movable arm 23 has a sixth shaft sleeve 233 on the other end, wherein the sixth shaft sleeve 233 has a third circular hole 234 axially penetrating through the center region.
The rotating shaft 24 has a respective locking hole 241 on each end. The rotating shaft 24 has a polygonal coupling part 242 between these two locking holes 241 corresponding to the first square hole 222 and the second square hole 232 .
Each aforesaid axial connecting base 26 has a seventh shaft sleeve 261 on one side, wherein the seventh shaft sleeve 261 has a third square hole 262 axially penetrating through the center region corresponding to the polygonal coupling part 242 . Each axial connecting base 26 has a slot 263 for fixedly connecting with sliding bushing 27 .
The wedging device 28 has an axial penetrating through hole 281 and a circularly laterally extending wedging part 282 . The wedging part 282 has a positioning pin 283 protruding from one surface. The second shaft sleeve 212 is pivotally connected between the third shaft sleeve 221 and the fifth shaft sleeve 231 via the rotating shaft 24 . The coupling part 242 of the rotating shaft 24 is inserted through the first circular hole 214 to allow the free rotation of the second shaft sleeve 212 , and the coupling part 242 is inserted correspondingly through the first square hole 222 and the second square hole 232 to immovably position the first square hole 222 and the second square hole 232 , whereby the locking holes 241 on both ends of the rotating shaft 24 are screwed between the first square hole 222 and the second square hole 232 . The outer sides of the first square hole 222 and the second square hole 232 are covered with the decorative devices 25 , respectively.
The aforesaid fourth shaft sleeve 223 is pivotally connected with the sixth shaft sleeve 233 via another rotating shaft 24 . In addition, the both ends of the rotating shaft 24 that penetrates through the fourth shaft sleeve 223 and the sixth shaft sleeve 233 are pivotally connected with the axial connecting bases 26 , respectively.
The coupling part 242 of one of the two rotating shafts 24 is inserted correspondingly through the third square holes 262 of two axial connecting bases 26 to immovably position the axial connecting bases 26 . The slots 263 of these two axial connecting bases 26 are fixedly connected to two sliding bushings 27 , respectively.
The axial connecting base 26 on the outer side of the sixth shaft sleeve 233 is further pivotally connected to the wedging device 28 . The locking holes 241 on both ends of the rotating shaft 24 are screwed between the third square hole 262 and the through hole 281 . The outer sides of the third square hole 262 and the through hole 281 are covered with the decorative devices 25 , respectively. The aforesaid axial connecting bases 26 are hung on one side of the aforesaid sliding rods 12 via the slots 263 and the sliding bushings 27 , and the wedging device 28 is rotated to posit the wedging part 282 and the positioning pin 283 on the other side of the sliding rods 12 for buckling the axial connecting bases 26 to the sliding rods 12 .
The connection means 3 is connected to the front end of the movable arm means 2 , and the connection means 3 comprises a rotating shaft base 31 , a first pivotal pin 32 , a sleeve 33 , several second pivotal pins 34 , and a monitor fixing frame 35 .
The rotating shaft base 31 has two first connecting parts 311 and two second connecting parts 312 , and the rotating shaft base 31 further has sliding trenches 313 and center holes 314 penetrating through the second connecting parts 312 .
The monitor fixing frame 35 has several first assembling parts 351 , a second assembling part 352 , several first assembling holes 353 penetrating through the first assembling parts 351 , and several second assembling holes 354 penetrating through the surfaces of the second assembling part 352 .
The aforesaid first shaft sleeve 211 is pivotally held between these two first connecting parts 311 via the first pivotal pin 32 . The both ends of the first pivotal pin 32 are covered with the decorative devices 25 , respectively. The sleeve 33 is held between these two second connecting parts 312 . The respective sides of these two second connecting parts 312 are located beside the first assembling parts 351 . These first assembling holes 353 on the first assembling part 351 are located corresponding to the sliding trenches 313 and the center holes 314 . The second pivotal pins 34 are inserted through the sliding trenches 313 , the center holes 314 , and the sleeve 33 , and pivotally connected to the first assembling parts 351 . The second assembling part 352 is screwed onto a first monitor 4 (shown in FIG. 6 ) by means of the second assembling holes 354 .
The operations of the aforesaid means are shown in FIG. 6 and FIG. 7 . According to the wall mounting monitor bracket of the present invention, the first monitor 4 is fixed on the monitor fixing frame 35 , and the elevational angle of the first monitor 4 is adjustable by means of the sliding trenches 313 . The rotating shaft base 31 is pivotally connected to the front end of the first movable arm 21 . The rear end of the first movable arm 21 is pivotally connected the front ends of the second movable arm 22 and the third movable arm 23 . The axial connecting bases 26 are respectively connected to the sliding rods 12 . By rotating the first movable arm 21 , the second movable arm 22 , and the third movable arm 23 , the horizontal angle of the first monitor 4 is adjustable, and the fist monitor 4 is shiftable leftward or rightward by shifting the axial connecting base 26 .
By using the aforesaid operations, the angle of the first monitor 4 is highly changeable.
Referring to FIG. 8 and FIG. 9 , a second preferred embodiment of the present invention is shown. The second preferred embodiment is suitable for use in a large-sized monitor. The second preferred embodiment and the first preferred embodiment have substantially identical structures. The difference is that the second preferred embodiment has at least a movable arm means 2 and at least a connection means 3 , wherein the connection means 3 comprises a rotating shaft base 31 , a first pivotal pin 32 , a sleeve 33 , several second pivotal pins 34 , and a monitor fixing frame 36 . The monitor fixing frame 36 is fixed on a second monitor 5 , whereby several movable arm means 2 and several connection means 3 provide the second monitor 5 with a stronger supporting force. | A wall mounting monitor bracket comprises a sliding base means, at least a movable arm means, and at least a connection means. The movable arm means is hung on the sliding base means via one end, and connected to the connection means via the other end. The other end of the connection means is attached to a first monitor. By adjusting the movable arm means and the connection means, the first monitor can be firmly and easily adjusted to different angles. | 5 |
FIELD OF THE INVENTION
The invention relates to a probe for use in apparatus and a method for measurement of gas concentrations in molten metal. More particularly, the invention relates to such a probe suitable for determination of dissolved hydrogen, oxygen, and/or nitrogen content in molten metals, such as steel.
BACKGROUND OF THE INVENTION
Various devices have been developed heretofore to measure the content of dissolved gases such as hydrogen in molten metals, such as molten aluminum or molten steel. An early device is described in U.S. Pat. No. 2,861,450 issued to Ransley et al. The device shown therein is referred to as the Telegas device. This device is included in an immersion head of generally a bell-shaped configuration and entails discharging or debouching a carrier gas into the molten metal and recapturing bubbles by the probe head. These devices entailed the recirculation of the gases through a closed loop until equilibrium is reached. The nitrogen reached an equilibrium with the dissolved hydrogen, which thus enables monitoring and measurement of the dissolved hydrogen content in the metal. These devices, as well as subsequent variations thereof, uses a membrane which is permeable to the gas, usually hydrogen, whose concentration is to be determined, but which is stated to be impermeable to molten metal. A need continues to exist for such probes which offer testing of increased speed and accuracy.
SUMMARY OF THE INVENTION
It is a principal object of the invention to provide a new and improved probe and processes for determination of dissolved gas contents in molten metals. The invention has important application to the determination of the concentrations of hydrogen, oxygen, and nitrogen dissolved in molten steel, but can be used also to determine concentrations of other dissolved gases in molten steel and in other molten metals. The invention, thus, has applicability to determination of dissolved gas concentrations in most other molten metals such as copper, aluminum, tin, or lead. The invention provides such devices and methods which enable simultaneous determination of the concentration of several gases by means of a single test procedure. In a preferred embodiment using a mass spectrometer, the dissolved gases are absolutely characterized by their molecular weights, as well.
An important aspect of the invention relates to providing of an immersion probe which eliminates the use of and need for a membrane which is impermeable to molten metal. A related aspect entails use of a porous material which, instead of being impermeable to molten metal, is of a type used as a strainer for removing solid impurities from a molten metal. The new probes, by eliminating the impermeable member and substituting a porous metal-permeable material enables more rapid determinations of gas contents than heretofore possible, and, the simultaneous determination by means of a single test procedure of the concentration of a number of gases including hydrogen, oxygen, and nitrogen.
Another aspect of the invention relates to the introduction of streams of inert gases which contain known concentrations of the gas or gases being measured, at least one of these gas streams having a known concentration higher than that of the gas in the metal being tested and another one of the gas streams having a concentration less than that of the gas in the metal being tested. The true amount of the gas being characterized in the metal is then computed to a high degree of accuracy.
Briefly, the invention provides an immersion probe for determination of the concentration of a gas dissolved in molten metal which includes a probe body in the form of an elongated housing. The probe body is formed of a gas and molten metal impervious material of sufficient thermal resistance to withstand immersion in molten metal for the analysis time and is connected to a gas conduit for inflow of an inert gas. The immersible end of the probe body has a porous member which, unlike previous devices, may be, in a preferred embodiment, permeable to both gas and liquid molten metal. The porous member is loosely fitted and unsealed in the probe head and serves to support a layer of loose insulation material, and acts as a heat and splash shield.
An inert carrier gas, such as nitrogen or argon, is used in practice of the process of this invention. After immersion, the probe of this embodiment is preferably purged with pure inert dry gas having a known concentration of hydrogen gas for about fifteen-thirty seconds, and then a negative pressure is drawn through a thermal conductivity device (TCD) such as a katharometer using a pump, a step which is continuous and reaches equilibrium within less than about forty-five seconds. Dissolved gas concentration is then rapidly determined by a connected analysis device.
The method for determining gas contents in molten metal in accordance with the invention includes the steps of providing a probe as defined above, the probe being connected by a gas flow conduit to a gas analysis device. The probe is immersed in the molten metal and then preferably purged and standardized with a pure inert carrier gas stream until an equilibrium is reached and recorded. Then, in accord with a preferred procedure, a stream of pure carrier gas is introduced through the probe which contains predetermined known concentrations of gases to be analyzed, usually hydrogen, oxygen, and/or nitrogen gas which are greater than those contained in the molten metal until equilibrium is recorded. The gases are recovered by the submerged hollow or bell-shaped submerged probe end as it bubbles through the metal bath. The analysis device is then used to determine the content of hydrogen, oxygen, and/or nitrogen contained in the gas flowing out of the metal. Subsequently, there is introduced into the molten metal, through the probe, a second gas stream of an inert carrier gas which contain second predetermined concentrations of hydrogen, oxygen, and/or nitrogen gas which are less than those contained in the molten metal. The second gas is also recovered and analyzed as it bubbles out of the metal to determine its content of hydrogen, oxygen, and/or nitrogen. The gas content determinations are then compared and used to accurately and absolutely compute the content of gases dissolved in the metal. If a mass analyzer, such as a quadrupole mass gas analyzer, is used as the gas analysis device, determinations of hydrogen, oxygen, and nitrogen contents may be effected with high accuracy using a single test procedure.
Other aspects and advantages of the invention will be apparent from the following detailed description, claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating the practice of the invention including a probe, shown in cross section, together with a fragmentary view of a molten metal bath;
FIG. 2 is a central cross sectional view of a preferred form of probe for use in connection with the invention;
FIG. 3 is a fragmentary sectional view taken along Line 3 — 3 of FIG. 2;
FIG. 4 is a central cross sectional view showing an alternative embodiment of a probe of the present invention;
FIG. 5 is a flow diagram showing a preferred arrangement for practice of the invention using a mass spectrometer;
FIG. 6 is a typical print-out of an analysis of dissolved gases in molten steel using a mass spectrometer;
FIG. 7 is a typical print-out of an analysis of dissolved hydrogen content in molten steel using a mass spectrometer; and,
FIG. 8 is a print-out of the analysis of dissolved hydrogen content in the same batch of molten steel as shown in FIG. 7, but obtained using an Alscan TCD (katharometer).
DETAILED DESCRIPTION OF THE INVENTION
Referring more particularly to the drawings, there is seen in FIG. 1 a schematic view illustrating the practice of the invention. In FIG. 1, probe 10 is immersible into a molten metal bath 34 to determine the content of gases dissolved therein. In accordance with the preferred embodiment of the invention, the content of hydrogen dissolved in a molten iron or steel bath is determined. Probe 10 includes an upper end 12 adapted to be supported on a steel pole and to be connected by conduits to a source of inert gas as well as to instrumentation (not shown) by means of appropriate connections. An inlet tube 14 which conducts a stream 15 of inert gas, such as nitrogen or argon, connects to a central internal nipple component 18 of a metal fitting 19 , as shown in figure four. An outflow line 16 is provided to direct the flow of gas emerging from the probe to an analysis device. Probe 10 is seen in greater detail in FIG. 4 .
Probe 10 includes a tubular body portion 24 , preferably formed of quartz. Tubular portion 24 has an open lower end 26 adapted to be immersed in molten metal 34 which is contained in a suitable containment vessel 36 . As the stream 15 of inert gas emerges from the bottom end of tube 30 , an equilibrium amount of the hydrogen contained in bath 34 is mixed with stream 15 , the bubbles emerging from bath 34 being captured by the lower end 26 of the probe 10 , as illustrated by arrows 32 . Unlike previous probes, probe 10 includes a disk 28 which is preferably molten metal permeable. Disk 28 is preferably loose fitting and serves as a splash protector while also supporting a free-flowing particulate insulation 50 .
As seen in FIG. 1, the stream of gas 32 containing hydrogen recovered as it diffuses from the molten metal 34 is drawn by vacuum into a thermal conductivity device 40 identified in the schematic drawing by its initials “TCD”. One example of such a device is a katharometer-based system, such as the Alscan analyzer available from Bomem Inc. of Quebec, Canada. Since such devices are known in the art and do not constitute a novel part of the present invention, they are thus not described in detail herein.
Also, it will be noted that by eliminating the use of a gas recirculating loop, heretofore a standard part of hydrogen detection probes used in molten metals, a vacuum pump 42 can be used to facilitate rapid flow of the stream of gas 32 through the thermal conductivity device 40 to increase the speed of the analysis procedure. After a stream of gases 32 flows through the thermal conductivity device, the stream is exhausted harmlessly into the atmosphere through an exhaust port 44 . In the drawings, the source of dry inert gas 31 is identified as being nitrogen gas. However, those skilled in the art will recognize that other inert gases, for example argon, can be substituted.
The thermal conductivity device may be, for example, a katharometer such as is described in “Gas Analysis by Measurement of Thermal Conductivity” H. A. Daynes, Cambridge University of Press, 1933. Other devices which may be substituted include gas chromatographs, thermal conductivity cells, or mass spectrometers.
Reference is again made to FIG. 4 relating to the details of the probe 10 . Filter element 28 is preferably a porous alumina disk of a type generally used to filter impurities from molten metal. The use of the very porous and loose-fitting metal molten metal permeable disk 28 enables freer flow and greater flow rates through the system of the carrier gases and more rapid recovery and analysis of the gas content of the metal. Higher speed determinations of the dissolved gas contents in the molten metal are thus facilitated. The interior of tubular body 24 is preferably filled with a loose inert particulate filler 50 . Filler 50 may be either in the form of solid or hollow particles generally in the size range of 5-200 μm in average diameter. Disk 28 serves to confine the filler 50 at the lower end thereof. A particulate filler 50 is confined at the upper end of the probe by another disk 52 which may simply be a layer of an inert material, such as ceramic “wool” fibers.
Filler 50 may be in the form of hollow ceramic spheres such as those sold under the trade name Duralum AB bubbles, available from Washington Mills Electrominerals Corporation of Niagara Falls, New York. Solid heat resistant inorganic particles may be used, instead, if desired.
As seen in FIG. 4, connector block fitting 19 is provided with an inner bore 20 which conducts the inflowing inert gas 15 from inflow port 14 into glass tube 30 . An O-ring connector 56 provides a leak proof seal between tube 14 and nipple end 18 of connector block fitting 19 . If desired, the tube 14 can be provided with a mating metal or plastic end (not shown) to connect to and fit tightly over nipple end 18 . Similarly, outer passageways 21 , which are spaced apart from bore 20 , accommodate the flow of gas for testing out from the probe body 24 into outflow tube 16 which is concentric with inflow tube 14 . Another O-ring 58 provides a leak proof connection between fitting 19 and outflow tube 16 . Again, a fitting (not shown) may be integral with the end of outflow tube 16 and adapted to fit tightly over the shoulder of fitting 19 which supports O-ring 58 .
The probe device 10 is supported on a cardboard tube 60 in conventional fashion. Cardboard tube 60 may be of any desired length, but typically will be of a length of approximately thirty four inches in order to facilitate support and handling of the probe 10 during immersion into bath 34 . A layer of ceramic fiber 62 preferably surrounds the body of probe 10 as shown. Ceramic fiber layer 62 is a high temperature resistant material which may be formed by drawing a fiber-colloidal ammonium silicate mixture under a vacuum. A layer of potting cement 66 may be used to bind together the parts of probe 10 as shown. In particular the potting cement 66 hardens to form a body supporting lower end of fitting 19 and glass tube 24 against the lower end of cardboard tube 60 to form an integral probe body.
Referring to FIG. 2, there is seen a modified version 110 of a probe of this invention. In the probe 110 of FIG. 2, parts which are numbered the same as in FIG. 2 refer to the same components. As seen, a modified connector block fitting 119 is provided with modified flow openings 121 which have an enlarged lower end 123 . An end view of the connector block fitting 119 is seen in FIG. 3 . In the modification of FIG. 2, the collecting tube 124 has a lower end 126 formed of a bell-shaped configuration 127 . The enlarged bell shaped portion 127 facilitates the collection of the stream of collected gas 32 which bubbles out of the molten metal bath 34 .
A metal and gas permeable disk 128 is modified in shape in order to fit between the interior of tube 124 and the exterior of the inner glass tube 30 . A porous disk 152 is also provided at the upper end of an appropriate shape to fit the upper end of glass tube 124 .
In FIG. 5, there is seen a flow diagram illustrating the relationship between the components of a preferred system used in the practice of the invention. In FIG. 5, rectangles 160 , 161 , 162 , and 163 indicate flow meters provided within the system. Valves 166 , 167 , 168 , 169 , and 170 are solenoid activated valves used to control the flow of gases through the system. Valves 172 , 173 , 174 , and 175 are metering valves. A vacuum pump 178 which exhausts to the atmosphere through a conduit 179 is provided to induce desirably rapid flow rates of gases through the system. Solenoid valves 166 , 168 , and 169 serve to control input of gases into the system. One line 190 is provided to supply pure inert carrier gas, such as nitrogen or argon. Another input line 192 controlled by solenoid valve 168 provides a supply of a carrier gas having a predetermined content of a gas, such as hydrogen or oxygen, to be determined mixed in the carrier gas. A further input conduit 194 controlled by solenoid valve 169 supplies containing a different concentration of gas, such as hydrogen or oxygen, which is to be tested for. Line 196 is an intake line to a mass spectrometer 197 used to determine the concentration of gases in the molten metal being tested. A katharometer device such as an Alscan TCD, may be used in addition to or instead of the mass spectrometer. Using Sievert's Law, the percent of a dissolved gas in the molten metal is derived from the partial pressure of that gas in the single line system at equilibrium.
Line 180 is a purge line used only during a purge cycle. Line 182 represents a constant purging line which may be open both during the purge cycle and the analysis cycle. Line 184 is a purge and intake line which purges during the purge cycle and serves to draw gases into the mass spectrometer 197 or other TCD, such as a katharometer, if used, during the analysis cycle. The preferred mass spectrometer includes its own turbomolecular pump to draw in a sample, in addition to pump 178 , whereas in the case of a katharometer, the pump 178 is needed to draw gases into the TCD.
When hydrogen is tested for, for example, a loss of hydrogen from the carrier gas to the molten steel takes place when the hydrogen content in the supplied carrier gas is higher than the hydrogen in the steel. A hydrogen content reading from higher hydrogen containing carrier gas has been found to be 0.3 to 0.4 ppm higher than a hydrogen reading using pure inert carrier gas. Hydrogen readings from carrier gases containing hydrogen mixtures lower than the hydrogen content in steel will read the same as or 0.1 to 0.2 ppm higher than a pure carrier gas. A processor is preferably used to compute the gas content in the metal based on comparison of the values obtained by a test using an elevated hydrogen and the value obtained by a test using a reduced hydrogen content. The later may either be zero or a preselected amount below the estimated content in the metal. The processor includes an output terminal to output the computed dissolved gas content.
The preferred system shown in the drawings system incorporates a non-recirculating single line gas analysis system to continuously supply fresh carrier gas to the system, bubble fresh carrier gas through the sensor, into the molten metal, collect the carrier gas containing the collected gases and dissolved gas such as hydrogen from the molten metal, and drawing the gases from the immersed sensor through the TCD instrument with vacuum, after which the gases are exhausted into the atmosphere. The single line from the carrier gas source to the atmospheric exhaust is broken only by the bubbling of the gas through the molten metal and the collection of the gases. This takes place in steel at the lower end of the sensor which is immersed from six to nine inches into the steel melt. This open exhaust single line system allows the quick removal of impurities that might be drawn into the system prior to the analysis or which exist, if any, in the expendable immersion probe or generated during the initial immersion and purge of the system. Impurities, for example, could result from the burning away of a paper slag cap, if used, the melting of the sensor's metal inner cap, or random minor impurities that may have been introduced into the sensor during the sensor manufacture, or, for example, water vapor remaining in the sensor as manufactured. These are purged through the system and completely exhausted from the system usually within eighten to twenty seconds during the pre-analysis immersion into the melt during the purge cycle and the initial part of the analysis cycle.
The system of this invention also does not require a device which signals that the probe is immersed into the steel, as seen in the prior art. An economical nitrogen inert carrier gas can flow continuously for short periods of time before the start of the purge cycle and after the completion of the analysis cycle in applications where nitrogen content is not being measured.
The timing sequences of a typical reading are as follows:
1. Push Start: Zero seconds;
2. Purge out of the molten metal: Fifteen to twenty five seconds;
3. Purge in the molten metal: ten to twenty seconds;
4. Zero setting: five seconds with pure nitrogen or argon;
5. Reading the equilibrium of the carrier and its unknown gas content: thirty to ninety seconds.
Sequence two allows time for the operator to get into position for immersion and allows the system to fully purge itself before immersion with the inert carrier gas. Sequence three is used to remove any impurities as discussed above from the sensor sampling chamber and to prevent and counteract the pressure of the molten metal from filling up the sampling chamber during immersion. Sequence four allows the TCD to memorize the base line zero reading of the inert gas carrier and establish a new zero point for each individual reading. Sequence five involves drawing unknown gases collected in up to three different carrier gases from the sensor through the detector and exhaust to the atmosphere using an aspirated vacuum or vacuum pump until an equilibrium measure is reached and read. The initial satisfactory equilibrium is reached between thirty five and sixty seconds, and sequential initial equilibria are reached in approximately, twenty seconds for each.
A preferred detection device for use with the sensor system of this invention is the PPT series of residual gas analyzers manufactured by NGS, a division of MKS Instruments, Inc., 24 Walpole Park South, Walpole, Mass. The instrument is a semi-portable, compact, computerized, low molecular weight mass spectrograph which operates under extremely high vacuums. The mass spectrograph characterizes analytically any gas collected by a carrier gas having a molecular weight less than two hundred with a potential sensitivity of one part per one hundred million. The mass spectrograph obtains a micro sample of gas from the gases being drawn from the immersion sensor device through the vacuum system and purged to the atmosphere, and within thirty seconds to one minute identifies and displays the analytical gases collected. An example Mass spectrograph display curve is shown in FIG. 6 wherein partial pressure traces are labeled by molecular weight. For example, hydrogen is one and two, oxygen is sixteen and thirty two, each curve being thus identified by the molecular weight of the detected gas.
Calibrations have been obtained to convert, by means of a microprocessor, partial pressures of the detected gases from the mass spectrometer display into part per million of hydrogen, oxygen, and nitrogen. For example, calibrations made to relate the partial pressure (in Torr) to the calculated hydrogen content (in ppm) in steel was accomplished by measuring high purity precisely standardized hydrogen/nitrogen mixtures from 1.5 ppm H 2 to 19.89 using an Alscan katharometer instrument simultaneously with the mass spectrometer and the comparative results plotted on an x/y scatter plot and a best-fit trend line. This type of comparison study can also be used to accurately calibrate other gases of interest, such as O 2 and N 2 , to the partial pressure readout of the mass spectrometer.
The Alscan instrument and the MKS Mass Spectrograph can be used simultaneously during the same steel plant production analysis cycle. One verifies the absolute accuracy and precision of the other's reading.
The MKS instrument is also able to determine oxygen in steel simultaneously with hydrogen in steel when using nitrogen carrier gas. The MKS Mass Spectrograph is also able to determine nitrogen, hydrogen, and oxygen in steel in ppm's precisely, accurately, and simultaneously using a different carrier gas, such as argon.
The qualitative and quantitative accurate simultaneous analyses of three different gases, hydrogen, nitrogen, and oxygen in steel using a mass spectrograph attached to a probe directly immersed in molten steel is a significant advance in the art. This procedure is applicable in ingot, production ladles, and continuous casting process equipment to levels lower than one ppm, by the mass spectrographic method with excellent precision and accuracy in less than two minutes, a total process time and accuracy heretofore unknown and unaccomplished in the trade.
While various preferred embodiments of the invention have been shown for purposes of illustration it will be understood that the invention is not be limited thereto, but includes equivalent structures falling within the true scope of the appended claims. | An immersion probe for determination of the concentration of a gas dissolved in molten metal includes a gas and molten metal-permeable, disk. A gas analysis method using the probe entails introducing into said metal through the probe inert gas streams which may contain a concentration of hydrogen, oxygen or nitrogen gas which is greater or less than that contained in the molten metal. The dissolved concentrations of the two gases after passage through the metal are compared and enable accurate computation of the content of hydrogen gas dissolved in the metal. Using a mass spectrometer with argon as an inert carrier, hydrogen, oxygen, and nitrogen concentrations may be determined by a single test procedure. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-In-Part application that claims the benefit of U.S. Non-Provisional patent application Ser. No. 11/833,864 filed Aug. 3, 2007, which is incorporated in its entirety herein by this reference.
FIELD OF THE INVENTION
This invention relates to the biological conversion of CO and mixtures of CO 2 and H 2 to liquid products.
BACKGROUND
The conversion of gas streams into liquid products by contact with a conversion medium in a liquid phase is well practiced in many fields. Where the solubility of the gas stream is limited, contacting and conversion of the gas stream of requires that the gas stream be disbursed within a liquid medium as a fine dispersion of micro bubbles to increase the mass transfer between the gas phase and the liquid phase. Getting the gas into the liquid phase is energy intensive and ways are continually sought to reduce the expense of providing the necessary energy to create a two phase dispersion of the gas and liquid.
A wide variety of devices are known for the dispersion of gas and liquid medium. Such devices include venturi injectors, slot injectors, or jet injectors and other high pressure mixers. Such gas transfer devices have found widespread use in a variety of fields including those of wastewater treatment and fermentation.
The field of fermentation is one in which particular application of this is of interest due to the increased emphasis on the conversion of renewable sources into liquid products such as motor fuels
Biofuels production for use as liquid motor fuels or for blending with conventional gasoline or diesel motor fuels is increasing worldwide. Such biofuels include, for example, ethanol and n-butanol. One of the major drivers for biofuels is their derivation from renewable resources by fermentation and bioprocess technology. Conventionally, biofuels are made from readily fermentable carbohydrates such as sugars and starches. For example, the two primary agricultural crops that are used for conventional bioethanol production are sugarcane (Brazil and other tropical countries) and corn or maize (U.S. and other temperate countries). The availability of agricultural feed stocks that provide readily fermentable carbohydrates is limited because of competition with food and feed production, arable land usage, water availability, and other factors. Consequently, lignocellulosic feed stocks such as forest residues, trees from plantations, straws, grasses and other agricultural residues may become viable feed stocks for biofuel production. However, the very heterogeneous nature of lignocellulosic materials that enables them to provide the mechanical support structure of the plants and trees makes them inherently recalcitrant to bioconversion. Also, these materials predominantly contain three separate classes of components as building blocks: cellulose (C 6 sugar polymers), hemicellulose (various C 5 and C 6 sugar polymers), and lignin (aromatic and ether linked hetero polymers). For example, breaking down these recalcitrant structures to provide fermentable sugars for bioconversion to ethanol typically requires pretreatment steps together with chemical/enzymatic hydrolysis. Furthermore, conventional yeasts are unable to ferment the C 5 sugars to ethanol and lignin components are completely unfermentable by such organisms. Often lignin accounts for 25 to 30% of the mass content and 35 to 45% of the chemical energy content of lignocellulosic biomass. For all of these reasons, processes based on a pretreatment/hydrolysis/fermentation path for conversion of lignocellulose biomass to ethanol, for example, are inherently difficult and often uneconomical multi-step and multi conversion processes.
An alternative technology path is to convert lignocellulosic biomass to syngas (also known as synthesis gas, primarily a mix of CO, H 2 and CO 2 with other components such as CH 4 , N 2 , NH 3 , H 2 S and other trace gases) and then ferment this gas with anaerobic microorganisms to produce biofuels such as ethanol, n-butanol or chemicals such as acetic acid, butyric acid and the like. This path can be inherently more efficient than the pretreatment/hydrolysis/fermentation path because the gasification step can convert all of the components to syngas with good efficiency (e.g., greater than 75%), and some strains of anaerobic microorganisms can convert syngas to ethanol, n-butanol or other chemicals with high (e.g., greater than 90% of theoretical) efficiency. Moreover, syngas can be made from many other carbonaceous feedstocks such as natural gas, reformed gas, biogas, peat, petroleum coke, coal, solid waste and land fill gas, making this a more universal technology path.
However, this technology path requires that the syngas components CO and H 2 be efficiently and economically dissolved in the aqueous medium and transferred to anaerobic microorganisms that convert them to the desired products. And very large quantities of these gases are required. For example, the theoretical equations for CO or H 2 to ethanol are:
6CO+3H 2 O→C 2 H 5 OH+4CO 2
6H 2 +2CO 2 →C 2 H 5 OH+3H 2 O
Thus 6 moles of relatively insoluble gases such as CO or H 2 have to transfer to an aqueous medium for each mole of ethanol. Other products such as acetic acid and n-butanol have similar large stoichiometric requirements for the gases.
Furthermore, the anaerobic microorganisms that bring about these bioconversions generate very little metabolic energy from these bioconversions. Consequently they grow very slowly and often continue the conversions during the non-growth phase of their life cycle to gain metabolic energy for their maintenance. Many devices and equipment are used for gas transfer to microorganisms in fermentation and waste treatment applications. These numerous bioreactors all suffer from various drawbacks. In most of these conventional bioreactors and system, agitators with specialized blades or configurations are used. In some others such as gas lift or fluidized beds, liquids or gases are circulated via contacting devices. The agitated vessels require a lot of mechanical power often in the range of 4 to 10 KW per 1000 liters—uneconomical and unwieldy for large scale fermentations that will be required for such syngas bioconversions. The fluidized or fluid circulating system cannot economically provide the required gas dissolution rates. Furthermore, most of these reactors in the process are configured for use with microorganisms in planktonic or suspended form i.e. they exist as individual cells in liquid medium.
In the field of fermentation the use of gas injection devices is known to disperse gas streams into liquids. U.S. Pat. No. 4,426,450 discloses a fermentation vessel that uses a plurality of jet injectors to mix air and a fermentation broth in the bottom of a fermentation vessel. The '450 reference requires a gas stream at sufficient pressure to overcome the hydraulic pressure of the liquid in the vessel.
Furthermore, for the suspended cultures to get high yields and production rates the cell concentrations in the bioreactor need to be high and this requires some form of cell recycle or retention. Conventionally, this is achieved by filtration of the fermentation broth through microporous or nonporous membranes, returning the cells and purging the excess. These systems are expensive and require extensive maintenance and cleaning of the membranes to maintain the fluxes and other performance parameters. Cell retention by formation of biofilms is a very good and often inexpensive way to increase the density of microorganisms in bioreactors. This requires a solid matrix with large surface area for the cells to colonize and form a biofilm that contains the metabolizing cells in a matrix of biopolymers that the cells generate. Trickle bed and some fluidized bed bioreactors make use of biofilms to retain microbial cells on solid surfaces while providing dissolved gases in the liquid by flow past the solid matrix. They suffer from either being very large or unable to provide sufficient gas dissolution rates.
Moving Bed Biofilm Reactors (MBBR) have been shown to be high-rate, compact system for wastewater treatment, particularly where slow growing organisms are involved. Hallvard, Odegaard describes the use of MBBR system for the treatment of wastewater in Innovations in wastewater treatment: the moving bed biofilm process—Water and Science & Technology Vol 53 No 9 pp 17-32. These biofilm type rectors are especially compatible with highly efficient (in terms of both gas transfer efficiency [power per mass of gas transferred] and dissolution efficiency) such as jet and/or slot aerators/gas transfer devices. The combination of the MBBR process and these gas transfer devices overcomes the problems associate with alternate approaches described above.
It is also highly desirable to retain the microorganisms in the form of a biofilm. It is known that single organism systems are susceptible to phase attack. However, forming a biofilm is one known method to reduce susceptibility of microorganisms to a phage attack.
SUMMARY OF THE INVENTION
The instant invention involves using a buoyant or suspended carrier as a media for supported the biomass in what is termed a MBBR. In this process the fermenting biomass adheres to and grows on the surfaces of an inert biomass carrier media as biofilm. The process delivers gaseous substrates CO and/or CO 2 /H 2 via any device that will promote high gas dissolution and utilization. Such devices include gas spargers and preferably a high efficiency gas transfer process such as jet or slot aerator/gas transfer devices. The gas injection device is positioned on a fermentation vessel in manner to provide direct injection of the gas and liquid into direct and immediate contact with microorganisms and fermentation broth. In addition the gas injector normally serves the additional function of creating eddy currents in the surrounding liquid for thoroughly mixing the contents of the fermentation vessel. Gas bubbles from the gas delivery device will rise to the liquid surface and provide additional mixing and gas dissolution. Desirably the fermentation vessel has sufficient depth to ensure high gas dissolution and utilization. Typically the fermentation vessel has a minimum depth of 9 meters that is wetted by the fermentation broth and achieves at least 80% gas dissolution and consumption. In a preferred form of this invention at least a portion of the microbubbles, after horizontal injection, will change direction and travel vertically through the fermentation broth for a distance of at least 9 meters feet. Other microbubbles may be absorbed into the fermentation broth before reaching the surface of the fermentation broth in the vessel.
The wetted depth of the fermentation broth provides the working volume where the motion of gas and liquid keeps the biomass carrier moving. The biomass carrier is typically maintained in the reactor via an outlet sieve or other suitable screening device. The turbulence created by any flow of gas and/or liquid through the vessel can also provide sufficient shear so as to maintain the biofilm thickness on the biomass carrier in the desirable range.
In a more specific embodiment this invention is a process for converting a feed gas containing at least one of CO, H 2 and CO 2 and a mixture of CO 2 , H 2 and CO to a liquid product. The process passes a feed gas into a vessel that retains a fermentation broth and microorganisms therein under anaerobic conditions with the fermentation broth supplying nutrients to the microorganisms that produce a liquid product from the feed gas. The feed gas and liquid medium pass into an injector to at least partially entrain the feed gas into the liquid medium as microbubbles and delivering the entrained feed gas and liquid medium to the fermentation broth as a plume. The plume gets injected into the vessel in a substantially horizontal direction. The term “substantially horizontal” means that the discharge direction of the injector along which it directs the gas and liquid, typically as plume varies by no more 35 degrees from the horizontal, preferably by no more than 30 degrees from the horizontal. The process retains the microorganism in the vessel on inert carriers having a surface supporting a biofilm of the microorganisms in the vessel. The carriers are arranged for circulation throughout the fermentation broth in the vessel. Circulation of the biomass carriers containing the microorganism and the broth in the vessel puts from time to time a portion of the carrier and the broth from in direct and immediate contact with the plume of feed gas and liquid medium at the location where the feed gas and liquid medium enter the vessel in a substantially horizontal direction. The plume passes upward and horizontally through the vessel after the substantially horizontal injection of the liquid medium and feed gas through the feed injector so that at least a part of the plume travels in a horizontal direction. Depending on the diameter of the vessel, the plume may travel across the width or diameter of the vessel, or with somewhat larger vessels at least half way across the width or diameter of the vessel. Very large vessels typically have substantially horizontal injection at multiple points around the circumference of the vessel so that broth and microorganisms and feed gas mix to deliver feed gas across the full cross section of the vessel. The process then withdraws fermentation broth containing liquid products from the vessel.
In other embodiments the process withdraws the fermentation broth through a carrier retainer to impede the withdrawal of the carrier material with the broth. The process is particularly suited for making ethanol. It has been observed that the presence of oxygenates such as ethanol in the fermentation media at as low as 1% (weight/volume) has a profound effect on gas transfer efficiency. The change in surface tension results in smaller bubbles being generated and therefore a significantly greater surface area of gas bubbles exposed to the liquid. The result is transfer rates of up to 3 times that observed for clean water.
The result of combining a MBBR process having a gaseous feed with a highly efficient gas transfer process, preferably such as a jet or slot aerators/gas transfer devices, results in an economical and high product volumetric production rate process for production of liquid products. One additional advantage of the slot and jet gas transfer devices is that they are relatively clog free and treatment of the syngas components for small particulates is not necessarily required.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing showing two different types of media for the MBBR biomass carrier.
FIG. 2 shows the carrier media of FIGS. 1( a ) and ( b ) with attached biofilm
FIG. 3 is a schematic drawing shows combination of a typical MBBR reactor and conventional gas sparging aerator for gas transfer
FIG. 4 is a schematic drawing shows combination of a typical MBBR reactor and slot aerator for gas transfer.
DETAILED DESCRIPTION OF THE INVENTION
Bioconversions of CO and H 2 /CO 2 to acetic acid, ethanol and other products are well known. For example, in a recent book concise description of biochemical pathways and energetics of such bioconversions have been summarized by Das, A. and L. G. Ljungdahl, Electron Transport Process in Acetogens and by Drake, H. L. and K. Kusel, Diverse Physiologic Potential of Acetogens, appearing respectively as Chapters 14 and 13 of Biochemistry and Physiology of Anaerobic Bacteria, L. G. Ljungdahl eds, Springer (2003). Any suitable microorganisms that have the ability to convert the syngas components: CO, H 2 , CO 2 individually or in combination with each other or with other components that are typically present in syngas may be utilized. Suitable microorganisms and/or growth conditions may include those disclosed in U.S. patent application Ser. No. 11/441,392, filed May 25, 2006, entitled “Indirect Or Direct Fermentation of Biomass to Fuel Alcohol,” which discloses a biologically pure culture of the microorganism Clostridium carboxidivorans having all of the identifying characteristics of ATCC no. BAA-624; and U.S. patent application Ser. No. 11/514,385 filed Aug. 31, 2006 entitled “Isolation and Characterization of Novel Clostridial Species,” which discloses a biologically pure culture of the microorganism Clostridium ragsdalei having all of the identifying characteristics of ATCC No. BAA-622; U.S. Pat. No. 8,143,037 entitled “Ethanolognic Clostridium species, Clostridum coskatii ” which discloses a biologically pure culture of the microorganism Clostridium coskatii and Clostridium autoethanogenum (Abrini et al., 1994) having all of the identifying characteristics of (DSMZ NO. 10061) all of which are incorporated herein by reference in their entirety. Clostridium carboxidivorans may be used, for example, to ferment syngas to ethanol and/or n-butanol. Clostridium ragsdalei may be used, for example, to ferment syngas to ethanol.
Suitable microorganisms and growth conditions include the anaerobic bacteria Butyribacterium methylotrophicum , having the identifying characteristics of ATCC 33266 which can be adapted to CO and used and this will enable the production of n-butanol as well as butyric acid as taught in the references: “Evidence for Production of n-Butanol from Carbon Monoxide by Butyribacterium methylotrophicum ,” Journal of Fermentation and Bioengineering, vol. 72, 1991, p. 58-60; “Production of butanol and ethanol from synthesis gas via fermentation,” FUEL, vol. 70, May 1991, p. 615-619. Other suitable microorganisms include Clostridium Ljungdahli , with strains having the identifying characteristics of ATCC 49587 (U.S. Pat. No. 5,173,429) and ATCC 55988 and 55989 (U.S. Pat. No. 6,136,577) and this will enable the production of ethanol as well as acetic acid. All of these references are incorporated herein in their entirety.
The instant invention uses MBBR in concert with highly efficient gas transfer devices, such as jet or slot aerators/gas transfer devices, to dissolve gases into the liquid phase for delivering CO and/or a mixture of H 2 and CO 2 to the anaerobic microorganism maintained as a biofilm on inert biomass carrier media. The microorganisms in the biofilm use the CO and/or H 2 /CO 2 in the gas and transform them into ethanol and other liquid products. The biomass support media allows the slow growing anaerobic microorganisms to be maintained in the fermentation vessel at concentrations well above what is possible with suspended culture. The result is a highly efficient and economical conversion of the CO and/or CO 2 /H 2 to liquid products.
This invention can be used with any stream that contains a suitable concentration of syngas components. Suitable streams will preferably contain a minimum of 10 wt. % CO and/or H 2 . The process will normally operate under anaerobic conditions.
Suitable media for the MBBR biomass carrier made from polymers have been recently developed and commercialized for wastewater treatment and purification applications. Typically these media are made from hydrophobic polymers such as polyethylene or polypropylene which are processed or formed to create a highly protected external or internal surface area for biofilm attachment and accumulation of high biomass concentrations. A protected surface is one in which the structure of the media minimizes direct contact between the microorganisms and other pieces of media. Several commercial organizations supply such media primarily as extruded cylindrical media.
Suitable media is commercially available from a number of companies including AnoxKaldnes, Siemens/Aqwise and Mutag. Some characteristics of the different media from AnoxKaldnes is given in the Table 1 below.
TABLE 1
Partial List of Commercially available MBBR media
Protected
Total
Length
Diameter
surface
surface
Company
Model
(mm)
(mm)
(m 2 /m 3 )
(m 2 /m 3 )
AnoxKaldnes
K1
7
9
500
800
K3
12
25
500
600
Natrix C2
30
36
220
265
Natrix M2
50
64
200
230
Biofilm-Chip M
2.2
48
1200
1400
Biofilm-Chip P
3
45
900
990
Hydroxyl
ActiveCell
15
22
448
588
The media employed are generally extruded cylindrical type media made from polypropylene, polyethylene or recycled plastics. These materials typically provide the media with a relative density of 0.9 to 0.98 with respect to the fermentation broth and a ratio of protected surface/total surface of at least 60%. The design of the media is such to maximize the overall surface area for attachment of a biofilm. Accordingly the internal or protected surface area will generally be at least 60% of the total surface area of the media. The media volume shall comprise between 30% and 70% of the wetted volume of the fermentation vessel.
FIGS. 1( a )- 1 ( d ) illustrate two examples of the many suitable structures that can supply the moving media for support of biofilms. FIG. 1( a ) depicts the transverse view of a spoke and hub type media. FIG. 1( a ) shows a cylinder 2 intersecting eight parallel vanes 4 that emanate from the center point of cylinder 2 and protrude outside its circumference. The internal sectors defined by the vanes and inner cylinder wall provide the interior surface for retention of a biofilm. FIGS. 1( c ) and 1 ( d ) illustrate another geometry for a support media 6 wherein an outer cylinder supports a rectangular grid work 10 of internal surfaces for the supporting a biofilm. FIGS. 1( b ) and 1 ( d ) depicts side views of the medial of FIGS. 1( a ) and 1 ( c ) respectively which typically have a nominal diameter of from 5 to 50 mm and a width between 2 and 50 mm.
FIG. 2 shows a biofilm growing on the support media 1 of FIGS. 1( a ) & 1 ( b ). The support media grows on the interior surfaces of the media. The internal vane structure blocks entry of surrounding carrier media to protect the biofilm while also providing additional surface for support of the biofilm.
FIG. 3 schematically shows a support media 3 suspended in a fermentation broth held by a fermentation vessel 16 of an MBBR process 14 . A conventional gas sparger 17 , of the type typically used for aeration, injects a feed gas 19 containing at least one of CO or a mixture of CO 2 and H 2 into the fermentation broth. The dispersed feed gas at least partially dissolves into the fermentation broth as it travels upwardly towards its liquid surface 18 . Gas recovery chamber 13 collects any residual feed gas and gaseous fermentation outputs for recovery as stream 11 . Stream 11 can undergo separation of gas components for recovery and/or recycle to stream 19 as desired.
The fermentation vessel maintains the fermentation broth and media at optimal metabolic conditions for the expression of the desired liquid products by the microorganisms. These conditions typically include a pressure of 1 to 5 bar and temperature of from 20 to 50.degree. C. within the fermentation vessel.
The dissolved feed gas feeds a biofilm that grows on support media 3 to produce the liquid products of this invention. A sieve device 5 screens the support media from flowing into an outlet 9 that recovers the liquid products from the vessel 16 . Preferably the sieve and outlet withdraw liquid from the upper section of the vessel but may withdraw liquid from any location at or below liquid level 18 .
The distance between the liquid level 18 and the bottom of vessel 16 defines the wetted depth of the MBBR process. Most applications will require a minimum wetted depth of at least 9 meters and wetted depths greater than 15 meters are preferred.
Liquid recovered via outlet 9 typically undergoes separation in a product recovery section (not shown) to recover liquid products. The product recovery section that removes the desirable product from liquid taken by outlet 9 , while leaving substantial amounts of water and residual nutrients in the treated stream, part of which is returned to the vessel 16 via line 7 . A nutrient feed may be added via to the broth as needed to compensate for the amount of water removed and to replenish nutrients. The nutrient feed may enter vessel 16 directly or via line 7 .
FIG. 4 depicts a generalized view of a flow arrangement similar to that of FIG. 3 except for the substitution of the conventional sparger 17 with a jet aerator 20 . The jet aerator 20 provides a high velocity “throat” or contact chamber 23 that educts the feed gas 19 ′ comprising CO and/or CO 2 /H 2 into intimate contact with fermentation broth withdrawn from outlet 9 . A line 22 transfer the broth from outlet 9 to a pump 17 that raises the pressure of the liquid to a range of about 3 to 5 bar. Pump 17 to provides the desired liquid velocity to subject the educted gas to high shear forces that dissolves some of the gas and generates relatively fine microbubbles (0.1 to 1.0 mm in diameter) with the remainder of the gas. Ejection of this mixture from the contact chamber 23 into the fermentation vessel creates a plume 21 that typically enters the fermentation vessel horizontally or at a slight downward angle. The force of the plume creates eddy currents in the surrounding liquid thoroughly mixing the contents of the fermentation vessel. As the plume dissipates, the gas bubbles rise to the liquid surface providing additional mixing and gas dissolution.
A 36 m 3 fermenter in the form of a fermentation vessel having a 1.5 meter diameter and a 20 meter wetted depth is used as a MBBR for the conversion of carbon monoxide and hydrogen into ethanol. The fermenter is filled approximately 50% of the liquid working volume with AnoxKaldnes K1 media. A gas of about 40% CO, 30% H 2 , and 30% CO 2 is fed to the vessel at 3.5 m 3 per minute and 3 bar absolute inlet pressure and the residual gas exits the module at less than 0.1 bar outlet pressure. This gas flow is added to a slot aeration/gas transfer device operated at a liquid recycle flow rate of 400 liters per minute. The fermentation medium having the composition given in Table 2 is used to fill the fermenter and maintained at about 37degrees c. The fermenter is maintained under anaerobic conditions.
The fresh fermentation medium contains the components listed in Tables 2 & 3(a)-(d). Initially, the bioreactor process is operated in the batch mode and inoculated with 2000 liters of an active culture of Clostridium ragsdalei ATCC No. BAA-622. The fermentation pH is controlled at pH 5.9 in the first 24 hours by addition of 1 N NaHCO 3 to favor cell growth and then allowed to drop without control until it reaches pH 4.5 to favor ethanol production. The process remains in the batch mode for 1 day to establish the attachment of the microbial cells on the media surface. Then, the process is switched to continuous operation, with continuous withdrawal of the fermentation broth for product recovery and replenish of fresh medium. With the continuous operation, suspended cells in the fermentation broth are gradually removed from the bioreactor process and decrease in concentration, while the biofilm attached on the media continues to grow until the biofilm reaches a thickness equilibrated with the operating conditions. The ethanol concentration at the end of the 10-day batch operation is 5 g/L. At the beginning of the continuous operation, a low broth withdrawal rate is selected so that the ethanol concentration in the broth does not decrease but increases with time. The broth withdrawal rate is then gradually increased. After 30 days of continuous operation, the ethanol concentration increases to 30 g/L with the broth withdrawal rate at 22 liters per minute. The attached cell concentration is approximately 5 g/L dry weight at this point in time.
TABLE 2
Fermentation Medium Compositions
Components
Amount per liter
Mineral solution, See Table 3(a)
25 ml
Trace metal solution, See Table 3(b)
10 ml
Vitamins solution, See Table 3(c)
10 ml
Yeast Extract
0.5 g
Adjust pH with NaOH
6.1
Reducing agent, See Table 3(d)
2.5 ml
TABLE 3(a)
Mineral Solution
Components
Concentration (g/L)
NaCl
80
NH 4 Cl
100
KCl
10
KH 2 PO 4
10
MgSO 4 •7H 2 O
20
CaCl 2 •2H 2 O
4
TABLE 3(b)
Trace Metals Solution
Components
Concentration (g/L)
Nitrilotriacetic acid
2.0
Adjust the pH to 6.0 with KOH
MnSO 4 •H 2 O
1.0
Fe(NH 4 ) 2 (SO 4 ) 2 •6H 2 O
0.8
CoCl 2 •6H 2 O
0.2
ZnSO 4 •7H 2 O
1.0
NiCl 2 •6H 2 O
0.2
Na 2 MoO 4 •2H 2 O
0.02
Na 2 SeO 4
0.1
Na 2 WO 4
0.2
TABLE 3(c)
Vitamin Solution
Components
Concentration (mg/L)
Pyridoxine HCl
10
Thiamine HCl
5
Roboflavin
5
Calcium Pantothenate
5
Thioctic acid
5
p-Aminobenzoic acid
5
Nicotinic acid
5
Vitamin B12
5
Mercaptoethanesulfonic acid
5
Biotin
2
Folic acid
2
TABLE 3(d)
Reducing Agent
Components
Concentration (g/L)
Cysteine (free base)
40
Na 2 S•9H 2 O
40 | A process for converting a feed gas containing at least one of CO, CO 2 , and/or H 2 to a liquid product using biomass that grow on the surface of carriers suspended in a fermentation broth within the vessel of a moving bed bioreactor (MMBR). An injector is used to at least partially dissolved the feed gas in the fermentation broth, at least partially entrain the gas in the broth as microbubbles and to introduce the mixture of the entrained gas and broth into the vessel in a substantially horizontal direction. The injection of the mixture creates eddy current in the surrounding liquid for thoroughly mixing the fermentation broth in the vessel and for keeping the biomass carrier moving to provide sufficient shear so as to maintain a biofilm thickness on the carrier in a desirable range. | 2 |
FIELD OF THE INVENTION
This invention relates to movable wall systems used to divide large rooms into smaller rooms.
BACKGROUND OF THE INVENTION
A movable wall system comprised of a plurality of continuously hinged panels is traditionally extended or retracted (stacked) by either manual means or with the assistance of an overhead electrical chain drive system. Electric systems may be desirable for a multitude of reasons, such as the weight of the panels (and the force required to move the wall) being prohibitive for a typical individual to move manually, or simply for convenience. Aptly powered electrical systems are successful in moving the wall, but, as described below, are often inefficient when "flattening" the wall once it is nearly fully extended and when "breaking" the wall to begin retracting the wall from its fully extended position. These inefficiencies are translated into increased costs in manufacturing and in maintaining the electrically driven systems. Alternatives need to be provided which are both efficient and cost effective.
When extending a movable wall, it is important that all of the wall panels be completely coplanar or "flattened" for a variety of reasons. Aesthetically, the wall will be more pleasing if it is entirely flat thereby appearing more like permanent walls. If the wall is dividing areas in which limited sound transmission between the rooms is of concern, there must be no gaps between the panels of the movable wall, nor should there be gaps at either end of the movable wall. Any gaps significantly reduce the acoustic quality of the wall. Also, it is very important that the wall be fully extended, rigid, and locked into position, so that the wall does not begin to retract if a force is inadvertently applied to move the wall toward the stacked position.
Some electrically driven systems incorporate large motors, that provide much more horsepower than actually required to move the wall, to solve the flatness problem. These systems use so much force to extend the wall that the panels "snap" into place from inertial force. This is an expensive solution, not only in terms of manufacturing costs, but also in the maintenance of the systems since the electric motor will experience undue loads while attempting to flatten the wall and, hence, its life cycle may be shortened.
To assist an electric system in solving the flatness problem, some systems connect adjacent panels with cables and/or springs to straighten the wall when near the fully extended position. These systems are costly to manufacture, are difficult to service as they require constant adjustment to function properly, and have a tendency to destroy the trim on the panel.
When retracting (stacking) the continuously hinged movable wall, several methods are used to begin the retraction process. The retraction process will begin very simply if a deflection is made in the joint between adjacent panels that are closest to the stack jamb. This is called "breaking" the wall. In some systems, this deflection must be made manually, i.e. by a person pushing the abutting edges of the two adjacent panels to cause the panels to pivot. Another method is to use a "retraction bar." This bar is connected via a pivot point to the top of the panel closest to the stack jamb and is fixed to the ceiling. As the drive motor urges the panels toward the retracted position, the retraction bar translates the backward force to a sideward force, causing the trailing panel to break. This type of breaking assembly still requires a large motor to create a break in the wall and imposes undue stress on the motor, thus reducing motor life span. In addition, a retraction bar is inappropriate for a movable wall system with stringent sound transmission requirements as the bar protrudes through the upper trim of the first panel. Moreover, a retraction bar is aesthetically undesirable as it is visible. Finally, the retraction bar is a control system independent from the electric drive, so the functions of each are not coordinated.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the invention to provide a movable wall panel system which does not require the use of a relatively large motor to either flatten or break the wall panels.
It is another object of the invention to provide a movable wall panel system that does not require cable and/or spring subsystems to connect adjacent panels to assist in completing the flattening process.
It is another object of the invention to provide a movable wall panel system in which the wall is automatically flattened.
It is another object of the invention to provide a movable wall panels system that does not require the use of a retraction bar to perform the break the walls from the fully extended position.
It is another object of the invention to provide a movable wall panel system in which breaking the wall from a fully extended position is accomplished by automatic means.
It is another object of the invention to provide a movable wall panel system in which mechanisms provided for breaking the wall from a fully extended position do not adversely affect the acoustic quality of the wall.
It is another object of the invention to provide a movable wall panel system in which flattening and breaking are accomplished through the use of an integrated system which requires only one power source.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an overhead diagrammatic view of a movable wall panel system in accordance with the present invention in which the wall panels are in a stacked position.
FIG. 2 shows an overhead diagrammatic view of a wall panel system in accordance with the present invention in which the wall panels are in a partially extended position.
FIG. 3 shows an overhead diagrammatic view of a movable wall panel system in accordance with the present invention in which the wall panels are in a fully extended position.
FIG. 4 shows an overhead diagrammatic view of the movable wall system of the present invention showing the wall panels in a non-extended position.
FIG. 5 shows a vertical section view of the movable wall panel system of the present invention showing an electrically powered actuator and the wall panels a fully extended position.
FIG. 6 shows a vertical section of the movable wall panel system in accordance with the present invention showing the electrically powered actuator having moved the panels into the non-extended position.
FIG. 7 shows a schematic of the electronic circuit in accordance with the present invention showing the interconnection of the drive motor, the timing motor, switches and wall switches.
SUMMARY OF THE INVENTION
A movable wall panel system comprises at least two connected movable wall panels, each panel having opposing sides, the wall panels being movable along a predetermined path having a midline, the panels being movable between an extended position in which the opposing sides of the panels are substantially coplanar, and a non-extended position in which the planes defined by the opposing sides of the panels intersect. An electrically powered actuator is disposed adjacent the path traversed by the wall panels, the actuator having a contact member capable of engaging at least one of the wall panels to apply a force against the wall panel to thereby move the wall panels from the extended position to the non-extended position. Each connected pair of adjacent wall panels can also be characterized in that one panel may pivot along a vertical pivot axis with respect to its connected adjacent wall panel, and the panels being movable between a fully extended position in which the planes defined by the respective opposing surfaces of the wall panels are coplanar, a partially extended position in which the planes defined by the respective opposing surfaces of the wall panels are not coplanar and in which each vertical pivot axis is on the same side of the midline of the predetermined path as when the panels are in the fully extended position, and a non-extended position in which the planes defined by the opposing surfaces of the wall panels are not coplanar and in which not all vertical pivot axes are on the same side of the midline of the predetermined path as when the panels are in the fully extended position. A means is provided for applying a forward force to the panels to thereby move the panels from the non-extended position toward the partially extended position. A motor means is provided for automatically applying a force in the reverse direction when the panels move from the non-extended position to the partially extended position, to thereby move the panels to the fully extended position.
DETAILED DESCRIPTION
Referring now to the FIG. 1, there is shown an overhead diagrammatic view of a wall panel system in accordance with the present invention with the panels located in the "stacked" face-to-face orientation. The movable panel system consists of leading panel 11, trailing panel 12, and intermediate panels 13, 14, 15 and 16. Leading panel 11 and each alternate panel thereafter is provided with upwardly projecting trolley 17 which fits into an overhead track (not shown) which defines a predetermined path extending across the room. The centerline of that predetermined path is the midline. Trailing panel 12 is hingedly connected to wall jamb 18 by hinge 19. Likewise, all other adjacent panels are connected by hinges 19, which thereby define a vertical pivot axis with respect to adjacent wall panels. The wall panel system of the present invention is preferably movable by an electric drive motor and associated hardware 20 which is positioned above the overhead track. Motor 20 drives chain 61 positioned in track channel 60 (as shown in FIGS. 5 and 6) which is connected to trolley 17 of leading panel 11. Motor 20 may be driven in either direction to extend the wall panels or to retract the wall panels. Moreover, in the preferred embodiment, drive motor 20 is of the capacitance inductance type to thereby provide additional power and torque when the motor is first actuated.
In order to extend the wall panels, electrical switches SW1 and SW2 (FIG. 7) are simultaneously actuated. In the preferred embodiment, switches SW1 and SW2 are positioned on alternate sides of the overhead track as shown in FIGS. 1, 2, 3 and 4, and therefore require two separate persons to independently actuate the switches. This provides a safety mechanism to prevent inadvertent injury to persons positioned near the wall panels.
As leading panel 11 is moved toward the opposite end of the room to the partially extended position shown in FIG. 2, the panels at the front of the train, namely panels 11, 16, 15 and 14, will tend to move into a "flattened" position. It will be appreciated that each wall panel is comprised of two opposing sides and that when adjacent panels are completely flattened, the opposing sides of adjacent panels will be substantially coplanar. However, the panels at the opposite end of the train will not usually automatically move into a position in which their opposing sides are coplanar with the panels toward the leading end of the train. As shown in FIG. 2, panels 12 and 13 are disposed in a slightly angular relationship. However, when the panels are in the partially extended position as shown in FIG. 2, each hinge is on the same side of the midline of the track as when the panels are in the fully extended position shown in FIG. 3. It will be appreciated by those of skill in the art that when hinge 31 is on the same side of the midline as when all panels are in the fully extended position, and a reversing force is applied from leading panel 11 toward jamb 18, that all panels will be moved into the fully extended or "flattened" position shown in FIG. 3.
It will further be appreciated that the reversing action of motor 20 should be actuated only after wall panels 12 and 13 have moved from the non-extended position to the partially extended position. As is evident by comparing FIG. 4 to FIG. 2, when wall panel 12 moves into the partially extended position, the gap between it and jamb 18 is reduced in size and accordingly, panel 12 depresses limit switch 70. As described below, this causes the forward motion of drive motor 20 to cease and causes drive motor 20 to momentarily move in the reverse direction.
It will further be appreciated that when a reverse force is applied from leading panel 11, and hinge 31 is on the opposite side of the track midline as shown in FIG. 4, that the reverse force will tend to push hinge 31 upward so that the panels begin to retract and move into the face-to-face stacked relationship shown in FIG. 1.
Accordingly, it may be appreciated that there may be defined three distinct types of positions in which the panels may be positioned, namely, a fully extended position in which the planes defined by the respective opposing surfaces of the wall panels are coplanar as shown in FIG. 3, a partially extended position as shown in FIG. 2 in which the planes defined by the respective opposing surfaces of the wall panels are not coplanar (i.e., the planes defined by panels 12 and 13 in FIG. 2) but in which the vertical pivot axes of each hinge is on the same side of the midline of the track as when the panels are in the fully extended position, and, a non-extended position as shown in FIGS. 1 and 4 in which the planes defined by the opposing surfaces of the wall panels are not coplanar and in which not all vertical pivot axes are on the same side of the midline of the track as when the panels are in the fully extended position.
It will be further appreciated by those of skill in the art that once the panels are in the fully extended position as shown in FIG. 3, that the panels must be "broken" before they may be moved to their retracted position shown in FIG. 1. Obviously, when the wall panels are flattened and a reverse force is applied to the leading panel 11, the force will only jam the edges of the panels together unless one of the panels is able to pivot. Accordingly, it is an important objective of the present invention to provide a system in which two adjacent panels may be "broken," i.e., the vertical pivot axis moved so that it is on the opposite side of the midline of the track.
In the preferred embodiment of the present invention, adjacent panels 12 and 13 may be broken by a contact member such as rotatable cam 40. Cam 40 is attached to the overhead track and is positioned to engage at least one of the wall panels to apply a force against the wall panel to thereby move the wall panels from the extended position to the non-extended position. In particular, with reference to FIG. 4, it will be appreciated that cam 40 has been rotated 180° from the position shown in FIG. 3 and cam 40 has contacted the cam engaging surface of the wall panel 12, such as cam follower 41 during this process. Moreover, in the preferred embodiment, the cam is rotated prior to power being supplied to the overhead drive motor to begin retracting the panels.
The movement of the cam in order to break the panels may be further appreciated with reference to FIGS. 5 and 6. FIG. 5 shows overhead track 51 which includes interior chamber 52 capable of receiving a dolly or trolley (not shown) which downwardly extends and connects to frame 53 of wall panel 12. Overhead track 51 also includes chain housing 60 and chain 61. As described above, chain 61 is connected to the trolley attached to leading panel 11. Sweeps 54 are disposed intermediate the upper portion of wall panel 12 and track 51. Wall panel 12 further includes an upwardly and outwardly projecting flange 55 which supports cam follower 41 by bolt 56. Overhead track 51 also has mounted on one side thereof an electrically powered actuator comprised of timing motor 57 which drives downwardly extending shaft 58 and is attached to cam 40. Also mounted on shaft 58 are limit switches LS5, LS3 and LS2 which are described in further detail below.
It will be appreciated that wall panel 12 as shown in FIG. 5 is in the fully extended position and its midline is parallel with the midline of overhead track 51. When timing motor 57 is actuated to turn cam 40, cam 40 engages cam follower 41 to move wall panel 12 to the side and to the non-extended position shown in FIG. 6.
A suitable drive motor system 20 for use with the present invention is the Modernfold 1000 drive unit available from Overhead Door Co., Inc. of Shelbyville, Ind. This system comes preconfigured with an additional limit switch, LS4 (as shown in FIG. 7), located on a shaft of the drive motor which may be adjusted to trip after the drive motor shaft has rotated a predetermined number of rotations. Accordingly, this trip switch is used to turn off the drive motor when the panels are retracted to the fully retracted position shown in FIG. 1.
To stack the wall, i.e., to move the wall from the fully extended position to a stacked position, both key switches SW1 and SW2 are placed in the stacked position. Key switches on both sides of the wall must be placed in this position to ensure that individuals on both sides of the wall are aware of the intention to begin stacking the wall. Once key switches SW1 and SW2 are engaged, timing motor 57 is actuated. Limit switch LS3 becomes activated only after cam 40 rotates 180 degrees. At that point, the panels will be "broken" and in the non-extended position. Once limit switch LS3 is activated, timing motor 57 is stopped and drive motor 20 is actuated, driving the panel system toward the stacked position. Once close to being completely stacked, limit switch LS4, which is located on the shaft of drive motor 20, is actuated, which stops drive motor 20.
To extend the movable wall system from its stacked position to the fully extended position, drive motor 20 is actuated after both key switches SW1 and SW2 are placed in the extend position. Key switches on both sides of the wall must be placed in this position to ensure that individuals on both sides of the wall are aware of the intention to begin extending the wall. Drive motor 20 continues to run and the wall continues to move toward the fully extended position until limit switch LS1 is activated. Limit switch LS1 as shown in FIGS. 1, 2, 3, and 4 is connected to the door jamb 18 in such a manner that when in movable wall panels are in the stacked or non-extended positions (shown in FIGS. 1 and 4 respectively) LS1 is not depressed or activated. In the partially extended position shown in FIG. 2, LS1 is activated by panel 12. In the fully extended position shown in FIG. 3, LS1 is depressed. In the preferred embodiment, at the time that limit switch LS1 is activated, drive motor 20 is stopped and timing motor 57 begins its reset cycle. The reset cycle of timing motor 57 starts by rotating cam 40 180 degrees. During that rotation, limit switch LS5 is activated and drive motor 20 is actuated to run in the reverse direction momentarily to bring the panels through to the fully flattened position. Timing motor 57 then continues to rotate until limit switch LS2 is activated. Once limit switch LS2 is activated, the reset cycle of timing motor 57 is complete.
It will further be appreciated that many changes could be made to the above embodiment which would be within the spirit and scope of the present invention. For example, any other actuating means, such as a solenoid, may be used to break the panels instead of the disclosed cam. Alternatively, electronic timers could be used to actuate the drive motor and breaking actuator, instead of the rotary limit switches. It would also be within the spirit of the invention to employ a depressible limit switch position at the far end of the wall system in lieu of the limit switch located in the stack jamb. | A movable wall system used to divide a large room into small rooms has a train of wall panels connected by hinges. The system includes a mechanism for automatically flattening the panels when moving them into their fully extended position by applying a momentary backward force to the panels as the panels approach the extended position. The system also includes a mechanism for breaking the panels to permit easy retraction and stacking of the panels. A rotatable cam positioned on the overhead track of the wall system forces a hinge of two connected panels outward so that the panels will stack when a reversing force is applied to the panels. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a fuel injection control system for an automobile engine to calculate a fuel injection quantity from an air induced quantity in cylinders of the engine in dependency on a throttle opening degree and an engine speed.
Generally, in the fuel injection control system of the type described above, a basic injection quantity Tp is first calculated with an induced air quantity and an engine speed as parameters and an actual fuel injection quantity Ti is then calculated by correcting the basic injection quantity Tp with various factors for the correction.
The induced air quantity is measured by an induced air quantity sensor arranged on a directly downstream side of an air cleaner in a L-jetronic system. On the other hand, the induced air quantity is estimated in response to the throttle opening degree (α) and the engine speed (N) in a so-called "α-N" system. The "α-N" system makes simple or compact the engine unit and, hence, is superior from the viewpoint of economics because of fewer problems. In these advantageous view points, the "α-N" system is widely used for various types of the engine units.
The air quantity induced into the cylinder has a time-lag of first order with a certain time constant. The time-lag of first order occurs according to a lag of changing an intake manifold with air. The induced air quantity estimated in response to the throttle opening degree and the engine speed at a transient state takes a value larger than an actual air quantity in the cylinder and, hence, an air-fuel ratio becomes rich when the throttle valve is rapidly opened at the transient state.
Particularly, in an MPI (multi-point injection) type engine, a calculation timing of the fuel injection quantity supplied into the respective cylinders is set just before the intake stroke, that is an intake valve is about open. So that, at the transient state wherein the induced air quantity is changed during the intake stroke, there occurs a difference between the induced air quantity at the calculation timing of the fuel injection quantity and the air quantity in the cylinder at the completion of the intake stroke. The difference adversely affects air-fuel ratio control characteristics.
In order to obviate such defect, the Japanese Patent Laid-open Publication No. 60-43135 discloses a system wherein an actual air quantity induced into the cylinder is estimated in dependency on the throttle opening degree at the initial stage of the transient state and the engine speed. The fuel injection quantity is changed with the time-lag of first order, so as to reach the fuel injection quantity corresponding to the estimated induced air quantity. Thus, an improvement in the air-fuel ratio control characteristics is attempted.
However, in the described prior art, there is no disclosure of means for estimating the required induced air quantity in dependency on the throttle opening degree and the engine speed.
In another aspect, in a prior application of the same applicant of the present application (Japanese Patent Application No. 63-257645), there is disclosed a system wherein an induced air quantity at this moment is first obtained in dependency on the throttle opening degree and the engine speed. Then the obtained air quantity is corrected by the correction factor depending on the subtracted difference between the obtained air quantity and the preliminarily obtained air quantity. Thus, the intake air quantity approximate to the actual air quantity induced in the cylinder is obtained.
Thus, as shown in FIG. 7, an estimated intake air quantity Map* set at a fuel injection point A of the first cylinder of BTDCθ0 (for example, BTDC 80° CA) before the intake stroke an induced air increasing quantity Map at an intake stroke completion point B is primarily estimated in dependency on the difference between an induced air quantity Map(tn) calculated from the throttle opening degree and the engine speed at the point A and the induced air quantity Map(tn-1) in the preceding cycle. A value obtained by adding the induced air quantity Map(tn) to the estimated induced air increasing quantity Map is the estimated induced air quantity Map* at the fuel injection point A. A basic fuel injection quantity Tp is calculated from the estimated induced air quantity Map* and a desired air-fuel ratio A/F as (Tp=Map*/A/F).
However, an acceleration of an engine equipped with more than four cylinders always starts on the intake stroke of a certain one cylinder and, hence, the aforementioned difference between the calculated air quantity and the actually induced quantity is caused in the present intake stroke of the certain cylinder. Therefore, an induced air quantity becomes lean by a quantity corresponding to a portion shown with hatching lines in FIG. 8.
Such a difference will be also caused during a deceleration cycle as a reverse phenomenon.
As a result, the air-fuel ratio control characteristics at the initial stage of the transient state becomes worse and a good response is not achieved. Moreover, the exhaust gas emission at the transient state becomes worse and, hence, the load to the catalyst increases.
SUMMARY OF THE INVENTION
An object of the present invention is to substantially improve defects or disadvantages encountered in the prior art and to provide a system for controlling fuel injection of an automobile engine capable of supplying fuel injection quantity corresponding to air quantity in a cylinder at the completion timing of an intake stroke even in an initial stage of a transient state as well as in a transient operation, thus improving a transient response and load applied to a catalyst.
This and other objects can be achieved according to the present invention by providing a system for controlling fuel injection of an engine having a cylinder, an intake passage, a throttle valve provided in the intake passage and a fuel injector. The system comprises: means for detecting a first engine speed with respect to a first reference crank angle before an intake stroke of the engine and a second engine speed with respect to a second reference crank angle on the intake stroke; means for detecting a first throttle opening degree with respect to the first reference crank angle and a second throttle opening degree with respect to the second reference crank angle; means for estimating a throttle opening degree and an engine speed in accordance with the first throttle opening degree and the first engine speed; means for calculating a first air quantity in the cylinder during the intake stroke with the first throttle opening degree and the first engine speed; means for calculating a first air quantity in the cylinder during the intake stroke with the first throttle opening degree and the first engine speed; means for calculating a second air quantity in the cylinder in accordance with the second throttle opening degree and the second engine speed; means for calculating a first fuel injection quantity in accordance with the first air quantity in the cylinder and a second fuel injection quantity in accordance with the second air quantity in the cylinder calculated by said air quantity calculating means so as to start the injection of the first quantity at the first reference crank angle; and means for calculating asynchronous interrupted fuel injection quantity in accordance with a difference value between the first and second fuel injection quantities calculated by said fuel injection calculating means so as to carry out the injection of the difference value at the second reference crank angle.
In a preferred embodiment of the present invention, the control system further comprises a unit arranged in association with the fuel quantity calculating means for setting an air-fuel ratio feedback correction coefficient and also comprises means for estimating a throttle opening degree and an engine speed in accordance with the first throttle opening degree and the first engine speed so as to transmit estimated results to the first air quantity calculating means.
According to the fuel injection control system of the engine described above, a throttle opening degree and an engine speed are primarily estimated with respect to the reference crank angle before the intake stroke and the estimated air quantity in the cylinder is calculated in the intake stroke with the estimated throttle valve opening degree and the engine speed as parameters. In addition, the air quantity in the cylinder is calculated in accordance with the throttle valve opening degree and the engine speed with respect to the reference crank angle on the intake stroke. The fuel injection quantities are calculated in accordance with the estimated air quantity in the cylinder so as to start the injection at the crank angle before the intake stroke quantity in the cylinder. Another fuel injection quantities are calculated in accordance with the air quantity in the cylinder. The asynchronous interrupt fuel injection quantity is calculated on the basis of the difference between both the fuel injection quantities.
Accordingly, it will be possible to supply the fuel injection quantity corresponding to air quantity in the cylinder in the completion of the intake stroke even in an initial stage of the transient state as well as during the transient operation. Thus, the transient response, the exhaust gas emission and the load to be applied to a catalyst are improved.
The other objects and features of the present invention will become understood from the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a fuel injection control system according to the present invention;
FIGS. 2A and 2B show flowcharts representing operational sequences of the fuel injection control system;
FIG. 3 is a schematic sectional view of an engine control system;
FIG. 4 is a schematic illustration showing an intake state;
FIGS. 5A to 5E are time charts showing fuel injection timing;
FIGS. 6A to 6C are graphs representing changing characteristics of a throttle valve opening degree, an intake air quantity and an air-fuel ratio, respectively;
FIGS. 7A and 7B are graphs showing a fuel injection quantity estimation based on a conventional technology; and
FIG. 8 shows a graph representing a delay of air quantity in a cylinder based on the conventional technology.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 to 6 represent one embodiment according to the present invention.
Referring to FIG. 3 showing a schematic arrangement of a fuel injection control system of an automobile engine, an engine 1 is provided with an intake port 1a with which an intake passage 2 communicates. A throttle valve 3 is assembled in the intake passage 2, and an air chamber 2a is formed between the throttle valve 3 and the intake port 1a. An air cleaner 4 is provided at an upstream side of the intake passage 2.
An intake air temperature sensor 5 is mounted to an expanded chamber of the air cleaner 4. A sensor 6 for detecting an opening degree of the throttle valve 3 is mounted thereto. An injector 7 having a nozzle directed to the intake port 1a is arranged downstream of the intake passage 2.
The engine 1 is also provided with an exhaust port 1b with which an exhaust pipe 8 communicates. A sensor 9 for detecting an air-fuel ratio is mounted to the exhaust pipe 8. A catalyst means 10 is disposed downstream of the air-fuel ratio sensor 9.
The engine 1 also includes a crank shaft 1c to which a crank rotor 11 is mounted. A plurality of projections 11a to 11d are formed on the outer periphery of the crank rotor 11. A crank angle sensor 12 is arranged at a portion opposing to the crank rotor 11.
In FIG. 3, only the #1 cylinder of the four-cylinder engine is shown. The projections 11a and 11b represent a reference crank angle θ 0 (for example, θ 0 =BTDC 80° CA) with respect to the #1 and #2 cylinders and the #3 and #4 cylinders, respectively. Accordingly, an opening angle between the projections 11a and 11b is 180°. An angle θ 1 is formed between the projections 11a and 11c and the projections 11b and 11d. An engine speed N is calculated from an angular speed by detecting the angle θ 1 .
The projection 11a designates a reference crank angle REF1 before the intake stroke representing the fuel injection start timing with respect to the #1 and #2 cylinders. And the projection 11a also designates a reference crank angle on the intake stroke with respect to the #3 and #4 cylinders. Furthermore, the projection 11b designates a reference crank angle REF2 before the intake stroke representing the fuel injection timing with respect to the #3 and #4 cylinders and also designates a reference crank angle on the intake stroke with respect to the #1 and #2 cylinders (see FIGS. 5B and 5C).
In FIG. 3, reference numeral 13 designates a control unit. A fuel injection control means 14 of the control unit 13 shown in FIG. 1 comprises estimating means 15, means 16 for calculating an estimated quantity of the air passing the throttle valve 3, means 17 for calculating an estimated pressure in the air chamber 2a, means 18 for calculating an estimated air quantity in the cylinder, means 19 for calculating an air quantity passing the throttle valve 3, means 20 for calculating a pressure in the air chamber 2a, means 21 for calculating an air quantity in the cylinder, means 22 for calculating a reference fuel injection quantity, means 23 for setting an air-fuel ratio feedback correction coefficient, means 24 for calculating a fuel injection quantity, and means 25 for calculating an asynchronous fuel injection quantity (ΔTi).
A fuel injection quantity Ti and the asynchronous injection quantity ΔTi are set to the cylinders, respectively. The quantities (Ti, ΔTi) will be referred to with respect to the #1 cylinder hereunder for the sake of convenience.
FIG. 4 represents a model of an intake system. Referring to FIG. 4, an air quantity per unit time dM/dt in the chamber 2a of the intake passage 2 is represented by a difference between an induced air quantity Mat (throttle valve passing air quantity) and an air quantity fed to the cylinder (air quantity in the cylinder).
The air quantity per unit time is represented as
dM/dt=Mat-Map (1)
The equation of state in the chamber 2a is
P·V=M·R·T (2).
where
P: inner pressure
V: inner volume
M: air quantity
R: gas constant
T: intake air temperature
From the above equations (1) and (2), an inner pressure per unit time dP/dt in the chamber 2a is calculated as
dP/dt=R·T·(Mat-MaP)/V (3).
Assuming that the gas constant R and the inner volume V in the equation (3) above are constant, R·T/V becomes a function with respect to the intake air temperature T. Accordingly, the quantity of air Map in the cylinder can be calculated in accordance with the values of the throttle valve passing air quantity Mat, the chamber pressure P and the intake air temperature T.
The estimating means 15 in FIG. 1 operates in the following manner. An estimated throttle valve opening degree α(tn), and an estimated engine speed N(tn) after a delay time (Td) in response to a present throttle valve opening degree α(tn) detected by the throttle valve opening degree sensor 6 as well as a present engine speed N(tn) detected by the crank angle sensor 12 are calculated in accordance with the following equation when a signal representing the reference crank angle (REF 1) before the intake stroke is output from a crank angle sensor 12 for detecting the projection 11a of the crank rotor 11.
The delay time (Td) means a time lapsed for a predetermined period from an angle of the fuel injection start timing to an angle corresponding to the middle of the intake stroke so as to be calculated in dependency on the engine speed. Almost all of the air quantity induced in the cylinder of the engine 1 is induced at the middle of the intake stroke. ##EQU1## where S: α or N
t: calculation cycle
tn: the present cycle of time
(tn-1): preceding cycle of time
Thus, a variation of the throttle valve opening degree or a variation of the engine speed after a certain time is calculated in the second term of the right side in the equation (4) and the throttle valve opening degree α(tn) or the engine speed N(tn) after a certain time is estimated by adding the present throttle valve opening degree α(tn) or the present engine speed N(tn) in the first term of the right side to the variation.
In a calculating element 16a of the throttle valve passing estimated air quantity calculating means 16, an estimated quantity of air Mat(tn) passing the throttle valve is calculated from the estimated throttle valve opening degree α(tn) and the engine speed N(tn) obtained by the estimating means 15 and an estimated pressure P(tn) in the chamber 2a calculated in the means 17 for calculating the estimated inner pressure therein.
Thus, the throttle valve passing estimated air quantity Mat(tn) is represented as ##EQU2## where C: air flow quantity coefficient
A: air passage sectional area
Ψ: Reynold's number
Pa: atmospheric pressure
ρa: atmospheric air density
In the equation (5), with respect to the Reynold's number Ψ, when P/Pa>{2/(k+1)} 1/ (K-1), ##EQU3## and when P/Pa<{2/(k+1)} 1/ (K-1), ##EQU4## where k: coefficient
g: air weight
In the means 16 for calculating the throttle valve passing estimated air quantity, there are provided an air passage sectional area table TB A for storing the air passage sectional area A preliminarily obtained through experiment with the throttle valve opening degree α as a parameter. The means 16 also has flow quantity coefficient map MPc for storing the flow quantity coefficient C obtained through experiment with the throttle valve opening degree u and the engine speed N as parameters. There are also provided a Reynold's number map MPΨ wherein the Reynold's number Ψ is obtained through experiment with the inner pressure P and the atmospheric pressure Pa as parameters. However, in FIG. 1, the atmospheric pressure Pa is considered to be a normal pressure and only the inner pressure P is considered as a parameter.
In the means 16, the air passage sectional area A is read from the air passage sectional area table TB A with the estimated throttle valve opening degree α(tn), calculated by the estimating means 15. The air flow quantity coefficient C is retrieved from the flow quantity coefficient map MPc with the estimated throttle valve opening degree α(tn) and the estimated engine speed N(tn). The Reynold's number Ψ is retrieved from the Reynold's number map MPΨ with the estimated inner pressure P(tn) calculated by the means 17.
The air quantity Mat(tn) is calculated in the calculating element 16a in accordance with the equation (5) on the basis of the air passage sectional area A, the air flow quantity coefficient C and the Reynold's number Ψ.
The estimated pressure calculating means 17 is provided with a coefficient table TB·R·T/V for storing a coefficient R·T/V obtained through experiment with an intake air temperature T and also provided with a calculating element 17a for calculating, with the intake air temperature T detected by the intake air temperature sensor 5, the estimated pressure P(tn+1) in dependency on the coefficient retrieved from the coefficient table TB·R·T/V, the air quantity Mat(tn) calculated by the air quantity calculating means 16, and the estimated air quantity Mat(tn) in the cylinder calculated by the means 18 for calculating the estimated air quantity.
In the means 18, the estimated air quantity Map(tn) is calculated in accordance with the following equation. ##EQU5## where D: stroke volume (piston displacement)
N: engine speed
ηv: volumetric efficiency
Thus, the coefficient D/2·R·T is considered to be a function of the intake air temperature T, so that the coefficient D/2·R·T can be preliminarily obtained through experiment from the coefficient table TB·D/2·R·T with the intake air temperature T. The volumetric efficiency ηv is also preliminarily obtained through experiment with the engine speed N and the throttle valve opening degree α and is then stored in the volumetric efficiency map MPηv.
The calculating means 18 is also provided with a calculating element 18a for retrieving the coefficient D/2·R·T from the coefficient table TB·D/2·R·T on the basis of the equation (6). The calculating element 18a retrieves the volumetric efficiency ηv from the volumetric efficiency map MPηv with the engine speed N and the throttle valve opening degree α estimated in the estimating means 15. The calculating element 18a further calculates the estimated air quantity Map(tn) from the estimated engine speed N(tn) and the estimated pressure P(tn) calculated in accordance with the program in the preceding cycle of time of the estimated pressure calculating means 17.
The estimated air quantity Map(tn) is calculated in accordance with the following equation: ##EQU6##
The means 19 for calculating air quantity passing through the throttle valve, the means 20 for calculating pressure in the chamber 2a, and the means 21 for calculating air quantity in the cylinder are also provided with the maps MPc, MPΨ, MPηv and the tables TB A , TB·R·T/V, TB·D/2·R·Tf as provided for the respective calculating means 16, 17 and 18.
The respective calculating means 19, 20 and 21 shown in FIG. 3 perform the calculations in response to the throttle valve opening degree α(tn'), the engine speed N(tn'), and the intake air temperature T at a time when the reference crank angle (REF2) signal on the intake stroke detecting the projection 11b of the crank rotor 11 is output from the crank angle sensor 12. However, since the intake air temperature T has less displacement per unit time, a sampling cycle may be long in comparison with the engine speed N.
In the air quantity calculating means 19, the air passage sectional area A is retrieved from the air passage sectional area table TB A with the throttle valve opening degree α(tn'). The air flow coefficient C is retrieved from the flow coefficient map MPc with the throttle valve opening degree α(tn') and the engine speed N(tn'). And the Reynold's number Ψ is retrieved from the Reynold's number map MPΨ with the pressure P(tn') detected by the pressure calculating means 20.
The calculating means 19 is provided with a calculating element 19a for calculating the throttle valve passing air quantity Mat(tn') in accordance with the equation (5).
In the means 20 for calculating the pressure in the chamber 2a, the coefficient RT/V is retrieved from the coefficient table TB·RT/V with the intake air temperature T. The calculating means 20 is provided with a calculating element 20a for calculating the pressure P(tn'+1) in accordance with the equation (3) in response to the coefficient RT/V, the throttle valve passing air quantity Mat(tn') calculated by the calculating means 19, and the air quantity Map(tn') calculated by the calculating means 21.
In the calculating means 21, the coefficient D/2·R·T is retrieved from the coefficient table TB·D/2·R·T with the intake air temperature T. The volumetric efficiency ηn is retrieved from the volumetric efficiency map MPηv with the engine speed N(tn') and the throttle valve opening degree α(tn'). Accordingly the air quantity Map(tn') is calculated as follows in accordance with the equation (6)in response to the pressure P(tn') calculated on the basis of the proceeding program of the calculating means 20 and the throttle valve opening degree α(tn'). ##EQU7##
In the basic fuel injection calculating means 22, the basic fuel injection quantities Tp and Tp (Tp=Map/A/F; Tp=Map/A/F) as the desired air-fuel ratio A/F are respectively calculated from the estimated air quantity Map (tn) and the air quantity Map(tn').
The air-fuel ratio feedback correction coefficient setting means 23 reads the output signal from the air-fuel ratio sensor 9 and sets the air-fuel ratio feedback correction coefficient K by the proportion-integration (PI) control.
The fuel injection quantity calculating means 24 carries out the feed back correction of the respective basic fuel injection quantities Tp and Tp calculated by the calculating means 22 in dependency on the air-fuel ratio feedback correction coefficient KFB set by the air-fuel ratio feedback correction coefficient setting means 23 and calculates the fuel injection quantities Ti and Ti (Ti=Tp·KFB; Ti=Tp·KFB).
Fuel injection pulse signal is output based on the fuel injection quantity Ti to the injector 7.
In the asynchronous interrupt injection calculating means 25, the fuel injection quantities Ti and Ti calculated by the fuel injection quantity calculating means 24 are compared. In case of Ti<Ti and Ti<T180 (lapse time for the rotation of 180° CA), a fuel injection signal corresponding to the difference ΔTi (ΔTi=Ti-Ti) is transmitted to the injector 7.
To the contrary, in case of Ti>T180 or Ti>Ti, the interrupt injection is not carried out.
Namely, as shown in FIGS. 5A to 5E, the regular fuel injection starts at a time when a signal representing the reference crank angle REF1 before the fuel induction stroke of the #1 cylinder is generated by the crank angle sensor 12. On the other hand, the asynchronous interrupt injection starts at a time when a signal representing the reference crank angle REF2 on the intake stroke is generated by the sensor 12. Both the reference crank angle signals REF1 and REF2 are output in accordance with the detection of the projections 11a and 11b of the crank rotor 11. Both the projections 11a and 11b have 180° CA phase as shown in FIG. 3. Accordingly, in a case where the fuel injection quantity Ti is larger than T180, the asynchronous interrupt fuel injection cannot be carried out. In addition, the asynchronous interrupt fuel injection quantity ΔTi calculated from the difference between Ti and Ti cannot be calculated, even in a case where the fuel injection quantity Ti is less than T180, but the fuel injection quantity Ti is larger than the fuel injection quantity Ti. Therefore, in such case, the asynchronous interrupt fuel injection is not carried out.
The control sequence of the fuel injection control means 14 will be described hereunder with reference to the flowchart of FIG. 2.
Referring to FIG. 2A, at the step S101, when the signal REF1 of the reference crank angle before the intake stroke is output, the estimated throttle opening degree α(tn) and the estimated engine speed N(tn) are calculated in response to the opening degree α(tn) and the engine speed N(tn), respectively.
At the step S102, the estimated air quantity Mat(tn) is calculated from the estimated throttle opening degree α(tn) and the estimated engine speed N(tn) calculated at the step S101 and the estimated pressure P(tn) calculated at the step S104.
Thereafter, at the step S103, the air quantity Map(tn) is calculated in accordance with the estimated throttle opening degree α(tn) and the estimated engine speed N(tn) calculated at the step S101, the intake air temperature T, and the estimated pressure P(tn) calculated at the step S104 of the preceding program.
At the step S104, the present estimated pressure P(tn+1) is calculated in accordance with the intake air temperature T, the throttle valve passing estimated air quantity Mat(tn) calculated at the step S102, and the estimated air quantity Map(tn) calculated at the step S103.
Thereafter, at the step S105, the basic fuel injection quantity Tp for the basis of the desired air-fuel ratio A/F preliminarily set is calculated (Tp=Map(tn)/A/F) in accordance with the estimated air quantity Map(tn) calculated at the step S103.
At the step S106, the fuel injection quantity Ti is calculated by correcting the basic injection quantity Tp calculated at the step S105 with the air-fuel ratio feedback correction coefficient KFB (Ti=Tp=KFB).
At the step S107, the fuel injection pulse based on the fuel injection quantity Ti is output to the injector 7.
An interrupt processing of the asynchronous interrupt fuel injection quantity is carried out at the step S108 when the signal REF2 of the reference crank angle on the intake stroke is output.
The interrupt processing will be represented by the flowchart of FIG. 2B.
First, at the step S201, the air quantity Mat(tn') passing the throttle valve is calculated from the throttle opening degree α(tn') and the engine speed N(tn') calculated at a time when the reference crank angle signal REF2 is generated on the intake stroke, and the pressure P(tn') calculated at the step 203 of the proceeding program.
Thereafter, at the step S202, the air quantity Map(tn') is calculated from the throttle opening degree α(tn') and the engine speed N(tn'), the intake air temperature T, and the pressure P(tn') calculated at the step S203 of the proceeding program.
At the step S203, the present pressure P(tn+1) is calculated in accordance with the intake air temperature T, the throttle valve passing air quantity Mat(tn') calculated at the step S201, and the air quantity Map(tn') calculated at the step S202.
Thereafter, the step proceeds to the step S204, the basic fuel injection quantity Tp for the basis of the desired air-fuel ratio A/F preliminarily set is calculated (Tp=Map(tn')/A/F) in accordance with the air quantity Map(tn') calculated at the step S202.
At the next step S205, the fuel injection quantity Ti is calculated by correcting basic injection quantity Tp calculated at the step S204 with the air-fuel ratio feedback correction coefficient KFB (Ti=Tp KFB).
In accordance with the steps, the interrupt processing is completed.
The completion of the interrupt processing, back to the steps of the flowchart of FIG. 2A, at the step S109, the fuel injection quantity Ti calculated at the step S106 and the fuel injection quantity Ti calculated at the step S205 are compared. And in case of Ti<Ti, the next step S110 starts, whereas in case of Ti≧Ti, the program is completed as shown in FIG. 2A.
At the step S110, the pulse cycle of the fuel injection quantity Ti calculated at the step S106 and the T180 (lapsed time for the rotation of 180° CA) are compared. In case of Ti≧T180, the program is completed, whereas in case of Ti≦T180, the next step S111 starts. The asynchronous interrupt fuel injection quantity ΔTi (ΔTi=Ti-Ti) is calculated from the difference between the fuel injection quantities Ti and Ti.
At the step S112, the fuel injection pulse in accordance with the asynchronous interrupt fuel injection quantity Ti calculated at the step S111 is output to the injector 7.
As described hereinbefore, as shown with respect to the #1 cylinder in FIG. 5D, in a case where it is discriminated that the fuel injection quantity Ti estimated before the intake stroke becomes short as the calculation result of the fuel injection quantity Ti on the intake stroke, the interrupt injection of the fuel corresponding to the underquantity is carried out on the intake stroke.
As a result, as shown in FIG. 6C, the air-fuel ratio control characteristic in the transient state can be remarkably improved in comparison with the case where no correction of the injection quantity is made on the intake stroke. In addition, as shown in FIG. 6B, the intake air quantity in the transient state changes from the air quantity with delay to the air quantity substantially the same as the actually induced air quantity. Accordingly, the control characteristic of the ignition cycle set on the basis of the intake air quantity and the engine speed can be also improved.
While the presently preferred embodiment of the present invention has been shown and described, it is to be understood that this disclosure is for the purpose of illustration and that various changes and modifications may be made without departing from scope of the invention as set forth in the appended claims. | A fuel injection control system for an automotive engine, including a device which, before an intake stroke cycle, estimates what an estimated throttle opening degree and an estimated engine speed will be for the engine after a predetermined time period in the intake stroke cycle has lapsed, based on the throttle opening degree and engine speed and calculates a first fuel injection quantity to be injected before an intake stroke cycle, and a device which, during the intake stroke cycle, calculates a second fuel injection quantity and computes an asynchronous interrupted fuel injection quantity to be injected during the intake stroke cycle, based on the difference between the first and second fuel injection quantity. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a divisional application of application Ser. No. 09/504,646, filed Feb. 14, 2000 now U.S. Pat. No. 6,481,136.
FIELD OF INVENTION
The present invention relates to the fashioning of extensions on ammunition magazines and more particularly to pull-tab and loop handle extensions that are positioned on the floor end of ammunition magazines by either replacing the floor plate, modifying the floor plate or extending the side magazine walls in order to aid with both the extraction of said ammunition magazine from ammunition pouches and the insertion into a weapon.
BACKGROUND OF THE INVENTION
The use of loops to aid in the removal of ammunition magazines from a storage compartment is known in the prior art. Likewise, the use of handle attachments or tabs or other extensions to carry ammunition magazines and other objects is also known. These attachments and modifications, while suitable for their individual purposes, are not as suitable for the purpose of this invention, namely providing an extension that is of one piece with an ammunition magazine or with the floor plate of said magazine for the purpose of extraction of said magazine from ammunition pouches worn on the user. For example, the current practice of forming duct tape tabs and cord loops on ammunition magazines; U.S. Pat. No. 6,212,815 to Fitzpatrick; U.S. Pat. No. 5,566,487 to Vaid; U.S. Pat. No. 4,442,962 to Musgrave; U.S. Pat. No. 2,825,991 to Stadelmann; U.S. Pat. No. 2,205,967 to Wise; U.S. Pat. No. 1,797,951 to Gaidos; U.S. Pat. No. 1,245,499 to Orme; U.S. Pat. No. 888,560 to White; and U.S. Pat. No. D-33,384 are all illustrative of the prior art.
Currently, in the field, soldiers use either loops of parachute cord attached to ammunition magazines by duct tape or they form tabs by folding duct tape over the butt end of their ammunition magazines. The loops and tabs aid soldiers in the extraction of said magazines from ammunition pouches carried on the user. However, the duct tape tends to wear and often needs replaced. The duct tape also leaves a sticky residue when removed and provides no other benefit other than the increased friction or fastening a pull loop to the ammunition magazine. Soldiers have also extracted the inside portion of a length of parachute cord, leaving the casing, tied said casing together and positioned the formed loop so that it encircles the floor plate of an ammunition magazine before they replaced said floor plate, with the loop, in the magazine. Thus they have formed a loop, extending from the bottom of the magazine.
While the aforementioned inventions accomplish their individual objectives, they do not describe an integral extension that is used primarily for the extraction of ammunition magazines from ammunition pouches, as evidenced by the duct tape modifications used in the field. Handle and loop attachments used in the prior art are mainly used for affixing an ammunition magazine to other objects, such as clothing or vehicles. In one of the two cases where handle attachments are used for extraction, the handle is a simple metal wire forming a loop and is not adapted for use in the various positions a user may wear an ammunition pouch. There are also disadvantages with the duct tape modifications, particularly regarding removal and in the amount of slack in a loop of parachute cord. Fitzpatrick '815 discloses a handle attached to an external sleeve, not a handle integral with the walls of the magazine. None of the other disclosed patents have a handle integral with the walls of the magazine. In this respect, the extensions according to the present invention depart substantially from the usual designs in the prior art. In doing so, this invention provides handle extensions integral with the walls of ammunition magazines that are primarily designed for the purpose of aiding the extraction of ammunition magazines from pouches worn on the user.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of attachments and grip extensions, this invention provides extensions for use on the base of ammunition magazines. As such, the present invention's general purpose is to provide new and improved integral extensions that will aid in the extraction of ammunition magazines from pouches worn on the user.
To attain this, the invention has three individual embodiments. The first embodiment essentially comprises a replacement floor plate, typically molded of a hard plastic or metal, with a tab or loop extending from the replacement floor plate, typically molded from a more resilient plastic or thermoplastic compound. The product would be manufactured by using a bifurcated molding process where the floor plate portion would be molded first and the extension would be molded onto the floor plate in a second molding step. Alternatively, the floor plate may be molded or fashioned with at least one anchoring hole and the handle then either injection molded onto the floor plate or pre-molded with at least one anchoring means and mechanically coupled to the floor plate. The second embodiment would require retrofitting all existing floor plates with at least one anchoring hole along the center of their elongated sides or boring a plurality of holes through a floor plate and either injection molding or mechanically coupling a handle onto the floor plate. In the third embodiment, a plastic magazine would be molded with a resilient loop or tab on its base end or a handle may be attached to the base end by mechanical, ultrasonic welding, or adhesive means. This application focuses on the third embodiment.
These designs have numerous advantages over the prior art. First, the extensions are integral with the magazine and have a lower incidence of grip failure. Second, the standard means of ejection causes the butt end of the magazine to impact the ground. The molded handle portion acts as a shock absorber for the magazine when it is ejected from the rifle and reduces impact damage to the magazine. Third, the extensions abut against the lid of the pouch. This abutment effectively anchors the magazine against the pouch lid and reduces noise caused by the rattling of magazines against pouch when the user is moving.
The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
The primary object of the present invention is to provide integral extensions for use on ammunition magazines to aid in their extraction from ammunition pouches.
Other objects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a standard M-16 magazine.
FIG. 2 is an exploded view of the magazine in FIG. 1 .
FIG. 3 is a perspective view of the invention detailing the side extension embodiment.
FIG. 4 is an exploded view of the adhesive embodiment of the invention.
FIG. 4 a is a perspective view of the invention in FIG. 4 assembled.
FIG. 5 is an exploded view of the invention using anchoring nodes on the magazine.
FIG. 5 a is a perspective view of the invention in FIG. 5 assembled
FIG. 6 is an exploded view of the invention using rivets to fasten the handle to the magazine.
FIG. 6 a is a perspective view of the invention in FIG. 6 assembled.
FIG. 7 is a perspective view of the invention with a single wall extended, thereby forming a tab.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, the preferred embodiment of the new and improved integral extensions for ammunition magazines embodying the principles and concepts of the present invention will be described. Specifically, it will be noted in the figures, especially FIGS. 3, 4 , 5 , and 6 that the invention relates to the addition of extensions to the sidewalls of ammunition magazines. Before the invention can be explained, a brief description of the structure of an ammunition magazine, shown in FIGS. 1 and 2, is necessary. The generic magazine 2 is a relatively simple structure. The outer casing 4 , formed by four sidewalls, is suitably sized and shaped to receive ammunition. The casing 4 has a feed end 6 and a floor, or butt, end 8 . The feed end 6 is designed to engage the weapon. Inside the casing, a follower plate 10 is in contact with the follower spring 12 , which is in turn, in contact with the floor plate 14 . When ammunition is loaded into the feed end 6 , the follower plate 10 compresses the follower spring 12 against the floor plate 14 . This compression is relaxed when a round of ammunition is loaded into the weapon's firing chamber and the spring 12 therefore raises the follower plate 10 , and associated ammunition relative to the magazine 2 and weapon. The raising readies the next round of ammunition for loading into the weapon's firing chamber after the first round's casing is expelled.
The preferred embodiment of the invention, shown in FIGS. 3, 4 , and 7 , at least one wall 32 of an ammunition magazine 30 is extended above the level of the floor plate 38 . The extension 35 may be fashioned into whatever shape a user desires, including extending a plurality of sides and molding them together, such as a loop 34 in FIG. 3 or the tab 74 in FIG. 7. A handle may be added to the magazine in a number of different methods. Referring to FIG. 5, the magazine may be molded with an anchor point 52 and a separate handle 54 may be either molded onto the anchor directly or may be ultrasonically welded onto the magazine 50 . Handle 54 , if molded separately, may have molded notch 56 to interface with the anchor point 52 . A handle may also be attached mechanically to a magazine, such as by the rivets 62 shown in FIG. 6 or by an adhesive anchoring base 42 in FIG. 4 . In FIG. 4, the improvement is the use of the handle 44 , which is superior to parachute cord and may be molded in any fashion disclosed above, along with broad adhesive bases 42 , with a temporary adhesive backing 44 . Unlike the “para-cord loops” the handle does not move relative to the magazine, allowing for the entire range of benefits of use of the handles with a lower cost than other handle embodiments.
Referring to FIG. 3, the handle 34 should extend approximately 1.5 to 1.75 inches above floor plate 32 . This will enable the handle 34 to engage the lid of an ammunition pouch and also allow enough space to remove the floor plate 32 , if necessary. With the loop handle version, the handle 34 should have a width varying from 1.0 to 0.5 inch. The handle 34 is thicker at its apex 36 so as to better withstand the stress of pulling the invention and the magazine out of the ammunition pouch by the handle 34 . The width of handle 34 at apex 36 is less than the rest of handle 34 so that a user's finger may curl around handle 34 . For ease of fabrication and to increase friction between a finger and the handle 34 , the underside of the apex 36 may be molded in a “step-like” pattern. For the purposes of this application, a “step-like” pattern consists of a series of parallel surfaces, each at a different relative level from the surfaces immediately adjacent to the given surface.
To utilize a tab style handle, shown in FIG. 7, handle 74 may be molded with a variety of shapes, including but not limited to ovals, cylinders, knobs, and wedges. Ideally, handle height should be between 1.0 and 1.75 inches. No limitation as to shape should be inferred from the drawings. For the illustrated variation, a small, reinforced hole 80 is provided in the handle 74 so that a user may hook the magazine onto a carabineer after ammunition is spent. In both variations, roughened recessed areas 35 , 79 should be provided. In the loop version, recessed area 35 extends along the length of handle 34 . The shape of handle determines recessed areas with the tab version shown in FIG. 7 . For the version of the tab shown in FIG. 7, recessed areas 79 are provided on the planar faces of the handle 74 . Also, the top of the handle 74 is molded with a ridge 77 to facilitate gripping.
Although the present invention has been described with reference to preferred embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. | Integral extensions to aid in the extraction of ammunition magazines from ammunition pouches are provided in three embodiments. In this embodiment, the sides of an ammunition magazine are extended, either by molding or affixing a handle directly to the sides of the magazine, to provide a handle. This embodiment provides a more steam-lined handle adapted for use specifically in the extraction of magazines from ammunition pouches and other storage means. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method for producing cephalosporins 7-substituted with an amino-thiazolylacetic group of formula
[0002] in which R 1 is hydrogen or a residue of a nucleophilic compound, R 2 is a hydroxyl or substituted hydroxyl, R 3 is hydrogen or methoxyl.
[0003] U.S. Pat. No. 5,567,813 describes a method for producing cephalosporins of formula (I)—in which however R 3 is only hydrogen—according to which an acyl group of formula
[0004] is introduced into the amino group of molecules of formula
[0005] by reacting a compound of formula (V) with a compound of formula
[0006] where R 4 is a C 1 -C 4 alkyl.
BACKGROUND OF THE INVENTION
[0007] The alkyl groups (II) and their preparation are described in U.S. Pat. No. 4,152,432 and U.S. Pat. No. 4,327,210; the preparation of the compounds of formula (IV) is described in U.S. Pat. No. 5,502,200 in the name of the same proprietor as U.S. Pat. No. 5,567,813.
DISCUSSION OF THE RELATED ART
[0008] According to U.S. Pat. No. 5,567,813, the compound (IV) is reacted with the compound (V) in which the reactive groups NH 2 and COOH are free: it has been noted that for certain meanings of R 1 , the method described in the US patent leads to the production of cephalosporins (I) with high yields and purities, whereas for other meanings of R 1 , to give certain important cephalosporins such as cefpirome (Examples 13 and 14) and cefepime (Examples 15 and 16), the yields are decidedly lower.
BRIEF SUMMARY OF THE INVENTION
[0009] The object of the present invention is to provide a process which can be easily implemented to produce all cephalosporins of formula (I) with the same ease and with high yields.
DETAILED DESCRIPTION OF THE INVENTION
[0010] This process is characterised by introducing an acyl group of formula
[0011] into the amino group of a molecule of formula
[0012] by reacting in an anhydrous organic solvent a compound of formula (III) with a compound of formula
[0013] where R 4 is a C 1 -C 4 alkyl, finally removing the trimethylsilyl groups by known methods, to give the cephalosporins of formula (I).
[0014] Preferably said residue of a nucleophilic compound is chosen from the group consisting of methoxy, acetoxy, (1-methyl-1H-tetrazol-5-yl)thio, (5-carboxymethyl-4-methyl-2-thiazolyl)thio, (2-furanylcarbonyl) thio, (2,5-dihydro-6-hydroxy-2 -methyl-5-oxo-as-triazin-3-yl)thio, 1-methylpyrrolidine, 2,3-cyclopentene-1-pyridine, 1-(5,6,7,8-tetra-hydroquinoline) and 1-pyridine, said substituted hydroxyl being chosen from the group consisting of methoxyl and 1-carboxy-1-methylethoxy.
[0015] Again preferably, said inert anhydrous organic solvent is chosen from the group consisting of methylene chloride, ethylacetate and DMF.
[0016] The compounds of formula (III) are easily obtained from molecules of formula (V) in the manner described in detail in EP-B-0612750. Some embodiments of the invention will now be described in detail.
EXAMPLE 1
[0017] 10 g of 7-amino-3-(2,5-dihydro-2-methyl-6-hydroxy-5-oxo-as-triazin-3-yl)thiomethyl-3-cephem-4-carboxylic acid are suspended in 70 ml of dichloromethane. 18.4 g of N,O-bis-(trimethylsilyl)acetamide are added and the mixture is agitated for 2 h at ambient temperature.
[0018] 16.2 g of diethylthiophosphoryl-(Z)-(2-aminothiazol-4-yl)methoxyimino acetate are added and the mixture left to react at ambient temperature for 4 hours. 30 ml of water are added to the reaction mixture and 30% NaOH is dripped in at 15°/20° C. until pH 7.5-7.8 is attained.
[0019] The aqueous phase is separated and is treated for 20 minutes at ambient temperature with 1 g of carbon, then filtered and washed with 15 ml of water. 60 ml of acetone and 3 2 g of NaCl are added. Crystallization commences and the mixture is left under agitation for 1 h.
[0020] 240 ml of acetone are finally dripped in to complete the precipitation. The mixture is filtered, washed with 20 ml of 9:1 acetone/water and then with 400 ml of acetone.
[0021] It is dried at +40° C. under reduced pressure.
[0022] 16.8 g of ceftriaxone disodium hemiheptahydrate are obtained (titre 84% as anhydrous acid). Molar yield: 94.6%.
[0023] Ceftriaxone is a compound of formula (I) in which R 1 is (2,5-dihydro-6-hydroxy-2-methyl-5-oxo-as-triazin-3-yl)thio, R 2 is methoxyl and R 3 is hydrogen.
EXAMPLE 2
[0024] 10 g of 7-amino-3-(2,5-dihydro-2-methyl-6-hydroxy-5-oxo-as-triazin-3-yl)thiomethyl-3-cephem-4-carboxylic acid are suspended in 50 ml of anhydrous DMF. 18.4 g of N,O-bis-(trimethylsilyl)acetamide are added and the mixture is agitated for 2 h at ambient temperature.
[0025] 16.2 g of diethylthiophosphoryl-(Z)-(2-aminothiazol-4-yl)methoxyimino acetate are added and the mixture left to react at ambient temperature for 4 hours. 30 ml of water are added to the reaction mixture and 30% NaOH is dripped in at +15/+20° C. until pH 7.5-7.8 is attained.
[0026] The aqueous solution is washed repeatedly with dichloromethane.
[0027] The resultant aqueous solution is treated for 20 minutes at ambient temperature with 1 g of carbon, then filtered and washed with 15 ml of water. 250 ml of acetone are rapidly added and the mixture is left under agitation to crystallize for 1 h.
[0028] The mixture is filtered, washed with 20 ml of 9:1 acetone/water and then with 400 ml of acetone.
[0029] It is dried at +40° C. under reduced pressure.
[0030] 16 g of ceftriaxone disodium hemiheptahydrate are obtained (titre 82% as anhydrous acid).
EXAMPLE 3
[0031] 10 g of 7-amino-3-(2,5-dihydro-2-methyl-6-hydroxy-5-oxo-as-triazin-3-yl)thiomethyl-3-cephem-4-carboxylic acid are suspended in 70 ml of dichloromethane. 5.9 g of trimethylchlorosilane and 8.7 g of hexamethyldisilazane are added. The mixture is agitated for 2 h at ambient temperature.
[0032] 16.2 g of diethylthiophosphoryl-(Z)-(2-aminothiazol-4-yl)methoxyimino acetate are added and the mixture left to react at ambient temperature for 18 hours.
[0033] Operating as in Example 1 results are obtained which are quantitatively perfectly superimposable.
EXAMPLE 4
[0034] 10 g of 7-amino-3-(2,5-dihydro-2-methyl-6-hydroxy-5-oxo-as-triazin-3-yl)thiomethyl-3-cephem-4-carboxylic acid are suspended in 70 ml of dichloromethane. 16.7 g of N,N′-bis-trimethyl-silylurea are added and the mixture is agitated for 2 h at ambient temperature.
[0035] 16.2 g of diethylthiophosphoryl-(Z)-(2-aminothiazol-4-yl)methoxyimino acetate are added and the mixture left to react at ambient temperature for about 10 hours.
[0036] 30 ml of water are added to the reaction mixture and 30% NaOH is dripped in at +15°/20° C. until pH 7.5-7.8 is attained.
[0037] The aqueous phase is separated and is treated for 20 minutes at ambient temperature with 1 g of carbon, then filtered and washed with 15 ml of water. 60 ml of acetone are added. Crystallization commences and the mixture is left under agitation for 1 h.
[0038] 240 ml of acetone are finally dripped in to complete the crystallization. The mixture is filtered, washed with 20 ml of 9:1 acetone/water and then with 400 ml of acetone.
[0039] It is dried at +40° C. under reduced pressure.
[0040] 16.7 g of ceftriaxone disodium hemiheptahydrate are obtained (titre 83% as anhydrous acid).
EXAMPLE 5
[0041] 10 g of 7-aminocephalosporanic acid are suspended in 70 ml of dichloromethane. 7.9 g of N,O-bis-(trimethylsilyl)acetamide are added and the mixture is agitated for 1 h at ambient temperature.
[0042] 8.1 g of diethylthiophosphoryl-(Z)-(2-aminothiazol-4-yl)methoxyimino acetate are added and the mixture left to react at ambient temperature for 8 hours.
[0043] On termination of the reaction the synthesis mixture is dripped into 80 ml of water at +15/+20° C., adjusting the pH to 7.5-7.8 with 15% NaOH during the dripping.
[0044] The aqueous phase is separated, diluted with 16 ml of isopropyl alcohol and then with water to a total of 195 ml. 5 ml of ethyl acetate are added to the solution obtained, it is cooled to 0° C. and 15% HCl added until pH 3.5 is achieved, where the first crystals appear. The mixture is agitated for 30 min and the pH then lowered to 2.7. It is again agitated for 30 min and filtered, washing with acetone.
[0045] It is dried at +40° C. under reduced pressure.
[0046] 8.5 g of cefotaxime acid are obtained.
[0047] Molar yield: 94.4%.
[0048] Cefotaxime is a compound of formula (I) in which R 1 is acetoxy, R 2 is methoxyl and R 3 is hydrogen.
EXAMPLE 6
[0049] 5.0 g of 7-aminocephalosporanic acid are suspended in 35 ml of anhydrous DMF.
[0050] 7.3 g of N,O-bis-(trimethylsilyl)acetamide are added while maintaining the temperature at +20°/+25° C. The 7-aminocephalosporanic acid dissolves rapidly and totally.
[0051] 7.5 g of diethylthiophosphoryl-(Z)-(2-aminothiazol-4-yl)methoxyimino acetate are added and the mixture left to react at ambient temperature for 18 hours. On termination of the reaction 65 ml of water and 65 ml of methylene chloride are added.
[0052] The mixture is adjusted to pH 7 with NaHCO 3 and the phases are separated. The aqueous phase is washed repeatedly with dichloromethane.
[0053] 6 ml of isopropyl alcohol are added to the aqueous phase and then diluted to a total of 195 ml with water. 5 ml of ethyl acetate are added to the solution obtained, it is cooled to 0° C. and 15% HCl added until pH 3.5 is achieved, where the first crystals appear. The mixture is agitated for 30 min and the pH then lowered to 2.7.
[0054] It is again agitated for 30 min and filtered, washing with acetone.
[0055] It is dried at +40° C. under reduced pressure.
[0056] 7.7 g of cefotaxime acid are obtained.
[0057] Molar yield: 93.5%.
EXAMPLE 7
[0058] 10 g of 7-amino-3-[(1-methyl-1-pyrrolidine)methyl]-3-cephem-4-hydroiodide are added to 300 ml of dichloromethane in a nitrogen atmosphere. Trimethylchlorosilane (4.7 ml) and hexamethyl disilazane (7.7 ml) are added, the temperature is adjusted to 25°/30° C. and the mixture is agitated for 2 hours, again at 25°/30° C. The mixture is cooled to 20° C., 11.5 g of diethylthiophosphoryl-(Z)-(2-aminothiazol-4-yl)methoxyimino acetate are added, and the mixture left under agitation at 20°/+25° C. overnight. The reaction mixture is added slowly to water (50 ml) and after 60 minutes of agitation the phases are separated. The aqueous phase is washed with dichloromethane and 6N hydrochloric acid and acetone (100 ml) are added to the aqueous phase. The mixture is left to crystallize for 30 minutes and further acetone (180 ml) are then added to complete the crystallization. After 60 minutes of agitation the mixture is filtered, washed with acetone and dried at 40° C. 12.2 g of cefepime dihydrochloride monohydrate are obtained.
[0059] Molar yield: 94.8%.
EXAMPLE 8
[0060] 5 g of 7-amino-3-(2-furanylcarbonyl)thiomethyl-3-cephem-4-carboxylic acid are suspended in 35 ml of dichloromethane. 5.5 g of N,O-bis-(trimethylsilyl)acetamide are added and the mixture is agitated for 3 h at ambient temperature.
[0061] 6.4 g of diethylthiophosphoryl-(Z)-(2-aminothiazol-4-yl)methoxyimino acetate are added and the mixture left to react at ambient temperature for 6 hours.
[0062] 50 ml of water are added to the solution at the end of the reaction and 30% NaOH is dripped in until pH 7.5 is attained. The aqueous phase is separated and decolorized with 1 g of carbon for 20 min.
[0063] After filtration 50 ml of 36% HCl are slowly dripped in until pH 3 is attained. The organic phase is separated, 3.5 g of sodium 2-ethylhexanoate are added and the mixture left to crystallize at 0° C. for 8 h, then filtered, washing with cold tetrahydrofuran.
[0064] It is dried at +30° C. under reduced pressure.
[0065] 9.2 g of ceftiofur sodium salt are obtained.
[0066] Molar yield: 90%
[0067] Proceeding in the same manner as the aforedescribed Examples, but using reagents of formula (III) in which R 1 is chosen from the group consisting of methoxy, (1-methyl-1H-tetrazol-yl)thio, (5-carboxymethyl-4-methyl-2-thiazolyl)thio, 2, 3-cyclopentene-1-pyridine, 1-(5,6,7,8-tetrahydro-quinoline) and 1-pyridine, and R 2 is chosen from the group consisting of methoxy and 1-carboxy-1-methylethoxy, other important cephalosporins are obtained, known by the name of cefmenoxime, cefodizime, cefpirome, cefpodoxime (from which cefpodoxime proxethyl can be prepared), cefquinome and ceftazidime. | A method for producing cephalosporins 7-substituted with an amino-thiazolylacetic group by reacting 7-ACA or its derivatives having the amino group and the carboxyl protected with reactive derivatives of amino-thiazolylacetic acid. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a liquid coating machine of a rotary screen printing press or the like.
[0003] 2. Description of the Related Art
[0004] In screen printing by a rotary screen printing press, ink is placed in a screen printing forme, and the screen printing forme is pressed against paper by a squeegee or a doctor roller to transfer the ink to a printing surface of the paper through the openings of the screen printing forme. The screen printing forme needs to be replaced each time a different printing product is to be printed.
[0005] The work of replacing the screen printing forme will be described, for example, in connection with an intaglio and rotary screen printing press as shown in FIG. 6 .
[0006] In this printing press (liquid coating machine), sheets of paper (sheets, for short) W are fed one by one from a feeder 10 onto a feedboard 11 . Then, the sheet W is passed from a swing arm shaft pregripper 12 on to a transfer cylinder 13 , and then gripped by grippers 14 a of an impression cylinder 14 for the purpose of transport (transport means). On the other hand, conventional inks are supplied from within ink fountains 20 to chablon rollers 17 via ink fountain rollers 19 and intermediate rollers 18 , and supplied to an ink collecting cylinder 16 (other device). Then, the inks are collectively supplied to an intaglio plate of a plate cylinder 15 . Also, special ink is directly supplied, in a constant amount in a predetermined pattern, from within a rotary screen cylinder (stencil printing cylinder) 22 to the intaglio plate of the plate cylinder 15 via a rubber roller 21 (liquid coating unit).
[0007] These inks have their surplus amounts removed by a wiping roller 23 , and are then transferred to the sheet W passed on to the impression cylinder 14 for the purpose of printing. The printed sheet W is transported and delivered by a delivery chain 26 via a delivery cylinder 25 .
[0008] In such a rotary screen printing press, when the screen printing forme (stencil printing plate) of the rotary screen cylinder 22 is to be replaced, it has been common practice for two operators to hold opposite end portions of the screen printing forme in places near entrances 28 to the machine. This is because a forme or plate replacing work space S for replacing the screen printing forme of the rotary screen cylinder 22 has its upper side closed with a printing unit or a transport unit for the sheet W, and has its fore-and-aft direction restrained by other printing devices. Thus, the space S is only a narrow space defined by these printing devices. Moreover, the machine entrances 28 formed on both sides of a machine frame 27 are narrow. These situations make it difficult for one operator to do replacing work while holding the screen printing forme.
[0009] Thus, the two operators have to do the work in a well-coordinated manner with an unnatural posture, thus posing the problems of decreasing the operators' work efficiency and imposing a burden on the operators.
SUMMARY OF THE INVENTION
[0010] The present invention has been proposed in light of the above-described problems. It is an object of the invention to provide a liquid coating machine by which only one operator is required to do the work of replacing a stencil printing plate with ease.
[0011] An aspect of the present invention is a liquid coating machine including transport means for transporting a sheet, a stencil printing cylinder, provided below the transport means, for coating a liquid on the sheet transported by the transport means, and a plate replacing work space whose upper side is closed, with respect to which a transport direction of the sheet is restrained by other device and a liquid coating unit including the stencil printing cylinder, which is open in at least one of directions orthogonal to the transport direction of the sheet, and where an operator performs work of replacing a stencil printing plate, the liquid coating machine comprising a plate rest provided below the stencil printing cylinder and supported to be movable to a first position within the liquid coating unit and a second position within the plate replacing work space.
[0012] The plate rest may be supported by a horizontal movement guide member to be movable to the first position and the second position.
[0013] A rolling body may be provided on a surface on a side of the plate rest supporting the stencil printing plate, and the stencil printing plate may be supported via the rolling body.
[0014] The liquid coating machine may further comprise a four-joint link for supporting the plate rest, and drive means for swinging the four-joint link, and the plate rest may be moved to the first position and the second position by the drive means via the four-joint link.
[0015] An ink pan may be supported by the plate rest, and the stencil printing plate may be supported by the plate rest via the ink pan.
[0016] A pair of plate bearers having inclined surfaces opposing each other may be integrally formed on an upper surface of the ink pan, and the stencil printing plate may be supported on the inclined surfaces of the plate bearers.
[0017] A pair of plate bearers having a plurality of rolling bodies annexed thereto may be integrally formed on an upper surface of the ink pan, and the stencil printing plate may be supported by the rolling bodies of the plate bearers.
[0018] The plate rest may be moved to reciprocate between the first position and the second position during the work of replacing the plate.
[0019] According to the liquid coating machine concerned with the present invention, one operator is enough to perform the work of replacing the stencil printing plate easily, by using the plate rest, while avoiding the expansion of the plate replacing work space or the machine entrance of the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] 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:
[0021] FIG. 1 is a schematic configurational sectional view of a rotary screen printing unit in a rotary screen printing press showing Embodiment 1 of the present invention;
[0022] FIG. 2 is a schematic right side view of the rotary screen printing unit in FIG. 1 ;
[0023] FIG. 3 is a perspective view of a slide rail;
[0024] FIG. 4 is an explanation drawing using a four-joint link and drive means (air cylinder) showing Embodiment 2 of the present invention;
[0025] FIG. 5A is an explanation drawing using rolling bodies (rollers) showing Embodiment 3 of the present invention;
[0026] FIG. 5B is an explanation drawing using the rolling bodies (rollers) showing the Embodiment 3 of the present invention; and
[0027] FIG. 6 is a schematic configurational view of a conventional intaglio and rotary screen printing press.
DETAILED DESCRIPTION OF THE INVENTION
[0028] A liquid coating machine according to the present invention will be described in detail by embodiments with reference to the accompanying drawings.
Embodiment 1
[0029] FIG. 1 is a schematic configurational sectional view of a rotary screen printing unit in a rotary screen printing press showing Embodiment 1 of the present invention. FIG. 2 is a schematic right side view of the rotary screen printing unit in FIG. 1 . FIG. 3 is a perspective view of a slide rail.
[0030] In a rotary screen printing unit in a rotary screen printing press (liquid coating machine), as shown in FIG. 1 , a rotary screen cylinder (stencil printing cylinder) 32 is supported between right and left frames 31 erected on a bed 30 via eccentric bearings 33 to be capable of throw-on and throw-off with respect to a rubber roller, an impression cylinder, etc. (not shown). The right and left eccentric bearings 33 are supported by the right and left frames 31 to be pivotable and slidable in the lateral direction (axial direction).
[0031] The rotary screen cylinder 32 comprises a cylindrical screen printing forme (stencil printing plate) 35 supported between right and left tubular end members 34 , and in small-diameter parts of the right and left tubular end members 34 , is also supported by the eccentric bearings 33 to be rotatable via bearings 36 . The screen printing forme 35 comprises a mesh-shaped body portion 35 a , and tubular mounting members 35 b attached to the opposite ends of the body portion 35 a.
[0032] A toothing 34 a is engraved in the outer periphery of the small-diameter part of the right tubular end member 34 , and a gear 37 meshes with the toothing 34 a . Thus, the rotary screen cylinder 32 is rotationally driven, and can be circumferentially registered, by a motor (not shown) via the above-mentioned gear mechanism.
[0033] In a slot formed in a flange portion 33 a of each of the right and left eccentric bearings 33 , a head 38 a of a bolt 38 is fitted to be rotatable and movable in the major-diameter direction of the slot, but immovable in the axial direction of the slot A threaded portion 38 b of the bolt 38 is screwed into a threaded bore of the frame 31 . A gear 39 a is secured to each of the heads 38 a of the right and left bolts 38 , and a gear 39 b secured onto an output shaft of a motor 40 meshes with each of the gears 39 a . The right and left motors 40 are mounted on support brackets 41 bound to the right and left frames 31 .
[0034] Thus, the right and left eccentric bearings 33 are slid in the lateral direction (axial direction) by the motor 40 via the aforementioned gear mechanism and feed screw mechanism to permit the tension adjustment of the screen printing forme 35 and the movement of the bearings during removal of the screen printing forme 35 .
[0035] A pipe-shaped support shaft 42 closed at a right end is inserted through the rotary screen cylinder 32 , and a rubber squeegee (not shown) is supported by the support shaft 42 . The leading end of this squeegee makes sliding contact with the inner peripheral surface of the screen printing forme 35 (body portion 35 a ) Thus, the ink (liquid) supplied through the interior of the support shaft 42 into the screen printing forme 35 is transferred onto a printing surface of the sheet via the openings of the body portion 35 a.
[0036] In the present embodiment, as shown in FIG. 2 as well, a quadrilateral frame-shaped forme or plate rest 50 having a withdrawing grip 51 annexed to each of right and left front parts thereof is disposed on the bed 30 , which is located below the rotary screen cylinder 32 in the assembled state, via slide rails 55 and angle members 56 to be described later.
[0037] An ink pan 53 , which receives ink dripping from the screen printing forme 35 of the rotary screen cylinder 32 during printing and during stoppage of printing, is placed on the forme rest 50 . A pair of (i.e., front and rear) forme or plate bearers 52 having inclined surfaces 52 a opposing each other are formed integrally with the ink pan 53 . A pull-out grip 54 is annexed to each of right and left parts of the ink pan 53 (the pull-out grip 54 may be provided at one of the right and left parts corresponding to one of machine entrances 31 a to be described later).
[0038] The forme rest 50 is supported by the right and left (paired) slide rails (horizontal movement guide members) 55 to be movable from the aforementioned position (a first position within the liquid coating unit, as indicated by solid lines in FIG. 2 ) to a second position (a position indicated by dashed double-dotted lines in FIG. 2 ) within a forme or plate replacing work space S which an operator can go into and out of through the machine entrance 31 a formed in at least one of the right and left frames 31 .
[0039] The slide rail 55 , as shown in FIG. 3 , comprises a moving rail 55 a , a stationary rail 55 b , and an intermediate rail 55 c slidably fitted to both of the moving rail 55 a and the stationary rail 55 b . The moving rail 55 a is fixed to the right and left parts of the forme rest 50 , while the stationary rail 55 b is fixed to the pair of (i.e., right and left) L-shaped angle members 56 laid in the fore-and-aft direction on the bed 30 .
[0040] The slide rail 55 has a locking mechanism (not shown) for locking and unlocking in the most contracted state at the first position within the liquid coating unit, and in the most extended state at the second position within the forme replacing work space S.
[0041] Because of the above-described features, the following work procedure is performed in replacing the screen printing forme 35 for printing a different printing product:
[0000] (1) First of all, the operator enters the forme replacing work space S through the machine entrance 31 a , and then while pressing the used screen printing forme 35 , operates a switch for moving the tubular end members 34 at the opposite ends of the rotary screen cylinder 32 outwards by driving of the motors 40 , thereby moving the tubular end members 34 outwards, and also detaching the used screen printing forme 35 from the tubular end members 34 . Then, the operator places the used screen printing forme 35 on the inclined surfaces 52 a of the forme bearers 52 of the ink pan 53 placed on the forme rest 50 .
(2) Then, the operator grasps the withdrawing grips 51 , and moves the forme rest 50 , together with the ink pan 53 , from the first position within the liquid coating unit toward the second position within the forme replacing work space S. During this movement, the operator goes out of the forme replacing work space S through the machine entrance 31 a.
(3) Then, the operator removes the used screen printing forme 35 placed on the ink pan 53 on the forme rest 50 located at the second position within the forme replacing work space S. On this occasion, if the screen printing forme 35 is severely soiled, for example, the pull-out grips 54 may be grasped, and the screen printing forme 35 may be taken out of the machine together with the ink pan 53 .
(4) Then, the operator places another screen printing forme 35 , which is used in subsequent printing, on the inclined surface 52 a of the forme bearers 52 of the ink pan 53 on the forme rest 50 .
(5) Then, the operator grasps the withdrawing grips 51 , and moves the forme rest 50 , together with the ink pan 53 , from the second position within the forme replacing work space S to the first position within the liquid coating unit.
(6) Finally, the operator enters the forme replacing work space S through the machine entrance 31 a , and while pressing the screen printing forme 35 to be used in subsequent printing, operates a switch for moving the tubular end members 34 at the opposite ends of the rotary screen cylinder 32 inwards by driving of the motors 40 , thereby moving the tubular end members 34 inwards, and also allowing the tubular end members 34 to support the screen printing forme 35 to be used in subsequent printing.
[0042] Since the screen printing forme 35 is replaced in the above-mentioned manner, one operator is enough to perform the work of replacing the screen printing forme 35 easily, by using the forme rest 50 , even if the forme replacing work space S or the machine entrance 31 a of the frame 31 is narrow, in other words, without the need to widen the space S or the entrance 31 a . Moreover, the machine can be downsized.
[0043] Furthermore, since the ink pan 53 is present, it brings the advantages that it can serve as an ink receptacle if an ink scatter, for example, occurs during printing, and that it can be carried to a utility room without the need for holding a dirty screen printing forme 35 at the time of replacement. Of course, the ink pan 53 may be omitted.
[0044] In the present embodiment, the forme rest 50 may be automatically withdrawn by an air cylinder or the like, instead of being withdrawn by the withdrawing grips 51 .
[0045] Moreover, the horizontal movement guide member, such as a mere slide table, other than the slide rails 55 , may be used.
Embodiment 2
[0046] FIG. 4 is an explanation drawing using a four-joint link and a drive means (air cylinder) showing Embodiment 2 of the present invention.
[0047] This is an embodiment in which the forme rest 50 can be moved between the first position within the liquid coating unit and the second position within the forme replacing work space S by air cylinders (drive means) 58 via four-joint links 57 instead of the slide rails 55 as the horizontal movement guide members of Embodiment 1.
[0048] The above feature obtains the advantage that the replacing work can be performed more promptly, in addition to the same actions and effects as those in Embodiment 1.
[0049] In the present embodiment, it is possible to substitute the air cylinder 58 by a gas damper without using the air cylinder 58 , attach an operating lever to the fulcrum, and provide a stopper at the position of attachment and detachment, thereby converting the mode of operation into a manual mode.
Embodiment 3
[0050] FIGS. 5A and 5B are explanation drawings using rolling bodies (rollers) showing Embodiment 3 of the present invention.
[0051] This is an embodiment in which many rollers (rolling bodies) 60 are discretely arranged in the longitudinal direction on the forme bearers 52 of Embodiment 1.
[0052] The above feature obtains the advantage that the screen printing forme 35 can be easily withdrawn from and placed in the machine, in addition to the same actions and effects as those in Embodiment 1.
[0053] While the present invention has been described in the foregoing fashion, it is to be understood that the invention is not limited thereby, but may be varied in many other ways. For example, the present invention can be applied to machines other than the rotary screen printing press, such as a stencil printing press and a coating machine for supplying varnish instead of ink and performing coating instead of printing. 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 appended claims. | A rotary screen printing press, which includes a rotary screen cylinder for coating ink on a sheet transported by transport means, and a plate or forme replacing work space whose upper side is closed, with respect to which a transport direction of the sheet is restrained by other device and a liquid coating unit including the rotary screen cylinder, which is open in at least one of directions orthogonal to the transport direction of the sheet, and where an operator performs work of replacing a screen printing forme, comprises a plate or forme rest provided below the rotary screen cylinder and supported to be movable to a first position within the liquid coating unit and a second position within the forme replacing work space. | 1 |
FIELD OF THE INVENTION
This invention relates to basins used for the collection of sewage and waste water and more particularly to an improved lid which permits ready access to the interior of such basins and which is of sufficient strength to support a substantial amount of weight.
BACKGROUND OF THE INVENTION
Sewage collection containers or basins are a necessity in many homes. Such basins are required when there is a need to pump sewage or waste water to a septic tank or to city sewer lines. Basins may be found in the basement of a home or outside of the home, and are usually located closely adjacent to a given wall between the home and the septic tank or city sewer lines. Sewage collection basins contain pumps which must occasionally be serviced, cleaned or repaired. Access to such basins is necessary in the event that they become clogged or need to be serviced. The structure and composition of such basins has evolved from hand laid concrete or brick materials to fiberglass® plastic to structural foam. Most replacement or new waste water basins are constructed of structural foam or comparably reliable materials.
The basin is generally located underground or in the well of some type. In order to provide access to the pump located inside the basin, the lid of the basin must be exposed. In almost all instances, the lid is at the level of the basement floor or, when outside, at ground level. In such a position, the lid of the basin is subject to damage or breakage. An unwary individual or child could step on and break through the lid and fall into the waste water.
Consequently, a lid had to be developed which would provide access and which would be of sufficient strength to support a substantial amount of weight. The lid of this invention meets or exceeds all of the necessary requirements for such utility.
Other objects of this invention will become apparent upon a reading of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention has been chosen for purposes of illustration wherein:
FIG. 1 is a perspective view of the split lid as positioned on top of a sewage basin.
FIG. 2 is bottom view of the split lid for sewage basins.
FIG. 3 is a partial sectional view of the split lid and basin.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The lid 10 of this invention is comprised of two separate interlocking sections 12, 14, both of which are fastened by suitable means, illustrated here as bolts 13 and nuts 15, to a basin 16.
The smaller section of lid 12 is normally permanently attached to basin 16. In those instances where the basin is inside a home, it is necessary to vent small lid section 12 to the outside by means of piping or tubing (not shown). Such piping or tubing is attached to small lid section 12 at opening 18. A second access opening 20, which is normally closed, is provided in lid section 12 as shown in FIG. 1.
In larger lid section 14 there are two openings 22, 24 of different diameters. The smaller opening 22 accommodates the power cord for the pump (not shown). The contents of the basin 16 are discharged through the larger opening 24, below which is found the pump and connected into which is the discharge of the pump. Piping extends from opening 24 to the septic tank or sewer lines.
The upper outer periphery of basin 16 is recessed to received lid 10. The edge 28 of lid 10 is formed to fit into recess 30 and includes openings 31 to accommodate bolts 13 for attachment to basin 16 as shown in FIG. 3.
Sections 12, 14 of lid 10 are provided with means for sealing and providing additional strength to the lid when assembled. Extending downwardly from the inner edge 32 of small lid section 12 is a hook or J-shaped extension 34. Inwardly spaced from edge 32 is a shallow groove 36 extending horizontally and parallel to J-shaped extension 34.
The inner edge 38 of larger lid section 14 includes an upset shoulder 39 which terminates in a downturned lip 40 which mates with shallow groove 36 in smaller lid section 12. Extending downwardly from edge 38 is a larger lip 42 which mates with J-shaped extension 34 of smaller lid section 12. The recess 30 at the top of basin 16 is formed with openings 43 to receive bolts 13.
The top of the basin is reinforced by ribs 19 to ensure structural stability. To strengthen the lid sections 12, 14, each is molded to include a series of ribs 44, as shown in FIG. 2. The ribs 44 of the larger lid section 14 extend radially and arcuately from and around the center 46 of the top of basin 16. Since larger lid section 14 covers more than half of the top of basin 16, the center 46 from which the ribs radiate is offset from its inner edge 38 and is located in the general center of lid 10. This arrangement further strengthens the structure. The ribs 44 of the smaller lid segment 12 run parallel to and laterally from its inner edge 32.
In operation, basin 16 is placed in a desired location. Piping (not shown) is connected to basin 16 at the side inlet 17. Lid section 12 is placed on the top of the basin and secured by bolts 13 and nuts 15. The venting pipe is then secured to lid opening 18.
The pump and the power cord attached to the larger lid section 14 as heretofore described is then lowered into position on basin 16. The outer edges 38 of lid section 14 fit into the recess 30 at the top of basin 16, and the downwardly protruding lips 40 and 42 are fitted into groove 36 and J-shaped extension 34 of smaller lid section 12. The lid segment 10 is then secured as shown by screws 48 and exposed nuts 50. Screws 48 are retained attached to edge 32 of lid section 12 by bonding or wedged fit.
A discharge pipe extends from the pump through opening 24 in a lid section 14. So attached, the lid 10 is of such strength as to support the weight of people or coverings such as earth. If the pump needs to be serviced, the larger lid section 14 may be readily removed without the need for loosening or removing the smaller lid section 12. The smaller lid section 12, once it is attached, need seldom be removed. Likewise, if the basin is clogged or needs cleaning, or if access is necessary for any reason, larger lid section 14 may readily be removed and reattached without disturbing smaller lid section 12 or the venting attachments.
While the preferred embodiment of this invention has been illustrated, it will be understood that changes in the structure may be made within the scope of the appended claims without departing from the spirit of the invention. | An improved lid for attachment to a sewage and waste water basin, which lid contains the safety provided by two sections having overlapping interlocking edges in which one section may be removed for access to the basin without the necessity of removing the other section. | 4 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a bit for earth boring and more particularly to a bit with a cone and a fluid conduit with the fluid directed upward.
(2) Description of the Prior Art
In oil well drilling, bits having at least one cone are well known. These cones may have teeth projecting from them or they may be studded with diamonds for drilling in the earth. Also, it is well known to have a bore through the bit, the bore being connect through by the drill stem to a source of fluid under pressure. The drill bit itself rather than being connected directly to the drill stem may be connected to a reamer and the reamer itself connected to drill collars.
In the prior art, the drilling fluid, either drilling mud or air, is conventionally directed by nozzles against the cone to wash the cuttings from the cone. Often the results of the direction of the drilling fluid against the cone is to trap some of the cuttings along the bottom of the hole so the cuttings are ground to a powder before they are removed. In the case of air being used for the drilling fluid, this is successful as long as the bottom of the hole is dry and the drilling proceeds with the cuttings being removed. However, in case there is water or oil in the formations, often an abrasive paste is formed which is not effectively removed by the air.
I was aware of the following patents at the time of filing this patent application:
______________________________________Saunders 270,488Reed et al 1,378,056Samuelson 1,678,201Dahl 1,754,671Crake 2,545,195Kirk 2,647,726Wyman 2,807,443Sandvig 2,969,846Wenneborg et al 2,730,592Mitchell et al 3,775,805Buschmann Nr201368 (German)______________________________________
SUMMARY OF THE INVENTION
(1) New and Different Function
I have discovered that if drilling fluid, such as drilling muds, is jetted upward, the bottom of the hole can be kept dry and the upward jetting of the drilling mud will cause a suction which will readily remove the cuttings in large chips. By removing the cuttings in large chips, the power and the wear on the bit is reduced. Breaking the big chips into a powder not only requires power but also causes additional wear on the drilling bit. Further, bringing out large chips is an aid and advantage to geological analysis because more information can be gained from the larger chips. Therefore, it is possible to know more about the formations being drilled from the larger chips. Furthermore, if a wet material is being drilled through, the procedures according to my invention will quickly suck up the moisture so it does not form an abrasive slurry or an abrasive mud in the bottom of the hole, but it is quickly dried out so that rapid drilling continues.
The main advantage of this invention is the quick removal of the drill chips so that drilling proceeds faster with less bit wear. Also, as opposed to air drilling, there will be the weight of the fluid column or mud above the drilling to prevent blowouts and to seal pervious formations. Therefore, it may be seen that drilling according to my invention has most of the advantages of both air drilling and mud drilling.
(2) Objects of the Invention
An object of this invention is to drill wells.
Other objects are to achieve the above with a device that is sturdy, compact, durable, simple, safe, efficient, versatile, and reliable, yet inexpensive and easy to manufacture, operate, and maintain.
Further objects are to achieve the above with a method that is versatile, rapid, efficient, and inexpensive, and does not require skilled people to operate and maintain.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawing, the different views of which are not necessarily to the same scale.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view of a one-cone bit in the hole according to my invention with the fluid passages shown in dotted lines and the bottom of the drill string shown in phantom lines.
FIG. 2 is a sectional view thereof taken substantially on lines 2--2 of FIG. 1.
FIG. 3 is a side elevational view of a two-cone bit according to my invention with fluid passages shown in dashlines.
FIG. 4 is a bottom view of the two-cone bit shown in FIG. 3.
FIG. 5 is a sectional view taken on line 5--5 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawing and more particularly to FIGS. 1 and 2 wherein there is shown a one-cone drill bit according to my invention. As is conventional, the bit has pin 10 forming a means for connecting bore 12 through the bit to a source of drilling fluid under pressure. The pin, of course, fits within a box of the bottom of drill string 16. Those skilled in the art will recognize as used herein that the bottom of the drill string may refer either to the bottom drill collar or to a reamer.
The pin 10 is at the top of the bit as is the bore 12 for the entry of the drilling fluid into the bit.
Cone 18 is on the bottom of the bit and it connects to body 20 of the bit by a single stub axle on the axle leg 26 as is well known in the art. As illustrated, the cone 18 has diamond studs 22 thereon for drilling hard surfaces. Those skilled in the art will understand that the cone could have teeth. As illustrated, the body 20 includes leg 24 opposite the axle leg 26 to which the cone 18 is connected. The leg 24 has the bore 12 extending down through it and terminates at threaded union terminal 28. Nozzle 30 is attached to the leg 24 by union 32 at the union terminal 28. Those skilled in the art will understand how to make a fluid tight connection by means of a union and further disclosure of this joint is omitted for brevity. Nozzle 30 is generally U-shaped so that discharge tip 34 of the nozzle is directed upward. The discharge tip of the nozzle is within discharge passage 36 which is formed within the body 20 of the bit. The discharge passage extends up and discharge 38 of the discharge passage 36 is pointed upward. The discharge passage 36 itself is generally vertically oriented.
It will be understood that when a large volume of drilling fluid, commonly called mud, is pumped through the drill string into the bore 12 and through the nozzle 30 and out the tip 34 that it will form a suction or a partial vacuum at mouth 40 of the discharge passage 36. This suction will suck up all the chips and other material dislodged by the drilling cone 18. Therefore, it is necessary that there be sufficient clearance between the nozzle tip 34 and the mouth of the passageway 36 for the chips to pass. I have had good success with the nozzle tip having an inside diameter of about 1/2" (13mm) and outside diameter of about 3/4" (20mm). The passageway 36 has an inside diameter of about 40mm.
It will be understood by those skilled in the art that the discharge passage 36 could have a taper thereto to increase the suction at the mouth 40. However, since the exact design of the shape is well within the skill of those having ordinary skill in the nozzle and venturi arts, this description is not burdened with the exact shape of these elements. Also, those skilled in the art will understand that the passageway 36 could have a liner of wear resistant material therein and not be merely a bore or passageway through the material of the body 20 of the bit.
It will be understood that it is desirable to have the suction low in the hole. As illustrated in FIG. 1, the suction is below the top of the cone 18. The diameter of the cone at the base is the maximum diameter of the cone and the bottom of the cone is the bottom of the bit. The mouth or the bottom of the discharge passage should be no more than one-half maximum cone diameter of the bottom of the bit. As illustrated in FIG. 1, the bottom of the discharge passage is about one-half of the maximum cone diameter of the bottom of the bit.
FIGS. 3, 4, and 5, illustrate a two-cone bit. It also has a bore 212 for drilling fluid to enter the bit at the top thereof. It likewise has a pin 210 forming a means for connecting the bore to a source of drilling fluid under pressure. There are two cones, cone 218 and cone 219. Each cone is attached to an axle leg 226 by a stud axle as is well known to those having ordinary skill in drill bits. The cones may be either toothed or diamond studded as illustrated. In this case there are two nozzles 230 and 231 extending downward from the body 220. The nozzles are connected with unions as before. The nozzle tips 234 and 235 are within discharge passages 236 and 237. In this embodiment, the nozzle tip has three diverging discharge ports to force three jets of fluid against the side at the discharge passage. As before, the discharge 238 from the discharge passages point upward. Therefore, as before, the jet of fluid discharged from discharge 238 will support the column in the annular space between the well bore and the drill string above the bit. The clearance between the reamer or drill collars immediately above the bit and the bore of the hole must be maintained small so that the force of the fluid discharged at 238 will support the fluid in the well above the bit. Therefore, the bottom of the well bore is kept dry and free of the drill fluid.
The drill fluid is used to carry the cuttings and chips upward once they are sucked upward through the discharge passages 236 and 237. The column of the drill fluid also prevents blowouts as is known in the drilling arts. However, since the bottom of the hole is kept free of the drilling fluid, there is a quick removal of the cuttings upward and away from the cutting area, which is the area at the bottom of the well. As discussed before, this distance is still within about one-half maximum cone diameter of the bottom of the bit. Normally the nozzle tip will be within 2 inches (50mm) of the bottom of the bit.
As an aid to correlating the terms of the claims to the exemplary drawing, the following catalog of elements is provided:
______________________________________10 pin 210 pin12 bore 212 bore16 drill string 220 body18 cone 218 cone20 body 219 "22 studs 226 axle leg24 leg 230 nozzle26 axle leg 231 "28 union terminal 234 nozzle tip30 nozzle 235 " "32 union 236 discharge passage34 discharge tip 237 " "36 "passage 238 discharge38 discharge40 mouth______________________________________
The embodiments shown and described above are only exemplary. I do not claim to have invented all the parts, elements or steps described. Various modifications can be made in the construction, material, arrangement, and operation, and still be within the scope of my invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims. The restrictive description and drawing of the specific examples above do not point out what an infringement of this patent would be, but are to enable the reader to make and use the invention. | A drill bit for drilling deep wells such as oil wells has a cone at the bottom and a fluid bore at the top. The fluid is directed by nozzles upward through a passageway so that the cone is maintained free of fluid and the cuttings from the cone are picked up by suction and carried through the discharge passageway. The jet from the discharge passageway supports the column of fluid surrounding the drill stem. | 4 |
FIELD OF THE DISCLOSURE
This disclosure generally relates to exploration for hydrocarbons involving conducting measurements relating to a borehole penetrating an earth formation. More specifically, this disclosure relates to protecting downhole devices using a protective housing.
BACKGROUND OF THE DISCLOSURE
Evaluating earth formations and borehole environments may involve conveying tools for conducting measurements into the borehole environment. The borehole environment may include rough borehole wall surfaces, objects in borehole fluids, and other physical hazards. Conveyance in the borehole environment may pose a risk of physical damage to tools conveyed in the borehole environment.
Some of these tools also require access to some or part of the tool when the tool is located on the surface. For example, sampling tanks that may be filled downhole may need removal on the surface, or an energy source may need adjustment or repair. Protecting the tool from physical damage in the borehole environment often means that the protection must be removed in order to gain access to the tool on the surface. What is needed is a protective housing that allows access to the necessary parts of the tool on the surface while providing protection downhole and does not require costly and time consuming disassembly/reassembly of the protective housing to gain/restrict access.
SUMMARY OF THE DISCLOSURE
In aspects, this disclosure generally relates to exploration for hydrocarbons involving conducting measurements relating to a borehole penetrating an earth formation. More specifically, this disclosure relates to protecting measurement devices using a protective housing.
One embodiment according to the present disclosure includes an apparatus for conducting downhole measurement related operations in a borehole penetrating an earth formation, comprising: a module configured to be conveyed in the borehole and configured to receive at least one device; and a housing disposed on an exterior of the module, the housing including at least one opening, wherein the housing is configured to move between a first position that provides access to one of the at least one device from an exterior of the housing and a second position that isolates the at least one device from the exterior of the housing, and wherein the housing is in the second position when the apparatus is in the borehole.
Another embodiment according to the present disclosure includes a method of conducting downhole measurement related operations in a borehole penetrating an earth formation, comprising: conducting a downhole measurement using an apparatus comprising: a module configured to be conveyed in the borehole and configured to receive at least one device; and a housing disposed on an exterior of the module, the housing including at least one opening, wherein the housing is configured to move between a first position that provides access to one of the at least one device from an exterior of the housing and a second position that isolates the at least one device from the exterior of the housing, and wherein the housing is in the second position when the apparatus is in the borehole.
Examples of the more important features of the disclosure have been summarized rather broadly in order that the detailed description thereof that follows may be better understood and in order that the contributions they represent to the art may be appreciated.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed understanding of the present disclosure, reference should be made to the following detailed description of the embodiments, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals, wherein:
FIG. 1 shows a schematic of a module deployed in a borehole with a housing along a wireline according to one embodiment of the present disclosure;
FIG. 2 shows a schematic of the housing on the module according to one embodiment of the present disclosure;
FIG. 3A shows a schematic of the housing with the opening in the first position relative to the module according to one embodiment of the present disclosure;
FIG. 3B shows a schematic of the housing with the opening in the second position relative to the module according to one embodiment of the present disclosure;
FIG. 4 shows a schematic of the housing and the module according to one embodiment of the present disclosure;
FIG. 5 shows a schematic of the housing and the module in the second position with flexible members and fasteners according to one embodiment of the present disclosure;
FIG. 6 shows a schematic of the housing and the module in the second position with flexible members and fasteners according to one embodiment of the present disclosure; and
FIG. 7 shows a flow chart of a method for conducting a measurement related operation according to one embodiment of the present disclosure.
DETAILED DESCRIPTION
This disclosure generally relates to exploration for hydrocarbons involving analysis of fluids. In one aspect, this disclosure relates to protecting measurement devices downhole using a protective housing while providing access to the devices at the surface without requiring disassembly of the protective housing.
Referring initially to FIG. 1 , there is schematically represented a cross-section of a subterranean formation 10 in which is drilled a borehole 12 . Suspended within the borehole 12 at the bottom end of a conveyance device such as a wireline 14 is a downhole assembly 100 . The wireline 14 is often carried over a pulley 18 supported by a derrick 20 . Wireline deployment and retrieval is performed by a powered winch carried by a service truck 22 , for example. A control panel 24 interconnected to the downhole assembly 100 through the wireline 14 by conventional means controls transmission of electrical power, data/command signals, and also provides control over operation of the components in the downhole assembly 100 . The data may be transmitted in analog or digital form. Downhole assembly 100 may include a measurement module 110 . The measurement module 110 may be at least substantially enclosed by a housing 120 . The housing 120 may be configured to protect the measurement module from contact with the wall of the borehole 12 and solids in the borehole 12 . Herein, the downhole assembly 100 may be used in a drilling system (not shown) as well as a wireline. While a wireline conveyance system has been shown, it should be understood that embodiments of the present disclosure may be utilized in connection with tools conveyed via rigid carriers (e.g., jointed tubular or coiled tubing) as well as non-rigid carriers (e.g., wireline, slickline, e-line, etc.). Some embodiments of the present disclosure may be deployed along with LWD/MWD tools.
FIG. 2 shows an exemplary embodiment of measurement module 110 . The measurement module 110 may be configured for at least one of: (i) performing a measurement, (ii) receiving a fluid sample, and (iii) carrying an energy source. The outer surface 210 of measurement module 110 may include one or more recessed areas 220 configured to receive devices 230 related to measurement. The devices 230 may include, but are not limited to, one or more of: (i) a fluid sample tank, (ii) a neutron source, (iii) a gamma ray source, (iv) a sensing element, (v) a dewar vessel, and (vi) a fluid supply tank. The housing 120 may include an opening 240 configured to provide access to the devices 230 when the housing 120 is in a first position relative to the module 110 . The first position may be configured to provide access to one or more of the devices 230 . The housing 120 may be configured to isolate the devices 230 from the borehole 12 in a second position. The second position may be configured to isolate all of the devices 230 . The isolation of the second position may be such that the devices 230 are protected from damaging physical forces, but not isolated from fluidic contact with the borehole 12 . The housing 120 may have an axis that may be identical or different from an axis of the module 110 . The housing 120 may be configured to move relative to the module 110 in at least one of: (i) a circumferential direction, (ii) an axial direction, (iii) a helical direction, and combinations thereof.
While housing 120 is shown as generally cylindrical in shape, this is exemplary and illustrative only, as the housing may be ellipsoid or any other suitable shape as understood by one skill in the art. Housing 120 may include, but is not limited to, one or more of: (i) metal, (ii) fiber compounds, (iii) matrix composites, and (iv) sandwich materials. In some embodiments, housing 120 may include materials known to be substantially transparent to particular energy sources. For example, if device 230 includes a neutron source, the housing 120 may have a composition that is substantially non-absorbing for neutrons.
In some embodiments, one or more of the devices 230 may be disposed in an interior (not shown) of the measurement module 110 . In some embodiments, the interior may be subdivided into internal sections that are physically isolated from one another.
FIG. 3A shows an exemplary embodiment of measurement module 110 with housing 120 . The housing 120 is shown in a first position where the opening 240 provides access to one of the devices 230 , in this instance 230 a of 230 a - d . In some embodiments, devices 230 a - d may be identical or different. There may be additional positions where access is provided to each of devices 230 b - d . Typically, positions that grant access to the devices 230 are used when the module 110 is on the surface or otherwise at a low risk of physical damage to the devices 230 . In some embodiments, housing 120 may have multiple openings 240 to allow access to more than one of the devices 230 at the same time.
FIG. 3B shows the exemplary embodiment of FIG. 3A with module 110 with housing 120 in a second position that isolates all of the devices 230 from the borehole 12 . In some embodiments, housing 120 may have multiple openings 240 . In some embodiments, the module 110 may have multiple recessed areas 220 . In some embodiments, the number of recessed areas 220 may exceed the number of openings 240 .
FIG. 4 shows the exemplary embodiment of FIG. 3B with a locking device 250 may be used to prevent the module 110 and housing 120 from moving from the second position. While the locking device 250 shown is with one or more bolts, this is exemplary and illustrative only, and other locking devices known to those of skill in the art may be used. In some embodiments, one or more fasteners 260 may be coupled to housing 120 to reduce the risk of buckling. Fasteners 260 may include, but are not limited to: (i) clamps, (ii) rings, and (iii) hooks.
FIG. 5 shows an exemplary embodiment of the module 110 and housing 120 in the second position with one or more flexible members 270 . Flexible member 270 may be coupled to the housing and/or disposed between the housing 120 and the module 110 . Flexible members 270 may be configured to prevent separation of the housing 120 from the module 110 and/or reduce the risk of overload of the housing 120 . Overload may include, but is not limited to, buckling. One exemplary flexible member 270 is a spring, but other overload protection/separation prevention devices, as understood by one of skill in the art, may be used. In this embodiment, module 110 and housing 120 have the same axis 510 . In some embodiments, the module 110 and housing 120 may have different axes.
FIG. 6 shows a different view of the exemplary embodiment of FIG. 5 . In some embodiments, housing 120 may be recess or have gaps configured to receive fastener 260 so that the surface of fastener 260 may be about flush with the surface of housing 120 . Flexible members 270 are shown at the ends of housing 120 in FIGS. 5 and 6 , however, this is exemplary and illustrative only, as flexible members 270 may be located in at other positions along housing 120 . In some embodiments, flexible member 270 may partly or completely surround a portion of module 110 .
FIG. 7 shows an exemplary method 700 according to one embodiment of the present disclosure. In method 700 , the housing 120 may be moved to a second position relative to the module 110 that physically isolates the devices 230 from the environment outside the housing 120 in step 710 . Then, in step 720 , the module 110 with housing 120 may be conveyed in borehole 12 . The housing 120 may be configured to reduce damage to the module 110 due to physical contact with the wall of the borehole 12 and objects in the borehole 12 . In step 730 , a measurement related operation may be conducted using module 110 . The measurement related operation may include, but is not limited to, at least one of: (i) performing a measurement, (ii) receiving a sample, and (iii) transmitting energy from an energy source within the module. In step 740 , the module 110 and housing 120 may be conveyed out of the borehole 12 . In step 750 , the housing 120 may be moved to a first position relative to the module 110 that provides access to at least one of the devices 230 through at least one opening 240 in housing 120 . The movement of the housing 120 from the second position to the first position may include, but is not limited to, movement in one or more of: (i) a circumferential direction and (ii) an axial direction. In step 760 , at least one of the devices 230 may be accessed. For example, if the device 230 is a fluid sample tank, the access operation may include, but is not limited to, removing a sample from the fluid sample tank or removing the fluid sample tank from the module. In some embodiments, step 760 may be performed before step 710 . In some embodiments, step 760 may be performed before step 710 and after step 750 .
While the foregoing disclosure is directed to the one mode embodiments of the disclosure, various modifications will be apparent to those skilled in the art. It is intended that all variations be embraced by the foregoing disclosure. | An apparatus and method conducting downhole measurement operations in a borehole penetrating an earth formation. The apparatus may include a module configured to be conveyed in a borehole and to receive at least one device. The module may receive the device internally or in one or more recessed areas. A housing with at least one opening may encompass the exterior of the module. The apparatus may have a first position that allows access to the module through the at least one opening, and a second position that isolates the module from the exterior of the housing. The method may include conducting downhole measurement related operations using the apparatus. The method may include moving the housing and module between the first position and the second position. | 4 |
This application is a continuation-in-part of the application Ser. No. 07/956,984 filed Oct. 6, 1992, now U.S. Pat. No. 5,318,959.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to novel triazole derivative as well as insecticide and acaricide containing the same as an active ingredient.
2. Description of the Related Art
Japanese Patent laid open No. 56-154464 and DE-A-3631511 disclose that various triazole derivatives develop insecticidal and acaricidal activities. However, it can not be said that the insecticidal and acaricidal activities of these compounds described in these specifications are satisfactory.
Up to the present, various compounds such as organophosphorus compound, organotin compound and the like have been used for the control of pests in farm and garden crops and mites. However, these compounds have been used over many years, so that the above injurious insects have a resistance to chemicals to a certain extent and it recently becomes difficult to control these insects. Particularly, this tendency is conspicuous in lepidopteran injurious insects, mites and aphids and becomes serious. As a result, it is demanded to develop new types of insecticide and acaricide having a different function.
SUMMARY OF THE INVENTION
The inventors have made various studies in order to create novel insecticides and acaricides having a very high effect against wide injurious pests and capable of safely using, which have never been found in the conventional technique, in the development of the insecticide and acaricide having a function different from that of the conventional one.
Further, the inventors have synthesized various triazole derivatives and examined their physiological activities. As a result, the inventors have found that novel triazole derivatives having a general formula [I] as mentioned later have an excellent effect against wide injurious pests in farm and garden crops, particularly lepidopteran injurious insects, mites and aphids and also develop a very high effect against eggs and larvae of mites and larvae of aphids having a resistance to the conventional chemicals, and the invention has been accomplished.
According to the invention, there is the provision of a triazole derivative having the following general formula [I]: ##STR2## (wherein R 1 is an alkyl group, X is a hydrogen atom, a halogen atom, an aklyl group, an alkoxy group, an alkylthio group, a nitro group, a cyano group or trifluoromethyl group, n is an integer of 1-5 provided that when n is 2 or more, X may be an optional combination of same or different atoms or groups, A is an oxygen atom, a sulfur atom, a lower alkylene group, a lower alkyleneoxy group, an oxy-lower alkylene group or a lower alkyleneoxyalkylene group, k is 0 or 1, R 2 is a hydrogen atom, a halogen atom, an alkyl group, an alkoxy group, trifluoromethyl group or trifluoromethoxy group, and m is an integer of 1-5 provided that when m is 2 or more, R 2 may be an optional combination of same or different atoms or groups).
Furthermore, the invention provides an insecticide or an acaricide containing the above triazole derivative as an active ingredient.
Throughout the specification, the term "lower" means that the carbon number in the group added with this term is not more than 6.
Further, the term "alkyl group" means a straight or branched-chain alkyl group having a carbon number of 1-30, which includes, for example, methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, sec-butyl group, t-butyl group, n-pentyl group, isoamyl group, neopentyl group, n-hexyl group, isohexyl group, 3,3-dimethylbutyl group, n-heptyl group, 5-methylhexyl group, 4-methylhexyl group, 3-methylhexyl group, 4,4-dimethylpentyl group, n-octyl group, 6-methylheptyl group, n-nonyl group, 7-methyloctyl group, n-decyl group, 8-methylnonyl group, n-undecyl group, 9-methyldecyl group, n-dodecyl group, 10-methylundecyl group, n-tridecyl group, 11-methyldodecyl group, n-tetradecyl group, 12-methyltridecyl group, n-pentadecyl group, 13-methyl-tetradecyl group, n-hexadecyl group, n-heptadecyl group, n-octadecyl group, n-nonadecyl group, n-eicosyl group and the like.
The terms "alkoxy group" and "alkylthio group" are (alkyl)-O-- group and (alkyl)-S-- group in which the alkyl portion has the same meaning as mentioned above, respectively.
The term "halogen atom" means fluorine, chlorine, bromine and iodine.
The term "lower alkylene group" means a straight or branched-chain alkylene group having a carbon number of 1-4, which includes, for example, --CH 2 --, --CH 2 CH 2 --, --CH(CH 3 )--, --CH 2 CH 2 CH 2 --, --CH(CH 3 )CH 2 --, --C(CH 3 ) 2 --, --CH 2 CH 2 CH 2 CH 2 --, --CH(CH 3 )CH 2 CH 2 --, --CH 2 CH(CH 3 )CH 2 -- and the like.
The term "lower alkyleneoxy group" means -(lower alkylene)-O-- group in which the lower alkylene portion has the same meaning as mentioned above.
The term "oxy-lower alkylene group" means --O-(lower alkylene)- group in which the lower alkylene portion has the same meaning as mentioned above.
The term "lower alkyleneoxyalkylene group" means -(lower alkylene)-O-(lower alkylene)- group in which the lower alkylene portion has the same meaning as mentioned above.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As a preferable compound according to the invention, there are mentioned compounds having the general formula [I] wherein R 1 is a straight or branched-chain alkyl group having a carbon number of 1-6, preferably methyl group, X is a hydrogen atom, a halogen atom, a straight or branched-chain alkyl group having a carbon number of 1-4, a nitro group, a cyano group or trifluoromethyl group, n is an integer of 1-3 provided that when n is 2 or 3, X may be an optional combination of same or different atoms or groups, A is an oxygen atom, a sulfur atom, a lower alkylene group having a carbon number of 1-4, methyleneoxy group or oxymethylene group, k is 0 or 1, R 2 is a hydrogen atom, a halogen atom, a lower alkyl group, a lower alkoxy group, trifluoromethyl group or trifluoromethoxy group, and m is an integer of 1-3 provided that when m is 2 or 3, R 2 may be an optional combination of same or different atoms or groups).
Concrete examples of the compounds having the general formula [I] according to the invention are shown in Table 1 to 8. Moreover, the compound No. is referred in subsequent description.
TABLE 1__________________________________________________________________________ ##STR3## Sub- Melting point (°C.)Compound stitution or refractiveNo. R.sup.1 X.sub.n position (A).sub.k R.sup.2.sub.m index (n.sub.D.sup.20)__________________________________________________________________________ 1 CH.sub.3 2-Cl 4- O H 2 CH.sub.3 2-Cl,6-F 4- O H 122.0-127.0 3 CH.sub.3 2-Cl 4- O 5-CF.sub.3 107.0-109.0 4 CH.sub.3 2-Cl,6-F 4- O 5-CF.sub.3 94.0-96.0 5 CH.sub.3 2-Cl 4- O 3-Cl,5-CF.sub.3 not measurable 6 CH.sub.3 2-Cl,6-F 4- O 3-Cl,5-CF.sub.3 not measurable 7 CH.sub.3 2-Cl 4- S 3-Cl,5-CF.sub.3 127.0-131.0 8 CH.sub.3 2-Cl 4- CH.sub.2 O H 9 CH.sub. 3 2-Cl,6-F 4- CH.sub.2 O H10 CH.sub.3 2-Cl,6-F 2- O 5-CF.sub.3 126.0-129.011 CH.sub.3 2-Cl,6-F 3- O H not measurable12 CH.sub.3 2-Cl,6-F 3- O 5-Cl not measurable13 CH.sub.3 2,6-F.sub.2 3- O 5-Cl14 CH.sub.3 2-Cl,6-F 3- O 6-Cl 124.0-127.015 CH.sub.3 2,6-F.sub.2 3- O 6-Cl16 CH.sub.3 2-Cl,6-F 3- O 4-CH.sub.317 CH.sub.3 2-Cl,6-F 3- O 5-CH.sub.3 not measurable18 CH.sub.3 2-Cl,6-F 3- O 6-CH.sub.3 not measurable19 CH.sub.3 2-Cl,6-F 3- O 4-C.sub.2 H.sub.520 CH.sub.3 2-Cl,6-F 3- O 6-C.sub.3 H.sub.721 CH.sub.3 2-Cl 3- O 3-CF.sub.3 not measurable22 CH.sub.3 2-Cl,6-F 3- O 3-CF.sub.3 122.0-124.023 CH.sub.3 2,6-F.sub.2 3- O 3-CF.sub.324 CH.sub.3 2-Cl,6-F 3- O 4-CF.sub.3 1.5820__________________________________________________________________________
TABLE 2__________________________________________________________________________ Sub- Melting point (°C.)Compound stitution or refractiveNo. R.sup.1 X.sub.n position (A).sub.k R.sup.2 m index (n.sub.D.sup.20)__________________________________________________________________________25 CH.sub.3 2,6-F.sub.2 3- O 4-CF.sub.326 CH.sub.3 2-Cl,6-F 3- O 5-CF.sub.327 CH.sub.3 2-Cl 3- O 5-CF.sub.3 not measurable28 CH.sub.3 2-Cl,6-F 3- O 5-CF.sub.3 65.0-68.029 CH.sub.3 2,6-F.sub.2 3- O 5-CF.sub.3 not measurable30 CH.sub.3 2,6-Cl.sub.2 3- O 5-CF.sub.331 CH.sub.3 2-Cl,6-F 3- s 5-CF.sub.3 82.0-86.032 CH.sub.3 2-Cl,6-F 3- CH.sub.2 5-CF.sub.333 CH.sub.3 2-Cl 3- CH.sub.2 O 5-CF.sub.334 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 5-CF.sub.3 96.0-97.535 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 5-CF.sub.336 CH.sub.3 2,6-Cl.sub.2 3- CH.sub.2 O 5-CF.sub.337 CH.sub.3 2-Cl,6-F 3- C.sub.2 H.sub.4 O 5-CF.sub.338 CH.sub.3 2-Cl,6-F 3- O 6-CF.sub.3 98.0-102.039 CH.sub.3 2,6-F.sub. 2 3- O 6-CF.sub.340 CH.sub.3 2-Cl,6-F 3- O 5-Cl,3-CF.sub.341 CH.sub.3 2,6-F.sub.2 3- O 5-Cl,3-CF.sub.342 CH.sub.3 2-Cl 3- O 5-Cl,3-CF.sub.3 71.0-73.043 CH.sub.3 2-Cl,6-F 3- O 5-Cl,3-CF.sub.3 109.0-111.044 CH.sub.3 2,6-F.sub.2 3- O 5-Cl,3-CF.sub.345 CH.sub.3 2-Cl 3- O 3-Cl,5-CF.sub.3 not measurable46 CH.sub.3 2-Cl,6-F 3- O 3-Cl,5-CF.sub.3 not measurable47 CH.sub.3 2,6-F.sub.2 3- O 3-Cl,5-CF.sub.3 115.0-116.048 CH.sub.3 2-Cl,6-F 3- O 3,5-(CF.sub.3).sub.2 91.0-95.049 CH.sub.3 2,6-F.sub.2 3- O 3,5-(CF.sub.3).sub.250 CH.sub.3 2-Cl,6-F 3- O 6-Cl,5-CF.sub.3 not measurable51 CH.sub.3 2,6-F.sub.2 3- O 6-Cl,5-CF.sub.352 CH.sub.3 2-Cl,6-F 3- O 4,5-(CF.sub.3).sub.2 122.0-126.053 CH.sub.3 2,6-F.sub.2 3- O 4,5-(CF.sub.3).sub.2__________________________________________________________________________
TABLE 3__________________________________________________________________________Com- Sub- Melting point (°C.)pound stitution or refractiveNo. R.sup.1 X.sub.n position (A).sub.k R.sup.2 m index (n.sub.D.sup.20)__________________________________________________________________________54 CH.sub.3 2-Cl,6-F 3- O 6-Cl,4-CF.sub.3 not measurable55 CH.sub.3 2,6-F.sub.2 3- O 6-Cl,4-CF.sub.356 CH.sub.3 2-Cl,6-F 3- O 4,6-(CF.sub.3).sub.2 1.545357 CH.sub.3 2,6-F.sub.2 3- O 4,6-(CF.sub.3).sub.258 CH.sub.3 2-Cl,6-F 3- O 6-CH.sub.3,4-CF.sub.3 121.0-123.059 CH.sub.3 2,6-F.sub.2 3- O 6-CH.sub.3,4-CF.sub.360 CH.sub.3 2-Cl,6-F 4- O 5-Cl 136.0-139.061 CH.sub.3 2,6-F.sub.2 4- O 5-Cl62 CH.sub.3 2-Cl,6-F 4- O 6-Cl 134.0-136.063 CH.sub.3 2,6-F.sub.2 4- O 6-Cl64 CH.sub.3 2-Cl,6-F 4- O 4-CH.sub.3 136.0-140.065 CH.sub.3 2-Cl,6-F 4- O 4-C.sub.2 H.sub.566 CH.sub.3 2-Cl,6-F 4- O 5-CH.sub.3 154.0-157.067 CH.sub.3 2-Cl,6-F 4- O 6-CH.sub.3 not measurable68 CH.sub.3 2-Cl,6-F 4- O 6-C.sub.3 H.sub.769 CH.sub.3 2-Cl,6-F 4- O 3-CF.sub.3 158.0-159.970 CH.sub.3 2,6-F.sub.2 4- O 3-CF.sub.371 CH.sub.3 2-Cl,6-F 4- O 4-CF.sub.3 110.0-114.072 CH.sub.3 2,6-F.sub.2 4- O 4-CF.sub.373 CH.sub.3 2-Cl,6-F 4- -- 5-CF.sub.374 CH.sub.3 2,6-F.sub.2 4- -- 5-CF.sub.375 C.sub.2 H.sub.5 2-Cl,6-F 4- O 5-CF.sub.3 not measurable76 CH(CH.sub.3).sub.2 2-Cl,6-F 4- O 5-CF.sub.3 not measurable77 CH.sub.3 2,6-F.sub.2 4- O 5-CF.sub.3 127.0-131.078 CH.sub.3 2,6-Cl2 4- O 5-CF.sub.3 127.0-130.079 C.sub.6 H.sub.13 2-Cl,6-F 4- O 5-CF.sub.3 1.557380 CH.sub.3 2-Cl 4- S 5-CF.sub.3 not measurable81 CH.sub.3 2-Cl,6-F 4- S 5-CF.sub.3 111.0-115.082 CH.sub.3 2,6-F.sub.2 4- S 5-CF.sub.3__________________________________________________________________________
TABLE 4__________________________________________________________________________ Sub- Melting point (°C.)Compound stitution or refractiveNo. R.sup.1 X.sub.n position (A).sub.k R.sup.2 m index (n.sub.D.sup.20)__________________________________________________________________________83 CH.sub.3 2,6-Cl.sub.2 4- S 5-CF.sub.384 CH.sub.3 2-Cl,6-F 4- CH.sub.2 5-CF.sub.385 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 5-CF.sub.386 CH.sub.3 2-Cl 4- CH.sub.2 O 5-CF.sub.387 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 5-CF.sub.3 1.585988 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 5-CF.sub.389 CH.sub.3 2,6-Cl.sub.2 4- CH.sub.2 O 5-CF.sub.390 CH.sub.3 2-Cl,6-F 4- C.sub.2 H.sub.4 O 5-CF.sub.391 CH.sub.3 2-Cl,6-F 4- O 6-CF.sub.3 97.0-101.092 CH.sub.3 2-Cl,6-F 4- O 3,5-Cl.sub.2 53.0-57.093 CH.sub.3 2-Cl,6-F 4- O 5-Cl,3-CF.sub.3 not measurable94 CH.sub.3 2,6-F.sub.2 4- O 5-Cl,3-CF.sub.395 CH.sub.3 2-Cl,6-F 4- S 3-Cl,5-CF.sub.3 not measurable96 CH.sub.3 2,6-F.sub.2 4- S 3-Cl,5-CF.sub.397 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 3-Cl,5-CF.sub.3 73.0-75.098 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 3-Cl,5-CF.sub.3 132.0-136.099 CH.sub.3 2-Cl,6-F 4- O 3,5-(CF.sub.3).sub.2 85.0-89.0100 CH.sub.3 2,6-F.sub.2 4- O 3,5-(CF.sub.3).sub.2101 CH.sub.3 2-Cl,6-F 4- O 6-Cl,5-CF.sub.3 108.0-112.0102 CH.sub.3 2,6-F.sub.2 4- O 6-Cl,5-CF.sub.3103 CH.sub.3 2-Cl,6-F 4- O 4,5-(CF.sub.3).sub.2 158.0-160.0104 CH.sub.3 2,6-F.sub.2 4- O 4,5-(CF.sub.3).sub.2105 CH.sub.3 2-Cl,6-F 4- O 6-Cl,4-CF.sub.3 not measurable106 CH.sub.3 2,6-F.sub.2 4- O 6-Cl,4-CF.sub.3107 CH.sub.3 2-Cl,6-F 4- O 4,6-(CF.sub.3).sub.2 125.0-129.0108 CH.sub.3 2,6-F.sub.2 4- O 4,6-(CF.sub.3).sub.2109 CH.sub.3 2-Cl,6-F 4- O 6-CH.sub.3,4-CF.sub.3 98.0-101.0110 CH.sub.3 2,6-F.sub.2 4- O 6-CH.sub.3,4-CF.sub.3__________________________________________________________________________
TABLE 5__________________________________________________________________________ Sub- Melting point (°C.)Compound stitution or refractiveNo. R.sup.1 X.sub.n position (A).sub.k R.sup.2 m index (n.sub.D.sup.20)__________________________________________________________________________111 CH.sub.3 2,6-F.sub.2 3- -- 5-CF.sub.3112 CH.sub.3 2,6-F.sub.2 3- S 5-CF.sub.3113 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 5-CF.sub.3114 CH.sub.3 2,6-Cl.sub.2 3- O 3-Cl,5-CF.sub.3115 CH.sub.3 2-Cl 3- S 3-Cl,5-CF.sub.3116 CH.sub.3 2-Cl,6-F 3- S 3-Cl,5-CF.sub.3117 CH.sub.3 2,6-F.sub.2 3- S 3-Cl,5-CF.sub.3118 CH.sub.3 2,6-Cl.sub.2 3- S 3-Cl,5-CF.sub.3119 CH.sub.3 2-Cl 3- CH.sub.2 O 3-Cl,5-CF.sub.3120 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 3-Cl,5-CF.sub.3 not measurable121 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 3-Cl,5-CF.sub.3122 CH.sub.3 2,6-Cl.sub.2 3- CH.sub.2 O 3-Cl,5-CF.sub.3123 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 3,5-(CF.sub.3).sub.2124 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 3,5-(CF.sub.3).sub.2125 CH.sub.3 2-Cl,6-F 3- CH.sub. 2 O 4,5-(CF.sub.3).sub.2 72.0-78.0126 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 4,5-(CF.sub.3).sub.2127 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 4,6-(CF.sub.3).sub.2 1.5360128 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 4,6-(CF.sub.3).sub.2129 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 6-CH.sub.3,4-CF.sub.3130 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 6-CH.sub.3,4-CF.sub.3131 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 5-Cl132 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 5-Cl133 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 5-CH.sub.3134 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 5-CH.sub.3135 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 3,5-Cl.sub.2126 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 3,5-Cl.sub.2127 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 5-Cl,3-CF.sub.3128 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 5-Cl,3-CF.sub.3129 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 6-Cl,5-CF.sub.3__________________________________________________________________________
TABLE 6__________________________________________________________________________ Sub- Melting point (°C.)Compound stitution or refractiveNo. R.sup.1 X.sub.n position (A).sub.k R.sup.2 m index (n.sub.D.sup.20)__________________________________________________________________________140 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 6-Cl,5-CF.sub.3141 CH.sub.3 2-Cl,6-F 3- CH.sub.2 O 6-Cl,4-CF.sub.3142 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 6-Cl,4-CF.sub.3143 CH.sub.3 2-Cl,6-F 3- O 3,5-Cl.sub.2 52.0-56.0144 CH.sub.3 2,6-F.sub.2 3- O 3,5-Cl.sub.2145 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 5-Cl 140.0-145.0146 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 5-Cl147 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 6-Cl148 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 6-Cl149 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 4-CH.sub.3150 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 4-CH.sub.3151 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 5-CH.sub.3152 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 5-CH.sub.3153 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 6-CH.sub.3154 CH.sub.3 2,6-F.sub. 2 4- CH.sub.2 O 6-CH.sub.3155 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 3-CF.sub.3156 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 3-CF.sub.3157 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 4-CF.sub.3158 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 4-CF.sub.3159 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 6-CF.sub.3160 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 6-CF.sub.3161 CH.sub.3 2-Cl 4- CH.sub.2 O 3,5-Cl.sub.2162 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 3,5-Cl.sub.2 121.0-124.0163 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 3,5-Cl.sub.2164 CH.sub.3 2,6-Cl.sub.2 4- CH.sub.2 O 3,5-Cl.sub.2165 CH.sub.3 2-Cl 4- CH.sub.2 O 5-Cl,3-CF.sub.3166 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 5-Cl,3-CF.sub.3 89.0-94.0167 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 5-Cl,3-CF.sub.3168 CH.sub.3 2,6-Cl.sub.2 4- CH.sub.2 O 5-Cl,3-CF.sub.3__________________________________________________________________________
TABLE 7__________________________________________________________________________ Sub- Melting point (°C.)Compound stitution or refractiveNo. R.sup.1 X.sub.n position (A).sub.k R.sup.2 m index (n.sub.D.sup.20)__________________________________________________________________________169 CH.sub.3 2,6-F.sub.2 3- CH.sub.2 O 6-Cl,5-CF.sub.3170 CH.sub.3 2,6-Cl.sub.2 4- CH.sub.2 O 3-Cl,5-CF.sub.3171 CH.sub.3 2-Cl 4- CH.sub.2 O 3,5-(CF.sub.3).sub.2172 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 3,5-(CF.sub.3).sub.2 87.0-91.0173 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 3,5-(CF.sub.3).sub.2174 CH.sub.3 2,6-Cl.sub.2 4- CH.sub.2 O 3,5-(CF.sub.3).sub.2175 CH.sub.3 2-Cl 4- CH.sub.2 O 6-Cl,5-CF.sub.3176 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 6-Cl,5-CF.sub.3 138.0-140.0177 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 6-Cl,5-CF.sub.3178 CH.sub.3 2,6-Cl.sub.2 4- CH.sub.2 O 6-Cl,5-CF.sub.3179 CH.sub.3 2-Cl 4- CH.sub.2 O 4,5-(CF.sub.3).sub.2180 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 4,5-(CF.sub.3).sub.2 113.0-116.0181 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 4,5-(CF.sub.3).sub.2182 CH.sub.3 2,6-Cl.sub.2 4- CH.sub.2 O 4,5-(CF.sub.3).sub.2183 CH.sub.3 2-Cl 4- CH.sub.2 O 6-Cl,4-CF.sub.3184 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 6-Cl,4-CF.sub.3 not measureable185 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 6-Cl,4-CF.sub.3186 CH.sub.3 2,6-Cl.sub.2 4- CH.sub.2 O 6-Cl,4-CF.sub.3187 CH.sub.3 2-Cl 4- CH.sub.2 O 4,6-(CF.sub.3).sub.2188 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 4,6-(CF.sub.3).sub.2189 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 4,6-(CF.sub.3).sub.2190 CH.sub.3 2,6-Cl.sub.2 4- CH.sub.2 O 4,6-(CF.sub.3).sub.2191 CH.sub.3 2-Cl 4- CH.sub.2 O 6-CH.sub.3,4-CF.sub.3192 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 6-CH.sub.3,4-CF.sub.3193 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 O 6-CH.sub.3,4-CF.sub.3194 CH.sub.3 2,6-Cl.sub.2 4- CH.sub.2 O 6-CH.sub.3,4-CF.sub.3195 CH.sub.3 2-Cl,6-F 4- CH.sub.2 CH.sub.2 O 3-Cl,5-CF.sub.3196 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 CH.sub.2 O 3-Cl,5-CF.sub.3197 CH.sub.3 2-Cl,6-F 4- CH.sub.2 CH.sub. 2 O 3,5-(CF.sub.3).sub.2__________________________________________________________________________
TABLE 8__________________________________________________________________________ Sub- Melting point (°C.)Compound stitution or refractiveNo. R.sup.1 X.sub.n position (A).sub.k R.sup.2 m index (n.sub.D.sup.20)__________________________________________________________________________198 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 CH.sub.2 O 3,5-(CF.sub.3).sub.2199 CH.sub.3 2-Cl,6-F 4- CH.sub.2 CH.sub.2 O 6-Cl,5-CF.sub.3200 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 CH.sub.2 O 6-Cl,5-CF.sub.3201 CH.sub.3 2-Cl,6-F 4- CH.sub.2 CH.sub.2 O 5-Cl,3-CF.sub.3202 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 CH.sub.2 O 5-Cl,3-CF.sub.3203 CH.sub.3 2-Cl,6-F 4- CH.sub.2 CH.sub.2 O 4,5(CF.sub.3).sub.2204 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 CH.sub.2 O 4,5-(CF.sub.3).sub.2205 CH.sub.3 2-Cl,6-F 4- CH.sub.2 CH.sub.2 O 6-Cl,4-CF.sub.3206 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 CH.sub.2 O 6-Cl,4-CF.sub.3207 CH.sub.3 2-Cl,6-F 4- CH.sub.2 CH.sub.2 O 4,6-(CF.sub.3).sub.2208 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 CH.sub.2 O 4,6-(CF.sub.3).sub. 2209 CH.sub.3 2-Cl,6-F 4- CH.sub.2 CH.sub.2 O 6-CH.sub.3,4-CF.sub.3210 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 CH.sub.2 O 6-CH.sub.3,4-CF.sub.3211 CH.sub.3 2-Cl,6-F 4- CH.sub.2 CH.sub.2 O 3,5-Cl.sub.2212 CH.sub.3 2,6-F.sub.2 4- CH.sub.2 CH.sub.2 O 3,5-Cl.sub.2213 CH.sub.3 2-Cl,6-F 4- S 3,5-Cl.sub.2214 CH.sub.3 2,6-F.sub.2 4- S 3,5-Cl.sub.2215 CH.sub.3 2-Cl,6-F 4- S 5-Cl,3-CF.sub.3216 CH.sub.3 2,6-F.sub.2 4- S 5-Cl,3-CF.sub.3217 CH.sub.3 2-Cl,6-F 4- S 3,5-(CF.sub.3).sub.2218 CH.sub.3 2,6-F.sub.2 4- S 3,5-(CF.sub.3).sub.2219 CH.sub.3 2-Cl,6-F 4- S 6-Cl,5-CF.sub.3220 CH.sub.3 2,6-F.sub.2 4- S 6-Cl,5-CF.sub.3221 CH.sub.3 2-Cl,6-F 4- S 4,5-(CF.sub.3).sub.2222 CH.sub.3 2,6-F.sub.2 4- S 4,5-(CF.sub.3).sub.2223 CH.sub.3 2-Cl,6-F 4- S 4,6-(CF.sub.3).sub.2224 CH.sub.3 2,6-F.sub.2 4- S 4,6-(CF.sub.3).sub.2225 CH.sub.3 2-Cl,6-F 4- CH.sub.2 CH.sub.2 3-Cl,5-CF.sub.3 1.5730226 CH.sub.3 2-Cl,6-F 4- CH.sub.2 O 6-Cl,3-CF.sub.3 113.0-116.0227 CH.sub.3 2-Cl,6-F 4- OCH.sub.2 4-Cl228 CH.sub.3 2-Cl,6-F 4- CH.sub.2 OCH.sub.2 H__________________________________________________________________________
The compounds according to the invention can be produced by the following methods. However, it is not intended to restrict the invention to these methods.
Production Method A
The compound of the general formula [I] according to the invention can be obtained by reacting an alkyl N-acyl(thio) imidate derivative of a general formula [II] with a hydrazine derivative of a general formula [III] in an inert solvent according to the following reaction formula (1): ##STR4## (wherein W is a sulfur atom or an oxygen atom, L is an alkyl group having a carbon number of 1-4 and R 1 , X, n, A, R 2 , m and k have the same meaning as mentioned above).
As the solvent, use may be made of any solvent not obstructing the reaction, which includes, for example, an alcohol such as methanol, ethanol or the like; an ether such as diethyl ether, tetrahydrofuran, dioxane, diglyme or the like; an aromatic hydrocarbon such as benzene, toluene, chlorobenzene or the like; an aliphatic hydrocarbon such as pentane, hexane, petroleum ether of the like; a halogenated hydrocarbon such as dichloromethane, dichloroethane, chloroform, carbon tetrachloride or the like; a nitrile such as acetonitrile or the like; an aprotic polar solvent such as N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide or the like; water and a mixture thereof.
In general, the compound of the general formula [III] is used in an amount of 1.0-5.0 moles per 1 mole of the compound of the general formula [II].
The reaction temperature is optional within a range of 0° C. to a boiling point of the solvent, but is preferably 0° C.-50° C. The reaction time is dependent upon the kind of compounds used, but is usually 1-72 hours.
A concrete example of this reaction is disclosed, for example, in Synthesis, page 483 (1983).
The compound of the general formula [II] as a starting material can be produced by the following method.
Production Method B
The compound of the general formula [II] can be obtained by reacting compounds of the general formulae [IV] and [V] in an inert solvent in the presence of a base according to the following reaction formula (2): ##STR5## (wherein a derivative of the general formula [IV] may be an acid addition salt (e.g. a salt with boron tetrafluoride, hydrogen chloride, hydrogen bromide, hydrogen iodide or the like), Z is a halogen atom, and L, W, X, n, A, k, R 2 and m have the same meaning as mentioned above).
As the base, use may be made of an inorganic base such as sodium carbonate, potassium carbonate, sodium hydrogen carbonate, sodium hydroxide, potassium hydroxide or the like; and an organic base such as diethylamine, triethylamine, diisopropylethylamine, pyridine, 4-N,N-dimethylamino pyridine or the like.
As the solvent, use may be made of a ketone such as acetone, methyl ethyl ketone or the like; an ether such as diethyl ether, tetrahydrofuran, dioxane, diglyme or the like; an aromatic hydrocarbon such as benzene, toluene, chlorobenzene or the like; an aliphatic hydrocarbon such as pentane, hexane, petroleum ether or the like; a halogenated hydrocarbon such as dichloromethane, dichloroethane, chloroform, carbon tetrachloride or the like; a nitrile such as acetonitrile or the like; an aprotic polar solvent such as N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide or the like; and a mixture thereof.
In general, the compound of the general formula [V] is used in an amount of 0.8-1.3 moles per 1 mole of the compound of the general formula [IV]. The amount of the base used is 1.0-2.0 moles per 1 mole of the compound of the general formula [IV].
The reaction time is dependent upon the kind of the compounds used, but is usually within a range of 1-24 hours. The reaction temperature is within a range of 0° C. to a boiling point of the solvent.
Production Method C
The compound of the general formula [I] according to the invention can be obtained by reacting an N-(phenylsulfonyl) benzohydrazonoyl chloride derivative of a general formula [VI] with a benzonitrile derivative of a general formula [VII] in an inert solvent in the presence of Lewis acid according to the following reaction formula (3): ##STR6## (wherein R 1 , X, n, A, k, R 2 and m have the same meaning as mentioned above, and R 3 is benzene or benzene substituted with an alkyl group having a carbon number of 1-4).
As the solvent, use may be made of any solvent not obstructing the reaction, which includes, for example, an ether such as diethyl ether, tetrahydrofuran, dioxane, diglyme or the like; an aromatic hydrocarbon such as benzene, toluene, chlorobenzene, dichlorobenzene or the like; an aliphatic hydrocarbon such as pentane, hexane, petroleum ether or the like; a halogenated hydrocarbon such as dichloromethane, dichloroethane, chloroform, carbon tetrachloride or the like; a non-protonic polar solvent such as nitrobenzene, N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide or the like; and a mixture thereof.
As the Lewis acid, use may be made of aluminum bromide, aluminum chloride, ferric chloride, boron trifluoride, titanium tetrachloride and the like.
In general, the amount of the compound of the general formula [VII] used is 1.0-2.0 moles per 1 mole of the compound of the general formula [VI], and the amount of the Lewis acid used is 1.0-2.0 moles per 1 mole of the compound of the general formula [VI].
The reaction temperature is optionally within a range of 0° C. to a boiling point of the solvent, but is preferably within a range of 50°-180° C. The reaction time is dependent upon the kind of the compounds used, but is usually within a range of 15 minutes to 8 hours.
A concrete example of this reaction is disclosed, for example, in BULLETIN of the CHEMICAL SOCIETY of JAPAN, vol. 56, pages 545-548 (1983).
Production Method D
The compound of the general formula [I] according to the invention can be obtained by reacting an N-(phenylsulfonyl) benzamidrazone derivative of a general formula [VIII] with a benzoylhalide derivative of the general formula [V] in the absence of a solvent or in the presence of an inert solvent according to the following reaction formula (4): ##STR7## (wherein R 1 , R 3 , X, n, Z, A, k, R 2 and m have the same meaning as mentioned above).
As the solvent, use may be made of any solvent not obstructing the reaction, which includes, for example, an ether such as diethyl ether, tetrahydrofuran, dioxane, diglyme or the like; an aromatic hydrocarbon such as benzene, toluene, chlorobenzene or the like; an aliphatic hydrocarbon such as pentane, hexane, petroleum ether or the like; a halogenated hydrocarbon such as dichloromethane, dichloroethane, chloroform, carbon tetrachloride or the like; an aprotic polar solvent such as N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide, 1-methyl-2-pyrolidinone or the like; and a mixture thereof.
In general, the amount of the compound of the general formula [V] used is 1.0-2.0 moles per 1 mole of the compound of the general formula [VIII].
The reaction temperature is optionally within a range of 0° C. to a boiling point of the solvent, but is preferably within a range of 50°-250° C. The reaction time is dependent upon the kind of the compounds used, but is usually within a range of 30 minutes to 5 hours.
A concrete example of this reaction is disclosed, for example, in BULLETIN of the CHEMICAL SOCIETY of JAPAN, vol. 56, page 548 (1983).
The compound of the general formula [VIII] as a starting material can be produced by the following method.
Production Method E
The compound of the general formula [VIII] can be obtained by reacting the compound of the general formula [VI] with ammonia gas in an inert solvent according to the following reaction formula (5): ##STR8## (wherein R 1 , R 3 , X and n have the same meaning as mentioned above).
As the solvent, use may be made of any solvent not obstructing the reaction, which includes, for example, an ether such as diethyl ether, tetrahydrofuran, dioxane, diglyme or the like; an aromatic hydrocarbon such as benzene, toluene, chlorobenzene or the like; an aliphatic hydrocarbon such as pentane, hexane, petroleum ether or the like; a halogenated hydrocarbon such as dichloromethane, dichloroethane, chloroform, carbon tetrachloride, dichlorobenzene or the like; an aprotic polar solvent such ass N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide or the like; and a mixture thereof.
In general, the amount of ammonia gas used is 5.0-10.0 moles per 1 mole of the compound of the general formula [VI].
The reaction temperature is optionally within a range of 0° C. to a boiling point of the solvent, but is preferably within a range of 20°-150° C. The reaction time is dependent upon the kind of the compounds used, but is usually within a range of 1-24 hours.
A concrete example of this reaction is disclosed, for example, in BULLETIN of the CHEMICAL SOCIETY of JAPAN, vol. 56, pages 545-548 (1983).
Production Method F
The compound of the general formula [I-1] according to the invention can be obtained by reacting compounds of general formulae [IX] and [X] in an inert solvent in the presence of the base according to the following reaction formula (6): ##STR9## (wherein B is a halogen atom or R 3 --SO 3 -- group and R 1 , R 2 , R 3 , X, m and n have the same meaning as mentioned above).
As the base, use may be made of an inorganic base such as sodium carbonate, potassium carbonate, sodium hydrogen carbonate, sodium hydroxide, potassium hydroxide or the like; a metal hydride such as sodium hydride, potassium hydride or the like; and an organic base such as triethylamine, pyridine or the like.
As the solvent, use may be made of a ketone such as acetone, methyl ethyl ketone or the like; an ether such as diethyl ether, tetrahydrofuran, dioxane, diglyme or the like; an aromatic hydrocarbon such as benzene, toluene, chlorobenzene or the like; an aliphatic hydrocarbon such as pentane, hexane, petroleum ether or the like; a halogenated hydrocarbon such as dichloromethane, dichloroethane, chloroform, carbon tetrachloride or the like; a nitrile such as acetonitrile or the like; an aprotic polar solvent such as N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide or the like; and a mixture thereof.
In general, the compound of the general formula [X] is used in an amount of 1.0-2.0 moles per 1 mole of the compound of the general formula [IX]. The amount of the base used is 1.0-2.0 moles per 1 mole of the compound of the general formula [IX].
The reaction time is dependent upon the kind of the compounds used, but is usually within a range of 1-24 hours. The reaction temperature is within a range of -20° C. to a boiling point of the solvent.
The compound of the general formula [IX] as a starting material can be produced by the following method.
Production Method G
The compound of the general formula [IX] can be obtained by reacting a triazole derivative of a general formula [XII] with a halogenating agent in a solvent, reacting the resulting compound of a general formula [XIII] with an acetoxylating agent in a solvent and then reacting the resulting compound of a general formula [XIX] with acid or alkali in a solvent according to the following reaction formula (7): ##STR10## (wherein R 1 , X, Z and n have the same meaning as mentioned above).
As the halogenating agent, use may be made of N-chlorosuccinimide, N-bromosuccinimide, N-bromophthalimide and the like. As the solvent, mention may be made of dichloromethane, dichloroethane, chloroform, carbon tetrachloride and the like. In this reaction, benzoyl peroxide, azobisisobutylnitrile or the like is required to be added in a catalytic amount as a radical initiator.
As the acetoxylating agent, use may be made of lithium acetate, sodium acetate, potassium acetate, calcium acetate and the like. As the acid, use may be made of inorganic acid such as hydrogen chloride, sulfuric acid or the like; a Lewis acid such as aluminum bromide, aluminum chloride or the like. In this case, as the solvent, use may be made of a ketone such as acetone, methyl ethyl ketone or the like; an ether such as diethyl ether, tetrahydrofuran, dioxane, dimethoxyethane or the like; an aromatic hydrocarbon such as benzene, toluene or the like; an aliphatic hydrocarbon such as pentane, hexane, petroleum ether or the like; a halogenated hydrocarbon such as dichloromethane, dichloroethane, carbon tetrachloride or the like; a nitrile such as acetonitrile or the like.
As the alkali, use may be made of sodium hydroxide solution, potassium hydroxide solution, sodium carbonate solution, potassium carbonate solution or the like. In this case, as the solvent, use may be made of an alcohol such as methanol, ethanol or the like; a ketone such as acetone, methyl ethyl ketone or the like; an ether such as tetrahydrofuran, dioxane, dimethoxyethane or the like; a nitrile such as acetonitrile or the like.
Production Method H
The compound of the general formula [I-2] according to the invention can be obtained by reacting a compound of a general formula [XV] with the compound of the general formula [X] in an inert solvent in the presence of the base according to the following reaction formula (8): ##STR11## (wherein R 1 , R 2 , X, n, B and m have the same meaning as mentioned above).
As the base, use may be made of an inorganic base such as sodium carbonate, potassium carbonate, sodium hydrogen carbonate, sodium hydroxide, potassium hydroxide or the like; a metal hydride such as sodium hydride, potassium hydride or the like; and an organic base such as triethylamine, pyridine or the like.
As the solvent, use may be made of a ketone such as acetone, methyl ethyl ketone or the like; an ether such as diethyl ether, tetrahydrofuran, dioxane, diglyme or the like; an aromatic hydrocarbon such as benzene, toluene, chlorobenzene or the like; an aliphatic hydrocarbon such as pentane, hexane, petroleum ether or the like; a halogenated hydrocarbon such as dichloromethane, dichloroethane, chloroform, carbon tetrachloride or the like; a nitrile such as acetonitrile or the like; an aprotic polar solvent such as N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide or the like; and a mixture thereof.
In general, the compound of the general formula [X] is used in an amount of 1.0-2.0 moles per 1 mole of the compound of the general formula [XV]. The amount of the base used is 1.0-2.0 moles per 1 mole of the compound of the general formula [XV].
The reaction time is dependent upon the kind of the compounds used, but is usually within a range of 1-24 hours. The reaction temperature is within a range of -20° C. to a boiling point of the solvent.
The compound of the general formula [XV] as a starting material can be produced by the following method.
Production Method I
The compound of the general formula [XV] can be obtained by reacting a compound of a general formula [XVII] with Lewis acid in an inert solvent according to the following reaction formula (9): ##STR12## (wherein R 1 , X and n have the same meaning as mentioned above).
As the Lewis acid, use may be made of aluminum bromide, aluminum chloride, ferric chloride, boron trifluoride, titanium tetrachloride and the like.
As the solvent, use may be made of any solvent not obstructing the reaction, which includes, for example, an ether such as diethyl ether, tetrahydrofuran, dioxane, diglyme or the like; an aromatic hydrocarbon such as benzene, toluene, chlorobenzene, dichlorobenzene or the like; an aliphatic hydrocarbon such as pentane, hexane, petroleum ether or the like; a halogenated hydrocarbon such as dichloromethane, dichloroethane, chloroform, carbon tetrachloride or the like; an aprotic polar solvent such as nitrobenzene, N,N-dimethylformamide, N,N-dimethylacetamide, dimethylsulfoxide or the like; and a mixture thereof.
In general, the Lewis acid is used in an amount of 1.0-5.0 moles per 1 mole of the compound of the general formula [XVII]. The reaction time is dependent upon the kind of the compounds used, but is usually within a range of 1-24 hours. The reaction temperature is within a range of -20° C. to a boiling point of the solvent.
The invention will be described concretely with reference to the following examples, formulation examples and test examples.
EXAMPLE 1
Production of 5-[4-(3-chloror-5-trifluoromethyl-2-pyridyloxymethyl)phenyl]-3-(2,6-difluorophenyl)-1-methyl-1H-1,2,4-triazole (Compound No. 98)
In 50 ml of toluene are dissolved 1.75 g of ethyl 2,6-difluorobenzimidate and 0.87 g of triethylamine, to which is added dropwise a solution of 3.0 g of 4-(3-chloro-5-trifluoromethyl-2-pyridyloxymethyl)-benzoyl chloride in toluene at room temperature. The resulting mixture is heated under reflux for 3 hours. After the reaction solution is cooled and extracted with 50 ml of toluene, the extract is washed with a diluted hydrochloric acid solution and further with a saline solution, and then dried over anhydrous magnesium sulfate.
The extract is added with 0.6 g of monomethylhydrazine and heated under reflux for 1 hour. After the completion of the reaction, the reaction solution is cooled, washed with a diluted hydrochloric acid solution and further with a saline solution and dried over anhydrous magnesium sulfate and the solvent is distilled off under a reduced pressure. The resulting concentrate is purified by a silica gel column chromatography using a mixed solution of hexane and ethyl acetate as a developing solvent to obtain 0.53 g of a given compound (melting point: 132.0°-136.0° C.).
NMR data (60 MHz, CDCl 3 solvent, δ value) 8.23-6.8 ppm (m, 9H) 5.53 ppm (s, 2H) 4.03 ppm (s, 3H)
EXAMPLE 2
Production of 3-(2-chloro-6-fluorophenyl)-5-[4-(3-chloro-5-trifluoromethylpyridin-2-yloxy)phenyl]-1-methyl-1H-1,2,4-triazole (Compound No. 6)
A mixture of 1.3 g of N-methyl-N-phenylsulfonyl-2-chloro-6-fluorobenzohydrazonoyl chloride, 1.0 g of 4-(3-chloro-5-trifluoromethylpyridin-2-yloxy)benzonitrile, 0.5 g of anhydrous aluminum chloride and 3 ml of o-dichlorobenzene is stirred in an oil bath at a temperature of 140° C. for 30 minutes. After the cooling, the mixture is dissolved in 100 ml of chloroform and washed with a diluted hydrochloric acid solution, a diluted sodium hydroxide solution and a saline solution in this order. The chloroform layer is dried over anhydrous magnesium sulfate and the solvent is distilled off under a reduced pressure. The resulting concentrate is purified by a silica gel column chromatography using a mixed solution of hexane and ethyl acetate as a developing solvent to obtain 0.7 g of a given compound (refractive index n 20 D : not measurable).
NMR data (60 MHz, CDCl 3 solvent, δ value) 4.07 ppm (s, 3H) 6.75-8.58 ppm (m, 9H)
EXAMPLE 3
Production of 3-(2-chloro-6-fluorophenyl)-1-methyl-5-[4-(5-trifluoromethylpyridin-2-yloxymethyl)phenyl]-1H-1,2,4-triazole (Compound No. 87)
A mixture of 3.6 g of N-methyl-N-(p-toluene-sulfonyl)-2-chloro-6-fluorobenzamidrazone and 3.2 g of 4-(5-trifluoromethylpyridin-2-yloxymethyl)benzoyl chloride is stirred in an oil bath at a temperature of 170°-180° C. for 4 hours. After, the cooling, the mixture is added with water and extracted with ethylacetate. The extract is washed with water and dried over anhydrous magnesium sulfate and the solvent is distllied off under a reduced pressure. The resulting concentrate is purified by a silica gel column chromatography using a mixed solution of hexane and ethyl acetate as a developing solvent to obtain 1.4 g of a given compound (refractive index n 20 D : 1.5859).
NMR data (60 MHz, CDCl 3 solvent, δ value) 4.03 ppm (s, 3H) 5.48 ppm (s, 2H) 6.77-8.40 ppm (m, 10H)
EXAMPLE 4
Production of 3-(2-chloro-6-fluorophenyl)-5-[4-(3-chloro-5-trifluoromethylpyridin-2-yloxymethyl)phenyl]-1-methyl-1H-1,2,4-triazole (Compound No. 97)
To 4.4 g of 60% sodium hydride washed with hexane is added 200 ml of dimethoxyethane, which is cooled to -5° C. To the resulting mixture is added dropwise a solution of 32.0 g of 3-(2-chloro-6-fluorophenyl)-5-(4-hydroxymethylphenyl)-1-methyl-1H-1,2,4-triazole in 10 ml of dimethoxyethane, which is stirred for 30 minutes. To the resulting reaction solution is added dropwise 24.0 g of 2,3-dichloro-5-trifluoromethylpyridine at -5° C. to -3° C. and the reaction is further continued for 1 hour. After the completion of the reaction, the reaction solution is turned to room temperature, added to water and extracted with ether. The extract is washed with water and dried over anhydrous magnesium sulfate and the solvent is distilled off under a reduced pressure. The resulting concentrate is crystallized by adding hexane to obtain 46 g of a crude crystal. Then, the crystal is recrystallized with a mixed solution of ethanol and n-hexane (3:7) to obtain 30 g of a given compound (melting point: 73.0°-75.0° C.).
EXAMPLE 5
Production of 3-(2-chloro-6-fluorophenyl)-5-[4-(3-chloro-5-trifluoromethylpyridin-2-yloxy)phenyl]-1-methyl-1H-1,2,4-triazole (Compound No. 6)
To 10 ml of dimethylformamide are added 0.6 g of 3-(2-chloro-6-fluorophenyl)-5-(4-hydroxyphenyl)-1-methyl-1H-1,2,4-triazole, 0.45 g of 2,3-dichloro-5-trifluoropyridine and 0.3 g of potassium carbonate, which are heated under reflux for 3 hours. After the cooling, the mixture is added with water and extracted with ethylacetate. The resulting organic layer is washed with water and dried over anhydrous magnesium sulfate and the solvent is distilled off under a reduced pressure. The resulting concentrate is purified by a silica gel column chromatography using a mixed solution of hexane and ethyl acetate (4:1) as a developing solvent to obtain 0.6 g of a given compound (melting point: not measurable).
NMR data (60 MHz, CDCl 3 solvent, δ value) 4.06 ppm (s, 3H) 6.82-8.50 ppm (m, 9H)
EXAMPLE 6
production of N-methyl-N-phenylsulfonyl-2-chlorobenzamidrazone
In 100 ml of N,N-dimethylformamide is dissolved 17.2 g of N-methyl-N-phenylsulfonyl-2-chlorobenzhydrazonoyl chloride, which is stirred at 60°-70° C. for 3 hours while introducing ammonia gas thereinto. After the cooling, the reaction solution is dissolved in 500 ml of ethyl acetate, washed with water, dried over anhydrous magnesium sulfate and concentrated under a reduced pressure. The resulting crystal is washed with n-hexane to obtain 15.4 g of a given compound (melting point: 94.0°-96.0° C.).
NMR data (60 MHz, CDCl 3 solvent, δ value) 2.75 ppm (s, 3H) 7.10-8.00 ppm (m, 9H)
EXAMPLE 7
Production of 3-(2-chloro-6-fluorophenyl)-5-(4-hydroxymethylphenyl)-1-methyl-1H-1,2,4-triazole
A mixture of 51 g of 3-(2-chloro-6-fluorophenyl)-5-(4-methylphenyl)-1-methyl-1H-1,2,4-triazole, 33 g of N-bromosuccinimide, 1.0 g of benzoyl peroxide and 300 ml of carbon tetrachloride is heated under reflux for 5 hours. After the cooling, the solvent is distilled off to obtain 130 g of a crude product of 5-(4-bromomethylphenyl)-3-(2-chloro-6-fluorophenyl)-1-methyl-1H-1,2,4-triazole. This product is dissolved in 300 ml of N,N-dimethylformamide and added with 47 g of potassium acetate, which is stirred at 120° C. for 6 hours. After the completion of the reaction, the resulting product is poured in a great amount of water and extracted with ethyl acetate. The extract is washed with water and dried over anhydrous magnesium sulfate and the solvent is distilled off under a reduced pressure to obtain 5-(4-acetoxymethylphenyl)-3-(2-chloro-6-fluorophenyl)1-methyl-1H-1,2,4-triazole. This compound is dissolved in 300 ml of ethanol and added with 200 ml of 10% sodium hydroxide solution, which is heated under reflux for 1 hour. After the completion of the reaction, ethanol is distilled off under a reduced pressure and the residue is poured into water and extracted with ethyl acetate. The extract is washed with water, dried over anhydrous magnesium sulfate and concentrated under a reduced pressure to obtain 88 g of a given crude crystal. This crystal is recrystallized with ethanol to obtain 54.3 g of the given compound (melting point: 128.0°-130.0° C.).
EXAMPLE 8
Production of 3-(2-chloro-6-fluorophenyl)-5-(4-hydroxyphenyl)-1-methyl-1H-1,2,4-triazole
A mixture of 11.9 g of 3-(2-chloro-6-fluorophenyl)-5-(4-methoxyphenyl)-1-methyl-1H-1,2,4-triazole, 15.0 g of aluminum chloride and 200 ml of benzene is heated under reflux for 1.5 hours. After the cooling, the solvent is distilled off and the residue is poured into water and extracted with ethyl acetate. The extract is washed with water and dried over anhydrous magnesium sulfate and the solvent is distilled off under a reduced pressure. The residue is washed with hexane to obtain 10.2 g of a given compound (melting point: 236.0°-240.0° C.).
NMR data (60 MHz, CDCl 3 solvent, δ value) 4.02 ppm (s, 3H) 6.60-7.80 ppm (m, 7H) 9.36-9.56 ppm (br, 1H)
The insecticide and acaricide according to the invention contain the triazole derivative represented by the general formula [I] as an active ingredient.
When the triazole compounds according to the invention are used as an active ingredient for insecticides and acaricides, these compounds themselves may be used alone, or may be compounded with a carrier, a surfactant, a dispersing agent, an adjuvant or the like usually used in the formulation to form dusts, wettable powder, emulsion, fine powder, granules or the like.
As the carrier used in the formulation, mention may be made of a solid carrier such as zeeklite, talc, bentonite, clay, kaolin, diatomaceous earth, white carbon, vermiculite, calcium hydroxide, quartz sand, ammonium sulfate, urea or the like; and a liquid carrier such as isopropyl alcohol, xylene, cyclohexane, methylnaphthalene or the like.
As the surfactant and dispersing agent, mention may be made of a metal salt of alkylbenzene sulfonic acid, a metal salt of dinaphtylmethane disulfonic acid, a sulfuric acid ester of alcohol, alkylarylsulfonate, lignin sulfonate, polyoxyethylene glycol ether, polyoxyethylene alkylaryl ether, polyoxyethylene sorbitan monoalkylate and the like.
As the adjuvant, mention may be made of carboxymethylcellulose, polyethylene glycol, gum arabi and the like.
In use, the compound according to the invention is directly applied or sprayed by diluting to a proper concentration.
The insecticide and acaricide according to the invention may be used by spraying onto stem and leaves, by applying to soil, by applying to a nursery box, by spraying onto water surface or the like.
In the formulation, the amount of the active ingredient used may be selected in accordance with the use purpose, but it is properly selected within a range of 0.05-20% by weight, preferably 0.1-10% by weight in case of the dusts or granules. In case of the emulsion or wettable powder, the amount of the active ingredient is properly selected within a range of 0.5-80% by weight, preferably 1-60% by weight.
The amount of the insecticide and acaricide applied is dependent upon the kind of the compound used as an active ingredient, injurious insect to be controlled, tendency and degree of insect injury, environmental condition, kind of formulation used and the like. When the insecticide and acaricide according to the invention are directly used as dusts or granules, the amount of the active ingredient is properly selected within a range of 0.05-5 kg, preferably 0.1-1 kg per 10 are. Furthermore, when they are used in form of a liquid as emulsion or wettable powder, the amount of the active ingredient is properly selected within a range of 0.1-5000 ppm, preferably 1-1000 ppm.
Moreover, the insecticide and acaricide according to the invention may be used by mixing with other insecticide, fungicide, fertilizer, plant growth regulator and the like.
The formulation will concretely be described with respect to typical examples. In this case, the kind of the compounds and additives and the compounding ratio are not limited to these examples and may be varied within wide ranges. Moreover, % is by weight otherwise specified.
Formulation Example 1
Emulsion
An emulsion is prepared by uniformly dissolving 30% of compound No. 10, 20% of cyclohexanone, 11% of polyoxyethylene alkylaryl ether, 4% of calcium alkylbenzenesulfonate and 35% of methylnaphthalene.
Formulation Example 2
Wettable powder
A wettable powder is prepared by uniformly mixing and pulverizing 40% of compound No. 80, 15% of diatomaceous earth, 15% of clay, 25% of white carbon, 2% of sodium dinaphthylmethane disulfonate and 3% of sodium lignin sulfonate.
Formulation Example 3
Dust
A dust is prepared by uniformly mixing and pulverizing 2% of compound No. 48, 5% of diatomaceous earth and 93% of clay.
Formulation Example 4
Granules
A mixture of 5% of compound No. 22, 2% of sodium salt of lauryl alcohol sulfuric acid ester, 5% of sodium lignin sulfonate, 2% of carboxymethyl cellulose and 86% of clay is uniformly pulverized and added with 20 parts of water based on 100 parts of the mixture, which is kneaded, shaped into granules of 14-32 mesh through an extrusion type granulating machine and dried to form granules.
The triazole derivatives according to the invention are effective to control planthoppers such as brown planthopper, white-backed planthopper, small brown planthopper and the like; leafhoppers such as green rice leafhopper, tea green leafhopper and the like; aphids such as cotton aphid, green peach aphid, cabbage aphid and the like; whiteflies such as greenhouse whitefly and the like; hemipteran injurious insects such as mulberry scale, corbett rice bug and the like; lepidopteran injurious insects such as diamond-back moth, lima-bean cutworm, tobacco cutworm and the like; dipteran injurious insects such as house maggot, mosquito and the like; elytron injurious insects such as rice plant weevil, soy bean weevil, cucrbit leaf beetle and the like; orthopteran injurious insects such ass american cockroach, stem fly and the like; mites such as two-spotted spider mite, kanzawa spider mite, citrus red mite and the like; and mites having an increased resistance to organotin, synthesized pyrethroid and organophosphorus chemicals.
Particularly, they develop a very excellent effect of controlling mites such as two-spotted spider mite, kanzawa spider mite, citrus red mite and the like.
The effect of the compounds according to the invention will be described with respect to the following test examples. Moreover, the following compounds are used as a comparative chemical, wherein a comparative chemical A is a compound described in Japanese Patent laid open No. 56-154464, and a comparative chemical B is a commercial product usually used for the control of mites.
Comparative chemical A
3,5-bis(o-chlorophenyl)-1-methyl-1H-1,2,4-triazole
Comparative chemical B
Hexythiazox (common name)
Test Example 1
Insecticidal test for diamond-back moth
The wettable powder prepared according to Formulation Example 2 is diluted with water so that the concentration of the active ingredient is 500 ppm. Cabbage leaves are immersed in the resulting diluted solution, dried in air and then placed in a vinyl chloride cup of 60 ml capacity. Ten larvae of 3rd instar diamond-back moth are released in the cup and thereafter a cover is placed thereon. Then, the cup is placed in a thermostatic chamber of 25° C. for 6 days, and the number of larvae died is counted to calculate the percentage of mortality. The test is carried out by double series. Moreover, the comparative chemical A is used for the comparison. The results are shown in Table 9.
TABLE 9______________________________________CompoundNo. Mortality (%)______________________________________ 4 100 48 95 56 100 60 100 71 100 77 100 81 95 87 100 91 100 97 100 98 100101 90103 100105 100107 100109 100120 100145 100162 100166 100172 100180 100184 100225 100Comparative 20chemical A______________________________________
Test Example 2
Insecticidal test for larvae of cotton aphid
The wettable powder prepared according to Formulation Example 2 is diluted with water so that the concentration of the active ingredient is 100 ppm. In the resulting diluted solution are immersed cucumber seedlings previously inoculated with larvae of cotton aphid and then subjected to a drying treatment in air. After the treatment, the cucumber seedlings are placed in a thermostatic chamber of 25° C. for 3 days and then the number of larvae died is counted to calculate the percentage of mortality. The test is carried out by double series. The results are shown in Table 10.
TABLE 10______________________________________CompoundNo. Mortality (%)______________________________________ 2 100 4 10011 10012 10024 10027 10028 10029 10045 10046 10047 10052 10067 10071 10080 10081 10087 10092 10093 10095 10097 10099 100105 100107 100109 100120 100143 100145 100162 100166 100172 100176 100180 100184 100225 100226 100______________________________________
Test Example 3
Ovicidal test for eggs of two-spotted spider mite
Female adults of two-spotted spider mite are placed on three leaf discs of kidney bean (diameter: 15 mm) and oviposited over 24 hours, and thereafter these adults are removed therefrom. The wettable powder prepared according to Formulation Example 2 is diluted with water so that the concentration of the active ingredient is 0.16 ppm. In the resulting diluted solution are immersed these leaf discs for 10 seconds. After the treatment, the leaf discs are placed in a thermostatic chamber of 25° C. for 7 days and then the number of unhatched eggs is counted to calculate the percentage of ovicidal activity. The test is carried out by double series. Moreover, the comparative chemicals A and B are used for the comparison. The results are shown in Table 11.
TABLE 11______________________________________Compound No. Mortality (%)______________________________________ 47 100 97 100 98 100143 100162 100166 100172 100184 100225 100Comparative 24chemical AComparative 95chemical B______________________________________
Test Example 4
Ovicidal test for eggs of chemical-resistant kanzawa spider mite
Female adults of kanzawa spider mite having a resistance to commercially available chemicals are placed on three leaf discs of kidney bean (diameter: 15 mm) and oviposited over 2 days, and thereafter these adults are removed therefrom. The wettable powder prepared according to Formulation Example 2 is diluted with water so that the concentration of the active ingredient is 4 ppm. In the resulting diluted solution are immersed these leaf discs for 10 seconds. After the treatment, the leaf discs are placed in a thermostatic chamber of 25° C. for 7 days and then the number of unhatched eggs is counted to calculate the percentage of ovicidal activity. The test is carried out by double series. Moreover, the comparative chemicals A and B are used for the comparison. The results are shown in Table 12.
TABLE 12______________________________________Compound MortalityNo. (%)______________________________________ 2 100 3 100 4 100 5 100 6 10010 10011 10014 10021 10022 10024 10027 10028 10029 10031 10038 10042 10043 10045 10046 10048 10050 10052 10054 10056 10058 10060 10064 10066 10071 10075 10077 10078 10080 10081 10087 10091 10093 10095 10097 10098 10099 100101 100103 100107 100109 100172 100184 100Comparative 31chemical AComparative 0chemical B______________________________________
Test Example 5
Insecticidal test for larvae of chemical-resistant kanzawa spider mite
Female adults of kanzawa spider mite having a resistance to commercially available chemicals are placed on three leaf discs of kidney bean (diameter: 15 mm) and oviposited over 2 days, and thereafter these adults are removed therefrom. Then, these leaf discs are placed in a thermostatic chamber of 25° C. for 5 days and the number of hatched larvae is counted. Separately, the wettable powder prepared according to Formulation Example 2 is diluted with water so that the concentration of the active ingredient is 20 ppm. After these leaf discs are sprayed with the resulting diluted solution, they are placed in a thermostatic chamber of 25° C. for 7 days and then the number of living adults is counted to calculate the percentage of mortality on the hatched larvae. The test is carried out by double series. Moreover, the comparative chemicals A and B are used for the comparison. The results are shown in Table 13.
TABLE 13______________________________________Compound No. Mortality (%)______________________________________ 97 100 98 100172 100184 100Comparative 55chemical AComparative 25chemical B______________________________________
Test Example 6
Ovicidal test for eggs of citrus red mite
Female adults of citrus red mite are placed on two laminate of citrus fruit (diameter: 10 mm) and oviposited over 2 days, and thereafter these adults are removed therefrom. The wettable powder prepared according to Formulation Example 2 is diluted with water so that the concentration of the active ingredient is 4 ppm. In the resulting diluted solution are immersed these laminate for 10 seconds. After the treatment, the laminate are placed in a thermostatic chamber of 25° C. for 7 days and then the number of unhatched eggs is counted to calculate the percentage of ovicidal activity. The test is carried out by double series. Moreover, the comparative chemicals A and B are used for the comparison. The results are shown in Table 14.
TABLE 14______________________________________Compound No. Mortality (%)______________________________________ 97 100Comparative 33chemical AComparative 90chemical B______________________________________ | A novel triazole derivative for use in an insecticide or an acaricide has a general formula [I]: ##STR1## (wherein R 1 is an alkyl group, X is a hydrogen atom, a halogen atom or the like, n is an integer of 1-5, A is an oxygen atom, a sulfur atom or the like, k is 0 or 1, R 2 is a hydrogen atom, a halogen atom or the like, m is an integer of 1-5) and controls various injurious insects and mites, particularly mites and aphids without damaging crops. | 0 |
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/075,645 filed Feb. 13, 2002 which is a continuation-in-part of U.S. patent application Ser. No. 10/038,219, filed Jan. 3, 2002 which is incorporated in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to replaceable self-aligning gauge modules for a tufting machine and is more particularly concerned with gauge modules with individually replaceable gauge elements which can be readily installed and removed.
BACKGROUND OF THE INVENTION
[0003] Tufting machines are built with precision so that the needles and loopers of the machine are accurately spaced from each other along the needle bar or looper bars. The loopers and needles must be spaced from each other so that the looper bills pass closely adjacent to the needles to engage and hold loops of yarns carried by the needles. When assembling a tufting apparatus, errors in positioning these gauge elements may accumulate as the work progresses. The present invention seeks to establish consistency with these parts across the width of the apparatus, to provide a tufting environment, suitable even for narrow gauge configurations. The present invention also addresses the problem of replacing individual gauge elements that become broken or damaged during tufting. In most modular designs, a broken gauge element requires discarding the entire modular block containing a set of about one to two dozen gauge elements. The present invention allows for quick and efficient replacement of individually damaged gauge elements.
[0004] The idea of replacing individual components of assemblies in tufting machines is not new. In the past, knife holder assemblies have been devised that allow for the replacement of individual knives. The knives were arranged in pre-assembled or modular fashion in a knife holder, each knife holder having a guide mechanism which enabled groups of knives, each group in a separate holder, to be positioned on a carrying member of a tufting machine and maintained in appropriate alignment. U.S. Pat. Nos. 4,608,934; 4,669,171; 4,691,646; and 4,693,191 illustrate such prior art knife holder assemblies in which parallel knives are disposed. These prior art knife holder assemblies are then disposed in transverse bars provided with guides for positioning the holders in appropriate positions on a tufting machine.
[0005] Needles have previously been individually secured in modular gauge blocks as shown in U.S. Pat. No. 4,170,949, and hooks and knives have also been individually secured in gauge parts mounting blocks as shown in U.S. Pat. No. 4,491,078. These designs have used individual clamping screws to hold each gauge element in place. These blocks were not mated with slots on the carrying members and were heavily machined. In addition, the clamping screws used in these gauge blocks have typically been flat ended and have relied upon the flat tip pushing directly against the gauge element to securely position those gauge elements. When the blocks are machined from relatively soft metals such as aluminum, there has been a tendency for the threads of the block to become worn and allow too much play for all of the screws to securely hold their corresponding gauge elements.
[0006] More recently attempts have been made to incorporate needles and loopers into replaceable modular blocks. U.S. Pat. Nos. RE 37,108, 5,896,821, 5,295,450 illustrate such modular gauge assemblies in which the gauge elements are permanently embedded into the modular block. The block is attached to the guide bar with a single screw allowing for removal and replacement of the block. One shortcoming of these modular blocks is that when a single gauge element breaks the entire modular block must be discarded.
SUMMARY OF THE INVENTION
[0007] The present invention includes a modular gauge assembly that attaches to a gauge bar. The gauge bar has a plurality of positioning recesses that allows a detent on an individual modular block to be accurately positioned along the gauge bar. Each modular block typically includes a front surface, a pair of side surfaces opposed to each other, a rear surface opposite to the front surface, and a bottom surface.
[0008] A tongue, which may or may not be a part of the cast block extends from a rear or bottom surface of the modular block. The tongue includes a threaded hole which along with a securing screw serves to mount the block to a gauge bar. The threaded hole aligns with the gauge bar receiving hole when the tongue of the modular block is positioned properly with a recess on the gauge bar. When sufficiently tightened, the securing screw holds the modular block to the gauge bar. Alternatively, the block may be positioned with pins fitting into recesses in the block and gauge bar.
[0009] At least the front surface of the block contains a plurality of spaced parallel slots so that gauge elements may be positioned in the slots with proper spacing. The proximal ends of the gauge elements may have apertures or channels recessed therein. In one embodiment of the present invention the proximal ends of the gauge elements are inserted into the block and secured there by a lateral pin that enters the block on one of the opposing side surfaces and passes through apertures on the proximal ends of the gauge elements. One alternative embodiment allows the pin to be placed by forming a channel in the block. Another alternative embodiment biases a lateral pin resting in a channel on the proximal ends of the gauge elements by tightening a securing bolt that is in communication with the lateral pin through an opening on the block. The securing bolts may have conical ends or flat ends depending upon their orientation with respect to the lateral pin to exert a wedging or camming force against the lateral pin. In either case the gauge elements are secured by a lateral pin engaging the gauge elements. Individual gauge elements can be replaced by demounting the affected block, removing the lateral pin and removing a selected gauge element. After the selected gauge element is removed a new gauge element may be re-inserted into the proper vertical slot and secured by the lateral pin and securing bolt.
[0010] A plurality of modular blocks are arranged along the surface of the gauge bar and are vertically positioned on the gauge bar by a horizontal surface of the gauge bar or of a guide bar that passes through a guide bar channel on the gauge bar. The width of each block is substantially equal to the distance between the positioning recesses of the gauge bar so that the edges of the blocks abut one another and the blocks are laterally positioned.
[0011] In an alternative embodiment of the present invention each modular gauge assembly attaches to a gauge bar having a plurality of positioning recesses that allows the detent on the individual modular block to laterally position the block on the gauge bar. Each modular block typically includes a front surface, a pair of side surfaces opposed to each other, a rear surface opposite to the front surface, and opposing bottom and top surfaces. The rear surface contains a rectangular tab or detent that includes a threaded hole to receive a securing screw. The threaded hole aligns with the gauge bar receiving hole when the modular block is positioned properly on the gauge bar. When tightened, the securing screw holds the modular block securely to the gauge bar. A plurality of gauge holes extend from the bottom toward the top surface, in some cases passing through the modular block. Gauge elements with proximal ends adopted to be received within the gauge holes may be positioned with proper spacing in the block. Gauge elements that have the proximal end inserted into the block are securely positioned by pin-screws that enter the block below the tab on the rear surface. The pin-screws are positioned beneath the tab. In this fashion, the pin-screws can be accessed without removing the modular block from the gauge bar. When engaging rounded gauge elements such as tufting needles, the pin screws may advantageously have conical ends to hold the gauge elements by wedging or camming force.
[0012] Of particular advantage is the use of lightweight aluminum alloys such as aluminum 7075 from which to manufacture modular blocks. When these modules are utilized with aluminum alloy or other lightweight material hook bar brackets, jack shaft rockers, and hook shaft drive levers, approximately 40% of the weight of these components, comprising some 200 pounds across the length of a broad loom tufting machine, can be removed from the moving action of the machine. This reduction in weight tends to correspondingly reduce the vibration of the tufting machine and facilitates operation of the tufting machine at higher speeds.
[0013] Accordingly, it is an object of the present invention to provide a tufting machine where the gauge elements of the tufting machine are accurately positioned within a modular block assembly.
[0014] Another object of the present invention is to provide in a tufting machine, a system which can facilitate the rapid change over of one or more damaged gauge elements, reducing to a minimum the downtime of the tufting machine.
[0015] Another object of the present invention is to provide in a modular block assembly, a system which can facilitate the rapid change over of individual damaged gauge elements, reducing the cost of repairing broken gauge elements and removing the need to replace entire modular blocks when a single gauge element becomes damaged.
[0016] Other objects, features, and advantages of the present invention will become apparent from the following description when considered in conjunction with the accompanying drawing wherein like characters of reference designate corresponding parts throughout several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a fragmentary perspective view of a modular block assembly with single looper modular blocks in place on a gauge bar.
[0018] FIG. 2 is an exploded perspective view of the modular block assembly of FIG. 1 with modular blocks removed from the gauge bar, and one looper modular block disassembled.
[0019] FIG. 3 is a perspective view of the rear surface of a modular block of FIG. 1 .
[0020] FIG. 4 is a fragmentary perspective view of a double looper modular block assembly with modular blocks in place on the gauge bar.
[0021] FIG. 5 is an exploded perspective view of the modular block assembly of FIG. 4 , with modular blocks removed from the gauge bar and one block disassembled.
[0022] FIG. 6 is a fragmentary perspective view of a modular needle block assembly with modular blocks in place on a gauge bar.
[0023] FIG. 7 is an exploded fragmentary perspective view of the modular needle block assembly of FIG. 6 with the modular blocks removed from the gauge bar and one block disassembled.
[0024] FIG. 8 is a rear perspective view of a modular block of FIG. 6 .
[0025] FIG. 9 is an exploded perspective view of a modular assembly having a single row of loop-pile hooks held in place by a lateral pin and securing bolts.
[0026] FIG. 10A is an exploded view of a modular block having a double row of loop-pile hooks held in place by lateral pins and securing bolts.
[0027] FIG. 10B is a top perspective view of the relative positions of the gauge elements, lateral pins and securing bolts of FIG. 10A when mounted in the block.
[0028] FIG. 10C is a bottom perspective view of the relative positions of the gauge elements, lateral pins and securing bolts of FIG. 10A when mounted in the block.
[0029] FIG. 10D shows in isolation a side elevation view of the relative positions of a single gauge element, lateral pin and securing bolt when mounted in the block.
[0030] FIG. 11A is an exploded view of a modular block having cut-pile hooks with lateral pins, and securing bolts.
[0031] FIG. 11B is a side elevation view of the block of FIG. 11A .
[0032] FIG. 11C is a side elevation view of the relative positions of the gauge elements, lateral pins and securing bolt of FIG. 11B when mounted in the block.
[0033] FIGS. 12A and 12B show the mounting of a series of needle modules according to the present invention to a needle bar.
[0034] FIGS. 12C and 12D are mirror image perspective exploded views of the needle modules utilized in FIGS. 12A and B.
[0035] FIG. 12E is a sectional view of the needle bar in FIG. 12A .
[0036] FIG. 12F is a perspective view of the needle modules of FIGS. 12A through E in assembled and unmounted form.
[0037] FIG. 13A is an exploded perspective view of an alternative needle module embodiment with an ovular aperture and round lateral pin.
[0038] FIG. 13B is a cross sectional view of the needle module of FIG. 13A .
[0039] FIG. 14A is an exploded perspective view of an alternative needle module embodiment having a round aperture and utilizing a rectangular lateral pin and flat head securing screws.
[0040] FIG. 14B is a cross sectional view of the module of FIG. 14A .
[0041] FIGS. 15A, 15B , and 15 D are cross sectional, front, and bottom views of an alternative needle module for use with two mounting screws and a single set pin.
[0042] FIG. 15C is a sectional view of dual needle bars having protruding mounting pins intended to be received in an aperture of a gauge block such as depicted in FIG. 15A .
[0043] FIG. 16A is a side view of an alternative needle block and gauge element configuration using a flat head set screw and round lateral pin and an oval aperture.
[0044] FIG. 16B reflects the hook element and lateral pins and set screw of the modular block of 15 A in isolation.
[0045] FIG. 17A is a front perspective view of a hook block for a dual needle bar tufting machine according to the present invention.
[0046] FIG. 17B is an exploded perspective view of the hook block of FIG. 17A .
[0047] FIG. 17C is a rear perspective view of the hook block of FIG. 17A .
[0048] FIG. 18A is a view of lateral pins and conical set screw utilized to position a looper element in isolation from a modular block.
[0049] FIG. 18B illustrates the elements of FIG. 18A within a modular block according to the present invention.
[0050] FIG. 19A is a perspective view of a looper block according to the present invention for a dual needle bar tufting machine.
[0051] FIG. 19B is an exploded perspective view of the looper block of FIG. 19A .
[0052] FIG. 19C is a rear perspective view of the looper block of FIG. 19A .
[0053] FIG. 20A is a top plan view of a hook that may be used as a gauge element in the modules of the present invention.
[0054] FIG. 20B is a side plan view of the hook of FIG. 20A .
[0055] FIG. 21 is a looper that may be used as a gauge element in the modular blocks of the present invention.
[0056] FIG. 22 is an alternative looper design that may be used in the modular blocks of the present invention.
[0057] FIG. 23 is a partial sectional view of the business area of a tufting machine.
DETAILED DESCRIPTION
[0058] The present invention is designed for use in tufting machines of the type generally including a needle bar carrying one or more rows of longitudinally spaced needles that are supported and reciprocally driven by a plurality of push rods. In the tufting zone shown in FIG. 23 , the needles 13 carry yarns 50 which are driven through a backing fabric 114 by the reciprocation of the needles. While penetrating the backing fabric, a plurality of longitudinally spaced hooks 18 , 14 cooperate with the needles to seize loops of yarns and thereby form the face of a resulting fabric. In some cases the hooks will cooperate with knives 113 to cut the loops of yarn seized on the hooks and thereby form a cut pile face 146 for the fabric. The present invention is directed to modular units for holding loopers or hooks and for holding needles to facilitate their cooperation during the tufting process.
[0059] Referring in detail to FIG. 1 , a modular block assembly 5 is illustrated having a single row of gauge elements 10 , in this case loopers, housed in a series of modular blocks 15 . The individual gauge elements 10 are fastened to each block 15 by a lateral pin 20 . As better illustrated in FIG. 2 , the lateral pin 20 enters the modular block 15 at one of the opposing side surfaces 22 a , 22 b . The gauge bar 25 and guide bar 30 are used in concert to position the modular blocks 15 relative to one another. The guide bar 30 extends laterally through channel 35 substantially the entire length of the gauge bar 25 . The tab breaks 115 of the modular blocks 15 engage with guide bar 30 as shown in FIG. 3 , to vertically align the individual blocks 15 in the modular block assembly 5 .
[0060] FIG. 2 illustrates a portion of the modular block assembly 5 with the blocks 15 detached from the gauge bar 25 . The gauge bar 25 has a plurality of vertical recesses 40 . The recesses 40 are crossed by lateral channel 35 so that guide bar 30 fits between the gauge bar 25 and the rear surfaces 45 of the modular blocks 15 . Guide bar 30 creates upper face 31 and lower face 32 which are normal to the side walls of recesses 40 . When tab breaks 115 of modular blocks 15 engage these faces 31 , 32 , the faces serve as restraining surfaces to hold blocks 15 in vertical alignment.
[0061] One modular block 15 in FIG. 2 is disassembled and removed from the gauge bar 25 to reveal spaced parallel slots 50 divided by vertical walls 51 located on the front surface 55 of the block for receiving the proximal ends 75 of the gauge elements 10 . The illustrated proximal ends 75 of the gauge elements 10 contain apertures such as pinholes 70 . When the gauge elements 10 are positioned in the modular block 15 the pinholes 70 align with apertures formed in side surfaces of the block such as pin opening 85 . Lateral pin 20 is then inserted through pin opening 85 in one of the opposing side surfaces 22 a , 22 b , and the pinholes 70 for each gauge element 10 to fasten the gauge elements 10 in block 15 .
[0062] In illustrated modular blocks 15 containing only a single row of gauge elements 10 , a tongue portion 60 extends from the rear surface 45 of the modular block 15 . The tongue 60 has an opening, preferably in the form of hole 90 , as shown in FIG. 3 . When the modular block 15 is positioned on the gauge bar 25 , threaded hole 90 aligns with another hole 100 located in a gauge bar recess 40 . Once a modular block 15 is positioned a securing screw 65 can be inserted through hole 90 and tightened into the hole 100 on the gauge bar 25 . A modular block 15 , once fixed in place by the securing screw 65 , is prevented from lateral and vertical movement. The screw 65 and side walls of vertical recesses 40 resist against horizontal movement while the screw 65 and faces 31 , 32 of the guide bar 30 resist against vertical movement. The fixed position of the blocks 15 insures that the gauge elements 10 remain properly aligned during the tufting process.
[0063] FIG. 3 shows the rear surface 45 of a modular block 15 having a single row of gauge elements 10 . On the rear surface 45 is a detent in the form of an elongated tab 110 extending vertically from the top 165 of the block to the bottom of the tongue portion 60 of the block. Tab 110 has a horizontal break 115 that engages with guide bar 30 to vertically position block 15 on the gauge bar 25 . The walls of break 115 are preferably substantially planar and parallel so that a part of the rectangular cross section of guide bar 30 closely fits within break 115 . The lower segment 120 of the tab contains the opening 90 where the securing screw 65 enters and attaches to a receiving hole 100 in the gauge bar 25 .
[0064] FIG. 4 illustrates a section of a modular block assembly 5 with three double gauge element modular blocks 130 mounted on the gauge bar 26 . Each modular block 130 contains two transverse gauge element rows 125 , the forward gauge elements 12 forming a first row 125 and rear gauge elements 11 forming a second row. Modular blocks 130 have two apertures such as pin openings 85 a , 85 b that are spaced apart on the side surfaces 22 a , 22 b of the block 130 . Unlike blocks 15 in FIG. 1 , a portion of the double gauge modular blocks 130 rests on top of the gauge bar 26 to vertically position blocks 130 . This is accomplished by using a downwardly extending detent such as tongue 60 illustrated near the center of the bottom 135 of blocks 130 .
[0065] FIG. 5 shows an exploded view of modular block 130 containing two rows 125 of gauge elements 11 , 12 . The gauge bar 26 in FIG. 5 has a plurality of vertical recesses 40 . Vertical recesses 40 receive tongues 60 to horizontally position blocks 130 along the gauge bar 25 . Vertical positioning is accomplished by resting part of the bottom surface 135 of gauge blocks 130 on the top surface of gauge bar 25 . Modular block 130 in FIG. 5 is disassembled and removed from the gauge bar 26 to reveal the spaced parallel slots 50 a, 50 b located on the front 55 and rear surface 45 of the block 130 for receiving the proximal ends 77 , 78 of the front and rear gauge elements 12 , 11 .
[0066] The proximal ends 77 , 78 of the gauge elements 12 , 11 contain openings such as pin holes 71 , 72 which when positioned in slots 50 a , 50 b of modular block 130 align with pin openings 85 a or 85 b , respectively. The lateral pins 20 a , 20 b are inserted through the pin openings 85 a or 85 b on one of the opposing side surfaces 22 a , 22 b and through pin holes 71 , 72 in the proximal ends of each gauge element 11 , 12 to fasten the gauge elements 11 , 12 in the modular block 130 .
[0067] In the illustrated modular blocks 130 the tongue portion 60 of the modular block 130 extends centrally from the bottom surface 135 . Tongue 60 defines an opening (not shown). When modular blocks 130 are positioned on gauge bar 26 , this opening aligns with a threaded receiving hole 100 , located in vertical recesses 40 of gauge bar 26 . Once the modular block 130 is positioned a securing screw 65 can be inserted through the opening in tongue 60 and tightened into threaded receiving hole 100 . Modular blocks 130 , once fixed in place by securing screws 65 , are prevented from lateral movement by the securing screw 65 and interface of the detent against walls of vertical recesses. Similarly, modular blocks 130 are prevented from vertical movement by securing screw 65 and interface of bottom surface 135 against the top surface 26 a of gauge bar 26 . The fixed position of the block 130 insures that the gauge elements 11 , 12 remain properly aligned during the tufting process.
[0068] Referring now to FIG. 6 , another aspect of the present invention depicts a section of a modular block assembly 5 having a row of gauge elements, in this case needles 13 , housed in clamping modular blocks 140 . FIG. 6 shows four clamping modular blocks 140 attached to gauge bar 27 . The clamping modular blocks 140 are positioned such that the lower portion 150 of the block 140 extends beneath the gauge bar 27 . This exposed lower portion 150 contains individual clamping elements, such as screw-pins 145 , shown in FIG. 7 , that hold the gauge elements 13 in place in the block 140 . The gauge bar 27 has a horizontal shelf portion 27 a and a vertical portion 27 b which join to form an interior right angle into which the blocks 140 are positioned.
[0069] FIG. 7 illustrates a portion of a modular block assembly 5 with screw-pin modular blocks 140 detached from the gauge bar 27 and one block 140 disassembled. The gauge bar 27 has a plurality of vertical recesses 40 on the inner surface of vertical portion 27 b of the gauge bar 27 . As illustrated, the recesses 40 do not extend the entire height of the wall portion 27 b of the gauge bar 27 . Each recess 40 preferably contains a clearance hole 100 which receives a securing screw 65 to attach blocks 140 to the gauge bar 27 . The rear surfaces 45 of modular blocks 140 have a detent such as tab 160 with an opening, such as threaded hole 90 (shown in FIG. 8 ), positioned to align with holes 100 , located in the vertical recesses 40 of gauge bar 27 . Once a modular block 140 is positioned in the interior right angle between the shelf portion 27 a and wall portion 27 b , with tab 160 received in a vertical recess 40 , the securing screw 65 can be inserted through the corresponding hole 100 in the wall portion 27 b into the threaded hole 90 in the tab 160 and tightened to hold the modular block 140 in place. Once fixed in place by securing screw 65 , the modular block 140 is prevented from lateral movement by the action of the tab 160 fitting between the vertical walls of the vertical recess 40 , by the screw 65 . Vertical movement is restrained by action of the screw 65 and the interface of the top surface 165 of block 140 with the bottom of shelf portion 27 a of the gauge bar 27 . The fixed position of the block 140 insures that the gauge elements 10 remain properly aligned during the tufting process.
[0070] FIG. 7 also depicts a disassembled clamping modular block 140 thereby revealing the spaced parallel gauge element openings 155 which extend from the top surface 165 to the bottom surface 135 of the block 140 . Openings 155 need not extend completely to the top surface 165 for satisfactory operation, however, it is convenient for manufacture. The individual needles 13 are fastened to the block 140 by dedicated clamps such as screw-pins 145 that fix individual gauge elements 10 within the block 140 . Screw pins 145 enter the block 140 at the rear surface 45 of the block 140 on its lower portion 150 . When the block is attached to the gauge bar 27 the screw-pins 145 remain accessible so that individual gauge elements 10 can be removed and replaced.
[0071] FIG. 8 illustrates the top 165 and rear surface 45 of the block 140 . Gauge element openings 155 can be seen on the top surface 165 of the block 140 . A rectangular tab 160 for positioning the block 140 on the gauge bar 27 is located centrally on the rear surface 45 of the block 140 . The rectangular tab 160 defines the opening 90 which aligns with the holes 100 in vertical recesses 40 and with securing screw 65 fixes the block 140 to the gauge bar 27 . Openings 170 for screw pins 145 are located horizontally along the lower portion 150 of block 140 .
[0072] Referring now to FIG. 9 , a preferred embodiment of the present invention depicts a modular block assembly 5 having a single row of gauge elements, in this case loop pile hooks 10 , housed in a single gauge modular block 15 . The modular block 15 may be mounted and attached to the gauge bar 25 with securing screw 65 extending through the block 15 into the gauge bar 25 . The gauge elements 10 are inserted in and removably secured to the block 15 by use of lateral pin 20 . The lateral pin 20 may be divided into two or more sections, or be formed of somewhat malleable material, to compensate for various differences in the heights of the gauging elements 10 .
[0073] Unlike the previous embodiments, the illustrated lateral pin 20 does not extend through openings in the gauge elements 10 , but merely abuts proximal ends of gauge elements 10 so that the gauge elements 10 are resting on the lateral pin 20 . The lateral pin 20 is then biased against the gauging elements 10 by a clamp such as securing bolt 38 received in threaded opening 39 on the top surface 165 of modular block 15 . Tightening securing bolts 38 biases the lateral pin 20 against the gauging elements 10 . In a preferred embodiment the lateral pin 20 is made of a soft metal such as brass so that when urged by the securing bolt 38 , the lateral pin 20 deforms slightly and compresses within channels 79 of individual gauge elements 10 . As a result of the clamp, the lateral pin 20 is held in place preventing lateral movement of the pin 20 into or out of the block 15 .
[0074] Due to differences in the width of the proximal ends 75 and channels 79 of the various gauge elements 10 , varying amounts of pressure are required along the length of pin 20 to sufficiently compress and restrain the gauge elements in a fixed position. Thus a preferred construction divides the pin 20 into segments to prevent the necessity of compressing a single pin 20 into all the gauge elements 10 .
[0075] This method of securing gauging elements to a block may also be employed for double gauge modular blocks 130 as seen in FIG. 10A . Rear and forward gauging elements 11 and 12 are arranged in parallel transverse rows on block 130 . The rear row of gauging elements 11 is held in position by rear lateral pin 20 a . Pin 20 a is biased against the rear gauging elements 11 by securing bolts 38 a which are received by threaded openings 39 a . Likewise, the forward gauging elements 12 are held in place by forward lateral pin 20 b biased against the forward gauging elements 12 by securing bolts 38 b which are received by threaded openings 39 b.
[0076] In FIGS. 10B and 10C , the gauge elements 11 , 12 are shown with lateral pins 20 a , 20 b and securing bolts as they would be positioned in blocks 130 , however, the blocks are not shown. Of particular interest is the conical point 89 of securing bolts 38 a , 38 b . The conical points 89 are aligned alightly off center of lateral pins 20 a , 20 b , so that the side wall rather than the vertice of the conical point makes contact with the pins 20 a , 20 b . This causes a wedge like or camming effect to pressure pins 20 a , 20 b against gauge elements 11 , 12 . When securing bolts 38 a , 38 b utilize camming action rather than mere frontal clamping pressure as would typically be the case if the bolts had flat ends, the bolts 38 a , 38 b will continue to function even when wear and operating stresses have introduced some play between the threads of the bolts 38 a , 38 b and their openings 38 a , 39 b.
[0077] FIG. 10D shows a single securing bolt 38 a with conical point 89 applying camming type pressure against lateral pin 20 a which is engaged in channel 79 of rear gauge element 11 . The modular block 130 that would hold these components is not shown so that the interaction of the gauge element, lateral pin 20 a and securing bolt 38 a can be clearly illustrated.
[0078] An additional embodiment of the invention is illustrated in FIG. 11A . The gauge elements, in this case cut-pile loopers 14 , 18 are shown removed from block 15 . When mounted in block 15 , the gauge elements 14 , 18 fit between lateral bracing pins 16 a , 16 b and secured lateral pin 20 . The bracing pins 16 a , 16 b , are slidably press fit within the block 15 and then gauge elements 14 , 18 are positioned. Bracing pins 16 a , 16 b preferably fit in channels 79 a , 79 b (shown in FIG. 11C ) of gauge elements 14 , 18 . Pin 20 is also biased against the gauge elements 14 , 18 by a clamping device such as securing bolts 38 proceeding through threaded openings 39 to engage the pin 20 . Once the gauge elements 14 , 18 are placed in the block 15 and the bracing pins 16 a , 16 b are positioned in channels 79 a , 79 b of those gauge elements 14 , 18 and lateral pin 20 is in place in block 15 , the securing bolts 38 are tightened to bias the securing pin 20 against the gauge elements 14 , 18 .
[0079] FIG. 11A shows a series of four securing bolts 38 . In a preferred embodiment, each securing bolt 38 contacts a dedicated segment of the pin 20 . Pin 20 may be made of a malleable metal such as brass and either cut or scored to create segments. Thus, pin 20 may be comprised of four separate pieces. The bolts 38 are sufficiently spaced across the block 15 so that each securing bolt 38 can contact a segment of the securing pin 20 and thereby bias between about two and about four individual gauge elements 14 , 18 . Even without cutting or scoring, the use of a pin of malleable material permits securing bolts to bias multiple gauge elements, which is particularly beneficial in avoiding the need to have apertures for bolts near the edges of the blocks.
[0080] FIGS. 11B and 11C are side plan views of the modular block 15 and cut pile loopers 14 , 18 of FIG. 11A , however, FIG. 11C shows the gauge elements 14 , 18 , lateral pins 16 a , 16 b , 20 , and securing bolts 38 without the modular block 15 . It can be seen that cut pile loopers 14 , 18 are designed to engage with rear and front rows of needles respectively, although a single length of looper could be used if only one row of needles was to be used to create cut pile tufts. As best seen in FIG. 11B , the side wall of conical point 89 exerts camming pressure against lateral pin 20 . Lateral pin 20 in turn engages with the proximal ends of gauge elements 14 , 18 . FIG. 11C shows that lateral pins 16 a , 16 b and 20 are advantageously set in channels 79 a , 79 b , 79 formed in the proximal ends of the gauge elements 14 , 18 .
[0081] Turning to FIG. 12A , a series of modular needle blocks 240 are mounted to staggered needle bar 227 . Each needle block 240 is held in place by one securing screw 265 and two pins 275 , each of which penetrates both the needle block 240 and needle bar 227 . It will be noted the alignment of the pins 275 and screw 265 is one fourth of the gauge of the block 240 (or one-sixteenth of an inch for a one-fourth inch gauge block) to the left of center of block 240 . This results in a one-fourth gauge space 271 at the end of needle bar 227 for the needle blocks 240 aligned on the front of the bar. However, for the needle blocks 240 aligned on the rear of the bar it results in a one fourth guage space 272 where the needle block 240 overruns the end of needle bar 227 . In this fashion, the needles of the front needle blocks are offset a total of one half guage from the needles of the rear needle blocks, thereby permitting identical needle blocks to be utilized on both sides of the needle bar while providing a staggered orientation for the two rows of needles. In this fashion, a composite one-eighth gauge staggered needle bar is formed from the front and back rows of one-fourth gauge needles.
[0082] More clearly shown in FIGS. 12C through 12F , the needle blocks 240 of the illustrated embodiment possess two openings 276 to receive pins 275 and a threaded aperture 241 to receive screws 265 . In addition, blocks 240 have plurality of threaded apertures to receive preferably flat headed set screws 245 which exert pressure against lateral pin 220 . The shaft end 213 A of needles 213 is placed through lower aperture 212 across channel 221 and into upper aperture 211 . The screws 245 exert pressure against rectangular, and preferably approximately square lateral pin 220 which in turn presses on needle shafts 213 A within apertures 211 , 212 and securely holds needles 213 in place. The use of rectangular channel 221 to position lateral pin 220 is preferred for manufacturing purposes relative to of the drilling of a round or oval aperture laterally through block 240 . To realize the benefits of manufacture, it is not necessary that channel 221 be perfectly rectangular, only that its upper and lower surfaces be substantially parallel to one another.
[0083] In the alternative embodiment depicted in FIGS. 13A and 13B , an oval opening 321 proceeds laterally through block 340 and conical set screws 345 are utilized to press round lateral pin 320 against upper needle shafts of 313 A while passing from bottom to top of block 340 through apertures 311 . The difficulty of forming true apertures 321 rather than channels 221 with an open side, as depicted in connection with FIG. 12 , as well as the difficulty of utilizing a conical set screw with a range of needle shaft sizes makes the construction of FIG. 13 slightly less preferable.
[0084] As shown in FIG. 14A a round hole may alternatively be utilized with a square or rectangular lateral pin 220 . When a square or rectangular pin is used, a flat headed set screws 245 are advantageously utilized to press pin 220 against upper needle shaft portions 313 A. Alternatively, a round pin may also be placed in aperture 322 with acceptable results.
[0085] In the alternative embodiments of FIGS. 15A through 15D , a block 440 is provided for use with two securing screws 465 and one pin 475 which is received in aperture 476 . The pin, which is only optional in the case where a plurality of securing screws are available, extends from needle gauge bar 427 into aperture 476 of block 440 . It is to be understood in reference to needle blocks 440 , 340 , 240 , the aperture 441 , 341 , 241 is preferably slightly larger than securing screw 465 , 365 , 265 so that the threads of the screw do not bind with the block and the screw head can exert camming action against the block toward the gauge bar 427 , 327 , 227 . When it becomes necessary to remove the block 440 , 340 , 240 from the gauge bar, the block may be removed by hand if it does not bind, or if tightly secured by action of pins 475 , 375 , 275 , then a removal bolt having larger threads (not shown) may be screwed into threaded apertures 441 , 341 , 241 to provide leverage for removal of the block. The threaded section of the larger removal bolt should not even fit into the threaded openings of the gauge bar.
[0086] FIGS. 16A and 16B illustrate another modular block 540 and the positioning of hook element 14 by pins 516 a and 516 b , lateral pin 520 and set screws 45 . The bottom of gauge element 14 is angled at approximately 7 . 5 degrees reflected by θ in FIG. 16B . This provides an acceptable angle for pressure by lateral pin 520 to securely hold hook element 14 in place.
[0087] FIG. 17A through C depict an entire block 540 with both short and long hooks 14 , 18 in exploded and front and rear perspective views. It will be appreciated that the blocks 540 may be used either with all hooks of one length in the case of a single row of needles, or with hooks of alternating lengths in the event that yarns are to be seized from two rows of needles, as might be the case on a staggered needle bar.
[0088] FIGS. 18A and B disclose another configuration of looper gauge elements 10 utilized in block 640 having lateral pin 620 pressed by conical screw 645 against the angled rear of gauge element 10 . Preferably the angle of the gauge element varies from a vertical by approximately 7.5 degrees as represented in θ in FIG. 18A . In all events, the angle of the gauge element should be between approximately 5 to 15 degrees.
[0089] FIGS. 19A through C reflect block 640 utilized with rows of alternating looper gauge elements 10 , 12 . It will be understood that block 640 may be utilized either with the alternating gauge elements in the case of cooperation with two rows of needles or with a single type of gauge element if the block is to be utilized to seize yarns only from a single row of needles.
[0090] FIGS. 20 through 22 depict the outlines of gauge elements as well as the approximate 7.5 degree variation represented by angle θ in each instance which permits a lateral pin 20 to securely hold the gauge element in place within a module according to the invention.
[0091] A further substantial benefit of hook and looper modular gauge element assemblies according to the present invention it is their relative light weight. By utilizing aluminum or other light weight material for modular blocks 240 , 340 , 440 , 540 , 640 a substantial weight reduction, on the order of fifty pounds on a broadloom tufting machine, is realized over traditional steel looper and hook assemblies. Furthermore, when other elements of the looper assembly as shown in FIG. 23 are also constructed of light weight materials, approximately 40% or over 200 pounds of the looper assembly can be removed from the tufting machine. Thus the modules 240 as well as link arms 137 , rocker arms 139 , looper arms 134 are all advantageously made of light weight materials such as aluminum alloy. The weights of knife shaft 44 and looper shaft 136 are not so critical as they rotate in place without substantial axial displacement. The resulting reduction of weight in the looper apparatus of the tufting machines substantially reduces vibration and results in smoother operation at high speeds. In addition, it is believed the use of aluminum blocks 240 , 340 , 440 , 540 and 640 assist in conducting heat away from the gauge bars and thereby minimizes thermal expansion of gauge bars and keeps the gauge elements of the tufting machine in better alignment throughout its operation.
[0092] Although preferred embodiments of the present invention have been disclosed in detail herein, it will be understood that various substitutions and modifications may be made to the disclosed embodiment described herein without departing from the scope and spirit of the present invention as recited in the appended claims. | Lateral pins ( 20 ) are used to provide a tufting machine modular gauge assembly that allows damaged or broken gauge elements ( 10 ) to be replaced individually. The modular gauge assembly consists of a gauge bar ( 25 ) with a plurality of modular blocks ( 15 ) removably attached to the bar. The modular blocks are six sided with a detent ( 110 ) and fastener mechanism ( 65 ) for attaching the block to the gauge bar. The gauge elements may be attached to the block by dedicated screw-pins ( 145 ) or by a lateral pin ( 20 ) that pastes through all the gauge elements within a block. The lateral pin may either pierce the gauge elements (at 70 ) or abut the gauge elements. Abutting pins may be malleable and segmented and secured in position by set screws. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a nonvolatile memory, and more particularly to a nonvolatile memory, such as EPROM or EEPROM, which is preferably used in applications which require a static readout operation (e.g., an application which requires static data output).
2. Description of the Related Art
Many conventional nonvolatile memories have employed a dynamic circuit for data readout operation, and therefore have suffered from a problem of high electric power consumption due to static current. Particularly, such nonvolatile memories consume a considerably large amount of electric power when a readout operation is performed continuously or data are output statically.
Some SRAMs employ six-transistor cells in order to decrease static current to 1 μA or less. However, conventional nonvolatile memories such as EPROMs and EEPROMs have had a drawback of large static current and therefore cannot be used in applications in which continuous a readout operation must be performed.
SUMMARY OF THE INVENTION
In view of the foregoing, an object of the present invention is to provide a nonvolatile memory which can maintain static current at a very low level even while in a readout state.
In order to achieve the above object, the present invention provides a nonvolatile memory comprising: paired memory elements each including a storage transistor having a control gate and a floating gate, in which, through a write operation, one of the storage transistors is brought into a depletion state and the other storage transistor is brought into an enhancement state; and connection means for serially connecting the paired memory elements during at least a readout operation, wherein an output signal is outputted from a connection line which connects the paired memory elements via the connection means.
Preferably, the connection means comprises switch means for serially connecting the paired memory elements during the readout operation.
Alternatively, the connection means comprises paired connection transistors, each of which shares at least the floating gate with the corresponding storage transistor and which are connected in series.
Preferably, each of the memory elements comprises a write transistor connected in series to the storage transistor.
In the nonvolatile memory according to the present invention, current other than leakage current does not flow during readout operation. Therefore, nonvolatile memories—which have conventionally consumed a large amount of electric power due to static current and therefore have been used in limited applications—can be applied to a broadened range of applications. Further, the nonvolatile memory of the present invention can be applied even to applications which require static data output.
In ordinary memory, since voltage written into a memory element is insatiable, a dedicated sense amplifier must be provided in order to stabilize the voltage. Further, the sense amplifier is operated during a readout operation only in order to reduce electric power consumed in the sense amplifier. In contrast, in the present invention, since the memory element itself outputs a memorized signal, such a sense amplifier is not required. This reduces consumption of electric power and simplifies the overall structure of a memory unit.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a circuit diagram of a 1-bit nonvolatile memory according to a first embodiment of the present invention;
FIG. 2 is a circuit diagram of a 1-bit nonvolatile memory according to a second embodiment of the present invention;
FIG. 3 is a circuit diagram of a 1-bit nonvolatile memory according to a third embodiment of the present invention; and
FIG. 4 is a circuit diagram of a 1-bit nonvolatile memory according to a fourth embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a circuit diagram of a 1-bit nonvolatile memory according to a first embodiment of the present invention. As shown in FIG. 1, the nonvolatile memory comprises two memory elements A and B. The memory element A comprises a storage transistor Tr 1 - 1 having a control gate CG 1 and a floating gate FG 1 , and a write transistor Tr 1 - 2 connected in series to the common side (Vss side) of the storage transistor Tr 1 - 1 . Similar to the memory element A, the memory element B comprises a storage transistor Tr 2 - 1 having a control gate CG 2 and a floating gate FG 2 , and a write transistor Tr 2 - 2 connected in series to the storage transistor Tr 2 - 1 . However, the memory element B differs in configuration from the memory element A in that the write transistor Tr 2 - 2 is connected to the power-source side (Vdd side) of the storage transistor Tr 2 - 1 .
Connecting means C according to the present embodiment is adapted to mutually connect the memory elements A and B in series. Specifically, the storage transistors Tr 1 - 1 and Tr 2 - 1 are connected with each other via a switching transistor Tr 3 serving as a switch means. In this case, an output OUT is obtained from a connection line which establishes connection between the memory elements A and B. In FIG. 1, the output OUT is obtained from the connection line on the drain side of the switching transistor Tr 3 .
In the case where the storage transistors Tr 1 - 1 and Tr 2 - 1 of the nonvolatile memory are of NMOS, write operation is performed as follows. In order to bring the level of the output to a “1” level, the switching transistor Tr 3 is first turned off in order to break the serial connection between the memory elements A and B. In this state, the storage transistor Tr 1 - 1 of the memory element A on the power-source side (Vdd side) is brought into a depletion mode, and the storage transistor Tr 2 - 1 of the memory element B on the common side (Vss side) is brought into an enhancement mode. Subsequently, the switching transistor Tr 3 is turned on so as to establish serial connection between the memory elements A and B. As a result, the output OUT assumes the “1” level. When the write operation is performed in such a manner that the storage transistor Tr 1 - 1 is brought into an enhancement mode and the storage transistor Tr 2 - 1 is brought into a depletion mode, the output OUT assumes a “0” level. As described above, in the case where the nonvolatile memory is of a single bit type, the serially connected memory elements A and B are not brought into the same mode but are brought into different modes during the writing operation.
In such an enhancement mode, the threshold voltage Vth increases to a value close to or greater than the power-source voltage Vdd. In ordinary EEPROMs, FN current (tunnel current) is used in order to bring the storage transistor into an enhancement mode. That is, when the nonvolatile memory is of NMOS type, a high voltage (typically, about 15V) is applied to the control gates CG 1 and CG 2 of the storage transistors Tr 1 - 1 and Tr 2 - 1 , and the operation voltage of an injector is set to become equal to the common voltage Vss. Specifically, while a high voltage is applied to control gates CG 1 and CG 2 , either the write transistor Tr 1 - 2 or Tr 2 - 2 is turned on. As a result, electrons are injected from the injector into the floating gate FG 1 of the storage transistor Tr 1 - 1 or the floating gate FG 2 of the storage transistor Tr 2 - 1 which is connected to the activated write transistor, so that the corresponding storage transistor has an elevated threshold voltage Vth, and thus comes into an enhancement mode. The threshold voltage Vth may be set to an arbitrary value through control of the length of the injection time. Typically, the threshold voltage Vth increases to 5V or greater through an injection of over 100 msec.
In contrast, in order to cause the storage transistor to have a lowered threshold voltage Vth and thus come into a depletion mode, electrons are removed from the floating gates FG 1 and FG 2 . For example, the operation voltage of the injector is increased to a high voltage (typically, about 15V), and the common voltage Vss is applied to control gates CG 1 and CG 2 .
In the nonvolatile memory having the above-described configuration, the switching transistor Tr 3 is turned on after the write operation. When the storage transistor Tr 1 - 1 has an elevated threshold voltage Vth and the storage transistor Tr 2 - 1 has a lowered threshold voltage Vth, the potential of the output OUT becomes equal to the power-source voltage Vdd. In this case, no current (other than a weak leakage current) flows through the storage transistor Tr 2 - 1 .
In contrast, when the storage transistor Tr 2 - 1 has an elevated threshold voltage Vth and the storage transistor Tr 1 - 1 has a lowered threshold voltage Vth, the potential of the output OUT becomes equal to the common voltage vss. In this case as well, no current (other than a weak leakage current) flows through the storage transistor Tr 1 - 1 .
As has been described, in the nonvolatile memory according to the present invention, other than leakage current, no current flows through the memory during the read operation (when the output is fixed).
The configuration of the above-described embodiment can be simplified through omission of the write transistors Tr 1 - 2 and Tr 2 - 2 , when the memory elements A and B are configured to eliminate the necessity of selecting either one of the storage transistors Tr 1 - 1 and Tr 2 - 1 by the write transistors Tr 1 - 2 and Tr 2 - 2 . FIG. 2 shows a 1-bit nonvolatile memory according to a second embodiment of the present invention having such a simplified structure. In both write and read periods, the nonvolatile memory according to the present embodiment operates in the same manner as the embodiment shown in FIG. 1, except that the write operation is performed individually for the storage transistor Tr 1 - 1 of the memory element A and the storage transistor Tr 2 - 1 of the memory element B.
In the nonvolatile memories shown in FIGS. 1 and 2, the connection means C for connecting the memory elements A and B is composed of a switching transistor Tr 3 serving as a switching means. However, in the third and fourth embodiments of the present invention, the connection means differs in configuration. The third and fourth embodiments will be described with reference to FIGS. 3 and 4. In FIGS. 3 and 4, elements functionally corresponding to those of the nonvolatile memories shown in FIGS. 1 and 2 are denoted by the same reference characters, and their descriptions are omitted so as to avoid redundancy.
As shown in FIG. 3, the nonvolatile memory of the present embodiment comprises two memory elements D and E and connection means F. The memory element D comprises a storage transistor Tr 1 - 1 having a control gate CG 1 and a floating gate FG 1 , and a write transistor Tr 1 - 2 connected in series to the storage transistor Tr 1 - 1 . The memory element E has the same configuration as the memory element D. Specifically, the memory element E comprises a storage transistor Tr 2 - 1 having a control gate CG 2 and a floating gate FG 2 , and a write transistor Tr 2 - 2 connected in series to the storage transistor Tr 2 - 1 .
The connection means F of the present embodiment functions to serially connect the memory elements D and E. Specifically, the connection means F comprises two connection transistors Tr 1 - 3 and Tr 2 - 3 which are mutually connected in series. The connection transistors Tr 1 - 3 and Tr 2 - 3 share the floating gates FG 1 and FG 2 with the storage transistors Tr 1 - 1 and Tr 2 - 1 , and are controlled by the control gates CG 1 and CG 2 . In this manner, the pair comprising the storage transistor Tr 1 - 1 and the connection transistor Tr 1 - 3 and the pair comprising the storage transistor Tr 2 - 1 and the connection transistor Tr 2 - 3 are configured such that the pairs always assume the same state. That is, when the storage transistor Tr 1 - 1 comes into an enhancement state or depletion state, the connection transistor Tr 1 - 3 comes into the same state. The same relationship exists between the storage transistor Tr 2 - 1 and the connection transistor Tr 2 - 3 . The output OUT is obtained from a connection line between the connection transistors Tr 1 - 3 and Tr 2 - 3 of the connection means F.
In the case where the storage transistors Tr 1 - 1 and Tr 2 - 1 and the connection transistors Tr 1 - 3 and Tr 2 - 3 are of NMOS, a write operation is performed as follows. In order to bring the level of the output to a “1” level, the storage transistor Tr 1 - 1 of the memory element D and the connection transistor Tr 1 - 3 of the connection means F, which are all located on the power-source side (Vdd side), are brought into a depletion mode, and the storage transistor Tr 2 - 1 of the memory element E and the connection transistor Tr 2 - 3 of the connection means F, which are all located on the common side (Vss side), are brought into an enhancement mode. In contrast, in order to bring the level of the output to a “0” level, the storage transistor Tr 1 - 1 of the memory element D and the connection transistor Tr 1 - 3 of the connection means F are brought into an enhancement mode, and the storage transistor Tr 2 - 1 of the memory element E and the connection transistor Tr 2 - 3 of the connection means F are brought into a depletion mode. As described above, in the case where the nonvolatile memory is of a single bit type, the serially connected memory elements D and E are not brought into the same mode but are brought into different modes during the writing operation.
In such an enhancement mode, as in the embodiment shown in FIG. 1, the threshold voltage Vth increases to a value close to or greater than the power-source voltage Vdd. That is, while a high voltage is applied to the control gates CG 1 and CG 2 , either the write transistor Tr 1 - 2 or the write transistor Tr 2 - 2 is turned on. As a result, electrons are injected from the injector into the floating gate FG 1 of the storage transistor Tr 1 - 1 or the floating gate FG 2 of the storage transistor Tr 2 - 1 which is connected to the activated write transistor, so that the corresponding storage transistor has an elevated threshold voltage Vth, and thus comes into an enhancement mode. The threshold voltage Vth may be set to an arbitrary value through control of the length of the injection time.
In contrast, in order to cause the storage transistor to have a lowered threshold voltage Vth and thus come into a depletion mode, electrons are removed from the floating gates FG 1 and FG 2 , as in the embodiment shown in FIG. 1 .
In the nonvolatile memory having the above-described configuration, when each of the storage transistors Tr 1 - 1 and the connection transistors Tr 1 - 3 has an elevated threshold voltage Vth, each of the storage transistors Tr 2 - 1 and the connection transistors Tr 2 - 3 has a lowered threshold voltage Vth, so that the potential of the output OUT becomes equal to the power-source voltage Vdd. In this case, no current (other than a weak leakage current) flows through the storage transistor Tr 2 - 1 and the connection transistor Tr 2 - 3 .
In contrast, when each of the storage transistors Tr 2 - 1 and the connection transistors Tr 2 - 3 has an elevated threshold voltage Vth, each of the storage transistors Tr 1 - 1 and the connection transistors Tr 1 - 3 has a lowered threshold voltage Vth, so that the potential of the output OUT becomes equal to the common voltage Vss. In this case, no current (other than a weak leakage current) flows through the storage transistor Tr 1 - 2 and the connection transistor Tr 1 - 3 .
As has been described, in the nonvolatile memory according to the present invention, other than leakage current, no current flows through the memory during the read operation (when the output is fixed).
The configuration of the above-described embodiment can be simplified through omission of the write transistors Tr 1 - 2 and Tr 2 - 2 , as in the case of the nonvolatile memory shown in FIG. 2 . FIG. 4 shows a 1 -bit nonvolatile memory according to a fourth embodiment of the present invention having such a simplified structure. The nonvolatile memory according to the present embodiment is configured such that each of the memory elements D and E is formed of a single storage transistor Tr 1 - 1 or Tr 2 - 1 and corresponds to the embodiment shown in FIG. 2 . In both write and read periods, the nonvolatile memory according to the present embodiment operates in the same manner as the embodiment shown in FIG. 3, except that the write operation is performed independently for the storage transistor Tr 1 - 1 of the memory element D and the storage transistor Tr 2 - 1 of the memory element E.
All the nonvolatile memories according to the embodiments shown in FIGS. 1-4 are of single bit type. However, needless to say, a plurality of the nonvolatile memories may be connected in parallel in order to form a nonvolatile memory having a desired number of bits. Further, the memory elements A, B, C, and D may be formed of PMOS. Even when the memory elements A, B, C, and D are formed of PMOS, similar action and effects are obtained although the logic of operation reverses. | A nonvolatile memory includes paired memory elements each including a storage transistor having a control gate and a floating gate. Through a write operation, one of the storage transistors is brought into a depletion state and the other storage transistor is brought into an enhancement state. Subsequently, a connection transistor is operated in order to serially connect the paired memory elements. As result, a binary signal corresponding to the statuses of the paired storage transistors is outputted. | 6 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a product in powder form, intended for protecting the casting molds used for the centrifugal casting of cast iron pipes; the casting molds used are commonly referred to by the name “shells”.
DESCRIPTION OF THE PRIOR ART
[0002] Unless otherwise indicated, all the values relating to chemical compositions are expressed in percentages by weight.
[0003] The coatings used for protecting centrifugal casting shells for cast iron pipes may consist of inoculants and refractories in powder form, and also blends of silica and bentonite, these being put into place by spraying an aqueous suspension. Such coatings are described for example in U.S. Pat. No. 4,058,153 (Pont-A-Mousson) and are known as wet-spray coatings. It is also usual to employ powders sprayed dry onto the shell before the iron is cast, these powders then being referred to as dry-spray powders.
[0004] Whatever the technique employed for depositing them, these products are used for several purposes, in particular:
to obtain a mold-release effect, that is to say making it easier to extract the pipe from the mold after solidification; to obtain a thermal barrier effect, limiting the temperature rise of the shell, thus contributing to an increase in its lifetime; to obtain an antipinhole effect, that is to say limiting the risk of pinholes appearing on the surface of the pipes; and to obtain an ultimate inoculating effect on the cast iron, so as to control the metallurgical structure of the pipe.
[0009] It is well known that insufficient inoculation in the iron results in the formation of carbides, considerable shrinkage upon cooling and rapid demolding, a gauge of high productivity. However, the castings thus obtained require a subsequent heat treatment, which may prove to be expensive.
[0010] It may, depending on the case, be preferable to inoculate further, even if this entails a reduction in the production rate, in order to avoid the final heat treatment, or on the contrary to inoculate less, in order to raise the productivity, and to subject the casting to heat treatment downstream.
[0011] The inoculability of the dry-spray product may therefore be positioned within quite broad limits; in contrast, the other required effects are subject to more constant requirements.
[0012] Products used as dry-spray products therefore generally consist of a blend of several components, including:
an inoculant of relatively high effectiveness, which may typically constitute 30 to 100% of the product; for example, ferro-silicon alloys may be used for this purpose, these containing 0.1 to 4% aluminum and calcium and, optionally, other elements capable of introducing a supplementary or complementary metallurgical effect in the cast iron; powders of elements or alloys giving specifically an antipinhole effect; these may typically be the elements or alloys of the reducing elements of column 2 of the Periodic Table of Elements; and an inert mineral filler, for example silica, which may constitute up to 70% of the product.
[0016] Patent FR 2 612 097 (Foseco) in particular describes the use, as treatment agent, of alloys of the Fe—Si—Mg type, the particles of which are triboelectrically charged.
[0017] They are generally deposited on the shell, immediately before the iron is cast, by a delivery system, which in general comprises:
one or more storage containers; an apparatus for defining the amount to be deposited and the moment of this deposition; and a system for transporting the powder right into the shell.
[0021] The products of the prior art have several drawbacks associated with the difficulty of obtaining a uniform distribution over the internal surface of the mold, this being manifested by excessive amounts in preferential regions and, conversely, lack or insufficient amounts of powder in other regions. One direct consequence of this is the creation of structural heterogeneities in the cast iron, and also surface defects on the cast pipe or product inclusions within this same pipe. Another consequence over time is nonuniform wear of the internal surface of the mold that the product has to protect, this having an impact on the surface of the cast iron pipe.
SUMMARY OF THE INVENTION
[0022] The subject of the invention is a powder product for protecting centrifugal casting molds for cast iron pipes by dry-spraying said product onto the internal surface of said mold, comprising an inoculating metal alloy or a blend of inoculating metal alloys, optionally powders of reducing elements or alloys having an antipinhole effect, and optionally an inert mineral filler, which product further includes at least one additive intended to improve the flowability characteristics of said powder product.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Preferably, the flowability is such that the flow time of 50 g of product via the 4 mm diameter hole of a funnel, the walls of which make an apex angle of 60 degrees, is between 17 and 27 seconds for a particle size distribution having a 300 μm undersize of between 99 and 100% and a 63 μm undersize of between 10 and 35%.
[0024] According to another preferred embodiment, the flow time, relative to the same product without said additive, is reduced by 5 to 10 s if said same product without said additive flows via the 4 mm diameter hole, and is between 20 and 27 s if said same product without said additive does not flow via said hole.
[0025] According to an advantageous embodiment, the additive is silicone oil, according to another embodiment it is potassium siliconate and according to yet another embodiment it is microsilica of density less than 0.1.
[0026] The additive may also be a blend in any proportions of one or more of the aforementioned additives.
[0027] Finally, according to a preferred embodiment, the proportion by weight of additive in said product is between 0.02 and 0.2%.
[0028] The products of the prior art used as dry-spray products in the manufacture of cast iron pipes by continuous centrifugal casting have a few drawbacks. In particular, the inert mineral filler added to the blend contributes to increasing the risks of fouling the molds and of forming inert mineral inclusions in the iron, which may result in the appearance of surface defects on the pipes.
[0029] The flowability of the powder must correspond to an optimum compromise between good capability of delivery and uniformity of distribution on the internal impression of the shell, and the need, after deposition on said impression, for the powder no longer to flow, in particular in front of the liquid iron front when said iron is poured into said shell. The latter also has, for this purpose, a hammered surface, consisting of a succession of cups, one of the purposes of which is to retain the powder so that it is not entrained by the liquid iron front. If the powder has too high a flowability, this precaution proves to be insufficient.
[0030] Moreover, the characteristics of the systems for handling, metering and delivering said powder differ from one user to another, with the result that, in practice, the characteristics of the powder and of the equipment are not always optimized one with respect to the other.
[0031] The choice of particle size distribution of said powder is also dictated in particular by requirements as regards its behavior during its interaction with the liquid iron in the shell so that it fulfils the abovementioned purposes.
[0032] Said powders, also called “inotubes” or “inopipes”, are consequently fine and thus:
they are very sensitive to the storage conditions, which may modify the flowability in the absolute and as regards its homogeneity during their end-use; and small variations in the manufacturing conditions (moisture, friability of the material, etc.) may also result in overall modifications and/or heterogeneities in their flowability.
[0035] The consequences of such a variation in the flowability are the following:
since the ability of the cups, created by the abovementioned hammering of the shell surface, to retain the deposited coating is somewhat variable, said coating may exhibit irregularities. This defect may result in particular in the product slipping toward the bottom of the shell, which is generally inclined, typically by 6%; and these flowability variations may also have an influence on the powder delivery systems, causing various problems in use (blocking, plugging, etc.) and irregularities in deposition of the product on the shell, also causing irregularities in its associated effects.
[0038] These irregular effects result in various types of defects in the final cast iron product, such as: localized pinholes, excessively high carbide content in the thickness of the pipe, etc. A lack of product in certain regions of the shell for example will result in the local insufficiency of inoculation, with the presence of surface carbides and consequently abrasion and wear of the shell. Conversely, an excess of product will result in lack of dissolution by the iron, and consequently surface defects on the pipe that may lead to it being scrapped.
[0039] To alleviate these drawbacks, the Applicant therefore sought to improve the flowability of the powder in order to facilitate the operations preceding its deposition and the deposition itself, while avoiding the negative effects after the powder has been deposited in the shell, that is to say ensuring a low flowability when the iron is poured into said shell.
[0040] This result can be obtained thanks to additives that help to improve the cold flowability of the powder, that is to say up to the time it is deposited. A judicious choice of said additive makes it possible, when the powder is subsequently deposited on hot shells, which are typically at between 250 and 300° C., to nullify this increase in flowability, the temperature of the powder rising owing to its contact with the hot shell.
[0041] These additives, the effect of which is described in the following examples, may comprise potassium siliconate, but other additives having a similar behavior as regards their effect on flowability can also be used, such as for example silicone oil, microsilica with a density of typically less than 0.1 (the usual density for microsilica of “chemical” grade) or a blend, in any proportions, of one or more of these products. The trials described below were carried out with 0.06% additive, but the usual proportion under industrial conditions may be between 0.02 and 0.2%.
[0042] The particle size of the powder particle according to the invention is less than 580 μm and preferably less than 250 μm.
EXAMPLES
[0043] The flowability characteristics of a powder for “inotubes” were determined by various tests, including in particular the flow time, namely the time for a given quantity to flow through a standardized funnel, measurement of the shear-under-load properties and, in particular, using the method known as the “Jenike test”, the flow time under load, which consists in measuring the maximum load under which the product can flow through a hole of given diameter, etc.
[0044] In the examples below, the flowability characteristics were determined by the flow time for 50 g of powder to flow through the 4 mm diameter hole of a funnel, the walls of which make an apex angle of 60 degrees.
[0045] In all cases, the particle size distribution had a 300 μm undersize between 99 and 100%.
[0046] The hierarchy of flow values thus obtained was the same if a test of the flow-under-load type, as mentioned above, were used.
[0047] Typically, said additives made it possible to obtain a flow time of the “inotube”, the particle size distribution of which had a 63 μm undersize of 10 to 35%, between 17 and 27 s.
Example 1
[0048] A powder blend was prepared from the following constituents:
76% of ferro-silicon powder, containing 65.5% Si, 1.3% Ca and 0.95% Al, with a particle size of less than 300 μm; 4% of fluorspar powder, with a particle size of less than 150 μm; and 20% of calcium-silicon alloy powder, known as “CaSi” powder, containing 30.3% Ca, with a particle size of less than 300 μm.
[0052] The particle size distribution measurement showed that it had a 63 μm undersize of 23%.
[0053] The flow time was 28 s.
[0054] This product, used in “dry-spray” form as reference trial, gave satisfactory results: the pipes were practically free of pinholes—the few pinholes present were shallow and allowed the specification to be met; the carbide content was 8%; and a ferritic iron thickness of 35 μm on the external surface of the pipe was noted.
Example 2
[0055] The product described in example 1 was stored in cloth sacks, known as “big bags”, under a shelter for two months.
[0056] After this storage:
the particle size distribution measurement showed that it still had a 63 μm undersize of 23%; and the product did not flow through the 4 mm diameter hole.
[0059] This product, used as dry-spray product, gave inferior results: the pipes showed pinholes in many regions and the scrap rate was considerably larger than in example 1. The carbide content was 12% on average, but this was characterized by a larger scatter than in example 1. Consequently, the duration of the subsequent annealing, intended to absorb the carbides, had to be extended. No ferritic iron on the surface of the pipe was detected.
Example 3
[0060] The same powder blend as in example 1 was prepared, but with the addition, during the uniform blending operation, of 0.06% of a 40% potassium siliconate solution in water.
[0061] The particle size distribution measurement showed that it had a 63 μm undersize of 23%.
[0062] The flow time was 21 s.
[0063] This product, used as dry-spray product, gave very good results: the pipes were completely free of pinholes; the carbide content was 8%; and a ferritic iron thickness of 35 μm on the external surface of the pipe was noted.
Example 4
[0064] The product described in example 3 was stored in big bags under a shelter for two months.
[0065] After this storage:
the particle size distribution measurement showed that it still had a 63 μm undersize of 23%; and the flow time was 27 s.
[0068] This product, used as dry-spray product, gave satisfactory results: the pipes were practically free of pinholes—the few pinholes present were shallow and allowed the specification to be met; the carbide content was 10%; and a ferritic iron thickness of 35 μm on the external surface of the pipe was noted.
Example 5
[0069] A powder blend was prepared from the following constituents:
76% of ferro-silicon powder, containing 65.5% Si, 1.3% Ca and 0.95% Al, with a particle size of less than 300 μm; 4% of fluorspar powder, with a particle size of less than 150 μm; and 20% of Ca—Si powder, containing 30.3% Ca, with a particle size of less than 200 μm.
[0073] The particle size distribution measurement showed that it had a 63 μm undersize of 31%.
[0074] The flow time was 35 s.
[0075] This product, used as dry-spray product, gave somewhat unsatisfactory results: the pipes exhibited pinholes and in some cases did not meet the specification; the carbide content was 12%; and a ferritic iron thickness of 15 μm on the external surface of the pipe was noted.
Example 6
[0076] The same powder blend as in example 5 was prepared, but with the addition, during the uniform blending operation, of 0.06% of a 40% potassium siliconate solution in water.
[0077] The particle size distribution measurement showed that it had a 63 μm undersize of 31%.
[0078] The flow time was 25 s.
[0079] This product, used as dry-spray product, gave satisfactory results: the pipes were practically free of pinholes—the few pinholes present were shallow and allowed the specification to be met; the carbide content was 8%; and a ferritic iron thickness of 35 μm on the external surface of the pipe was noted.
[0080] It may be seen that, thanks to the additive, the flow time is reduced by 7 s and 10 s for the blends which, without additive, flowed through the 4 mm diameter hole (examples 3 and 6 compared with examples 1 and 5, respectively), and brought to 27 s in the case of a blend which, without additive, does not flow through said hole (example 4 compared with example 2).
[0081] More generally, it may be stated that this time is reduced by 5 to 10 s if the blend without additive flows through the 4 mm diameter hole and is between 20 and 27 s if the blend without additive does not flow through said hole.
[0082] Moreover, the additive makes the flowability characteristics of the product largely independent of its physical or physico-chemical characteristics, which may be seen in particular by comparison between the flow times before and after storage of the “inotubes” of examples 3 and 4, whereas the products without additive (examples 1 and 2) are appreciably sensitive thereto. | The invention concerns a powdery product, of the type known as dry spray, for protecting centrifuge casting molds of cast iron pipes, comprising the usual components for this type of use, as well as an adjuvant for improving the flowability characteristics of said product when it is being deposited and make them less dependent on its physical or physico-chemical characteristics. Said adjuvant can be in particular silicone oil, potassium siliconate or microsilica of density less than 0.1, as well as a mixture in any proportions of one or more of those. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application Ser. No. 60/612,384, filed on Sep. 23, 2004. The disclosure of the above application is incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to convertible roofs and, more particularly, to in-folding convertible roofs.
Traditional soft-top convertible roofs for automotive vehicles typically employ three, four or five roof bows, having an inverted U-shape spanning transversely across the vehicle for supporting a vinyl, canvass or polyester fabric pliable roof cover. A number one roof bow is mounted to a pair of front roof rails and is typically latched to a stationary front header panel of the automotive vehicle body disposed above the front windshield. A number two roof bow is typically mounted to either the front roof rails or to a pair of center roof rails which are pivotally connected to the front roof rails. Furthermore, a number three, four and any additional optional roof bows are commonly mounted to either the center pair of roof rails or to a pair of rear roof rails which are pivotally coupled to the center roof rails. The roof cover can also have a hard or rigid portion along with the pliable portion. For example, reference should be made to U.S. Pat. No. 5,429,409 entitled “Convertible Top”, which is incorporated by reference herein.
Most traditional convertible roofs are stowed in a bootwell or stowage compartment that is located aft of a passenger compartment in the vehicle. A boot or tonneau cover is then used to cover the bootwell and conceal the convertible roof from view and/or protect the stowed roof from the environment. Optionally, a portion of the convertible roof can be visible when in the stowed position and provide a desired appearance for the vehicle.
Traditional soft-top convertible roofs, such as those discussed above, can present a packaging (stowing) difficulty when it is desired to use a “Z” folding roof. The difficulty is more pronounced when a “Z” folding roof is desired to be used on a larger vehicle (vehicle having front and rear seating areas). Additionally, the use of three pairs of coupled roof rails also adds to the packaging difficulty. The three pairs of coupled roof rails are pivoted relative and stacked upon one another. The packaging size of such a retraction mechanism requires the stowage compartment to accommodate the various lengths of the roof rails.
The available space for the stowage compartment in a vehicle, however, may be at a premium. That is, while it is desirable to provide a vehicle with a convertible roof, it is also desirable to provide sufficient storage space in the vehicle for use in storing objects other than the convertible roof. Thus, it would be advantageous to minimize the packaging space required to stow the convertible roof while maximizing the available space for other purposes, such as maintaining or increasing the size of the passenger compartment and/or the size of the general storage area or trunk of the vehicle when produced with a convertible roof.
Moreover, when the convertible roof spans a large passenger seating area the controlling of the final movements of the convertible roof when being raised or retracted may cause significant stress or torque to be exhibited on the components of the convertible roof. This increased force may be undesirable and may cause a reduction in the lifespan of the components that comprise and drive the convertible roof. Thus, it would be advantageous to minimize the impact or force imparted on the driving components of the convertible roof when reaching the fully extended or fully retracted state.
In accordance with the present invention, a convertible roof is provided which includes a segmented pair of front roof rails that in-fold when being retracted. The in-folding advantageously reduces the packaging space required to stow the convertible roof. In another aspect of the present invention, in-folding of the segmented front roof rails is controlled by synchronizing linkages between the segmented portions and the number one roof bow which synchronize the in-folding of the segmented front roof rails. The synchronization advantageously eliminates side-to-side drift of the convertible roof when moving between the raised and stowed positions. In accordance with another aspect of the present invention, a damper is employed to dampen a portion of the motion of the convertible roof as the top reaches a fully extended and fully retracted position. The dampening advantageously reduces high forces or stresses that are imparted on the drive mechanisms during the movement of the convertible roof between the extended and retracted positions.
Along with reducing the packaging space and/or excessive force or stress, additional objects, advantages and features of the present invention will become apparent from the following description and the pending claims, taken in conjunction with the accompanying drawings. It should be understood that the detailed description and the specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a perspective view of an automotive vehicle having an alternate embodiment of a convertible roof according to the principles of the present invention showing the convertible roof in the raised position;
FIGS. 2A-2C are various views of the convertible roof of FIG. 1 in an intermediate position between the raised and stowed positions;
FIGS. 3A and 3B are respective side elevation and plan views of the convertible roof of FIG. 1 in the stowed position;
FIGS. 4A and 4B are fragmented perspective views of a portion of the convertible roof of FIG. 1 respectively in a raised position and partially retracted position showing the linkage assemblies between the center and front roof rail and between the segmented portions of the front roof rail;
FIG. 5 is a simplified schematic representation of the various linkage assemblies used in the segmented front roof rail to provide the in-folding of a portion of the front roof rail in the convertible roof of FIG. 1 ;
FIG. 6 is a perspective view of an automotive vehicle having a preferred embodiment of a convertible roof according to the principles of the present invention showing the convertible roof in the raised position;
FIG. 7 is a perspective view of the convertible roof of FIG. 6 in an intermediate position between the raised and stowed positions;
FIGS. 8A and 8B are respective perspective and top plan views of the convertible roof of FIG. 6 in the stowed position;
FIGS. 9A and 9B are fragmented perspective views of a portion of the convertible roof of FIG. 6 respectively in a raised position and partially retracted position showing the linkage assemblies between the center and front roof rails and between the segmented portions of the front roof rail;
FIG. 10 is a bottom plan view of the front portion of the convertible roof of FIG. 6 showing the details of the synchronizing linkage assemblies when the convertible roof is in the raised position;
FIGS. 11A-C are side fragmented simplified cutaway views illustrating the attachment of the rear roof rail to the fixed pivot and the damper attached to the rear roof rail of the convertible roof of FIG. 6 in a stowed, intermediate and raised position, respectively; and
FIGS. 12A and 12B are bottom plane views of alternate embodiments of synchronizing linkage assemblies according to the principles of the present invention that can be used with an in-folding convertible roof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. As used herein, the term “substantially perpendicular” allows for some limited deviation from 90°, such as 90°±5°.
FIGS. 1-5 show an alternate embodiment of an in-folding convertible roof 20 according to the principles of the present invention. Convertible roof 20 is employed on an automotive vehicle 22 having a passenger compartment 24 with front and rear passenger seating areas 26 , 28 and a generally U-shaped bootwell or stowage compartment 30 . Stowage compartment 30 is positioned aft of passenger compartment 24 with quarter trim portions extending along a portion of sides of passenger compartment 24 . Convertible roof 20 is of the type utilizing a folding or top stack mechanism 34 and a roof cover 36 (shown in FIG. 2A only) and is operable between a fully raised position, as shown in FIG. 1 , through intermediate positions, such as those shown in FIGS. 2A-2C , to a fully stowed position, as shown in FIGS. 3A and 3B . Roof cover 36 is made from a pliable material, such as vinyl, canvass or a polyester fabric. If desired, roof cover 36 can include a hard or rigid portion that, optionally, can be covered by the same material that comprises the soft portion of the cover to give a uniform appearance. A backlight (not shown) is attached to roof cover 36 and is not pivotally coupled to top stack mechanism 34 . For example, reference should be made to U.S. Pat. No. 5,887,936 titled “Backlight System for Use in an Automotive Vehicle Convertible Roof,” by Cowsert, and U.S. Pat. No. 6,102,467 titled “Backlight Retention System for Use in an Automotive Vehicle Convertible Roof,” by Laurain et al., both of which are herein incorporated by reference. The backlight can be made of either a rigid material, such as glass, or a pliable transparent material, such as vinyl.
In the figures, convertible roof 20 and top stack mechanism 34 are shown symmetrical about a longitudinal, fore-and-aft center line 40 (shown in FIG. 3B ) of vehicle 22 . Center line 40 , thus, also serves as a longitudinal center line for convertible roof 20 and top stack mechanism 34 . Top stack mechanism 34 includes right and left roof linkages on the respective right and left sides of vehicle 22 . For brevity, at times only one side of top stack mechanism 34 and convertible roof 20 may be shown and/or discussed. However, it should be understood that the other side linkages are also provided as part of top stack mechanism 34 and convertible roof 20 and are mirrored images of the side depicted and/or discussed. Also, when using the terms “fore” and “aft,” “front” and “back,” and “forward” and “rearward” in describing the movement and components of top stack mechanism 34 and convertible roof 20 , such reference refers to the orientation of the components when top stack mechanism 34 and convertible roof 20 are in the fully raised position.
Top stack mechanism 34 includes a number one roof bow 44 that extends transversely across vehicle 22 and is disposed above the front windshield header when in the fully raised position, as shown in FIG. 1 . Roof cover 36 is attached to number one roof bow 44 . Number one roof bow 44 is coupled to a pair of segmented front roof rails 46 by synchronizing linkage assemblies 48 , described in more detail below.
Segmented front roof rails 46 include an in-folding portion 46 a and a straight-folding portion 46 b . In-folding and straight-folding portions 46 a , 46 b are pivotally connected together at pivot 50 and are interconnected by in-folding linkage assemblies 52 , described in more detail below. Straight-folding portions 46 b are pivotally connected to front portions of a pair of center roof rails 54 at pivots 56 and are interconnected with intermediate linkage assemblies 57 , described in more detail below.
Rear portions of center roof rails 54 are pivotally connected to front or top portions of rear roof rails 58 at pivots 60 . Referring now to FIG. 2A , the opposite ends of rear roof rails 58 are pivotally connected to fixed brackets 62 at pivots 64 . Pivots 64 are aligned along a pivot axis 65 which is generally perpendicular to longitudinal center line 40 . Rear roof rails rotate about pivots 64 and pivot axis 65 during extension and retraction of top stack mechanism 34 , as describe below. Brackets 62 are fixed to vehicle 22 within stowage compartment 30 .
Still referring to FIG. 2A , one end of a balance link 66 is pivotally coupled to bracket 62 at pivot 68 while an opposite end of balance link 66 is pivotally coupled to a rear portion of center roof rail 54 at pivot 70 . The interconnection between center roof rail 54 , rear roof rail 58 , bracket 62 and balance link 66 forms a rear four-bar linkage assembly defined by pivots 60 , 64 , 68 and 70 . A fluidic actuator 71 is pivotally connected to vehicle 22 and balance link 66 . Actuator 71 is operable to move top stack mechanism 34 and convertible roof 20 between the raised and stowed positions, as described in more detail below. For brevity, a portion of the rear linkage assembly (balance link 66 and bracket 62 ) along with actuator 71 are shown only in FIG. 2A .
The rear linkage assembly and intermediate linkage assembly 57 are interconnected by a control link 72 . One end of control link 72 is pivotally connected to an extension of rear roof rail 58 at pivot 74 . An opposite end of control link 72 is pivotally connected to intermediate linkage assembly 57 at pivot 76 . Control link 72 causes intermediate linkage assembly 57 to rotate front roof rail 46 relative to center roof rail 54 during extension and retraction of top stack mechanism 34 , as described in more detail below.
Intermediate linkage assembly 57 , as best seen in FIGS. 4A and 4B , interconnects straight-folding portion 46 b of front roof rail 46 with center roof rail 54 . Intermediate linkage assembly 57 includes a first link 80 having an intermediate portion pivotally connected to straight-folding portion 46 b at pivot 82 while an end is pivotally connected to one end of a second link 84 at pivot 76 . An opposite end of second link 84 is pivotally connected to an intermediate portion of center roof rail 54 at pivot 86 . Intermediate linkage assembly 57 forms a four-bar linkage assembly including straight-folding portion 46 b , first link 80 , second link 84 and center roof rail 54 and is defined by pivots 82 , 76 , 86 and 56 . Intermediate linkage assembly 57 controls the movement of front roof rail 46 relative to center roof rail 54 during the movement of top stack mechanism 34 between the raised and stowed positions, as described below.
A second roof bow 100 extends transversely across vehicle 22 and is fixedly attached to straight-folding portion 46 b of front roof rail 46 . Similarly, a third roof bow 102 extends transversely across vehicle 22 and is fixedly attached to rear roof rails 58 . If desired, second and/or third roof bows 100 , 102 can be formed or cast integrally with straight-folding portions and rear roof rails 46 b , 58 , respectively, if desired. Roof cover 36 is loosely attached to second and third roof bows 100 , 102 .
Referring now to FIGS. 2A-2C and 4 A- 4 B, details of in-folding linkage assembly 52 are shown. In-folding linkage assembly 52 includes a first in-folding link 104 having one end pivotally connected to straight-folding portion 46 b of front roof rail 46 at pivot 106 and an opposite end pivotally connected to an end of a second in-folding link 108 at pivot 110 . The opposite end of second in-folding link 108 is pivotally connected to in-folding portion 46 a of front roof rail 46 at pivot 112 . In-folding linkage assembly 52 thereby forms a four-bar linkage assembly including straight-folding portion 46 b , in-folding portion 46 a , second in-folding link 108 and first in-folding link 104 and is defined by pivots 50 , 112 , 110 and 106 . In-folding linkage assembly 52 controls the relative movement of in-folding portion 46 a relative to straight-folding portion 46 b during the extension and retraction of top stack mechanism 34 , as described in more detail below.
A coupling link 114 interconnects in-folding linkage assembly 52 with intermediate linkage assembly 57 . One end of coupling link 114 is connected to an end of first link 80 of intermediate linkage assembly 57 adjacent pivot 82 with a ball joint 116 . The opposite end of coupling link 114 is coupled to in-folding linkage assembly 52 adjacent pivot 110 with a ball joint 118 . Ball joints 116 , 118 allow three degrees of movement of coupling link 114 relative to first link 80 and in-folding linkage assembly 52 . Coupling link 114 transfers the motion of intermediate linkage assembly 57 to in-folding linkage assembly 52 to control and coordinate the extension and retraction of top stack mechanism 34 , as described in more detail below.
Referring now to FIGS. 2A-2C and FIG. 5 , details of synchronizing linkage assembly 48 are shown. Each synchronizing linkage assembly 48 includes a first synchronizing link 120 having one end pivotally connected to in-folding portion 46 a of front roof rail 46 at pivot 122 and an opposite end pivotally connected to number one roof bow 44 at pivot 124 . One end of a second synchronizing link 126 is pivotally connected to an intermediate portion of first synchronizing link 120 at pivot 128 while an opposite end of second synchronizing link 126 is pivotally connected to one end of a synchronizing crank 130 at pivot 132 . An opposite end of synchronizing crank 130 is pivotally connected to the second synchronizing link 126 on the other side of top stack mechanism 34 . A central portion of synchronizing crank 130 is pivotally connected to number one roof bow 44 at pivot 134 . Synchronizing linkage assemblies 48 keep the two sides of top stack mechanism 34 in sync with one another as top stack mechanism 34 moves between the raised and retracted positions. Synchronizing linkage assemblies 48 also prevent cross car drift of top stack mechanism 34 during movement between the raised and stowed positions.
In operation, convertible roof 20 is movable between the raised position, shown in FIG. 1 , through intermediate positions, such as those shown in FIGS. 2A-2C , to a fully stowed position, as shown in FIGS. 3A and 3B . To move convertible roof 20 from the raised position to the stowed position, number one roof bow 44 is unlatched from the front header of vehicle 22 . Actuators 71 are commanded to retract and pull on balance links 66 , causing balance links 66 to rotate rearwardly. As balance links 66 rotate rearwardly, rear roof rails 58 pivot rearwardly about pivots 64 while center roof rails 54 pivot forwardly relative to rear roof rails 58 about pivots 60 . Rearward rotation of rear roof rails 58 cause control links 72 to pull intermediate linkage assemblies 57 rearwardly.
The rearward pulling of intermediate linkage assemblies 57 causes pivots 76 to move rearwardly and second links 84 to rotate rearwardly relative to center roof rails 54 about pivots 86 . First links 80 pull on straight-folding portions 46 b , causing rearward rotation relative to center roof rails 54 about pivots 56 . The movement of first links 80 pull coupling links 114 rearwardly relative to straight-folding portions 46 b . Coupling links 114 pull in-folding linkage assemblies 52 rearwardly, causing in-folding portions 46 a of front roof rails 46 to pivot inwardly about pivots 50 toward center line 40 of vehicle 22 .
As in-folding portions 46 a of front roof rails 46 pivot inwardly, the ends of first synchronizing links 120 attached to in-folding portions 46 a also rotate inwardly about pivots 124 and second synchronizing links 126 approach one another and cause synchronizing crank 130 to rotate clockwise in the orientation shown in FIG. 2A . The movement of first and second synchronizing links 120 , 126 allow synchronizing linkage assemblies 48 to constrain the in-folding of in-folding portions 46 a of front roof rail 46 and draw number one roof bow 44 rearwardly. The constraining of the in-folding of in-folding portions 46 a prevents top stack mechanism 34 from drifting side-to-side during the retraction and extension processes, thereby enabling smooth and aesthetically pleasing operation of convertible roof 20 . Actuators 71 continue to retract until top stack mechanism 34 reaches its stowed position, as shown in FIGS. 3A and 3B , wherein convertible roof 20 is disposed within stowage compartment 30 .
To move convertible roof 20 from its stowed position to its raised position, actuators 71 are commanded to extend in length and push on balance links 66 causing forward rotation about pivots 68 . The forward rotation is transferred to center roof rails 54 and rear roof rails 58 . As convertible roof 20 rises, rear roof rails 58 rotate forwardly about pivots 64 and center roof rails 54 rotate rearwardly relative to rear roof rails 58 about pivots 60 . Control links 72 push intermediate linkage assemblies 57 forwardly, thereby causing straight-folding portions 46 b of front roof rails 46 to rotate forwardly relative to center roof rails 54 about pivots 56 . This action causes pivots 76 to approach pivots 56 . Coupling links 114 push forwardly on in-folding linkage assemblies 52 . In-folding portions 46 a of front roof rails 46 rotate outwardly relative to straight-folding portions 46 b about pivots 50 .
First synchronizing links 120 pivot about pivots 122 , 124 and approach in-folding portions 46 a as top stack mechanism 34 approaches the fully raised position. Second synchronizing links 126 move away from one another and rotate synchronizing crank 130 counterclockwise in the orientation depicted in FIG. 2 A. Actuators 71 continue to expand in length until top stack mechanism 34 has been moved to the fully raised position, as shown in FIG. 1 . Number one roof bow 44 can then be latched to the front header of vehicle 22 to secure top stack mechanism 34 in the fully raised position.
While various aspects of convertible roof 20 and top stack mechanism 34 have been disclosed, it will be appreciated that many other variations may be employed without departing from the scope of the present invention. For example, the in-folding linkage assemblies 52 and intermediate linkage assemblies 57 can be more than four-bar linkages. Actuators 71 can be other than fluidic actuators, such as solenoids and rotary actuators among others. Furthermore, top stack mechanism 34 may be manually operated. Moreover, while pivots 64 and pivot axis 65 are shown as being fixed, it should be understood that pivots 64 and pivot axis 65 can move, such as when in a slot or when brackets 62 move, while still maintaining pivot axis 65 substantially perpendicular to center line 40 . The exact location of the various pivots of top stack mechanism 34 can vary from the locations shown in drawings and still be within the scope of the present invention. Furthermore, the specific configurations and orientations of the various linkages and roof rails can have shapes that differ from those shown and still be within the scope of the present invention. Additionally, the roof can be stowed in the rear seating area of the passenger compartment.
Referring now to FIGS. 6-11C , the preferred embodiment of an in-folding convertible roof 220 according to the principles of the present invention is shown. Convertible roof 220 is employed on an automotive vehicle 222 having a passenger compartment 224 with front and rear passenger seating areas 226 , 228 accessible by front and rear doors 229 a , 229 b and a generally U-shaped bootwell or stowage compartment 230 . Stowage compartment 230 is positioned aft of passenger compartment 224 with quarter trim portions 232 extending along a portion of sides of passenger compartment 224 . Convertible roof 220 utilizes a folding or top stack mechanism 234 and a roof cover 236 (shown in FIG. 7 only) and is operable between a fully raised position, as shown in FIG. 6 , through intermediate positions, such as that shown in FIG. 7 , to a fully stowed position, as shown in FIGS. 8A and 8B . Roof cover 236 is made from a pliable material, such as vinyl, canvas or a polyester fabric. If desired, roof cover 236 can include a hard or rigid portion that, optionally, can be covered by the same material that comprises the soft portion of the cover to give a uniform appearance. A backlight (not shown) is attached to roof cover 230 and is not pivotally coupled to top stack mechanism 234 . The backlight can be made of either a rigid material, such as glass, or a pliable transparent material, such as vinyl.
In FIGS. 6-11C , convertible roof 220 and top stack mechanism 234 are shown symmetrical about a longitudinal, fore-and-aft center line 240 (shown in FIG. 8B ) of vehicle 222 . Center line 240 , thus, also serves as a longitudinal center line for convertible roof 220 and top stack mechanism 234 . Top stack mechanism 234 includes right and left roof linkages on the respective right and left sides of vehicle 222 . For brevity, at times only one side of top stack mechanism 234 and convertible roof 220 may be shown and/or discussed. However, it should be understood that the other side linkages are also provided as part of top stack mechanism 234 and convertible roof 220 and are mirrored images of the side depicted and/or discussed. Also, when using the terms “fore” and “aft,” “front” and “back,” and “forward” and “rearward” in describing the movement and components of top stack mechanism 234 and convertible roof 220 , such reference refers to the orientation of the components when top stack mechanism 234 and convertible roof 220 are in the fully raised position.
Top stack mechanism 234 includes a number one roof bow 244 that extends transversely across vehicle 222 and is disposed above the front windshield header when in the fully raised position, as shown in FIG. 6 . Roof cover 236 is attached to number one roof bow 244 . Number one roof bow 244 is coupled to a pair of segmented front roof rails 246 by synchronizing linkage assemblies 248 , described in more detail below.
Segmented front roof rails 246 include an in-folding portion 246 a and a straight-folding portion 246 b . In-folding and straight-folding portions 246 a , 246 b are pivotally connected together at pivots 250 and are interconnected by in-folding linkage assemblies 252 , described in more detail below. A number two roof bow 253 is fixedly attached to a front portion of straight-folding portions 246 b . Number two roof bow 253 includes a U-shaped extension 253 a (shown in FIG. 6 only) that extends forwardly from the main section. Extension 253 a supports roof cover 236 and prevents roof cover 236 from interfering with the operation of synchronizing linkage assemblies 248 during the retraction and extension of convertible roof 220 . Straight-folding portions 246 b are pivotally connected to front portions of a pair of center roof rails 254 at pivots 256 and are interconnected with intermediate linkage assemblies 257 , described in more detail below. A number three roof bow 260 extends transversely across vehicle 220 and is pivotally connected to intermediate portions of center roof rails 254 at pivots 262 . Number three roof bow 260 is loosely attached to roof cover 236 and moves with the movement of roof cover 236 .
Rear portions of center roof rails 254 are pivotally connected to front or top portions of rear roof rails 258 at pivots 264 . The opposite ends of rear roof rails 258 are pivotally connected to fixed brackets 266 at pivots 268 . Pivots 268 are aligned along a pivot axis 269 which is generally perpendicular to longitudinal center line 240 . Rear roof rails 258 rotate about pivots 268 and pivot axis 269 during extension and retraction of top stack mechanism 234 , as describe below. Brackets 266 are fixed to vehicle 222 within stowage compartment 230 .
One end of a balance link 270 is pivotally coupled to bracket 266 at pivot 272 while an opposite end of balance link 270 is pivotally coupled to a rear portion of center roof rail 254 at pivot 274 . The interconnection between center roof rail 254 , rear roof rail 258 , bracket 266 and balance link 270 forms a rear four-bar linkage assembly 275 defined by pivots 264 , 268 , 272 and 274 . A number four roof bow 276 extends transversely across vehicle 220 and is fixedly attached to a front or top portion of balance link 270 . An actuator 278 is attached to bracket 266 and coupled to balance link 270 . Actuator 278 includes an electric motor 280 and a gear box 282 . A linkage assembly 284 interconnects gear box 282 with balance link 270 thereby enabling actuator 278 to cause balance link 270 to rotate about pivot 272 . Rotation of balance link 270 about pivot 272 causes convertible roof 220 to move between the raised and stowed positions, as described in more detail below.
A number five roof bow 286 extends transversely across vehicle 222 and is pivotally coupled to brackets 266 at pivots 288 . Number five roof bow 286 is attached to roof cover 236 and moves with the movement of roof cover 236 . A number six or rearmost roof bow 292 extends transversely across vehicle 222 and is pivotally coupled to brackets 266 with connecting links 294 . One end of a connecting link 294 is pivotally coupled to an end of number six roof bow 292 while the opposite end of connecting link 294 is pivotally coupled to bracket 266 . An actuator 296 , in this case in the form of a fluidic actuator, is pivotally coupled to bracket 266 and to number six roof bow 292 . Extension of actuator 296 causes number six roof bow 292 to rotate upwardly and forwardly and retraction of actuator 296 causes number six roof bow 292 to move downwardly and rearwardly, as described in more detail below. Number six roof bow 292 is also coupled to linkage assembly 284 to allow actuator 278 to move number six roof bow 292 into and out of stowage compartment 230 . A rear portion of roof cover 236 is attached to number six roof bow 292 . Number six roof bow 292 rests on a moveable tonneau cover 298 of vehicle 222 when convertible roof 220 is in the raised position, as shown in FIG. 6 .
Rear linkage assembly 275 and intermediate linkage assembly 257 are interconnected by a control link 300 . One end of control link 300 is pivotally connected to an end of balance link 270 at pivot 302 . An opposite end of control link 300 is pivotally connected to intermediate linkage assembly 257 at pivot 304 . Control link 300 causes intermediate linkage assembly 257 to rotate front roof rails 246 relative to center roof rails 254 during extension and retraction of top stack mechanism 234 , as described in more detail below.
Intermediate linkage assembly 257 , as best seen in FIGS. 9A and 9B , interconnects straight-folding portion 246 b of front roof rail 246 with center roof rail 254 . Intermediate linkage assembly 257 includes a straight-folding linkage assembly 308 and an in-folding control linkage assembly 310 . Straight-folding linkage assembly 308 includes a first link 312 having one end pivotally coupled to a front portion of center roof rail 254 at pivot 314 and a second end pivotally coupled to a second link 316 at pivot 318 . The end of control link 300 is pivotally connected to an intermediate portion of first link 312 at pivot 304 . The opposite end of second link 316 is pivotally connected to a rear portion of straight-folding portion 246 b of front roof rail 246 at pivot 320 . Straight-folding linkage assembly 308 thereby forms a four-bar linkage assembly including straight-folding portion 246 b , center roof rail 254 , first link 312 and second link 316 and is defined by pivots 256 , 314 , 318 and 320 . Straight-folding linkage assembly 308 controls the movement of front roof rail 246 relative to center roof rail 254 during movement of top stack mechanism 234 between the raised and stowed positions, as described below.
In-folding control linkage assembly 310 includes a first link 322 having one end pivotally connected to a front portion of center roof rail 254 at pivot 324 and an opposite end pivotally connected to an end of a second link 326 at pivot 328 . An intermediate portion of second link 326 is pivotally connected to a rear portion of straight-folding portion 246 b of front roof rail 246 at pivot 320 (which is also shared with link 316 ). An opposite end of second link 326 is coupled to a coupling link 330 at ball joint 332 . Coupling link 330 is also coupled to in-folding linkage assembly 252 and interconnects in-folding linkage assembly 252 with in-folding control linkage assembly 310 , as described in more detail below. In-folding control linkage assembly 310 thereby forms a four-bar linkage assembly including straight-folding portion 246 b , center roof rail 254 , first link 322 and second link 326 and is defined by pivots 256 , 324 , 328 and 320 . In-folding control linkage assembly 310 is driven by movement of straight-folding portion 246 b relative to center roof rail 254 . The movement of straight-folding portion 246 b relative to center roof rail 254 is controlled by straight-folding linkage assembly 308 . Thus, movement of in-folding control linkage assembly 310 is driven by the movement of straight-folding linkage assembly 308 , as described in more detail below.
Referring now to FIGS. 9A , 9 B and 10 , details of in-folding linkage assembly 252 are shown. In-folding linkage assembly 252 includes a first in-folding link 340 having one end pivotally connected to straight-folding portion 246 b of front roof rail 246 at pivot 342 and an opposite end pivotally connected to an end of a second in-folding link 344 at pivot 346 . The opposite end of second in-folding link 344 is pivotally connected to in-folding portion 246 a of front roof rail 246 at pivot 348 . In-folding linkage assembly 252 thereby forms a four-bar linkage assembly including straight-folding portion 246 b , in-folding portion 246 a , second in-folding link 344 and first in-folding link 340 and is defined by pivots 250 , 348 , 346 and 342 . In-folding linkage assembly 252 controls the movement of in-folding portion 246 a relative to straight-folding portion 246 b during the extension and retraction of top stack mechanism 234 , as described in more detail below. In-folding linkage assembly 252 is driven by movement of coupling link 330 . It should be noted that in-folding linkage assembly 252 operates in a plane that is perpendicular to the plane that intermediate linkage assembly 257 operates in. That is, when viewed in the orientation shown in FIG. 6 , in-folding linkage assembly 252 operates in a generally horizontal plane while intermediate linkage assemblies 257 (including straight-folding linkage assembly 308 and in-fold control linkage assembly 310 ) operate in a generally vertical plane.
Coupling link 330 interconnects in-folding linkage assembly 252 with in-folding control linkage assembly 310 . One end of coupling link 330 is connected to an end of link 326 at ball joint 332 while an opposite end of coupling link 330 is connected to an intermediate portion of first in-fold link 340 at ball joint 350 . Ball joints 332 , 350 allow three degrees of movement of coupling link 330 relative to links 326 and 340 and accommodates the differing planar movements. Coupling link 330 transfers the motion of in-folding control linkage assembly 310 to in-folding linkage assembly 252 to control and coordinate the extension and retraction of top stack mechanism 234 , as described in more detail below.
Referring now to FIGS. 7 and 10 , details of synchronizing linkage assembly 248 are shown. Synchronizing linkage assembly 248 includes right and left links 356 , 358 , that are disposed along the respective right and left sides of top stack mechanism 234 , and a synchronizing link 360 that interconnects right and left links 356 , 358 . One end of right link 356 is pivotally connected to an inwardly extending extension on the right side in-folding portion 246 a of front roof rail 246 at pivot 362 while an opposite end of right link 356 is pivotally connected to a right side portion of number one roof bow 244 at pivot 364 . One end of left link 358 is pivotally connected to an inwardly extending extension on the left side in-folding portion 246 a of front roof rail 246 at pivot 366 while an intermediate portion (near the opposite end) of left link 358 is pivotally coupled to the left side portion of number one roof bow 244 at pivot 368 . Pivots 364 and 368 on number one roof bow are generally aligned with one another. That is, a line connecting pivots 364 , 368 is generally perpendicular to the fore-aft center line 240 . One end of synchronizing link 360 is pivotally connected to an intermediate portion of right link 356 at pivot 370 slightly rearward of pivot 364 , while an opposite end of synchronizing link 360 is pivotally connected to the end of left link 358 at pivot 372 forward of pivot 368 . With one end of the synchronizing link 360 being pivotally coupled to right link 356 rearwardly of pivot 364 while the opposite end of synchronizing link 360 is pivotally coupled to left link 358 forward of pivot 368 , synchronizing link 360 operates to synchronize the movement of the left and right in-folding portions 246 a of front roof rail 246 . That is, synchronizing link 360 limits the degrees of freedom of number one roof bow 244 relative to in-folding portions 246 a of front roof rails 246 and prevents cross-car drift of top stack mechanism 234 during movement between the raised and stowed positions.
To reduce some of the stress at pivots 362 , 364 , 366 and 368 , slotted connections with pins that ride therein are provided. Specifically, right and left links 356 , 358 each have a pin 374 that rides within slots 376 on the respective right and left in-folding portions 246 a . Similarly, right and left links 356 , 358 also each have a pin 378 that rides within slots 380 on the respective right and left sides of number one roof bow 244 . Engagement between pins 374 , 378 and slots 376 , 380 provides additional support for right and left links 356 , 358 , number one roof bow 244 and the right and left in-folding portions 246 a . The engagement between these slots and the pins does not affect the kinematics of the operation of synchronizing linkage assembly 248 .
Referring now to FIGS. 11A-11C , simplified details of a dampening system 390 used with convertible roof 220 are shown. Dampening system 390 is located within brackets 266 and is operable to dampen the motion of top stack mechanism 234 at various times during the extending and retracting of convertible roof 220 , as described in more detail below. The views depicted in FIGS. 11A-11C are simplified and a majority of bracket 266 and the other components therein or attached thereto are removed for ease of illustration and explanation. Dampening system 390 includes a damper 392 that dampens some movements of top stack mechanism 234 while allowing unimpeded (undampened) movement of top stack mechanism 234 during other movements. Damper 392 includes a cylindrical housing 394 with an extendable rod 396 extending therefrom. A piston 397 is attached to rod 396 inside cylindrical housing 394 . A fluid, in this case hydraulic fluid, is also contained within housing 394 . The hydraulic fluid dampens the movement of rod 396 (via the piston) relative to housing 394 . The movement of rod 396 is dampened only in one direction. That is, rod 396 is relatively free to be moved into housing 394 while being restrained or dampened when being moved outwardly from housing 394 . Thus, movement of top stack mechanism 234 that causes damper 392 to shorten in length is not dampened while movement of top stack mechanism 234 that causes damper 392 to be elongated is dampened, as described in more detail below. A suitable damper 392 is a model MB-22 hydraulic damper available from Ace Controls Inc. of Farmington Hills, Mich.
One end of damper 392 is pivotally connected to bracket 266 at pivot 398 while an opposite end of damper 392 is pivotally connected to a bottom extension 400 of rear roof rail 258 at pivot 402 . The orientation of pivot 402 relative to pivot 268 (about which rear roof rails 258 rotate) causes damper 392 to be both shortened and elongated during the movement of top stack mechanism 234 between the raised and stowed positions. As shown in FIG. 11A , when convertible roof 220 and top stack mechanism 234 are in the fully stowed position, pivot 402 is forward of pivot 268 . As top stack mechanism 234 moves from the stowed position toward the raised position (rear roof rail 258 rotating counter-clockwise in the views of FIGS. 11A-11C ), rod 396 will be pushed into cylindrical housing 394 and damper 392 will offer little or no resistance to this motion. Rod 396 will continue to be pushed into housing 394 until an on-center position occurs, as shown in FIG. 11B , wherein pivots 398 , 402 and 268 are all aligned with one another. Further movement of convertible roof 220 and top stack mechanism 234 toward the raised position causes damper 392 to move away from the on-center position and pull rod 396 out from housing 394 . The pulling of rod 396 out from housing 394 is dampened by the engagement between piston 397 and the hydraulic fluid therein. Thus, during continued motion of top stack mechanism 234 toward the raised position (after damper 392 has passed the on-center position), the movement is dampened by the resistance of rod 396 from being pulled from housing 394 . This dampening helps support top stack mechanism 234 and relieves some stress from actuators 278 , linkage assemblies 284 and the other components of top stack mechanism 234 . Furthermore, this dampening helps diminish the force and velocity with which number one roof bow 244 may contact the front header of vehicle 222 . When in the fully raised position, pivot 402 is located below and rearward of pivot 268 , as shown in FIG. 11C .
During the movement of convertible roof 220 and top stack mechanism 234 from the raised position ( FIG. 11C ) to the stowed position ( FIG. 11A ), the initial movement of rear roof rail 258 will push rod 396 into housing 394 while damper 392 offers little or no resistance to this movement. This pushing of rod 396 into housing 394 continues until an on-center position is reached, as shown in FIG. 11B . Continued rearward rotation of rear roof rail 258 about pivot 268 causes damper 392 to pass the on-center position and extension 400 to begin to pull on rod 396 . The movement of rod 396 out of housing 394 is resisted by the engagement between the piston and the hydraulic fluid thereby dampening the continued rearward rotation of rear roof rail 258 toward the stowed position. Damper 392 thereby removes some of the stresses and strains on actuator 278 , linkage assemblies 284 and other components of top stack mechanism 234 during the final phases of movement of top stack mechanism 234 to the stowed position. Additionally, the dampening helps limit the force and velocity of top stack mechanism 234 into stowage compartment 230 .
In operation, convertible roof 220 is moveable between the raised position, shown in FIG. 6 , through intermediate positions, such as that shown in FIG. 7 , to a fully stowed position, as shown in FIGS. 8A and 8B . To move convertible roof 220 from the raised position to the stowed position, number one roof bow 244 is unlatched from the front header of vehicle 222 . Actuators 296 are commanded to extend thereby pushing number six roof bow 292 upwardly. When number six roof bow 292 has been pushed upwardly a sufficient distance, tonneau cover 298 can then be moved from the closed position to an open position (not shown). Actuators 296 are commanded to retract and pull on number six roof bow 292 causing number six roof bow 292 to return to its nominal position. With tonneau cover 298 in the open position, access to stowage compartment 230 is available and convertible roof 220 can be retracted into stowage compartment 230 . Actuators 278 are commanded to drive linkage assemblies 284 and pull on balance links 270 , causing balance links 270 to rotate rearwardly. As balance links 270 rotate rearwardly, rear roof rails 258 pivot rearwardly about pivots 268 while center roof rails 254 rotate forwardly relative to rear roof rails 258 about pivots 264 . Rearward rotation of balance links 266 also cause control links 300 to pull straight-folding linkage assemblies 308 rearwardly. Movement of linkage assembles 284 also cause number six roof bow 292 to move downwardly and into stowage compartment 230 .
The rearward pulling on straight-folding linkage assemblies 308 cause links 312 to rotate rearwardly about pivots 314 relative to center roof rails 254 . This movement of links 312 pull on links 316 which in turn cause straight-folding portions 246 b to rotate rearwardly relative to center roof rails 254 about pivots 256 .
The rearward rotation of straight-folding portions 246 b relative to center roof rails 254 cause pivots 328 that interconnect links 322 and 326 of in-folding control linkage assembly 310 to also move rearwardly. This in turn pulls coupling links 330 rearwardly relative to straight-folding portions 246 b . The rearward movement of coupling links 330 pulls in-folding linkage assemblies 252 rearwardly, causing in-folding portions 246 a of front roof rails 246 to pivot inwardly about pivots 250 toward center line 240 of vehicle 222 . It should be noted that the rearward movement of in-folding linkage assemblies 252 are in planes that are perpendicular to the planes of the rearward movement of intermediate linkage assemblies 257 .
As in-folding portions 246 a of front roof rails 246 pivot inwardly, the ends of right and left links 256 , 258 that are pivotally connected to in-folding portions 246 a rotate inwardly about their respective pivots 364 , 368 on number one roof bow 244 . Due to the offset arrangement of pivots 370 , 372 that interconnect synchronizing link 360 to right and left links 356 , 358 , synchronizing link 360 moves toward the left side of top stack mechanism 234 . Synchronizing link 360 constrains the in-folding of in-folding portions 246 a of front roof rails 246 as number one roof bow 244 is pulled rearwardly. The constraining of the in-folding movement prevents top stack mechanism 234 from drifting side-to-side during the retraction and extension process, thereby enabling smooth and aesthetically pleasing operation of convertible roof 220 .
During the later portion of the retraction cycle (after dampers 392 go over-center), dampening system 390 via dampers 392 resist the movement of top stack mechanism 234 which dampens and slows the movement of top stack mechanism 234 , as describe above. Actuators 278 continue to cause top stack mechanism 234 to retract into stowage compartment 230 until the stowed position is reached, as shown in FIGS. 8A and 8B , wherein convertible roof 220 is disposed within stowage compartment 230 . Tonneau cover 298 is then moved back to its closed position covering an entirety or a portion of convertible roof 220 within stowage compartment 230 .
To move convertible roof 220 from its stowed position to its raised position, tonneau cover 298 is moved from the closed position to the open position and actuators 278 are commanded to cause linkage assemblies 284 to push on balance links 270 causing forward rotation about pivots 272 . The forward rotation is transferred to center roof rails 254 and rear roof rails 258 . Additionally, linkage assemblies 284 cause number six roof bow 292 to move upwardly and out of stowage compartment 230 . As convertible roof 220 extends, rear roof rails 258 rotate forwardly about pivots 268 and center roof rails 254 rotate rearwardly relative to rear roof rails 258 about pivots 264 . Control links 300 push intermediate linkage assemblies 257 forwardly, thereby causing straight-folding portions 246 b of front roof rails 246 to rotate forwardly relative to center roof rails 254 about pivots 256 . This action causes pivots 304 , 328 to approach pivots 256 . Coupling links 330 push forwardly on in-folding linkage assemblies 252 . In-folding portions 246 a of front roof rails 246 rotate outwardly relative to straight-folding portions 246 b about pivots 250 .
The outward rotation of in-folding portions 246 a cause right and left links 356 , 358 to rotate outwardly about their respective pivots 364 , 368 . This in turn causes synchronizing link 360 to move toward the right relative to vehicle 222 . Synchronizing link 360 constrains the out-folding of in-folding portions 246 a of front roof rails 246 as number one roof bow 244 is pushed forwardly. The constraining of the out-folding movement prevents top stack mechanism 234 from drifting side-to-side during the extension cycle, thereby enabling smooth and aesthetically pleasing operation of convertible roof 220 .
During the later portion of the extension cycle (after dampers 392 go over-center), dampening system 390 via dampers 392 resist the movement of top stack mechanism 234 which dampens and slows the movement of top stack mechanism 234 , as describe above. Additionally, the force with which number one roof bow 244 may contact the front header of vehicle 222 is also reduced. Actuators 278 continue to cause balance links 270 to rotate forwardly until top stack mechanism 234 has been moved to the fully raised position, as shown in FIG. 1 . Actuators 296 are then commanded to extend and cause the rear portion of number six roof bow 292 to move upwardly and forwardly. When number six roof bow 292 has been moved a sufficient distance, tonneau cover 298 is then moved from the open position to the closed position. Actuators 296 are then commanded to retract and cause number six roof bow 292 to move downwardly and on top of tonneau cover 298 and into its nominal position. Number one roof bow 244 is then latched to the front header of vehicle 222 to secure top stack mechanism 234 in the fully raised position.
Referring now to FIG. 12A , a second alternate embodiment of a synchronizing linkage assembly 500 for constraining the in-folding of a convertible roof is shown. The view depicted in FIG. 12A is a simplified bottom plan view of the front portion of the in-folding convertible roof system of FIG. 6 with synchronizing linkage assembles 500 thereon. Each synchronizing linkage assembly 500 includes an in-folding link 502 having one end pivotally connected to an in-folding portion 504 of a front roof rail at pivot 506 while the opposite end is pivotally connected to number one roof bow 508 at pivot 510 . One end of a synchronizing link 512 is pivotally connected to an intermediate portion of in-folding link 502 at pivot 514 while an opposite end is pivotally connected to an end of a synchronizing crank 516 at pivot 518 . An intermediate portion of synchronizing crank 516 is pivotally connected to number one roof bow 508 at pivot 520 . The other end of synchronizing crank 516 is pivotally connected to a slide joint 522 on one end of a synchronizing slider 524 . Synchronizing slider 524 is slidably connected to number one roof bow 508 in a slide channel 526 on number one roof bow 508 . The slide joint 522 on the opposite end of synchronizing slider 524 is connected to an end of a synchronizing crank 516 on the other side of the number one roof bow 508 . Slider 524 can move forwardly and rearwardly relative to number one roof bow 508 within slide channel 526 .
During retraction of the convertible roof, the front ends of in-folding roof rail portions 504 rotate inwardly and cause the ends of in-folding links 502 attached to pivots 506 to rotate inwardly about pivots 510 . The rotation of in-folding roof rail portions 504 also cause in-folding links 502 to move rearwardly and pull number one roof bow 508 rearwardly. The rotation of in-folding links 502 pushes synchronizing links 512 inwardly which cause synchronizing cranks 516 to rotate about pivots 520 and move pivots 518 rearwardly. The rotation of synchronizing cranks 516 via slide joints 522 push synchronizing slider 524 forwardly relative to number one roof bow 508 within slide channel 526 . The interaction between in-folding links 502 , synchronizing links 512 , synchronizing crank 516 and synchronizing slider 524 constrain the movement of the top stack mechanism and keep the two sides of the top stack mechanism in sync during the retraction cycle. The interaction also prevents cross car drift. During the extension cycle of the top stack mechanism, the interactions are reversed and the movement of the top stack mechanism remains synchronized and constrained. Thus, synchronizing linkage assemblies 500 are operable to synchronize and constrain the movement of the top stack mechanism during retraction and extension cycles.
Referring now to FIG. 12B , a third alternate embodiment of a synchronizing linkage assembly 600 for constraining the in-folding of the convertible roof is shown. The view depicted in FIG. 12B is a simplified bottom plan view of the front portion of the in-folding convertible roof system of FIG. 6 with synchronizing linkage assembly 600 thereon. Synchronizing linkage assembly 600 includes right and left side in-folding links 602 a , 602 b that have one end pivotally connected to in-folding roof rail portions 604 on the respective right and left sides of the top stack mechanism at pivots 605 . The opposite ends of in-folding links 602 a , 602 b are fixed to respective right and left side pulleys 606 a , 606 b . Pulleys 606 a , 606 b are pivotally connected to respective right and left sides of number one roof bow 608 at respective pivots 610 a , 610 b . One end of first and second cables 612 , 614 are each fixed to an outer portion (when the top stack mechanism is fully raised) of right pulley 606 a while the other end of first and second cables 612 , 614 are each fixed to an outer portion (when the top stack mechanism is fully raised) of left pulley 606 b . First cable 612 extends around a front portion of right pulley 606 a across the top stack mechanism and around a rear portion of left pulley 606 b . In contrast, second cable 614 extends around a rear portion of right pulley 606 a across the top stack mechanism and around a front portion of left pulley 606 b . The opposite wrapping of cables 612 , 614 allows synchronizing linkage assembly 600 to constrain the in-folding of the roof rail during retraction and extension of the top stack mechanism.
During retraction of the top stack mechanism, the front ends of in-folding roof rail portions 604 rotate inwardly and cause the ends of in-folding links 602 a , 602 b attached to pivots 605 to rotate inwardly. The rotation of in-folding roof rail portions 604 also cause in-folding links 602 a , 602 b to move rearwardly and pull number one roof bow 608 rearwardly. The rotation of in-folding links 602 a , 602 b cause the respective pulleys 606 a , 606 b to rotate in opposite directions (counter clockwise and clockwise respectively in the view depicted) about pivots 610 a , 610 b . The opposite rotation of pulleys 606 a , 606 b maintains the tension in cables 612 , 614 . Maintaining the tension in cables 612 , 614 constrains the movement of the top stack mechanism and minimize cross car drift of the top stack mechanism during the retraction cycle. During the extension cycle of the top stack mechanism, the interactions are reversed and tension in cables 612 , 614 remains the same and constrains the movement of the top stack mechanism. Thus, synchronizing linkage assembly 600 is operable to synchronize and constrain the movement of the top stack mechanism during retraction and extension cycles.
While various aspect of convertible roof 220 and top stack mechanism 234 have been disclosed, it will be appreciated that many other variations may be employed without departing from the scope of the present invention. For example, while actuators 278 are shown as being an electric motor 280 coupled to a gear box 282 , other types of actuators could be employed. For example, linear actuators, such as fluidically-driven cylinders, can be employed. Furthermore, fluidically-driven rotary actuators could also be employed. Moreover, the use of the in-folding control linkage assembly 310 may be eliminated by configuring link 316 into a desired orientation and attaching control link 330 to second link 316 , providing a desired motion can be translated to coupling link 330 via the movement of straight-folding linkage assembly 308 .
Additionally, while pivots 268 and pivot axis 269 are shown as being fixed, it should be understood that pivots 268 and pivot axis 269 can move, such as when in a slot or when brackets 266 move, while still maintaining pivot axis 269 substantially perpendicular to center line 240 . The exact location of the various pivots of top stack mechanism 234 can vary from the locations shown in drawings and still be within the scope of the present invention. Furthermore, the specific configurations and orientations of the various linkages and roof rails can have shapes that differ from those shown and still be within the scope of the present invention. Additionally, the roof can be stowed in the rear seating area of the passenger compartment.
Moreover, while dampening system 390 is shown as using a fluidic damper 392 , it should be appreciated that other types of dampers could be employed. For example, a spring-loaded damper that resists elongation could be employed. Moreover, a curved rack and a biased pinion may also be employed. Furthermore, fluids other than hydraulic fluid could also be used for a fluidic damper. Moreover, the fluidic damper could connect to other components of top stack mechanism 234 to dampen the motion. For example, the damper could be coupled to the balance link or other components. Additionally, it should be appreciated that the dampening system of the present invention could also be employed on convertible roofs that do not include in-folding features and/or are shorter in length. Additionally, the dampening system could also be used on convertible roofs that utilize hard panels or rigid panels in lieu of or in addition to the soft roof cover. Additionally, the dampening system can employ dampers at different locations along the top stack mechanism to dampen different portions of the top stack mechanism and/or include multiple dampers spaced at different locations along the top stack mechanism.
It should also be appreciated that the in-folding aspects and the synchronizing linkage assemblies utilized in the present invention could be employed on a convertible roof system that utilizes more or less roof rails, such as a bi-fold top stack mechanism with a segmented front roof rail. Furthermore, it should be appreciated that the synchronizing linkage assemblies can take other forms with different shaped components and/or pivot points and/or more or less components.
Thus, the foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims. | A convertible roof includes a segmented pair of front roof rails that in-fold when being retracted, thereby reducing the packaging space required to stow the convertible roof. The in-folding of the segmented front roof rails is controlled by linkages between the segmented portions and the number one roof bow and synchronizes and constrains the in-folding of the segmented front roof rails. A dampening device is utilized to dampen a portion of the movement of the top stack mechanism between extended and retracted positions. | 1 |
FIELD OF THE INVENTION
The present invention relates to a method of securing a framed panel subjected to shock, for example, high winds and explosions, and also to a framed panel so secured.
BACKGROUND OF THE INVENTION
Framed panels made of shattering materials tend to shatter when subjected to shock and the shattered fragments of the panels may be propelled at high speeds into the room in which the framed panel is located, causing injury to personnel and/or damage to the room.
Non-shattering panels, such as panels made of laminated glass, polycarbonates or glass coated in protective film, are frequently used to prevent such injury to personnel and damage to property, and are generally effective for this purpose. However, it is not uncommon, eg during an external explosion, for the entire panel, whether made of shattering or non-shattering material, to be forced out of the frame and to travel at high speed into the room in which it is located. This is particularly problematic when the panel is held in a relatively weak frame, such as a timber frame. Such panels can travel at up to 10 m/s (approximately 30 feet per second) and can cause serious injury to personnel, as well as significant damage to property.
Attempts have been made to arrest the movement of such a panel from the surrounding frame by reinforcing the frame with steel bars. However, it has been found that such steel bars can also be forced away from the frame and driven into the room at high speed, potentially causing serious injury to personnel and damage to property.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method for securing a framed panel subjected to shock, in which the above disadvantages are overcome.
The invention provides a method of securing a framed panel a claimed in claim 1 . The invention also provides a secured framed panel as claimed in claim 17 .
The invention is particularly applicable to the petrochemical industry, in which explosions re relatively common. The framed panel to be secured is preferably made of a non-shattering material. In a preferred embodiment of the invention, the shock cord has a maximum elasticity of 10%.
The ends of the shock cord are preferably protected. In a preferred embodiment the ends of the shock cord are protected by heat shrinking. Alternatively, the ends of the shock cord are protected by a cap on the cleat.
The cleat is preferably attached to the frame. In a preferred embodiment, the cleat is attached to the frame by means of one or more buttress screws. In a further preferred embodiment of the invention the shock cord is held at both ends by a cleat.
The panel to be secured is preferably made of a polycarbonate material. In a preferred embodiment the panel is a window and is made of laminated glass. Alternatively, the window is made of glass covered by window film. The shock cord is preferably a polyester braided rope. In a further preferred embodiment, two or more shock cords are arranged across the panel.
Embodiments of the invention will now be described with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a framed panel secured in accordance with the invention;
FIG. 2 is a side view of one end of a shock cord held in a cleat;
FIG. 3 is an end view of the cleat of FIG. 2 ;
FIG. 4 is a side view of one end of a shock cord held in an alternative cleat with a cover and;
FIG. 5 is an end view of the shock cord and cleat of FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 a secured framed panel 1 has a non-shattering panel 2 mounted in a frame 3 . The term “non-shattering” refers to a material which does not shatter when subjected to shock, but also includes materials which do shatter but are provided with means for holding the shattered pieces together, such as window film, so that the shattered pieces remain joined together in such a way that the shattered panel retains substantially the same shape as in the unshattered state.
A flexible shock cord 4 is arranged across the framed panel 1 , at such a height on the framed panel as to adequately support the framed panel 1 . The ends 5 a and 5 b of the shock cord 4 are located in cleats 6 a and 6 b , respectively, attached to the frame 3 . Alternatively, the cleats 6 a and 6 b may be attached to the wall in which the framed panel is mounted. The cleats 6 a and 6 b are attached by means of buttress screws 7 a and 7 b , respectively. Butress screws have a relatively high pull-out pressure and are thus well-suited for this application, in which the loads to which the framed panels are subjected are relatively high. However, it is posible to attach the cleats by means of other screws.
FIGS. 2 and 3 show the arrangement of the end 5 a of the shock cord 4 in the cleat 6 a in detail. It will be appreciated that the arrangement of the end 5 b in clean 6 b will be similar. The end 5 a of the shock cord 4 is arranged as a loop 8 having opposing sides 8 a and 8 b . The side 8 a of the loop 8 is arranged in a recess 9 in the cleat 6 a and the opposing side 8 b is arranged in a channel 10 in the cleat 6 a . The channel 10 is arranged above the recess 9 and is substantially parallel thereto. The recess 9 and channel 10 are located on the central vertical plane A—A of the cleat 6 a and are separated by a dividing portion 11 . The end 5 a of the shock cord 4 has been treated by heat shrinking to prevent unravelling of the cord 4 . FIGS. 4 and 5 show the arrangement of the end 5 a of the shock cord 4 in an alternative cleat 6 a 1 . Again, the end 5 a of the shock cord is arranged as a loop 8 1 having opposing sides 8 a 1 and 8 b 1 . The side 8 a 1 is arranged in a recess 9 1 and the opposing side 8 b 1 is arranged above a dividing portion 11 1 . A cap 12 is arranged around the cleat 6 a 1 and the side 8 b 1 , so that the end of the shock cord 4 is completely covered to protect the end of the shock cord.
When the framed panel 1 is subjected to shock, such as a gust of strong wind or an explosion, the panel 2 starts to move away from the frame 3 . The shock cord arrests the movement of the panel 2 and prevents it from travelling at high speed into the interior of the room, in which it is located. Although, in extreme cases, the panel 2 may fall into the interior of the room, it is likely to fall close to the frame 3 and not travel across the room. The shock cord 4 also stretches and absorbs a significant portion of the energy of the explosion or gust of wind, thus reducing the load on the frame 2 . In the event that the shock cord 4 is forced out of the cleats 6 a and 6 b , the damage caused by the shock cord will be minimal in comparison to the damage that would be caused if a steel bar were to be used.
A number of different cleats can be used to hold the shock cord 4 but the “CL255 Omega” cleat manufactured by Clamcleats Limited of Watchmead, Welwyn Garden City, Hertfordshire, AL7 1AP, England, and coverd by UK Pat. No. 2 299 366 is particularly suitable. This type of cleat wedges the shock cord 4 in a groove. However, alternative types of cleat, such as T-shaped cleats, in which the shock cord 4 is wound around the cleat would also be suitable. The shock cord 4 is a braided polyester/nylon interlayer with a woven polyester shield. However, any other suitable shock cord, such as an elasticated rubber (bungee) shock cord, may be used. Suitable shock cords generally have a maximum elasticity of 10%. However, it has been found that shock cords having higher elasticity can still be effective, provided that the pressures applied to the system are relatively low.
In the embodiments described above each end of the shock cord 4 is held in a cleat. However, it is possible for only one end of the shock cord 4 to be held in a cleat, the other end being held by another device, for example, a clamp. Similarly, while two buttress screws are used to hold each cleat in the present embodiment, it would be possible to secure a cleat of suitable design using one screw only.
In the embodiments described above, one shock cord is arranged horizontally across the framed panel. In taller framed panels, it may, however, be necessary to use several shock cords, arranged one above the other. Alternatively, a shock cord can be arranged either vertically or diagonally across the framed panel.
The method can be applied to existing framed panels relatively quickly and inexpensively, particularly in comparison with steel bars. | A framed panel ( 1 ) consists of a panel ( 2 ) mounted in a frame ( 3 ). In order to secure the panel, a shock cord ( 4 ) is fastened across the panel ( 2 ), one or both ends of the shock cord ( 4 ) being held in a cleat ( 6 a , 6 b ), so that the panel ( 2 ) is arrested when subjected to shock. | 4 |
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,039,879 describes a process for making cottage cheese which includes the treatment of milk under special conditions of temperature and time to effect a conditioning of the protein in the milk. The resultant product does not have as smooth a texture as the product of the invention.
DESCRIPTION OF THE INVENTION
Changes in on-farm milk harvesting methods as well as storing milk longer in refrigerated bulk tanks are thought to contribute to the problem of psychrotrophic organisms in milk. Heat treating milk prior to storage appears to control psychrotrophs and reduces ADV values.
This invention relates on the one hand to a process for improving the storage stability of milk. On the other hand, this invention relates to a process for making cottage cheese, quarg or similar cheese products whereby substantially improved yield is obtained.
In either of the above two processes fresh milk, preferably within a few hours after leaving the cow, and generally within thirty minutes after leaving the cow, is heated to a temperature of at least about 150° F., and preferably 165° F. for about 10 seconds or 260° F. for 2 seconds, or at an equivalent intermediate temperature and time, to provide a milk which can still be considered at least partially raw by phosphatase analysis, but which does not contain a bacterial count of in excess of 100,000 until after seven days normal refrigerated storage.
In the cheese making process of the invention, in addition to a heat treating step, the heat treated cheese is aged prior to being employed to make cottage cheese or quarg. Generally the milk is aged under refrigerated conditions for at least about two days and preferably six to ten days or longer, up to a time when noticable changes in flavor begin to occur, before it is employed in a cheese making process. The precise effect of the aging step is not known, but the aging enhances cheese yields.
While aging the heat treated milk for at least about two days, and preferably six to ten days, appears essential to enhancing the yields in the cheese making process, conventionally the milk heat treated soon after it leaves the cow, as described above, is passed into a refrigerated holding tank, on a regular daily or bi-daily basis. Thus, typically, milk withdrawn from the tank would represent a blend of milk aged between the age of the first addition and last addition to the tank. Such milk blends where the oldest milk has been aged for at least three to five days and preferably six to ten days can be satisfactorily employed in the cheese making process of the invention to enhance cheese yields.
With respect to the cheese making process, it appears that heat treatment apparently in conjunction with the post treatment aging step provides a milk which apparently has at least a significant portion of the milk protein partially denatured, (as opposed to complete denaturization of a significant portion of the milk protein as taught in U.S. Pat. No. 3,039,879). In the cheese making process it is theorized that this partially denatured protein is absorbed into the particles being formed increasing the amount of protein in the cheese product in a manner which provides a product which is smooth to the palate, with no discernible graininess.
The cheese making process of this invention can be any conventional process for making cottage cheese or quarg. The presently employed process is that described by Emmons and Tuckey "Cottage Cheese and Other Culture Products" Pfizer Cheese Monograph, Vol. 3 (1967).
EXAMPLE 1
Milk was collected over many trials from several farms and promptly heated to different temperatures ranging from 120° F. to 165° F. for different time periods. Milk so treated was stored at 7° C. (45° F.) and monitoried over time for the following quality parameters: standard plate count (SPC), psychrotrophic count, acid degree value (ADV), and organoleptic evaluation.
The goal set forth was to learn whether or not heat treating of milk would protect milk's delicate qualities longer than unheated milk.
Data from the bench top studies showed that heated milk would last longer and keep better.
The next step was to scale up the size of this study. We segregated the heat treated milk from the farms regular tank by collecting it in a separate 250 gallon bulk tank which was installed specifically to store heat treated milk. Some milk was heat treated on the farm as produced and was added daily to our small bulk tank over seven days. On day eight milk was then transported to the milk processing plant where it was pasteurized and packed in containers similar to the regular milk which is sold to on-campus dining and through a public sales outlet (a dairy store). The data generated from the study was similar to bench top information. One goal in the project was to continue the heat treating of milk long enough to see if seasonal variation interferes with the information collected.
There appears to be an added interest in the work which is energy-related. It seems reasonable to think that the dairy industry may be able to pick heat treated bulk milk up less frequently.
Review of Farm Data
A series of heat treating experiments with on-farm milk were carried out over several months. There were some variations in acid degree values among individual experiments, but the average values pretty much showed similar patterns.
These results are similar to those obtained in earlier experiments where milk was heated in our pilot plant at different temperatures for different times. At that time, eight to ten gallons of raw milk were collected in a milking parlor from a sampling point located in a milking system pipeline just before the milk flowed into an in-line cooling tube. Within 30 minutes from the time the sample was taken, this milk was heat treated and cooled using an APV Junior heat exchanging system (APV Company, Inc., Buffalo, N. Y. 14207).
Heat treated samples and unheated control samples were immediately chilled and stored under refrigeration at 7° C., or about 45° F., and analyzed for select parameters over several days. Besides SPC, pyschrotrophs, ADV and organoleptic tests, the milk samples were always checked for inhibitory substances using the Delvotest method (pages 338-346 in "Standard Methods for the Examination of Dairy Products," 1978, pub. American Public Health Association).
Initially, duplicate psychrotroph counts were carried out simultaneously using a modified bacteriological method [Parmelee, Dairy and Ice Cream Field, 157 (8):38] and with the standard method of enumerating such counts. The statistical correlation of accuracy between the two methods was 0.9983 which compares with the value of 0.99 reported by Oliveria and Parmelee, J. Milk Food Technology, 39 (4):269-272. The reason for running both tests for determining psychrotrophic bacteria was to show that a faster test than the standard method to determine psychrotrophs was valid for our system. In subsequent work, we discontinued the standard methods test for psychrotrophs and used the Oliveria and Parmelee method, a 25 hour test versus a ten-day incubation period. (Parmelee test, 25 hrs. at 21° C. using standard plate count agar. Standard Methods is 10 days at 7° C. using standard plate count agar.)
As other workers have already shown, unheated raw milk increases from about 10,000 to more than 370,000 organisms/ml within 3 days at 7° C. When milk is heated to 150° F. (66° C.) for 10 seconds, the bacterial counts do not exceed 100,000 count until it's stored for seven days. Milk heat treated this way is still partially raw by phosphatase analysis. The 165° F. (74° C.) heated milk retains a low bacterial count beyond 8 days.
Each day about 40 gallons of fresh heated milk were added to the tank as a farmer might do if he or she heated milk in a heating system as it flowed from cows to storage before cooling.
These data are similar to our previous results where we heated milk in laboratory-like situations.
Pasteurizing 8-Day Old Milk
Segregated farm heated milk was transported to a plant in the regular over-the-road tank truck and treated similar to the regular milk supply.
The plant processes milk which it sells to dormitory food centers and to an on-site dairy store. Milk is processed at 165° F. (74° C.) for 15 seconds and then pumped through an aerovac (ARO-VACS high temperature heater-Cherry Burrell Corp, Cedar Rapids, Iowa) where it is heated under vacuum at 202° F. (94° C.) for less than a second.
The regular and experimental milk was stored in the plant's coldroom at about 6° C. (43° F.) for different time periods and regularly examined for quality parameters using biological, chemical and organoleptic methods (Table 1 shows select data).
TABLE 1______________________________________Comparing bacterial counts and acid degree values ofstored farm heated milk.sup.1 with its control whentransported to a milk plant and pasteurized.Items Weeks.sup.2 Control Experimental______________________________________SPC 0 93 68 1 178 120 2 870 235Psychrotrophs 0 2 2 1 26 7 2 355 129ADV 0 0.89 0.67 1 1.17 0.76 2 1.37 1.08______________________________________ .sup.1 Experimental milk was heated on the farm at 165°/10 sec. .sup.2 After pasteurization in a milk plant both milks were stored at 4° C. in the walkin cooler.
Trained dairy students and faculty personnel checked the milk organoleptically as did a random group of consumers. People were given milk samples to taste prior to their going for lunch in cafeterias and asked the following questions:
(a) Do you drink milk?
(b) How often do you drink milk?
(c) Can you detect differences in the milk you sampled?
(d) Which milk do you prefer?
The results of these trials showed that farm heated milk can be stored up to four times longer than regular bulk milk and still grade as well as a more conventional milk supply. In addition, different trials were made with experimental 8-day old farm heated milk where it was pasteurized in the dairy plant without running it through the aerovac. This milk was compared with the regular milk supply which was also processed without using the aerovac and stored like regular processed milk.
About 500 people tasted these milks over several days and again there were no significant differences in 2-day old milk versus 10-day old milk. Table 2 summarizes these data.
TABLE 2______________________________________Taste Test.sup.1 By Milk Drinkers Of Aged FarmHeated Stored Milk Versus A Regular Supply% PreferenceExperimental Control No Preference______________________________________A 27.6 26.7 45.7B 25.6 36.6 37.8X-- 26.6 31.7 41.8______________________________________ .sup.1 Test was conducted at two locations (A & B) over a period of 3 weeks where approximately 500 consumers were involved.
Using Aged Milk in Cultured Products
Most defects in cultured products probably relate to poor milk, undesirable starter, and/or a breakdown in sanitation. Into the web of failure we could also include inadequate workmanship and a weak or poorly thought out quality assurance program. For example, we believe that a defect or breakdown of milk fat to cause rancidity is associated with a growth of bacteria as well as through enzymatic degradation.
Our data conflict with the work of others who believe that bacterial numbers in milk have to exceed 10 6 organisms/ml before people can taste flavor defects.
Some researchers speculate that high count milk with proteolytic psychrotrophic bacteria break down cheese-making protein casein enough to cause vat failures. If cheese is made from such milk, then the casein particles are so damaged as to make cheesemaking difficult and produces poor quality finished goods. They suspect that the casein micella is altered so a firm curd will not be formed. The yield of cottage cheese is influenced by psychrotrophic microorganisms. Researchers published work that showed that when cheese was made with milk contaminated with psychrotrophs, it lost about 0.5% in yield even without vat failures. Yield decreased from 14.88% based on 20% solids to 14.48%. When psychrotrophic organisms were isolated from milk obtained from a cheese plant having operational problems and these were inoculated into cottage cheese milk used at the same research station, then their yield dropped to 14.38%.
Cheesemakers have always complained about cheese quality when it was manufactured from milk stored too long prior to pasteurization. Bacteriological problems in today's milk are different than those they had to live with a few years ago. Milk generally doesn't sour due to lactic acid bacteria, but now the supply will be degraded or spoiled by cold storage microorganisms growing at 5° C. which work on fat and protein to break down these constituents with more subtle defects. Stored farm heated milk reacts favorably to different culturing situations. Culture activity between fresh milk and 8-day old milk are not dissimilar. The yogurt culture was run along with cultured milk starter because yogurt processing tends to be more sensitive to inhibitory material in milk then cultures for cheesemaking, at least in the early stage of the make process.
Some phases of processing in cheesemaking can be improved by heat treating milk on farms. Cultured products like buttermilk and yogurt can be made about as well with aged heated farm milk as with fresh milk.
EXAMPLE 2
Milk, as it flowed from cows, was intercepted as it left the milking parlor and was heated to 165° F. for ten seconds. (This was not pasteurization and, in fact, the milk is still slightly raw as tested by regulatory agencies by the phosphatase test). The milk was then cooled to about 40° F. and stored in a refrigerated farm bulk tank. Additional milk which was similarly treated was added to the tank daily over several days. On day seven the milk was picked up by an over-the-road tanker and brought to a dairy plant where it was processed (pasteurized or converted into milk products).
Eight day old farm heated stored milk, as above, was converted into cottage cheese and quarg using an otherwise conventional process. The data indicate that the yields of cottage cheese and quarg increase between 5% and 10% by the preheat treatment, as compared to unheated skim milk.
TABLE 3______________________________________Cottage Cheese Yields Adjusted to 80% H.sub.2 O Skim milk treatment Yield (Kg)/20 Kg skim milk______________________________________Experiment 1 unheated raw #1 2.89 stored-raw* 2.95 heated #1** 3.10 heated #2** 3.23Experiment 2 unheated raw 2.86 stored-raw 3.20 heated #1 3.03 heated #2 3.18Experiment 3 unheated raw #1 3.18 stored-raw 3.06 heated #1 3.15 heated #2 3.18Experiment 4 unheated 2.92 stored-raw 3.15 heated #1 3.26 heated #2 3.32Experiment 5 unheated 3.09 stored-raw 3.23 heated #1 3.22 heated #2 3.26______________________________________ *stored-raw = 5 days refrigerated storage **different batches both treated at 165° F. for 10 seconds
TABLE 4______________________________________Quarg Yields Adjusted to % Water Skim milk treatment Yield (Kg)/19 Kg skim milk______________________________________Experiment 1 unheated #1 3.32 stored-raw 3.54 heated #1 3.40 heated #2 3.63Experiment 2 unheated 3.18 stored raw 3.12 heated 3.09Experiment 3 unheated 3.01 stored raw 2.86 heated #1 2.95 heated #2 3.12Experiment 4 unheated 2.75 stored raw 2.92 heated #1 3.10 heated #2 3.20______________________________________
While yield variations varying from batch due to the fact that cheese making involves active biological systems, the above data, plus other accumulated data demonstrate that, on average, the heat treatment-aging process of the invention results in a 5-10% increase in cheese yield. | The flavor stability of milk is enhanced by heating fresh milk at a temperature and for a time sufficient to significantly lower its bacterial count. Further the yields in a convention cottage cheese or quarg making process are enhanced when milk is similarly heat treated and then aged prior to use in the cheese making process. | 0 |
BACKGROUND TO THE INVENTION
1. Field of the Invention
The invention relates to nitro-carburised metal rings for use as piston rings or sealing rings.
Piston rings and sealing rings are commonly made of steel or cast iron and are generally rectangular in cross-section. The ring is located in and projects from a groove and has a radially outer surface in sliding contact with a co-operating surface of, for example, a cast iron cylinder. Two generally radially extending surfaces (herein after called "sides") engage with walls of the groove during the sliding movement. As a result of this both the radially outer surface and the sides are subjected to wear. Various techniques have been proposed for reducing some of this wear in order to increase the life of the ring and particular attention has been given to the reduction of the wear of the radially outer surfaces and the co-operating cylinder or liner. More recently, however, engine life requirements not only reduced wear of the radially outer surfaces but also reduced wear of the sides and the co-operating groove walls.
2. Review of the Prior Art
One technique for reducing wear of the radially outer piston ring surfaces is immersing the rings in a nitro-carburising salt bath containing sodium and potassium salts with the rings heated to a temperature of, say, 400° C. In this nitro-carburising process, certain steels and cast irons of all types, e.g. grey irons, carbidic, martensitic, bainitic and spheroidal (nodular graphitic irons), have nitrogen and carbon simultaneously diffused into their surface to form a hardened surface layer.
British Patent Specification No. 1,576,143 discloses a process of salt bath nitro-carburising the surface of a sintered metal piston ring or sealing ring. The rings are immersed in the salt bath in a stack i.e. with their sides in contact under the pressure of a weight. This is necessary because, if spaced apart, the rings will warp and lose their shape and flatness and also because individual treatment of each ring would be time consuming and expensive.
In this process, however, only the radially outer surfaces of the rings are nitro-carburised, because the rings are in a closed stack. In addition, the use of a salt bath is both slow and messy.
An alternative technique has been chromium plating in which the rings are again placed in a closed stack with their radially extending side surfaces in contact and then plated on their radially outer surfaces with chromium in a conventional way. In order to prevent the plating bridging adjacent rings, it is necessary to chamfer the edges of the rings between the radially outer surface and the sides. This is shown in FIG. 1 which is a photo-micrograph of a part of a cross-section of a piston ring at a corner between a radially outer surface of the ring and a side of the ring.
In this process only the radially outer surfaces of the rings are plated as will be seen from FIG. 1. The sides can be chromium plated in a subsequent plating operation but this is relatively expensive. The chamfered edges of the rings, when in use, tend to increase oil seepage past the rings and thus tend to increase oil consumption, as well as reducing the effectiveness of the seal between the ring and the cylinder so increasing blow-by. Thus chamfers are undesirable. Further, chromium plating softens progressively at temperatures above 250° C. to 300° C. and this is also a disadvantage. In addition, the chromium plated rings require finishing operations which involve lapping and this increases the cost of their production.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, there is provided a process for nitro-carburising metal rings of generally rectangular cross-section for use as piston rings or sealing rings, and comprising forming a stack of rings with adjacent rings in contact, placing the stack of rings in a chamber from which air is excluded and then supplying to the chamber a gaseous mixture of a carburising gas and a nitrogenous gas in the ratio of from 25:75 to 75:25 (% by volume) at a temperature of from 450° C. to 650° C. to nitro-carburise the radially outer surface and the sides of the rings.
It has been found that the use of gaseous nitro-carburising allows the nitro-carburising treatment to extend not only over the radially outer surfaces of the rings in a stack but also over the sides even though the rings are in a stack. This therefore gives all these three surfaces a hardened finish, thus increasing their overall wear resistance.
According to a second aspect of the invention, there is provided a piston ring for an engine or a compressor or a sealing ring for a shock absorber when made by the method of the first aspect of the invention.
According to a third aspect of the invention, there is provided a metal ring of generally rectangular cross-section for use as a piston ring or a sealing ring, the ring having a radially outer surface and sides hardened by nitro-carburising and being finish machined before nitro-carburising.
BRIEF DESCRIPTION OF THE DRAWINGS
The following is a more detailed description of some embodiments of the invention, by way of example, reference being made to the accompanying drawings, in which:
FIG. 1 is a photo-micrograph of a prior art chromium plated piston ring,
FIG. 2 is a photo-micrograph of a cross-section of a part of a nitro-carburised piston ring at the corner between a radially outer surface of the ring and a side of the ring,
FIG. 3 is a graph of hardness against penetration (in millimeters) for a first example of a piston ring prepared in accordance with the invention, and
FIG. 4 is a graph of hardness against penetration (in millimeters) for a second example of a piston ring prepared in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A piston ring is prepared and is finished machined to be of generally rectangular cross-section with a gap cut through the ring to afford two free ends. The ring thus has a radially outer surface which, in use, will be in sliding contact with an engine cylinder, and two radially extending surfaces or `sides` which will contact the walls of a piston ring groove in a piston in which the ring is mounted. The piston ring may be of the rail type used as oil control rings or a top ring (i.e. the ring closest to the crown of the associated piston), in particular a top compression ring.
The ring may be of any suitable ferrous material which can be satisfactorily nitro-carburised and which maintains its hardness, and hence its spring and resistance-to-set, both when treated and when run in an engine. Two such materials are high strength carbitic cast irons and steel. For example, a suitable steel has the composition 0.47% carbon, 0.25% silicon, 0.75% manganese, 0.55% nickel, 1% chromium, 1% molybdenum, 0.1% vanadium, remainder iron (all by weight) hardened and tempered to a hardness of 450-500 HV.
A plurality of such finish machined rings are placed on a jig in a stack with their sides in contact and with their gaps open. This ensures that during subsequent operations the rings remain flat and undistorted.
The stack of rings are then placed in a chamber from which air is excluded. Next a nitrogenous gas, such as ammonia, and a carburising gas, such as an exothermic hydrocarbon gas, are fed into the chamber at a temperature of between 450° C. and 650° C. The proportion of the two gases, nitrogenous to carburising, may be between 25:75 (% by volume) and 75:25 (% by volume) although tests with ammonia and exothermic hydrocarbon gas have shown that ratios of 50:50 (% by volume) or 60:40 (% by volume) give improved results.
The gases reach the radially outer surfaces of the stacked rings and also penetrate between the rings to reach the sides of the rings. Carbon and nitrogen from the gases diffuse from these surfaces into the cast iron of the rings forming a white "ξ" layer between 2 and 10 micrometers thick from which diffusion takes place into the body of the rings. For a particular material, the total depth of penetration depends on the time for which the gases are supplied and this may be regulated to give, for example, a white layer 5 micrometers thick and a total penetration of 0.1 m to 0.3 mm. A surface hardness of 700-800 HV is achievable decreasing progressively to the hardness of the basic material. This hardness is maintained on subsequent exposure of of the rings to temperatures of up to 600° C.
The stack of rings is then removed from the chamber and the rings separated from the stack. This is achieved without difficulty and the rings are ready for use forthwith without any further treatment. The piston rings so produced may be compression rings or oil control rings. The treatment is rapid and clean and provides in a single treatment a ring which is hardened on three surfaces.
A part of a finished ring is shown in FIG. 2. It will be seen that the nitro-carburised surface extends over both the radially outer surface 10 and the side 11. It will also be seen that the corner between these two surfaces is a sharp right angle.
The following Examples are given by way of illustration.
EXAMPLE 1
A piston ring of high strength carbitic steel was nitro-carburised as described above at a temperature of 550° C. In one embodiment, the piston ring was exposed to the nitro-carburising gases for a time which gave a total penetration of 0.10 mm and a compound white surface "ξ" layer whose thickness was 0.005 mm. The surface layer had a hardness of HVM700-800.
A typical hardness penetration curve for such a piston ring is as shown in FIG. 3.
Nitro-carburised piston rings prepared as described above were used as the top compression piston rings in a two liter engine of a motor car. The rings were found not to scuff and to give satisfactory performance. In contrast, chromium plated piston rings prepared as described above with reference to FIG. 1 were found to scuff and be unusable. As a result of this, the engine had previously used hard flame sprayed molybdenum rings, which are expensive and difficult to manufacture.
Nitro-carburised piston rings, prepared as described above with reference to Example 1 were also compared with chromium plated piston rings prepared as described above with reference to FIG. 1 by fitting the nitro-carburised rings in the top ring grooves of the piston in cylinders 1 and 3 of a 4-cylinder 1.3 liter petrol engine. The chrome plated rings were fitted in the top ring grooves of cylinders 2 and 4.
After 50,000 miles the following results were obtained:
__________________________________________________________________________CylinderSurface Ring Side Groove Side Ring Radial Max. BoreNo. Treatment Wear (m × 10.sup.-4) Wear (m × 10.sup.-4) Wear (m × 10.sup.-4) Wear (m × 10.sup.-4)__________________________________________________________________________1. N.C. 0.25 0.104 1.65 0.632. Chrome 0.61 0.12 1.9 0.513. N.C. 0.18 0.11 2.03 0.514. Chrome 0.76 0.12 1.9 0.63__________________________________________________________________________ N.C. Ring nitrocarburised on O.D. and side faces as described above by way of example. Chrome Plated on outside diameter only not treated on side faces.
The piston ring of Example 1 has an elastic modulus and core hardness which are unaffected by the treatment. The fatigue strength is increased by approximately 10%. Although the piston ring of Example 1 is more brittle than an untreated ring, when subjected to excessive twisting or gap opening, the ring still meets the required minimum ring tensile and bending strengths as laid down for untreated rings.
EXAMPLE 2
A piston ring of steel was prepared, the steel having the following composition by weight:
carbon: 0.47%
silicon: 0.25%
manganese: 0.75%
nickel: 0.55%
chromium: 1%
molybdenum: 1%
vanadium: 0.1%
balance iron
The piston ring was hardened and tempered to a hardness of 450-500 HV and then nitro-carburised as described above. In one embodiment, the piston ring was exposed to the nitro-carburising gases for a time which gave a total penetration of 0.015-0.020 mm and a compound white surface "ξ" layer whose thickness was 0.005-0.008 mm. The surface layer had a hardness of about HVM800.
A typical hardness penetration curve for such a ring is as shown in FIG. 4.
Nitro-carburised piston rings prepared as described above were used in the top compression piston rings in a two liter engine of a motor car. The rings were found not to scuff and to give satisfactory performance. In contrast, chromium plated piston rings prepared as described above with reference to FIG. 1 were found to scuff and be unusable. As a result of this the engine had previously hard flame sprayed molybdenum rings, which are expensive and difficult to manufacture. Nitro-carburised piston rings, prepared as described above with reference to Example 2 were also compard with chromium plated piston rings prepared as described above with reference to FIG. 1 by fitting the nitro-carburised rings in the top ring grooves of the piston in cylinders 1 and 3 of a 4-cylinder liter petrol engine. The chrome plated rings were fitted in the top rings grooves of cylinders 2 and 4.
After 180 hours (equivalent to 15,000 miles under high speed test conditions) the following results were obtained:
__________________________________________________________________________CylinderSurface Ring Side Groove Side Ring Radial Max. BoreNo. Treatment Wear (m × 10.sup.-4) Wear (m × 10.sup.-4) Wear (m × 10.sup.-4) Wear (m × 10.sup.-4)__________________________________________________________________________1. N.C. 0.013 0.10 0.025 0.082. Chrome 0.051 0.10 0.51 0.153. N.C. 0.025 0.08 0.025 0.134. Chrome 0.08 0.08 0.38 0.18__________________________________________________________________________ N.C. Ring nitro carburised on O.D. and side faces as described above by way of example. Chrome Plated on outside diameter only not treated on side faces.
The piston ring of Example 2 maintained its spring and wall pressure at top ring groove operating temperatures. Its loss in gap when enclosed in a sleeve of bore diameter equal to the ring diameter and heated for 6 hours at 350° C. and cooled in the sleeve, was 5.5%. This compares with 7-10% for martensitic spheroidal grey modular cast iron rings (not nitro-carburised) and 15% or more for medium phospherous grey cast iron rings (not nitro-carburised) individually cast.
It will be seen from the foregoing Examples 1 and 2 that the wear on the radially outermost surface of the nitro-carburised rings is comparable with that of chromium plated rings but that the wear of the sides is very much less than the side wear of the chromium plated rings. It will be appreciated that this wear resistance is achieved in a single treatment step. This reduction in wear improves the sealing performance of the rings and also increases their life because the increase in fatigue strength coupled with reduced side wear reduces the incidence of breakage and reduces the rate of increase of blowby.
The radially outer surfaces of nitro-carburised rings have a better scuff-resistance than the corresponding surfaces of chromium plated rings. This is partly because of the better resistance of nitro-carburised surfaces to temperatures above 250° C. to 300° C. and because oil does not readily wet chromium whereas the nitro-carburised surface retains the cavities formed by graphite flakes in the iron and these act as oil reservoirs.
It will further be appreciated that the nitro-carburising process described above with reference to FIG. 2 may be used to harden the surfaces of any form of piston ring such as oil control rings or intermediate compression rings, or any form of sealing ring, such as sealing rings for shock absorbers.
When the rings are made of steel, the use of the nitro-carburising technique described above by way of example allows the width of the rings to be reduced to 1 mm or less because the reduced side wear reduces the incidence of breakage. Where the rings are of the rail type, the nitro-carburising of the sides of the ring reduces wear between the ring and the expander used in such oil control ring assemblies and minimises the cut into the rail of lugs provided on the expander. | A metal ring of generally rectangular cross-section has its radially outer surface and its side surfaces treated by being stacked with its sides in contact with other rings in a chamber. Air is excluded from the chamber and a gaseous mixture of a carburizing gas and a nitrogenous gas at a temperature of 450° C. to 650° C. is supplied to the chamber. The proportions (% by volume) of the gases is between 25:75 and 75:25. The mixture nitro-carburizes both the radially outer surface of the stacked rings and the sides of the ring. If the rings are finish machined before treatment, they are ready for use as soon as they are removed from the chamber. The nitro-carburizing treatment reduces wear on the treated surfaces. The rings are used as piston rings or sealing rings. | 5 |
STATEMENT OF RELATED APPLICATIONS
[0001] This application depends from and claims priority to U.S. Provisional Application No. 61/898,088 filed on 31 Oct. 2013.
FIELD OF THE INVENTION
[0002] The present invention relates to an improved sacrificial isolation ball for use with a ball seat to fluidically isolate a targeted geologic zone for hydraulic fracturing operations to enhance production of hydrocarbons from a well drilled into the targeted geologic zone.
BACKGROUND OF THE RELATED ART
[0003] Hydraulic fracturing is the fracturing of rock by a pressurized liquid. Some hydraulic fractures form naturally. Induced hydraulic fracturing or hydro-fracturing, commonly known as “fracking,” is a technique in which a fluid, typically water, is mixed with a prop-pant and chemicals to form a mixture that is injected at high pressure into a well to create small fractures in a hydrocarbon-bearing geologic formation along which the hydrocarbon fluids such as gas, oil or condensate may migrate to the well for production to the surface. Hydraulic pressure is removed from the well, then small grains of the proppant, for example, sand or aluminum oxide, hold the fractures open once the formation pressure achieves an equilibrium. The technique is commonly used in wells for shale gas, tight gas, tight oil, coal seam gas and hard rock wells. This well stimulation technique is generally only conducted once in the life of the well and greatly enhances fluid removal rates and well productivity.
[0004] A hydraulic fracture is formed by pumping fracturing fluid into the well at a rate sufficient to increase pressure downhole at the target zone (determined by the location of the well casing perforations) to exceed that of the fracture gradient (pressure gradient) of the rock. The fracture gradient is defined as the pressure increase per unit of the depth due to its density and it is usually measured in pounds per square inch per foot or bars per meter. The rock cracks and the fracture fluid continues further into the rock, extending the crack still further, and so on. Fractures are localized because pressure drop off with frictional loss attributed to the distance from the well. Operators typically try to maintain “fracture width,” or slow its decline, following treatment by introducing into the injected fluid a proppant—a material such as grains of sand, ceramic beads or other particulates that prevent the fractures from closing when the injection is stopped and the pressure of the fluid is removed. The propped fracture is permeable enough to allow the flow of formation fluids to the well. Formation fluids include gas, oil, salt water and fluids introduced to the formation during completion of the well during fracturing.
[0005] The location of one or more fractures along the length of the borehole is strictly controlled by various methods that create or seal off boles in the side of the well. A well may be fracked in stages by setting a ball seat below the geologic formation to be fracked to isolate one or more lower geologic zones open to the well from the anticipated pressure to be later applied to a zone closer to the surface. A ball of a predetermined diameter is introduced into the well at the surface and pumped downhole. When the ball reaches the ball seat installed in the bore of a casing, the ball seats in the ball seat to form a seal that isolates geologic formation zones below the ball seat from the anticipated hydraulic fracturing pressure to be exposed on a geologic formation zone above the ball seat.
[0006] Hydraulic-fracturing equipment used in oil and natural gas fields usually consists of a slurry blender, one or more high-pressure, high-volume fracturing pumps (typically powerful triplex or quintuples pumps) and a monitoring unit. Associated equipment includes fracturing tanks, one or more units for storage and handling of proppant, high-pressure treating iron, a chemical additive unit (used to accurately monitor chemical addition), low-pressure flexible hoses, and many gauges and meters for flow rate, fluid density, and treating pressure. Chemical additives are typically 0.5% percent of the total fluid volume. Fracturing equipment operates over a range of pressures and injection rates, and can reach up to 100 megapascals (15,000 psi) and 265 litres per second (9.4 cu. ft./sec or 100 barrels per min.).
[0007] A problem that can be encountered in a fracking operation involves the impairment to subsequent operations that can result from the presence of the ball. After the fracking operation is concluded, the surface pressure is restored to a pressure at which the well will flow and produce formation fluids to the surface for recovery. A fracking ball having a sufficiently low density can be floated or back-flowed from the well, but a ball having a low density may be deformed by the large pressure differential applied across the ball and ball seat and thereby compromised during fracturing operations. If the ball is of a material that is more dense so that it can not be floated or back-flowed from the well to the surface, then the ball may present an unwanted obstruction that has to be removed from the well to prevent impairment of subsequent well operations.
[0008] A workover operation can be implemented in which a drilling instrument is introduced into the well to drill out and to mechanically destroy the ball, but a workover operation requires that a workover rig be brought to the surface location of the well for downhole operations. The need for the rental, transportation, rigging up and use of a rig imposes substantial delays and substantial costs.
[0009] What is needed is a fracking ball that has a sufficient density and resistance to deformation so that it can be used in conjunction with a ball seat to reliably isolate geologic formation zones below the ball seat from anticipated large fracturing pressures applied to geologic formation zones above the ball seat and that does not impair subsequent well operations.
BRIEF SUMMARY
[0010] One embodiment of the present invention provides a fracking ball for sealing with a ball seat in a well. The fracking ball contains an explosive charge for fragmenting the fracking ball after use. The fracking ball is constructed in a manner that provides sufficient resistance to deformation of the ball as a large pressure differential is applied across the ball and the engaged ball seat.
[0011] An embodiment of the present invention provides a fracking ball that can be fragmented by detonation of an explosive charge provided within an interior chamber of the ball to produce, upon detonation of the explosive charge, a plurality of ball fragments that do not interfere with subsequent well operations. In one embodiment, the use of a ceramic spherical body provides sufficient resistance to fracking ball deformation under large pressure differentials across the fracking ball and ball seat applied during fracking operations. In addition, these materials can provide for favorable fragmentation of the ball upon detonation of the explosive charge stored within an interior chamber of the ball to prevent unwanted obstacles having a substantial size from obstructing flow in the well.
[0012] In one embodiment of the ball of the present invention, a battery, a pressure sensor and a circuit are included within the interior chamber of the fracking ball along with the explosive charge. The pressure sensor is disposed in fluid communication with an exterior surface of the ball through an aperture in the ceramic structure. The pressure sensor detects a predetermined pressure threshold and initiates a predetermined timer delay period prior to detonation. Upon elapse of the predetermined timer delay period, a circuit is completed that generates an electrical current from the battery to the explosive charge to detonate the explosive charge and to thereby fragment the ball. In one embodiment in which the ball is a dissolvable ball, the fragmentation of the ball dramatically increases the aggregated surface area exposed to the fluids in the well to provide a much more rapid rate of dissolution as compared to a dissolvable ball that is not fragmented.
[0013] The higher fracking pressures achievable by use of embodiments of the fracking ball of the present invention, along with the lack of obstruction of subsequent well operations due to fragmentation, increase the success and effectiveness of the fracking process, lowers or eliminates workover rig rental costs, and prevents unwanted delays in subsequent well operations after the fracking process.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0014] FIG. 1 is a sectional view of a well drilled into the earth's crust and illustrating a series of hydraulic fractures disposed at a predetermined spacing to enhance production and recovery of formation fluids from a hydraulically fractured subsurface geologic formation.
[0015] FIG. 2 is the sectional view of the well of FIG. 1 illustrating the lack of fractures within the targeted geologic formation prior to the creation of the hydraulic fractures and illustrating a location of a desired placement of a ball and a ball seat to receive the ball to thereby isolate zones deeper in the well than the ball seat (to the right) from zones shallower in the well than the ball seat (to the left).
[0016] FIG. 3 is a sectional elevation of an embodiment of a ball of the present invention received in a ball seat set within the casing of the drilled well illustrated in FIG. 2 to create an isolating seal.
[0017] FIG. 4 is a sectional view of an embodiment of a ball of the present invention.
[0018] FIG. 5 is a sectional view of an alternate embodiment of a ball of the present invention.
[0019] FIG. 6 is an illustration of the fragments resulting from the detonation of the explosive charge contained within the interior chamber of the ball of the present invention.
[0020] FIG. 7 is an illustration of a safety feature that may be used to enhance the safety of personnel that may handle, prepare and deploy an embodiment of the ball of the present invention.
DETAILED DESCRIPTION
[0021] One embodiment of the present invention provides a ball having an outer surface of sufficient smoothness to enable the ball to seat within and to seal with a ball seat, wherein the ball has substantial resistance to deformation by an applied pressure differential across the seal created by the ball received within the ball seat. The embodiment of the ball contains an explosive device that can be detonated to destroy the ball from within and to thereby fragment the ball into a large plurality of small fragments. The embodiment of the ball may include a filler material received within the hollow interior of the ball, along with the explosive device, wherein the filler material comprises a non-compressible fluid such as, for example, a gel, or particles or pieces of such a small size that they can be released in the well without concern for the particles or pieces interfering with the function or operation of any downhole components that might be contacted. The filler material may comprise one of sand, ceramic beads or some other filler material that exhibits substantial resistance to deformation and resistance to compression. The filler material may also comprise an incompressible fluid, such as water. It will be understood that the temperature at which the ball will reside prior to detonation of the explosive charge should be considered when choosing a filler material as an incompressible fluid may result in excessive internal pressure at elevated temperatures.
[0022] The manner in which an embodiment of the fracking ball of the present invention is made may vary, but will generally include the steps of providing a ceramic outer shell having a hollow interior and, optionally, a hole through which a pressure sensor may be inserted into the fracking ball. An embodiment of a fracking ball of the present invention may include an explosive device and a filler material that can be disposed within the hollow interior. In one embodiment of the ball, a first hemispherical portion and a second hemispherical portion are secured together to form a spherical ball.
[0023] In one embodiment, a ceramic sphere may consists of two or more pieces secured together to form a spherical body. In another embodiment the ceramic sphere consists of a unitary spherical body having a hole for insertion of a safety fuse such as, for example, a pressure sensor, to enable the explosive charge and the timer-controlled detonator. It will be understood that the pressure sensor may be provided to generate a signal that enables or initiates the circuit that ultimately delivers the detonating current flow from the battery to the explosive charge, and that the provision of the pressure sensor to complete and thereby enable the fracking ball circuit would cause the pressure sensor to function as a safety fuse without which the fracking ball would be unable to self-destruct.
[0024] In one embodiment, the ceramic ball may comprise one of zirconium oxide, silicon nitride, tungsten carbide, zirconia toughened alumina, bulk metallic glass (BMG) and aluminum oxide. The high compressive strengths of these ceramic materials enable the fracking ball to seat in the ball seat and to cooperate with the ball seat to isolate deeper well zones from shallower well zones to be fracked. This requires the ball and ball seat to withstand a very high fracking pressure on an uphole side of the ball and a substantially lower pressure on a downhole side of the ball. Embodiments of the ceramic fracking ball of the present invention may be manufactured by, for example, but not by way of limitation, isostatic pressing, hot isostatic processing (HIP), injection molding, slip casting or gel casting techniques. In one embodiment, a ball comprising zirconia with a very thin wall thickness of only 0.060 inches can be gel cast and subsequently hot isostatically pressed to increase the flexural strength of the fracking ball so it can be seated m the ball seat to withstand very high differential pressures while yielding less debris material subsequent to fragmentation by the explosive charge. Less debris material will result in a much lower probability of any debris for fragments of a size sufficient to interfere with or obstruct equipment to be used in fracking other, deeper or lower zones.
[0025] FIG. 1 is a sectional view of a well 20 drilled from the surface 21 into the earth's crust 29 and illustrating a series of proposed hydraulic fractures 26 disposed at a predetermined spacing 28 to enhance production and recovery of formation fluids from a hydraulically fractured subsurface geologic formation 24 . The drilled well 20 may include multiple layers of surface casing as is known in the art. The drilled well 20 may include one or more turns or changes in direction to align the portion of the well 20 to be perforated or otherwise to gather fluids within a known geological structure, seam or formation 24 . The fractures 26 created in the formation 24 are generally disposed at a predetermined spacing 28 selected for optimal drainage. The targeted formation 24 may reside between a top layer 22 and an underlying layer 23 within the earth's crust 29 . It will be understood that fluids entering the well 20 flow according to a pressure gradient in the direction of the arrow 27 to the surface for processing, storage or transportation.
[0026] FIG. 2 is the sectional view of the well 20 of FIG. 1 illustrating the lack of fractures 26 (seen in FIG. 1 ) within the targeted geologic formation 24 prior to the creation of the hydraulic fractures shown in FIG. 1 . FIG. 2 illustrates, using a circle, a location of a desired placement of a ball (not shown) and a ball seat (not shown) to receive the ball to thereby isolate a zone 50 , that is deeper in the well than the ball seat (i.e., to the right) from a zone 51 that is shallower in the well 20 than the ball seat (i.e. to the left). It will be understood that the ball and ball seat are to be placed in a portion of the casing 62 that lies within the targeted geologic formation 24 and that the pressure at any given location within the well 20 is approximately equal to the pressure at a wellhead 49 at the surface 21 plus the product of the vertical elevation change 46 times the density (as measured in units corresponding to the unit used to measure depth) of a fluid residing in the well 20 , assuming that the well 20 is filled with the fluid.
[0027] FIG. 3 is a sectional elevation of an embodiment of a ball 10 of the present invention received in a ball seat 44 that has been previously set within a section of a casing 62 of the drilled well 20 (not shown in FIG. 3 ) illustrated in FIG. 2 to create an isolating seal. It will be understood that a number of tools exist for setting the ball seat 44 within the portion of the casing 62 in which the seal is to be affected, and that those tools and the methods of setting those tools are not within the scope of the present invention. FIG. 3 is provided merely to illustrate the manner in which an embodiment of a ball 10 moves through the bore 70 of the casing 62 to engage the ball seat 44 after the ball seat 44 is set in the portion of the casing 62 and after the ball 10 is introduced into the well 20 and moved to the ball seat 44 . The ball 10 and ball seat 44 together form a seal to isolate a lower portion of the bore 71 from the upper portion of the bore 70 that is uphole to the ball 10 and ball seat 44 .
[0028] FIG. 4 is a sectional view of an embodiment of a ball 10 of the present invention. The ball 10 of FIG. 4 comprises a hollow interior consisting of a hollow interior 15 of a first hemispherical portion 11 and a hollow interior 16 of a second and matching hemispherical portion 12 . The circular rim 13 of the first hemispherical portion 11 is manufactured to correspond in shape for mating engagement with the circular rim 14 of the second hemispherical portion 12 . Securing of the first hemispherical portion 11 to the second hemispherical portion 12 provides a spherical ball having an exterior surface consisting of the exterior surface 17 of the first hemispherical portion 11 and the exterior surface 18 of the second hemispherical portion 12 .
[0029] FIG. 5 is a plan view of a hollow interior 15 of the first hemispherical portion 11 of FIG. 4 . An aperture 30 in the ceramic hemispherical shell 11 is fluidically connected by a conduit 31 to a pressure sensor 32 . The pressure sensor 32 closes a switch upon sensing a predetermined threshold pressure through the aperture 30 and the conduit 31 .
[0030] Upon receiving the signal from the pressure sensor 32 , a timer is activated. After a predetermined amount of time from activation, a signal is sent to a detonator to explode the explosive charge within the fracking ball. Upon detonation of the explosive charge 36 , the outer shell of the fracking ball 10 is fragmented.
[0031] FIG. 6 illustrates a fragmented ceramic ball 10 A as it might appear immediately after the moment of detonation of the explosive charge 36 within a hollow interior of the fracking ball 10 to fragment the ball 10 into numerous ball fragments 49 , which are then dispersed into well fluids moving throughout the interior bore of the casing 62 . It will be understood that such fragmentation dramatically increases the cumulative surface area of the ball fragments 49 exposed to the fluids in the well. This will provide a correspondingly dramatic increase in the rate at which any dissolvable material will degrade and dissolve in the fluids in the well.
[0032] FIG. 7 illustrates a safety feature that may be used to enhance the safety of personnel that may handle, prepare and deploy an embodiment of the ball 10 of the present invention. FIG. 7 illustrates the first hemispherical portion 11 of the ball 10 having a fuse aperture 52 to receive the safety fuse (such as a pressure sensor) 53 . Upon deployment of the ball 10 from the surface, the safety fuse 53 can be inserted into and through the fuse aperture 52 to engage and enable a critical connection. For example, but not by way of limitation, the safety fuse 53 may be inserted and seated in the fuse aperture 52 to engage, within the hollow interior 15 of the ball 10 , a pair of conductive leads bridged by the safety fuse 53 that completes an electrical circuit that will later, after the pressure sensor 32 senses the threshold pressure and after the delay period has run, enable the battery 40 to detonate the preliminary explosive charge 35 . Alternately, the safety fuse 53 may engage and enable the circuit 33 so that, upon detection of the threshold pressure by the pressure sensor 32 , the circuit 33 will begin the delay period. It will be understood that there are various ways of enabling the explosive charge using a safety fuse 53 , that multiple safety fuses 53 may be used. In one embodiment, no safety fuse 53 is used, but this is not recommended for obvious reasons. In the embodiment illustrated in FIG. 7 , the safety fuse 53 comprises an enlarged head 54 that limits the extent to which the safety fuse 53 can be inserted through the fuse aperture 52 . This head 54 and the safety fuse 53 length may be customized to precisely position the safety fuse 53 relative to the other components 31 , 32 , 33 , 34 , 35 , 36 and 40 within the fracking ball 10 .
[0033] The configuration of the well 20 and the depth at which the ball seat 44 and the ball 10 are to be used determine the size of the ball seat 44 and the ball 10 . The range of sizes of the ball 111 may be within the range from 4.45 cm (1.75 inches) to 10 cm (4.0 inches), or larger. The filler material, if any, may comprise particles or beads that vary in size and material, but are preferably in the range from 0.2 mm (0.008 inch) to 1 mm (0.04 inch) diameter. A noncompressible fluid, such as a gel, can also be used as the filler material.
[0034] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components and/or groups, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.
[0035] The corresponding structures, materials, acts, and equivalents of all means or steps plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but it is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | An embodiment of a fracking ball cooperates with a ball seat to isolate a well first portion of an earthen well drilled into the earth's crust from a well second portion and comprises an interior chamber to receive an explosive charge. The explosive charge may be surrounded by a filler material that is resistant to deformation. A pressure sensor, a circuit, and a battery are also received into the chamber. The ball material, may comprise one of zirconium oxide, aluminum oxide, bulk metallic glass, silicon nitride or tungsten carbide, and the ball is resistant to deformation within the ball seat under the application of a substantial pressure differential across the ball and ball seat. Detonation of the explosive charge fragments the ball to prevent the ball from presenting an obstruction to subsequent well operations. A safety fuse may be included to enable safe handling and transport. | 4 |
BACKGROUND ART
This invention relates to a clearer apparatus applied to a draft roller for use as a drafting apparatus for a spinning machine equipment, and more particularly to a clearer apparatus which consists of a clearer in the form of a plate which can remove cotton waste or the like on a draft roller with certainty using a clearer pad member formed from rubber, a synthetic resin material or the like.
A clearer apparatus for a bottom draft roller of a drafting apparatus is already known wherein a clearer pad member comprising of leather, artificial leather, natural rubber, synthetic rubber, laminated non-woven fabric or the like which is cut into a fragment is used and held on a support frame in the form of a plate formed with a length substantially equal to a length between roller stands such that a portion of the clearer pad member is projected outwardly from the support frame until the outwardly projected portion contacts with a peripheral face of a drafting portion of a draft roller. Also the applicant of the present patent application has proposed a clearer of the pad type and a supporting apparatus for a clearer of such construction in Japanese Patent Laid-Open Application No. Sho 63-35831 and Japanese Utility Model Laid-Open Application No. Sho 63-24279.
While it is known that such a clearer of the pad type as described above can exhibit a superior cleaning effect comparing with a conventional clearer of the rotary type, the clearer of the pad type has a problem that, after continuous use for a long period of time, cotton waste and so forth will accumulate on a projected portion of the clearer pad member or the like.
In order to prevent such accumulation, various solutions have been proposed including means wherein a support frame or the like is rocked to change the orientation angle of the same and another means wherein the position at which the projected portion of the clearer pad member contacts is moved in a circumferential direction of the draft roller. However, the solution which only involves a change of the angular orientation of the support frame or involves a movement of the contacting position of the projected portion of the clearer pad member cannot remove accumulated substance actively from the draft roller and consequently cannot achieve sufficient removal of accumulated substance.
In addition, the solution which involves a change of the angular orientation of the support frame has another problem that the mounting structure for the support frame and so forth become complicated and the operation for maintenance and so forth are troublesome.
OBJECT OF THE INVENTION
The present invention has been made to solve the problems described above and provides a clearer apparatus which can remove cotton waste and so forth accumulated on a support frame, a clearer pad member and so forth with certainty while the mounting structure thereof at a position opposing to a draft roller is simple.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view showing a preferred embodiment of the present invention;
FIG. 2 is a partial schematic perspective and partial cutaway view, of the clearer apparatus shown in FIG. 1;
FIG. 3 is a schematic view showing a mounting condition of the clearer apparatus shown in FIG. 1;
FIGS. 4A to 4C are schematic views illustrating different stages of operation of the clearer apparatus shown in FIG. 3;
FIG. 5 is a schematic perspective view showing a shape of an alternative bracket for use in an embodiment according to the present invention;
FIG. 6 is a schematic side elevational view showing another preferred embodiment of the present invention;
FIG. 7 is a schematic perspective view showing a profile of an alternative clearer pad member for use with a clearer apparatus shown in FIG. 6; and
FIG. 8 is a schematic side elevational view showing a further preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a partially cutaway side elevational view showing a preferred embodiment of the present invention which is applied to a front bottom roller 1, and generally shows a drafting apparatus for a ring fine spinning frame. The drafting apparatus includes a pair of front rollers 1 and 1a, a pair of apron rollers 2 and 2a, a pair of third rollers 3 and 3a, and a pair of back rollers 4 and 4a. The top rollers 1a, 2a, 3a and 4a of the drafting apparatus are supported for rotation on a weighting arm 7 and disposed so as to be pressed against the bottom rollers 1, 2, 3 and 4, respectively. Meanwhile, the bottom rollers 1, 2, 3 and 4 are supported for rotation on a roller stand 6. A plurality of drafting sections are formed corresponding to spinning portions of spindles (normally 4 to 8 spindles) in a stuff between each pair of such roller stands 6 (for example, a flute section (see FIG. 3) as a drafting portion is formed for the front bottom roller 1).
Such a clearer 5 in the form of a plate as shown in FIG. 2 is disposed in parallel to a longitudinal direction of the front bottom roller 1. The plate-formed clearer 5 consists of a support frame 10 having a U-shaped cross section and a plurality of clearer pad members 9 inserted in the support frame 10. Each of the clearer pad members 9 has a generally cross-shaped configuration and is projected outwardly from a corresponding one of window holes 10a formed in the support frame 10. The projected portion of the clearer pad member 9 is restricted in projected length such that a pair of stopper portions 9a thereof each in the form of a tongue contacts with a folded portion of the support frame 10. A plurality of arresting holes 10b are formed at side portions of a rear portion of the support frame 10, and a resilient stopper 9b formed from a leaf spring is fitted in each of the arresting holes 10b and fixedly grasps the corresponding pad member 9. Meanwhile, a pair of projecting members 10c (only one is shown in the Figures) is provided at the opposite ends of the support frame 10 which constitutes the plate-formed clearer described above. Support shafts 10d serving as a pivotally supporting member are disposed on each of the projecting members 10c and extend in parallel to the axes of the draft rollers. It is to be noted that the support shafts 10d are preferably provided on the portions of the projecting members 10c adjacent the projected portions of the pad members 9 such that, when the entire clearer member 5 is supported at the support shafts 10d at the opposite ends of the support frame 10, the projected portions of the pad members 9 may be inclined upwardly so that engagement thereof with the draft roller which will be described hereinafter may be performed rapidly. In addition, it is recommended that collars made of synthetic resin for assuring an enhanced slipping property be fitted on the support shafts 10d.
Another window hole 10e separate from the window holes 10a for the pad members 9 is formed at a portion of the support frame 10 adjacent the projected portions of the pad members 9 (adjacent the draft roller), and a stopper 11 having a curved or bent profile is mounted in the window hole 10e. In particular, in the arrangement shown in FIG. 2, the stopper 11 on which an insertion restricting portion 11b is formed is inserted into the window hole 10e and then a stopping member 12 in the form of a plate is inserted from the opposite side into the support frame 10 to fix the stopper 11 to the support frame 10. The stopper 11 is formed from a synthetic resin material, a spring steel material or the like so as to restrict pivoting motion of the plate-formed clearer 5 around the common axis of the support shafts 10d in such a manner as seen in FIG. 3 (or FIG. 6) (which will be described hereinafter in detail). Meanwhile, when the stopping member 12 is to be inserted, preferably a channel-shaped operating resilient plate 13 is inserted into and fixed in the support frame 10 at the same time so that the operating elastic plate 13 may be fixed in a projected condition at a rear portion of the support frame 10 (opposite side of the projected portion of the pad member 9). It is to be noted that preferably an abrasion resisting member 11c (see FIG. 6) made of a polyimide resin or the like is mounted at an end of the stopper 11 adjacent the draft roller in order to prevent abrasion of the end of the stopper 11 by the draft roller.
In the meantime, a bracket 15 is mounted on the roller stand 6 by means of a bolt 18 as shown in FIG. 3. The bracket 15 has an elongated slot 15a formed therein such that it is inclined obliquely (substantially in parallel to a tangential line to the draft roller), and one of the support shafts 10d is fitted in the elongated slot 15a. The support shafts 10d formed on the opposite ends of the plate-formed clearer 5 are fitted in the elongated slots of the brackets 15 provided on the opposing roller stands 6, 6 to support the plate-formed clearer 5 for free pivoting motion. It is to be noted that the structure for supporting a support shaft 10d is not limited to such arrangement as described above, but may be such an alternative arrangement as shown in FIG. 8 wherein, as described hereinabove, the structure includes a bearing of a slot-shaped, circular or elongated hole or the like. Meanwhile, the pivotally supporting member may be of such a structure that supporting holes or slots are formed in the projecting members 10c at the opposite ends of the plate-formed clearer and shafts which are fitted in the holes or slots are provided on the bracket or roller stand.
The plate-formed clearer 5 shown in FIG. 3 is assembled in the following manner and operates in such a manner as shown in FIGS. 4A, 4B and 4C. When the support shafts 10d are inserted into the elongated slots 15a as indicated by an arrow mark of a chain line in FIG. 4A, the projected portions of the pad members 9 are contacted with a peripheral face of the front bottom roller 1 which rotates in the direction indicated by an arrow mark so that a force acts upon the plate-formed clearer 5 to press the whole thereof upwardly and the stopper 11 is contacted with the draft roller 1 and held in such a stable condition as shown in FIG. 4B. At that time, the projected portions of the pads 9 are contacted in a curved condition with the peripheral face of the roller 1 so that they exhibit such a cleaning effect as to brush away cotton waste and so forth sticking to the peripheral face of the roller 1. In this condition, since the plate-formed clearer 5 is acted upon from the roller 1 by an upwardly pressing force as described above, it will not drop along the elongated slots 15a. Further, rearward movement of the plate-formed clearer 5 around the support shafts 10d is restricted by the stopper 11 contacting with the roller 1, and the pad members 9 will not be spaced away from the peripheral face of the roller 1.
By the way, a projected end 13b of the operating resilient plate 13 is contacted with a peripheral face of the apron roller 2 as shown in FIG. 3, and an arresting ring 21 is secured to the circumferential face of the roller 2. An arresting plate 21a extends from the circumferential face of the roller 2, and each time the roller 2 rotates, engagement and disengagement of the arresting piece 21a and the projected end 13b of the operating resilient plate 13 are repeated. Thus, the operating resilient plate 13 is pulled upwardly by such engagement. Accordingly, when the operating elastic plate 13 is pulled upwardly in the direction indicated by an arrow mark from the condition shown in FIG. 4B, the plate-formed cleaner 5 is pivoted around the axis of the support shafts 10d as shown in FIG. 4C, whereupon the projected portions of the pad members 9 are spaced away from the peripheral face of the roller 1 and are inclined downwardly so that cotton waste and so forth accumulated on the projected portions of the pad members 9 and so forth are dropped. Then, when disengagement of the operating elastic plate 13 takes place, the elastic plate 13 drops, whereupon the plate-formed clearer 5 is pivoted upwardly in the direction indicated by an arrow mark D in FIG. 4C around the axis of support shafts 10d to return to the condition shown in FIG. 4B. In this instance, since frictional resistance is present between the support shafts 10d and the elongated slots 15a, the plate-formed clearer 5 is pivoted before the support shafts 10d slip down in the elongated slots 15a. Then, when ends of the projected portions of the pad members 9 are contacted with the peripheral face of the roller 1 upon such pivoting motion, the entire plate-formed clearer 5 is acted upon by an upwardly pressing force by a force of rotation of the roller 1 so that it is held in a stable condition as shown in FIG. 4B. The arresting piece 21a is not limited to that formed on the apron roller 2 just above, but may be provided on the third bottom roller or the back bottom roller.
It is to be noted that a removing operation of the plate-formed clearer 5 may proceed such that the support frame 10 is moved, holding the opposite ends thereof by hands, in parallel downwardly along the elongated slots 15a, whereupon the projected portions of the pad members 9 are spaced away from the roller 1 so that the plate-formed clearer 5 can be removed readily from the bracket 15.
As described above, the plate-formed clearer 5 exhibits, in the condition shown in FIG. 4B, a cleaning effect of removing cotton waste and so forth sticking to the peripheral face of the front top roller 1 and besides can be inclined, each time the apron roller 2 is rotated, downwardly so as to drop cotton waste and so forth accumulated on the plate-formed clearer 5, thereby exhibiting a superior cleaning effect for the draft roller.
FIG. 6 is a schematic side elevational view showing a clearer apparatus of another embodiment of the present invention. A plurality of clearer pad members 9 mounted on a plate-formed clearer 5 are each formed such that an end portion 9d thereof adjacent a draft roller has a reduced width with a pair of recesses 9c formed on the opposite side portions of the end thereof as shown in FIG. 7. Meanwhile, an operating elastic plate 13 is formed substantially in an L-shaped profile from a leaf spring made of steel, and a mounting end 13a, a repulsive portion 13 c1 and an arresting projecting end 13b are formed in a body on the operating elastic plate 13. The mounting end 13a of the operating resilient plate 13 is fixed to the plate-formed clearer 5, and the arresting projected end 13b is engaged with and urged by or disengaged from an arresting piece 21a of an apron roller 2. In particular, such construction is recommended wherein, when the arresting projected end 13b of the operating elastic plate 13 is engaged by the arresting piece 21a of the arresting ring 21 and is lifted upwardly to the position indicated by a chain line, the repulsive portion 13 c1 of the operating resilient plate 13 is curved as indicated by a chain line (13 c2 ) and accordingly is acted upon by such a repulsive force as indicated by a blank arrow mark, and then when the engagement is released, the plate-formed clearer 5 can be pivoted readily as indicated by an arrow mark of a broken line.
A bracket 15 having a most preferable profile is shown in FIG. 6. The bracket 15 has a seat portion 15b formed thereon and adapted to be contracted with and mounted on a roller stand RS, and an elongated slot 15a is formed in the bracket 15 such that it extends either substantially in parallel to an imaginary axial line L 1 (another line L 1 a parallel to this) which passes the centers of the bottom rollers 1 and 2 or a little obliquely such that it is spaced away a little from the draft roller 1 in the direction opposite to the drafting direction. Further, an opening portion 15 a1 of the elongated slot 15a is formed such that it is opposed downwardly on the exit side of the drafting direction while a slot bottom portion 15 a2 is formed such that it extends deeply to the interior (to the right-hand side in FIG. 6) in the direction opposite to the drafting direction from an imaginary normal line L 2 which expends perpendicularly to the axial line L 1 and passes the center of the draft roller 1. Accordingly, when the support shafts 10d are fitted into the slot bottom portions 15 a2 of the elongated slots 15a, the plate-formed clearer 5 is held in a stable posture on the entering side of draft yarns with respect to the imaginary normal line L 2 .
It is to be noted that the location of each of the shafts 10d of the plate-formed clearer 5 may be an arbitrary position adjacent the draft roller 1 or remote from the draft roller 1 but preferably is a position adjacent the draft roller 1 (on the left side in FIG. 6) such that the clearer pad members 9 may be readily pivoted upwardly around the axis of the support shafts 10d.
FIG. 8 is a schematic side elevational view showing a further preferred embodiment of the present invention. In the present embodiment, a shaft 6A provided projectingly on a roller stand RS and a U-shaped bearing 10A provided at an end of a plate-formed clearer 5 are used as pivotally supporting members. In particular, a pair of U-shaped bearings 10A are mounted in a body at the opposite ends of a support frame 10 of a plate-formed clearer 5, and a pair of shafts 6A adapted to be fitted in the bearing 10A are provided projectingly on a pair of opposing roller stands RS such that the plate-formed clearer 5 is supported for pivoting motion on the roller stands RS. It is to be noted that a stopper 11 and an operating elastic plate 13 similar to those of the preceding embodiments described hereinabove are mounted on the support frame 10. Meanwhile, the shafts 6A may otherwise be provided projectingly on a bracket which is mounted on the roller stands RS.
The clearer pad members of the present invention are not limited to those of the embodiments described above, and the projected portion of each of the clearer pad members may have such a profile wherein the cross section thereof decreases toward an end thereof as shown in FIGS. 6 and 7 and an end thereof has a cylindrical cross section. Further, the number of such pad members can be changed arbitrarily and may be made of a synthetic resin material or a soft elastic synthetic resin material such as an urethane resin or the like. Further, the bracket 15 may be mounted directly on an arm of a roller stand as shown in FIG. 5. It is to be noted that, while the bracket 15 is shown having an elongated slot 15a formed on only one side of the stand in FIG. 5, such elongated slots may be formed on the opposite sides of the stand such that plate-formed clearers provided on the left and right sides of the stand may be supported in the elongated slots.
Since a clearer apparatus for a draft roller of the present invention has such construction as described above, cotton waste and so forth accumulated on an upper face of a clearer pad member and so forth can be dropped with certainty by intermittently pivoting plate-formed clearer. Further, a support frame of the plate-formed clearer has a structure which can be mounted and removed readily onto and from a bracket which is provided on a roller stand or the like, and further, the plate-formed clearer is held stably at a predetermined position at which it opposes to a draft roller so that cotton waste and so forth on a peripheral face of the draft roller can be brushed away with certainty by the clearer pad member. | A clearer device for removing accumulated debris on a draft roller has a clearer pad member mounted in a support frame which pivots so as to permit the clearer pad member to come into and out of contact with the draft roller thereby allowing accumulated wastes to escape. A stopper plate is biased against the draft roller by the clearer pad member thus keeping the clearer pad member in contact with the draft roller. An elastic member protrudes from the support frame and contacts a rotating shaft which has a protrusion. The protrusion periodically engages the elastic member which pivots the support frame disengaging the clearer pad member from the draft roller and releasing accumulated wastes. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a rotor blade of a wind power plant, wherein the rotor blade has a longitudinal extension, which extends from a rotor blade root substantially to a rotor blade tip, wherein, at least in one region of the rotor blade, an aerodynamic cross-sectional profile is provided, which has a leading edge (nose) and a trailing edge, which are connected via a suction side and a pressure side of the cross-sectional profile.
[0003] Furthermore, the invention relates to a method for fabricating a corresponding rotor blade. Moreover, the invention relates to a method for producing a belt pair of a rotor blade and a fabrication mold for the production of a belt pair for use in a rotor blade.
[0004] 2. Description of Related Art
[0005] Rotor blades for wind power plants are normally built in two shells, namely one shell on the suction side of the rotor blade and one shell on the pressure side of the rotor blade, and adhered together. Two webs or spars, which are adhered to the belt for the suction side and to the belt for the pressure side and ensure buckling safety in the blade, are usually located between the shells. The belts provide in particular for the torsional or bending stiffness of the rotor blade and represent, in combination with the webs or respectively spars, the support structure of the rotor blade.
[0006] In particular in the case of large rotor blades, the production of the rotor blades is time-consuming and expensive. For this reason, such large rotor blades are produced in several parts as just two shells and then adhered. The individual parts hereby become smaller, whereby the production time and the costs from potential production errors are reduced. For example, refer to DE 31 13 079 A1 and EP 1 965 074 A2.
[0007] Also, reference is made to WO 03/093672 A1, which discloses a rotor blade for wind power plants with a shell, the airfoil cross-section of which is reinforced against bending in the flapwise direction through belts provided pairwise and opposite the airfoil chord of the rotor blade and through webs between them, wherein the belts consist of plastic fiber reinforced in the longitudinal direction and have a glass fiber and a carbon fiber reinforced section in the longitudinal direction.
BRIEF SUMMARY OF THE INVENTION
[0008] The object of the present invention is to provide for a rotor blade that is to be produced simply and precisely as well as cost-effectively, a corresponding method for fabricating said rotor blade as well as an efficient method for producing a belt pair and a corresponding fabrication mold for the production of a belt pair for use in a corresponding rotor blade.
[0009] The object is achieved through a rotor blade of a wind power plant, wherein the rotor blade has a longitudinal extension, which extends from a rotor blade root substantially to a rotor blade tip, wherein, at least in one region of the rotor blade, an aerodynamic cross-sectional profile is provided, which has a leading edge (nose) and a trailing edge, which are connected via a suction side and a pressure side of the cross-sectional profile, which is further formed in that the rotor blade is subdivided at least in a longitudinally extended section into a front rotor blade section with the leading edge and a rear rotor blade section with the trailing edge, wherein the rear region of the front rotor blade section and the adjacent front region of the rear rotor blade section are connected by an I-beam.
[0010] By providing an I-beam, which can also be called a double-T beam within the framework of the invention, a very efficient and cost-effective production of a corresponding rotor blade is possible. The rotor blade can hereby be prefabricated in two halves and the connection, in particular adhering of adjacent webs, which extend from a suction side to a pressure side and which are in particular connected with respective belts to an I-beam, contribute to a high stability. It was hereby surprisingly determined that one component, which contributes to the stabilization or respectively strength of the rotor blade and, as an important component, has a load-bearing function, can first be split in the fabrication of the rotor blade and, through corresponding connection of the parts of the load-bearing structure, in particular adhering, a still sufficient stability or respectively preferably even increased stability is generated.
[0011] The longitudinal extension, which extends from the rotor blade root substantially to a rotor blade tip, means in particular that the longitudinal extension does not have to be present exactly up to the rotor blade tip; it can also be offset at an angle so that the longitudinal extension from the rotor blade root lies at an angle to a longitudinal extension, which would go to the rotor blade tip. The angle can hereby lie, for example, between −5° and 5°. The angle can also be so large that, in the case of a rotor blade fabrication, in which a prefabricated rotor blade tip with an extension in the longitudinal direction of up to 5 m is attached to the rest of the partial span, for example the longitudinal extension to the trailing edge or leading edge can lie on the seam at the joining edge of the partial span to the rotor blade tip. It is particularly preferred if in the longitudinal extension from the rotor blade root to the rotor blade tip a shift towards the leading edge or trailing edge of the rotor blade of 200 mm to 300 mm from the rotor blade tip is provided so that a corresponding angle of the longitudinal extension to an imaginary longitudinal extension from the rotor blade root to the rotor blade tip results.
[0012] The I-beam preferably has a web, which extends from the pressure side to the suction side within the rotor blade, and also a belt on the pressure side as well as a belt on the suction side. The belt is hereby preferably inserted within the rotor blade and is connected with an outer lying shell.
[0013] The web preferably comprises web feet, which form with the web the shape of a square bracket or the shape of a Z.
[0014] A particularly simple and efficient fabrication is given when the I-beam is divided in the longitudinal extension. The I beam parts are preferably connected with each other, in particular adhered. The I-beam preferably has I-beam parts, which comprise a web, wherein the I-beam is divided in longitudinal extension and two-dimensionally, in particular in a plane, which is defined by the web. The web is hereby a substantially two-dimensional component, wherein the plane of the division passes right through the web, substantially parallel to the lateral surfaces of the web. Through the adhesion, which can in particular also be realized using glass fibers, and is realized for example with a plastics technique using at least one resin and at least one fiber layer, in particular glass fibers and/or carbon fibers and/or aramid fibers, an adhesion, for example with a transfer molding technique, an infusion technique or a vacuum-supported infusion technique, can occur.
[0015] If two belts each close the I-beam preferably towards the suction side and towards the pressure side, which have a distance from each other, which is smaller than the extension of the belts in the direction from the leading edge to the trailing edge of the rotor blade, a particularly stable construction of the rotor blade is possible.
[0016] The spaced belts are preferably connected on the suction side and/or on the pressure side through adhesion, each with one web foot of the web. The web foot then has a corresponding extension in the chord direction between the leading edge and the trailing edge or respectively an almost tangential extension to the airfoil in the area of the web, which enables a sufficient rigid or respectively stable connection of the belts both on the pressure side as well as on the suction side.
[0017] The rotor blade is preferably divided in particular during the production additionally at the leading edge and/or the trailing edge. This results in an even more simple and exact fabrication option for the rotor blade. For a corresponding fabrication method and a corresponding fabrication mold, which enables this, we refer in full to the patent application of the patent applicant from Aug. 12, 2008 with the title “Verfahren and Fertigungsform zur Fertigung eines Rotorblatts für eine Windenergieanlage”, with file reference DE 10 2008 038 620.0.
[0018] Another solution of the object is a rotor blade of a wind power plant, wherein the rotor blade has a longitudinal extension, which extends from a rotor blade root substantially to a rotor blade tip, wherein, at least in one region of the rotor blade, an aerodynamic cross-sectional profile is provided, which has a leading edge (nose) and a trailing edge, which are connected via a suction side and a pressure side of the cross-sectional profile, which is further formed in that a belt divided in the longitudinal extension of the rotor blade is provided, the belt parts of which have a distance from each other, which is smaller than the extension of a belt part in the direction from the leading edge to the trailing edge. The distance of the belts in the chord direction of the airfoil is thus smaller than the width of a belt part.
[0019] The divided belt hereby has substantially the contour of the rotor blade in the area, in which the belt is arranged in the rotor blade, i.e. the divided belt is accordingly curved and twisted in the longitudinally axial direction, wherein the twist represents, in particular, a type of wringing around the longitudinal axis or respectively around the longitudinal extension and the curvature is, in particular, a type of bending of the rotor blade toward the longitudinal axis. The divided belt is thus correspondingly preferably “flexed” and “twisted.”
[0020] The division of the belt should be understood in particular such that a corresponding distance is provided from the rotor blade leading edge to the rotor blade trailing edge. Alternatively, the divided belt can also be understood as two belts arranged next to each other, the distance of which is comparatively small. The divided belt can thus also be two belts arranged next to each other, which are designed in particular such that they withstand the load of a normally used single belt. Using a divided belt or respectively two belts arranged next to each other, the fabrication accuracy of rotor blades, which consist in the longitudinal extension of two parts or respectively rotor blade sections or respectively comprise them, is particularly high.
[0021] The distance is preferably less than 1 / 2 , in particular preferably less than ¼ of the extension of a belt part or respectively of a belt in the direction from the leading edge to the trailing edge of the rotor blade. The divided belt is preferably substantially provided over the entire longitudinal extension of the rotor blade.
[0022] A web, which extends from the suction side to the pressure side of the rotor blade, is preferably connected, in particular adhered, with the belt parts so that the web forms an I-beam with the belt parts. A particularly stable rotor blade is hereby possible.
[0023] The object is further achieved through a method for fabricating a rotor blade of a wind power plant, wherein the fabricated rotor blade in its longitudinal extension, which extends from a rotor blade root substantially to a rotor blade tip, has at least one region, in which the rotor blade has an aerodynamic cross-sectional profile, which has a leading edge (nose) and a trailing edge, which are connected via a suction side and a pressure side of the cross-sectional profile, with the following method steps:
Providing at least two rotor blade sections fabricated and divided in the longitudinal direction of the rotor blade, wherein the division is arranged between the leading edge and the trailing edge, Applying or inserting of a first web part extending substantially from the pressure side to the suction side into a first divided rotor blade section and a second web part extending substantially from the pressure side to the suction side into a second divided rotor blade section and Connecting, in particular adhesion of, the first web part with the second web part so that a double web forms.
[0027] The stability of the web is already increased through the establishment of a double web. The application or insertion of a first web part extending substantially from the pressure side to the suction side into a first divided rotor blade section and a second web part extending substantially from the pressure side to the suction side into a second divided rotor blade section includes the application or insertion of these respective web parts into the inside of the rotor blade sections so that they are attached to the inner wall of the rotor blade sections or respectively of a belt arranged there. The understanding of application or insertion also includes attachment.
[0028] The application or insertion of the first and the second web part preferably comprises a connection, in particular adhesion, of the first and second web part, each to one belt on the pressure side and one belt on the suction side per rotor blade section.
[0029] Through the connection, in particular adhesion, of the first, in particular square-bracket-shaped, web part with the second, in particular square-bracket-shaped, web part, an I-beam preferably forms, comprising at least four belts and a double web. It is hereby particularly simple to connect the two rotor blade sections with each other so that a very stable structure results.
[0030] According to the invention, a method for fabricating a rotor blade of a wind power plant is provided, wherein the fabricated rotor blade in its longitudinal extension, which extends from a rotor blade root substantially to a rotor blade tip, has at least one region, in which the rotor blade has an aerodynamic cross-sectional profile, which has a leading edge (nose) and a trailing edge, which are connected via a suction side and a pressure side of the cross-sectional profile, wherein the following method steps are provided:
Providing at least two rotor blade sections fabricated and divided in the longitudinal direction of the rotor blade, wherein the division is arranged between the leading edge and the trailing edge, Applying or inserting a web extending substantially from the pressure side to the suction side, which has at least two web feet, into a first divided rotor blade section so that a part of the web feet protrudes out of the rotor blade section: Connecting, in particular adhesion of, the protruding parts of the web feet with a second divided rotor blade section.
[0034] An I-beam, comprising four belts and the web, preferably forms through the connection, in particular adhesion, of the web with the rotor blade sections. The terms application or insertion can also include an attachment.
[0035] During the production of the rotor blade, preferably a rotor blade tip area and/or a rotor blade root can be provided as prefabricated insert, each of which do not necessarily have to be divided in the longitudinal extension. The longitudinal extension of these prefabricated insert parts can extend from a few centimeters up to 5 m.
[0036] Preferably, one suction side section and one pressure side section are connected, in particular adhered, with each other at least for one rotor blade section for the provision of two rotor blade sections fabricated and divided in the longitudinal extension of the rotor blade.
[0037] The two rotor blade sections preferably form a nose box and/or an end box of a rotor blade.
[0038] Preferably, one belt is respectively connected, in particular adhered, to a suction side and a pressure side of each rotor blade section for the provision of two rotor blade sections fabricated and divided in the longitudinal extension of the rotor blade.
[0039] The method according to the invention and the further developments of the method according to the invention are preferably carried out in a joining device, which is designed to hold the rotor blade sections or respectively suction side sections and pressure side sections as well as webs and the like with corresponding holding devices. Alternatively, these components can also still be at least partially arranged or respectively held in a fabrication mold. A corresponding fabrication mold is disclosed in the aforementioned German patent application DE 10 2008 038 620.0.
[0040] The object is further achieved through a method for producing a belt pair of a rotor blade of a wind power plant, in particular for the production of a rotor blade according to the invention, wherein the belt pair is produced in a fabrication mold, which has the contour of the rotor blade in the area of the belt pair and extends at least over the length of a section of the rotor blade, in particular in the longitudinal extension.
[0041] It is hereby possible to produce very precisely a belt pair for use in a rotor blade, which is arranged in the one hand on the suction side and/or on the pressure side of the rotor blade and serves in particular to connect shell segments or respectively rotor blade sections or suction side and pressure side sections with the belt pair so that a very exact fabrication of a rotor blade fabricated with it is possible. In particular, a very high joint accuracy or respectively connection accuracy can be established by adhering to a preferably constant distance between the belt pair over the length of the section, in particular of the aerodynamic region, of the rotor blade and preferably from the blade root up to the blade tip or substantially from the blade root substantially up to the blade tip.
[0042] The section preferably extends from a region near the rotor blade root up to the rotor blade tip or up to a section end of the rotor blade near the rotor blade tip. In particular, in the last variant with the extension up to a section end of the rotor blade near the rotor blade tip, a fabrication of the rotor blade is hereby provided, in which a prefabricated rotor blade tip is attached to a longitudinally extending, divided rotor blade section. For this, the belt pair is then adjusted according to the section length of the divided rotor blade sections, namely in the longitudinal extension of the divided rotor blade sections. The prefabricated rotor blade tip section or respectively the prefabricated rotor blade tip can hereby have a length of a few centimeters up to several meters, in particular of up to 5 m.
[0043] An intermediate web, in particular middle web, is preferably provided in the fabrication mold, which is designed either as a single piece with the fabrication mold as intermediate web, in particular middle web, or as a removable intermediate web, in particular middle web. A constant distance can hereby be achieved very exactly between the belt pairs. Within the framework of the invention, the term “belt pair” also means two belts, which are produced next to each other in a fabrication mold, or also the term “in the longitudinal direction or respectively longitudinal extension of the rotor blade of the divided belt.”
[0044] The object is finally achieved through a fabrication mold for the production of a belt pair of a rotor blade of a wind power plant, in particular for use in a rotor blade according to the invention such that the fabrication mold has the contour of the rotor blade in the area of the belt pair on the suction side or the pressure side of the rotor blade and extends at least over the length of a section, in particular of the aerodynamic region, of the rotor blade.
[0045] The fabrication mold preferably has an intermediate web, in particular middle web, which is designed either as a single piece with the fabrication mold or as a removable intermediate web, in particular middle web. A recess is preferably provided for the removable intermediate web, in particular middle web. This simplifies the production of the belt pair.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] The invention is described below based on embodiments without restricting the general idea of the invention; explicit reference is made to the figures with regard to all particulars according to the invention not explained in more detail in the text. The drawings show in:
[0047] FIG. 1 a schematic representation of a rotor blade of a wind power plant according to the invention,
[0048] FIG. 2 a schematic representation of corresponding components of a rotor blade in corresponding joining devices in a first step in the fabrication of the rotor blade,
[0049] FIG. 3 a schematic representation of a state of the fabrication of a rotor blade that is more advanced compared to FIG. 2 ,
[0050] FIG. 4 a schematic representation of a state of the rotor blade fabrication that is more advanced compared to FIG. 3 ,
[0051] FIG. 5 a schematic representation of a state of the rotor blade fabrication that is more advanced compared to FIG. 4 ,
[0052] FIG. 6 a sectional representation of a fabrication mold according to the invention for the production of a belt pair,
[0053] FIG. 7 a schematic sectional representation of a further production mold according to the invention for the production of a belt pair,
[0054] FIG. 8 a schematic representation of a rotor blade of a wind power plant according to the invention,
[0055] FIG. 9 a schematic representation of the fabrication of a rotor blade in an advanced state,
[0056] FIG. 10 a schematic sectional representation of a part of a fabricated rotor blade according to the invention,
[0057] FIG. 11 a schematic sectional representation of a part of a fabricated rotor blade according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0058] In the following figures, the same or similar types of elements or respectively corresponding parts are provided with the same reference numbers so that a corresponding re-introduction can be omitted.
[0059] FIG. 1 schematically shows a rotor blade 10 according to the invention, which has a longitudinal extension 11 from a rotor blade root 12 to a rotor blade tip 13 . A cross-sectional profile 15 , which is aerodynamically active and has a suction side 18 and a pressure side 19 , is represented in rotor blade 10 . The aerodynamic cross-sectional profile 15 also has a leading edge 16 (nose) and a trailing edge 17 .
[0060] Furthermore, a belt pair consisting of the belts 28 and 29 is represented schematically, which have a distance 50 from each other and are arranged, for example, on the suction side 18 . The belts 28 and 29 are provided in section 20 , i.e. in this exemplary embodiment of FIG. 1 from the blade root 12 to the rotor blade tip 13 . A corresponding belt pair consisting of the belts 30 and 31 on the pressure side 19 of the rotor blade 10 is not shown. The aerodynamic region 14 of the rotor blade 10 is also sketched, which substantially ensures the lift. The section 20 can also be accordingly shorter, for example end with a specifiable first distance from the rotor blade tip 13 and/or with a specifiable second distance from the rotor blade root 12 . The rotor blade 10 can be divided during production in the area of the longitudinal extension 11 shown in FIG. 1 . Furthermore, it can also be divided at the leading edge 16 and the trailing edge 17 .
[0061] FIG. 2 shows an apparatus for fabricating a rotor blade 10 , wherein two joining devices 36 and 37 are provided, onto which shell segments 32 , 33 , 34 , 35 of a rotor blade 10 are held. The shell segment 32 corresponds with a rotor blade shell on the pressure side 19 associated with a leading box or respectively a nose box 21 and the shell segment 34 belongs to the suction side 18 of the leading box or respectively of the nose box 21 . Corresponding belts 28 and 30 are connected, in particular adhered, with the shell segments 32 and 34 . The adhesion can be realized, for example, with a resin. The shell segments 32 and 34 are fixed by means of a few suction elements 44 using suction air in the joining device 36 . The shell segments 33 and 35 are accordingly fixed through suction elements 44 through suction air in the joining device 37 .
[0062] The shell segment 33 can belong to the suction side of an end box 23 and the shell segment 35 to the pressure side of an end box 22 . The shell segments 32 through 35 can be made for example of a glass fiber reinforced fabric with a resin, e.g. epoxy resin. The rotor blade parts are preferably fabricated using a plastics technique. In the plastics technique, a resin and at least one fiber layer, in particular made of glass fibers and/or carbon fibers and/or aramid, such as kevlar fibers in particular, are preferably used. A resin transfer molding (RTM) technique or a resin infusion molding (RIM) technique, in particular a vacuum-assisted resin (VAR) infusion technique and/or a laminating technique, for example with so-called prepregs, can be used for fabrication of the rotor blade shell segments 32 - 35 . The fabrication of the rotor blade shell segments 32 - 35 is already finished in FIG. 2 so that the fabricated shell segments can be applied onto or respectively inserted into the joining devices 36 and 37 .
[0063] The belts 28 - 31 applied on the shell segments or respectively connected or respectively adhered with them can already be connected with the shell segments in the fabrication in a fabrication mold.
[0064] The joining devices 36 and 37 each have pivot axes 45 and 46 in order to be able to pivot the pivot parts 38 - 41 .
[0065] FIG. 3 represents an advanced stage of fabrication of the rotor blade according to the invention. A web part 26 is fixed via suction elements 44 on a positioning device 63 attached precisely to the second pivot part 39 or respectively aligned with it. The web part 26 has a web foot 65 towards the suction side 18 and a web foot 67 towards the pressure side 19 . The web foot 65 is adhered precisely with the belt 30 by means of an adhesion 60 , for example made of a resin. Accordingly, a positioning device 62 is connected or aligned with the third pivot part 40 . A web part 27 is fixed on the positioning device 62 via suction elements 44 . The web part 27 has web feet 64 and 66 . The web foot 65 is connected with the belt 31 via an adhesion 61 . A precise alignment of the web part 27 with the belt 31 and the shell segment 33 is also possible here.
[0066] Subsequently, as shown in FIG. 4 , the first pivot part 38 is pivoted around the pivot axis 45 so that an adhesion 68 of the web foot 67 with the belt 28 can take place. This can also be done in a precise manner. Furthermore, an adhesion 77 of the shell segment 32 with the shell segment 34 is realized via an adhesion part 78 connected with the shell segment 34 in the nose area of the nose box 21 .
[0067] In order to produce an end box 22 , the fourth pivot part 41 is pivoted around the pivot axis 46 and the web foot 66 is adhered with a glue 69 with the belt 29 so that a precise adhesion takes place between the web 27 and the belt 29 or respectively the shell segment 35 . The trailing edge of the rotor blade is also connected correspondingly via an adhesion 76 .
[0068] The joining devices 36 and 37 preferably have, in addition to the pivot axes 45 and 46 , a linear motion device (not shown), with which the molded parts 38 and 39 or respectively 40 and 41 , that is the corresponding pivot parts 38 through 41 , can be closed in a straight-line movement.
[0069] As shown by arrow 85 , the joining device 37 provided with the wheels 42 and 43 is subsequently moved in the direction of the joining device 36 , namely after a hardening of the adhesions 60 , 68 , 77 , 61 , 69 and 76 and after a removal of the positioning devices 62 and 63 .
[0070] As represented schematically in FIG. 5 , a glue gap results between the web parts 26 and 27 . Therein, a flow medium, for example a glass fiber entanglement 70 , is provided. This can be one or more layers of continuous mat, glass fabric, glass cloth or a spun material compressible in the thickness direction. The glue gap is preferably sealed vacuum-tight all around. Seals 72 and 73 are provided for this, which can be realized as vacuum film or as a solid sealing surface. Corresponding rubber seals, which do not have reference numbers, are also indicated.
[0071] A resin sprue 74 is indicated on the bottom end of the glue gap and a vacuum connection 75 on the top end. When establishing negative pressure or respectively vacuum, a gluing medium in the form of, for example resin 71 , is suctioned into the glue gap through the sprue so that the gap is completely filled. The leading and trailing web or respectively the web parts 26 and 27 hereby result in a web, which can also be called the middle web, which is located in the middle of the belts 28 , 29 and 30 , 31 . It can be seen that the belts 28 and 29 have a distance from each other and the belts 30 and 31 have a corresponding distance from each other. The gluing medium can be an infusion resin or a low-viscosity adhesive resin. The arrangement of sprue 74 or respectively resin sprue 74 and vacuum connection 75 can also be interchanged.
[0072] Over the longitudinal extension of the rotor blade 10 , more sprues may be necessary under certain circumstances. Accordingly, several vacuum connections can also be provided. In particular when the blade length is relatively long, for example around 60 m.
[0073] The arrangement of the rotor blade 10 or respectively the rotor blade shell segments 32 - 35 with the suction side elements facing downward is not absolutely necessary. It can also be positioned the other way round.
[0074] After the resin sprue, for an aerodynamically sensible connection and for closing the gap between the belt parts or respectively the belt pairs 28 , 29 and 30 , 31 , this gap can be closed flush with a resin and, if applicable, also with a glass fiber entanglement or the like.
[0075] The web parts 26 and 27 can be made for example of biaxial fabric, i.e. of glass fiber or carbon fiber or respectively aramid fiber fabric or comprise them. The fabrics have orientations of ±20° to ±50° and lie in particular in a range of ±30° to ±45°. Towards the inside, i.e. towards the glass fiber entanglement 70 , a layer of fabric, in particular biaxial fabric, can be provided and, for example, four layers of biaxial fabric in the area of the rotor blade root 12 can be provided on the outer surface and a layer of biaxial fabric in the area of the rotor blade tip 13 . The distance of the web parts 26 and 27 preferably lies in a range between 1 mm and 20 mm, in particular preferably between 2 mm and 3 mm.
[0076] In order to achieve a sufficient buckling resistance of the produced rotor blade 10 , the blade can also have a trailing edge web outside the area of the I beam 25 , which results from the adhesion of the web parts 26 , 27 with the belts 28 , 29 and 30 , 31 . The trailing edge web is preferably arranged in the end box 22 and can be arranged there on the suction side and/or on the pressure side and reaches, for example, in the case of a 61 m blade from approx. 8 m to 52 m calculated from the rotor blade root 12 .
[0077] The joining device 36 , 37 is preferably used since the occupancy time of the rotor blade production mold is thus reduced. The four shell segments 32 through 35 are correspondingly aligned in the pivot parts 38 through 41 . The adhesion of the web parts 26 and 27 takes place in particular two-dimensionally. The particularly exact positioning and alignment of the shell segments 32 through 35 and the web parts 26 and 27 preferably takes place through the positioning device indicated in FIGS. 1 through 5 , which are represented as suction elements 44 and are preferably adjustable in height or respectively distance to the pivot parts. The very large mold accuracy is thereby achieved in that the belts or respectively belt parts 28 , 29 and 30 , 31 are each produced together, that is the belts 28 and 29 together and the belts 30 and 31 together in one fabrication mold. For this, schematic sectional representations of corresponding fabrication molds, in which the corresponding belts 28 and 29 , which serve as examples here, are fabricated, are shown in FIGS. 6 and 7 .
[0078] In the fabrication molds 54 and 55 , two cavities for the belts 28 and 29 to be produced, which are divided in the middle, are correspondingly provided. In the exemplary embodiment according to FIG. 6 , the division takes place through a middle web 56 insertable in a recess 58 and in the exemplary embodiment according to FIG. 7 through a middle web 57 fabricated as one piece with the fabrication mold 55 .
[0079] Dry glass fibers are laid into the mold and immersed through a resin sprue 74 in the cavities with a resin 71 . Through the fixed mold division or respectively the production of the two belts 28 and 29 in one single mold, the two belts 28 and 29 always fit together perfectly. Both belts have an identical curvature and twist, which corresponds with the rotor blade 10 to be fabricated in the area of the respective belts. The fabrication of the belts 28 and 29 occurs in the exemplary embodiments according to FIGS. 6 and 7 preferably with a vacuum-supported infusion technique, for which resin sprue connections 83 and 84 and vacuum connections 81 and 82 are provided. A vacuum film 80 is provided for sealing, which is connected left and right in the FIGS. 6 and 7 with sealing strips, which have no reference number and, for example, can be designed as rubber lips, with the fabrication molds 54 or respectively 55 . After fabrication, the belt 28 has an extension 52 and the belt 29 an extension 52 ′ according to the embodiment according to FIG. 6 and in FIG. 7 the belt 28 has an extension 53 and the belt 29 an extension 53 ′. Accordingly, the distance 50 in the case of the use of a middle web 56 according to FIG. 6 is smaller than in the case of a middle web 51 according to FIG. 7 , since the middle web 51 in FIG. 7 is sloped or respectively beveled.
[0080] In the case of the embodiment according to FIG. 6 , both belts 28 , 29 are demolded from the fabrication mold 54 together and the parting strip is subsequently removed. Smaller alignment errors of the parting strip can hereby occur, which are however insignificant, since the two belt halves are always designed complementarily, i.e. substantially uniformly. The embodiment according to FIG. 7 enables lower tolerances of the belts 28 , 29 or respectively a lower tolerance or respectively differences in the distance 51 in the longitudinal extension of the rotor blade, but leads to greater distances 51 and thus to greater glue gaps between the web parts 25 and 26 in FIG. 5 . The distance of the web parts 25 and 26 can then lie in the range of 10 mm or more.
[0081] The joint fabrication of two belts in one fabrication mold saves production space and time during fabrication. Moreover, belts produced in this manner, which are then used in the longitudinal extension of the rotor blade on a pressure side or a suction side, also instead of a web, which connects the belts and which is adhered in the middle, i.e. a double web, for example in a connection by means of a box spar according to patent application DE 10 2008 038 620.0, can be used.
[0082] A controllable, process-secure and accessible web-to-shell adhesion is possible through the invention. High forces can be transferred through a large-area middle web adhesion or respectively web adhesion, through which an I-beam forms. It is also not necessary to use an external pressing force to displace the glue, since the web parts 26 and 27 are pressed onto each other through the supplied vacuum. The web parts are resilent to tension, but are relatively soft in themselves. Local differences in the thickness of the glue gap, that is the gap between the web parts 26 and 27 , which result from tolerances in the adhesive surfaces or respectively of the web surfaces, are leveled out to the thickness of the flow medium through the vacuum. The flow medium also ensures the resin flow through the pressed-together surfaces. This is not visible on the fabricated blade.
[0083] FIG. 8 shows a schematically represented rotor blade 10 according to the invention. In the case of this rotor blade, a longitudinal division of the rotor blade 10 into rotor blade sections 21 and 22 is provided, wherein the division takes place along a longitudinal extension 11 or respectively 11 ′ or 11 ″. The longitudinal extension 11 goes from the rotor blade root to the rotor blade tip 13 . The longitudinal extension 11 ′ runs from the rotor blade root substantially to the rotor blade tip 13 and ends in the area of the rotor blade tip 13 at a distance h 2 from this tip. Accordingly, in the case of a distribution in the longitudinal extension 11 ″, it can go up to an edge in the area of the rotor blade tip 13 , which shows a connection edge 95 between a prefabricated rotor blade tip and the rest of the rotor blade or respectively rotor blade section 20 . In this case for example, the rotor blade tip does not have to be divided in the longitudinal extension.
[0084] The distance to the connection edge 95 is specified with h 1 . It can be up to 5 m. However, a distance of a few centimeters can also be provided. As mentioned above, the rotor blade tip section 94 can be prefabricated separately. Accordingly, angle α and β to longitudinal extension 11 ′ or respectively longitudinal extension 11 ″ can be provided between the longitudinal extension 11 between the rotor blade root 12 and the rotor blade tip 13 . α can lie, for example, in the range from 0.1 to 2° and β in the range from 2° to 5°.
[0085] FIG. 9 shows a schematic sectional representation through the fabrication device, in which corresponding rotor blade sections are already inserted, wherein in this case in the trailing rotor blade section 22 , i.e. in the end box, a web 90 is glued in, which has web feet 92 and 93 , each of which overlap to the left and right and are adhered to the belts 29 and 31 with corresponding adhesions 69 and 61 . The protruding parts of the web feet 92 and 93 are then adhered to the belts 28 and 30 after the removal of the positioning device 62 and the pushing together of the rotor blade sections in the direction of the arrow 85 .
[0086] FIG. 10 and FIG. 11 show further schematic cross-sectional representations of connection options of rotor blade sections, which are not shown here. The belts 29 through 31 , which are adhered with corresponding adhesions 110 to the respective web feet 97 and 98 of the web 96 , are represented. The web 96 has the shape of a square bracket or respectively of a square C. The web feet 97 and 98 protrude beyond the distance of the belts 28 and 29 or respectively 30 and 31 .
[0087] Accordingly, FIG. 11 shows a connection, in which a web 99 is provided that is Z-shaped. Accordingly, the web feet 100 and 101 are adhered to the belts 28 and 29 or respectively 30 and 31 through adhesions 110 .
[0088] All named characteristics, including those taken from the drawings alone, and individual characteristics, which are disclosed in combination with other characteristics, are considered alone and in combination as important to the invention. Embodiments according to the invention can be fulfilled through individual characteristics or a combination of several characteristics.
REFERENCE NUMBER LIST
[0000]
10 Rotor blade
11 , 11 ′, 11 ″ Longitudinal extension
12 Rotor blade root
13 Rotor blade tip
14 Aerodynamic area
15 Cross-sectional profile
16 Leading edge
17 Trailing edge
18 Suction side
19 Pressure side
20 Section
21 Nose box
22 End box
23 Trailing area
24 Leading area
25 I-beam
26 Web part
27 Web part
28 Belt
29 Belt
30 Belt
31 Belt
32 Shell segment
33 Shell segment
34 Shell segment
35 Shell segment
36 Joining device
37 Joining device
38 First pivot part
39 Second pivot part
40 Third pivot part
41 Fourth pivot part
42 Wheel
43 Wheel
44 Suction element
45 Pivot axis
46 Pivot axis
47 Double web
50 Distance
51 Distance
52 , 52 ′ Extension
53 , 53 ′ Extension
54 Fabrication mold
55 Fabrication mold
56 Middle web
57 Middle web
58 Recess
60 Adhesion
61 Adhesion
62 Positioning device
63 Positioning device
64 - 67 Web foot
68 Adhesion
69 Adhesion
70 Glass fiber entanglement
71 Resin
72 Seal
73 Seal
74 Resin sprue
75 Vacuum connection
76 Adhesion
77 Adhesion
78 Adhesion part
80 Vacuum film
81 Vacuum connection
82 Vacuum connection
83 Resin sprue connection
84 Resin sprue connection
85 Arrow
90 Web
91 Web
92 Web foot
93 Web foot
94 Rotor blade tip section
95 Connection edge
96 Web
97 Web foot
98 Web foot
99 Web
100 Web foot
101 Web foot
110 Adhesion
h 1 Distance
h 2 Distance
α Angle
β Angle | A rotor blade ( 10 ) of a wind power plant, wherein the rotor blade ( 10 ) has a longitudinal extension ( 11 ), which extends from a rotor blade root ( 12 ) substantially to a rotor blade tip ( 13 ), wherein, at least in one region of the rotor blade ( 10 ), an aerodynamic cross-sectional profile ( 15 ) is provided, which has a leading edge ( 16 ) (nose) and a trailing edge ( 17 ), which are connected via a suction side ( 18 ) and a pressure side ( 19 ) of the cross-sectional profile ( 15 ).
The rotor blade is characterized in that the rotor blade ( 10 ) is subdivided at least in a longitudinally extended section ( 20 ) into a front rotor blade section ( 21 ) with the leading edge ( 16 ) and a rear rotor blade section ( 22 ) with the trailing edge ( 17 ), wherein the rear region ( 23 ) of the front rotor blade section ( 21 ) and the adjacent front region ( 24 ) of the rear rotor blade section ( 22 ) are connected through an I-beam ( 25 ). | 1 |
This application is a continuation-in-part of copending application Ser. No. 443,127, filed Nov. 19, 1982 now U.S. Pat. No. 4,527,198, entitled "Improved Followspot Parameter Feedback", and includes subject matter in Disclosure Document No. 118,922 filed July 20, 1983.
BACKGROUND OF THE INVENTION
This application relates to performance lighting and, more specifically to an improved control system for fixtures capable of varying beam parameters during use.
Performance lighting systems have long employed large numbers of fixtures each selected and adjusted to produce a beam of a particular size, shape, and color aimed at a fixed location on the stage. The only beam parameter variable during the performance is intensity, and the character of the lighting effect onstage is adjusted solely by changing the relative intensities of the variety of fixtures provided.
The advantage of this "one function/one fixture" approach is its use of relatively low technology hardware involving no moving parts and hence relatively high reliability and simple maintainance. The disadvantage is the need for many more fixtures than are used at any one time--or would be required if the fixtures were capable of varying other beam parameters during the performance. There is the direct cost to buy or rent the large number of fixtures required plus their associated supporting structure, dimming equipment, and interconnecting cables as well as the time and labor required to install, adjust, and service this amount of equipment.
It has long been apparent that were fixtures able to change beam parameters in addition to intensity (like color, beam size, or even azimuth and elevation), either as the result of integral remotely actuatable mechanisms and/or devices (like color changers) which may be retrofitted to conventional fixtures, then lighting effects could be varied by actually changing the fixtures' beams rather than dimming between otherwise identical fixtures with different fixed adjustments--requiring fewer fixtures to produce a given lighting design with consequent savings.
Each such "multi-variable" fixture could, over the course of the performance, duplicate the results it currently requires many fixtures to achieve--as well as adding dynamic changes in the beam to the lighting effects possible
The viability of employing fixtures with remotely adjustable beam size, color, shape and/or angle as a method of reducing system size depends upon a control system, first disclosed in U.S. Pat. No. 3,845,351, capable of storing absolute desired parameter values for each of the controlled parameters in each of the desired lighting effects and of automatically conforming the fixture's incrementally adjusted beam varying mechanisms to those values.
Similar systems were subsequently disclosed in U.K. Pat. No. 1,434,052 and U.S. Pat. No. 4,392,187, and today, the rental of such systems to concert, television, and theatrical productions is a multi-million dollar industry.
There have, however, been unexpected difficulties with developing a truly practical embodiment of such a control system.
Two approaches have been employed:
One, represented by the Vari-Lite™ system (of Vari-lite, Ltd., Dallas, Tex.), as disclosed in U.S. Pat. No. 4,397,187, employs completely custom hardware and software.
Any such custom control system is very expensive because the number of such systems built relative to even the limited number of conventional lighting memory consoles produced is very small. No significant volume cost reductions are possible and the considerable investment in the "ground up" development of a specialized control system handling up to eight times the amount of data per fixture (relative to a conventional console) can be amortized across only a limited number of units.
Further, it is inevitable that the features and controls provided by any specialized controller will not meet the requirements of all users, and that changes will be requested by users over time. This requires a further investment by the manufacturer in hardware and software revisions, amortizable across the same relatively limited volume.
It had also been widely assumed that remotely adjustable devices (whether color changers, remote yokes, or multi-variable fixtures) would be used on an exclusive basis to maximize the purported gains in system efficiency. Due to a variety of factors including the high cost of such equipment, it has instead been the case that the number of such devices per system may vary widely and that, contrary to expectations, devices of several different types (such as both color changers and remote fixtures) may be employed in the same system, together with conventional fixtures and their controllers.
These "real world" conditions further complicate the development of a suitable memory system, for the unit must be capable of economically driving a handful of such devices or dozens or even hundreds. Clearly, it is difficult to design a single control system capable of varying its memory capacity and outputs over a range of 10:1. Therefore, competing at both ends of this range of applications may require the use of an "overqualified" control system for smaller numbers of fixtures and/or two or more control systems for the large ones. The only alternative is the development of different models of the same control system with a consequent increase in development cost.
It should also be noted that the 10:1 range in the number of controlled devices required by the applications for such equipment also requires an equally flexible method of reliably distributing the necessary data. While the use of multiplexed data links for this purpose has long been known, the inherently higher data rates of multi-variable control systems requires either multiple data links of limited capacity (with a variety of practical drawbacks) or a single data link capable of extremely high data rates without EMI susceptability.
Further, as the control system is optimized for a given controlled device, driving dissimilar devices or major revisions of the same device may be difficult or impossible. Once the commitment has been made to a given control structure and data transmission means, changes in the design of the controlled device which require that additional or different data be stored and transmitted may require an expensive revision of the control system as a whole and/or may render the encoded data on the data link between the control system and the controlled devices incompatable with existing decoder hardware.
This "upwards-incompatability" and lack of "cross-compatability" with other remote devices, are an impediment both to the user (in requiring multiple control systems and operators to attempt to synchronize the different remote devices) and to the manufacturer (in increasing the cost of the revisions required to maintain competitiveness). Such systems will also suffer from further disadvantages when features requiring more sophisticated data manipulation such as the conversion of absolute beam location data to required azimuth and elevation are sought. Because the control system operates on a time-shared basis among the various controlled devices, a relatively modest number of machine cycles required by a given feature must be multiplied by the number of controlled fixtures. The total increase in processor workload may exceed the remaining processor "overhead" and an expensive and time-consuming change of processors may be required.
The second approach to the construction of such systems, typified by the Pana-Spott™ multi-variable fixture (of Morpheus Lights, San Jose, Ca.), does not employ a custom control system, but instead configures the fixtures to allow use of any conventional lighting memory console, such as disclosed in U.S. Pat. No. 3,898,643.
Specifically, the inputs to the Panaspott™ remote fixture are configured to accept 11 parallel 0-10 volt DC outputs as produced by any standard lighting control console; four employed for analog values (azimuth, elevation, beam size and intensity) and seven employed for essentially single-bit digital values (representing the in/out condition of each of the seven frames in the color changer).
The use of a modern memory controller provides a variety of sophisticated features including a CRT, keyboard, data carrier, and cue manipulations without the development costs which attend the creation of a custom controller. There have, however, been several severe drawbacks to the use of such stock consoles
One is relative cost. Given the need for storing only one fixture variable and the fact that it is generally desirable for multiple fixtures to share the same discrete output, one $22,000 console generally suffices for a system of 300 conventional fixtures, representing a front-end control cost of only $70 per fixture. In the case of the Panaspot™, eleven discrete outputs are required for each fixture and, by definition, such fixtures achieve their benefits only if each fixture's inputs are discrete outputs of the console.
Therefore one $22,000 console is required for each eleven remote fixtures for a front end control cost of $2000 per fixture. The number of fixtures controlled per console can be increased by using the same console output as an input to more than one fixture, but this limits the versatility of the fixtures and, in so doing, erodes the justification for their use.
The use of stock lighting consoles for this purpose has also proven to present severe operational disadvantages relative to a custom controller.
Because the "stock" controller's benefits derive from use of a standard lighting control product optimized for cue-to-cue intensity operation, the operator is also required to use input devices and data display formats which are not designed for multi-variable fixture control.
While such a console records and displays the variables for each fixture, all variables for all fixtures are presented uniformly as two numbers: the channel number and a percentage value. A time consuming reference to a list or table is required to determine that the beam size for fixture #8 is controlled by channel #93. Conversely, the CRT display of values is useless without conversion.
Further, such consoles generally provide input devices allowing manual or keyboard adjustment of only a single output or group of outputs at a time. Therefore, most recording operations for remote fixtures require a lengthy series of adjustments, with reference to a table of 100 or more functions between each one.
Such consoles also do not provide data manipulation features unique to multi-variable fixture use, nor can their outputs be reconfigured to provide resolutions greater than or less than 8-bits.
One might suggest modifying the standard memory controller with more appropriate input devices, display modes, outputs, and software, but that contradicts the whole purpose of using an existing controller. Further, such modifications would require the participation of the console manufacturer, either in performing the actual modifications or in providing the documentation to the fixture manufacturer or a third party necessary to do the work. The major dimming equipment manufacturers have made it clear that the size of the market for such modifications does not justify their participation.
A practical control system for remotely-adjustable fixtures therefore requires the development of a new control system approach providing: input devices suited to the needs of the controlled fixture; shared portions of the system of minimum cost; economical operation from a few units to several hundred; a data link capable of handling the maximum data rate reliably, yet inexpensive to decode; capable of mixing various types and generations of controlled device on the same system without modification; capable of modification to meet user requirements at minimal cost.
It is the object of the present invention to provide an improved control system for multi-variable fixtures meeting these requirements.
SUMMARY OF THE INVENTION
The improved control system of the present invention achieves this and additional objects.
Prior art systems employ a centralized control system with a single memory means connected to the plurality of controlled fixtures. In the system of the present invention, outputs of a supervisory control unit at a central location are coupled to the inputs of a plurality of local control systems. Each such local control system has an associated memory means in which are stored desired parameter values for at least one remotely adjustable fixture, the output of the local control system serving as an input to a means for conforming the adjustable parameters of the controlled fixtures to the desired values.
Desired parameter values for the fixtures may be entered into the memory means associated with the local control system prior to the performance by means of input devices and/or a data carrier associated with either the local control system and/or the supervisory control unit.
During the performance, an output of the supervisory control unit selects the location in the memory means of the local control systems at which the desired parameter values for a given lighting effect are stored, causing the fixtures to be conformed to the desired values.
The same output of the supervisory control unit may be supplied to all local control systems, causing selection of stored values at corresponding memory locations, but preferably means are also provided to select data stored at different addresses in different local control systems.
The same output of the supervisory control unit may cause both the selection of the desired stored parameter values and the conforming of the fixture's mechanisms to those values or separate outputs may be employed for each function.
Direct control of the fixture from the supervisory control unit may also be provided during the performance.
The benefits of the control system of the present invention are many and immediate:
The number of such local control systems (and as such fixtures) which may be controlled by the same supervisory control unit is essentially unlimited.
The supervisory unit need contain no cue memory of its own and negligible processor power, but simply serve as a terminal providing input controls and a data carrier along with the minimum of hardware required for communication with the local control systems.
The data rate between the supervisory control unit and the local control systems during performances is minimal and remains so regardless of the number of controlled devices
Preferably, a duplicate memory means is provided at the supervisory level to further reduce communications requirements.
As a result, it will be practical to employ desirable techniques, like power line communications between the supervisory unit and the local systems, in many applications which had heretofore not been useable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a multi-variable fixture as may be employed with the control system of the present invention.
FIG. 5A and 5B are detailed views of a color changing method as may be employed with the control system of the present invention.
FIG. 2 is a block diagram of the control system of the present invention.
FIG. 3 is a detailed view of one embodiment of the supervisory control unit of FIG. 2.
FIG. 4 is a detailed view of one embodiment of a local control system of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
Refer now to FIG. 1, a sectional view of a multivariable fixture as may be employed with the control system of the present invention, equivalent to FIG. 1B of the patent application Ser. No. 443,127. Parts having the same function in both Figures are identified with the same reference number
The optical system of the fixture includes light source 101 with its associated reflector and a gate or aperture 103 imaged by a pair of lenses 105 and 107.
Beam intensity may be remotely adjusted by means of dowser 111 and its associated beam intensity actuator 429, although an electronic dimmer as disclosed in U.S. Pat. No. 3,397,344 may also be employed.
Beam size may be remotely adjusted by means of iris 104 and its associated actuator 421, and/or by other means such as changes in system focal length by relative movement of lenses 105 and 107 or a variable curvature mirror 605 as disclosed in U.S. Pat. No. 4,460,943.
Beam shape may be varied by means of gobo wheel 623 and its associated actuator 621.
Beam edge sharpness may be varied by moving the aperture assembly along the optical axis with actuator 627, although more conventional movement of a lens may also be employed.
Beam azimuth and elevation may be adjusted by means of either two-axis displacement of the fixture, as disclosed in U.S. Pat. Nos. 1,680,685 and 1,747,279, or of a beam-directing mirror as disclosed in U.S. Pat. No. 2,054,224. Preferably, however, beam angle is adjusted by reflection from mirror 605 which is mounted by bracket 640 to motor 401 which, in turn, is mounted to the forward end of the fixture chassis 642. This allows the rotation 646 of the beam in a first plane perpendicular to the optical centerline. The fixture chassis 642, in turn, is supported at its center of gravity by a yoke and pivot driven by motor 635 which allows the rotation 636 of the fixture in a second plane parallel to the optical centerline yet always perpendicular to that of the first plane of rotation for the beam.
Similarly, the color of the beam 601 may be varied by any conventional means including a color wheel (as disclosed in U.S. Pat. No. 1,820,899); a semaphore changer (as disclosed in U.S. Pat. No. 2,129,641); or a roller changer (as disclosed in U.S. Pat. No. 3,099,397). Preferably, however, the color changing system illustrated in FIG. 5A and 5B would be employed. Three segments of interference-type filter material 905, 907, and 909 (such as manufactured by Optical Coating Laboratories, Inc., Santa Rosa, Ca.) of additive color primaries with CIE chromaticity coordinates 905C, 907C, and 909C form an array supported by rim 903 and rotated by motor 701 via rollers 902 and 904 mounted to support plate 915. Support plate 915, which is located in a hyperfocal region of the optical system, may be displaced along an axis in a plane perpendicular to the optical centerline of beam 601 on linear bearings 919 riding on rail 918 by motor 921 driving lead screw 922, such that the relative proportion of beam 601 passing through the filter array may be varied. Opening 917 in plate 915 allows passage of the beam. The combination of array rotation 929 and displacement 928 allows varying both the proportion of primaries and their saturation to synthesize any color sensation within area 931C.
While the fixture illustrated in FIG. 1 provides means to vary all beam parameters it will be understood that the improved control system of the present invention may be employed with fixtures designed or adapted to remotely adjust any number or combination of parameters, and with devices like color changers and remote yokes designed for use with conventional fixtures.
Similarly, a variety of actuators and actuator drives may be employed in either open or closed loop operation.
Referring now to FIG. 4B of the parent application Ser. No. 443,127, reproduced as FIG. 2, the structure of the improved control system of the present invention will be described.
A performance employs a plurality of multi-variable fixtures 480-485, together with conventional fixtures 494 whose intensity is controlled by electronic dimmers 495 responsive to conventional memory console 493.
The improved control system of the present invention employs a plurality of local control systems 486-491, which may be similar to that illustrated in FIG. 4A of the parent application Ser. No. 443,127. Each such local control system 486-491 includes a memory means 311 in which may be stored desired parameter values for the fixtures controlled by that system for each of a plurality of lighting effects. Each such local control system provides an input 322, which may be used to select the location in memory 311 at which the parameter values for a given lighting effect are stored. A means is provided, illustrated here as line 497, to couple the setting selection input 322 of the local memory means to the supervisory control unit 493. A single output of supervisory unit 493 may be employed, such that all local control systems are invariably directed to the same memory location, but preferably, the system allows different local control systems to be directed to different addresses as a method of increasing both flexibility and effective memory capacity.
The local control systems may conform their associated fixtures to the desired parameter values upon receipt of a setting selection input, but preferably, a separate output of the supervisory unit, illustrated as line 498 to input 324 of local control system 486, can be employed for a "Load" instruction.
The local control systems may record desired intensity in their memory means, but preferably, alternate and/or supervisory control of intensity may also be exercised from the supervisory unit, illustrated as line 499 to input 449 of control system 486.
As noted in the referenced application, in the most basic embodiment, each local control system must be provided with input, display, and data carrier facilities.
Accordingly, the parent application Ser. No. 443,127 discloses means for transferring data to and from shared input, display, and data carrier facilities at the supervisory level, illustrated as data busses 560 and 561 which are common to the input ports 327 and output ports 323 of the local control systems 486-491. Means are provided, in the form of "System Select" lines 562-567, to selectively couple local control systems to the busses under the control of the supervisory data carrier 585. Similarly, means are provided in the form of line 575, for the supervisory data carrier 585 to cause selected local control systems to record data present on buss 560 in their memory means. Supervisory controls 587 and displays 589 may also be coupled to the parameter value busses between the supervisory level and the local control systems. In the manner described in the parent application Ser. No. 443,127, parameter data may be transferred between the supervisory level and the local control systems for the recording, adjustment, and display of desired parameter values, and their up-loading to and down-loading from a common data carrier. These supervisory facilities may be provided by the conventional lighting controller 493 or by custom hardware or by a combination of the two. However, unlike prior art systems, the centralized portion of the system of the present invention need contain no cue memory of its own and negligible processor power, simply serving as a terminal providing input controls and a data carrier along with the minimum of hardware required for communication with the local control systems, minimizing its cost and complexity, whether a custom controller or modification of a conventional one. In fact, the preferred embodiment employs the combination of the conventional memory controller used for the conventional fixtures and a custom controller providing input devices, displays, data carrier, and an output for the multi-variable fixtures, with an output of the conventional controller used as the setting selection input to the multi-variable fixtures as a method of synchronizing the operation of the two groups of fixtures. Synchronization of the two groups of fixtures thus requires that the conventional lighting controller produce only a cue number and "Load", a relatively modest request, involving no reduction of channel capacity or processor time.
Conversely, as many such consoles provide for an external "go" command, the supervisory control unit could maintain the cue sequence and drive the conventional controller rather than vice versa.
Refer now to FIG. 3 where constructional details of a supervisory control unit are illustrated.
Supervisory controls 587 include a two master mode switches: a System Record switch 519 which causes the local control systems to store parameter values at the address specified by the Setting Select switch 517; and a System Load switch 512 which causes the local systems to conform fixture parameters to the selected values. A Fixture Select switch 505 and input controls 507 and 509 for setting the desired values of two parameters are provided. A port 516 is provided so that setting selections may be entered from an external device, such as a conventional lighting controller, in the manner previously described.
Outputs 497S and 562S of the Setting Select and Fixture Select switches form an address buss 513 which serves as an input to memory means 511, display 589, and data carrier 585S. The outputs 508 and 510 of parameter input controls 507 and 509 form a data buss 560S which serves as an input to memory means 511, display 589, and data carrier 585S. Outputs 575, 498, 497, 562, and 560S are also provided to encoder 560E for transmission via transmitter 560T to the plurality of local control systems 486-491 via data link 560A.
The use of multiplexed communications between the system controller and multi-variable fixtures is disclosed in U.S. Pat. Nos. 3,845,351 and 4,392,187, and is widely employed. Circuitry for digital asynchronous communication between a lighting controller and a plurality of receivers is described in particular detail in U.S. Pat. No. 4,095,139.
Refer now to FIG. 4 where constructional details of a local control system are illustrated.
Local control system 486 includes local memory means 311 whose data port is connected to parameter value buss 560L which also serves as an input to register 405, whose load input is connected to System Load line 498 via AND gate 576B, whose second input is connected to output 562L of address decoder 562D. The output of register 405 serves as input to motor drives 403 and 420. The address port of memory means 311 is connected to setting select line 497. The fixture select buss 562 is connected to address decoder 562D, which is strapped to recognize the address assigned to the fixture, and which produces an output on line 562L upon doing so. This output serves as an input to AND gate 576 whose second input is the System Record line 575, and whose output is connected to the Record input of memory means 311. Inputs 497, 498, 562, 575, and 560L are connected to the output of decoder 560D which receives data from the supervisory unit over data link 560A via receiver 560R.
It will be apparent that parameter values may be entered into the register 405 of local control system 486 by closing the System Load switch 512, selecting the desired fixture with Fixture Select switch 505, and adjusting input controls 507 and 509 as required. Once the desired values have been reached, they may be entered into local memory means 311 by selecting a cue number with Setting Select switch 517 and closing System Record switch 519.
Desired values can also be "blind recorded" without display onstage by closing the System Record switch 519 with the System Load switch 512 open.
Fixture parameters can be conformed to recorded values by selecting the desired cue number with the Setting Select switch 517 and closing the System Load switch 511.
As previously described, the parameter value data stored in the memory means 311 of the local control systems can be up-loaded to a common display 589 or data carrier 585A at the supervisory level. Accordingly, FIG. 4 illustrates parameter data buss 560L as paralleled to both decoder 560D and encoder 561E via tristate driver 568. Parameter data present on buss 560L will thus be transmitted via data link 561A to the supervisory unit for display or recording, in the manner described in the parent application Ser. No. 443,127, when the appropriate fixture address is present on input 562. It will, however, be apparent, that either two simplex or one duplex data link are required for such communication, and that sophisticated display capabilities at the supervisory level will require significantly higher data rates on the data links as the supervisory unit querries the local control systems. It is, therefore, an object of the present invention to provide an improved control system which allows centralized display and data carrier facilities with little or no requirement for bidirectional communication.
Refer now to FIG. 3, where an additional memory means 511 is illustrated, connected in parallel to the output of the supervisory unit to the local control systems. It will be apparent that through the normal operation of the system as disclosed, each parameter value stored in a local memory means 311 of a local control system will automatically be duplicated in memory means 511 of the supervisory unit. The display of parameter values or their storage thus may employ the duplicated values stored in memory means 311, without consulting the memory means 311 of the local control systems, minimizing communications requirements on the data link 561A (and indeed permitting simpler embodiments of the system to be simplex in operation). The improved system of the present invention, however, still allows central display and data carrier features. And, while it does require a memory means 511 of sufficient capacity to store all parameter values in all cues, because for actual operation only the local memories 311 are employed, the supervisory memory 511 may comprise a comparatively economical device (in some cases, the data carrier itself).
An additional benefit of the reduction in data rates between the supervisory unit and the local systems is the ability to use data links such as infrared, ultrasonic, or power line carriers which had heretofore not been practical for such applications because of the limits on their maximum data rates.
While the operation of the system of the present invention is illustrated with hardware, microprocessors may be employed at either or both the local or the supervisory level. Indeed, it will be understood that the use of a processor at the local control system offers additional benefits.
One such benefit is increased sophistication in the transfer of data between the local system and the supervisory level--and indeed the transfer of data between local systems, such as between the system associated with a damaged fixture and that associated with a spare.
Another such benefit is the use of the local processor to perform data manipulation for its associated fixture. The employment of a microprocessor is for each local control system produces a "parallel processor" architecture in which, unlike prior art central systems, relatively sophisticated data manipulation can be performed without a substantial increase in system cost by "jobbing out" the task to the local control systems. As each increase in the number of controlled devices is accompanied by an increase in local control systems and with them, processor power, the improved control system of the present invention minimizes the cost of the shared portion (the supervisory control unit) and allows variations in system size from a few fixtures to several hundred with no modification to the supervisory unit, to the local control systems, or loss of response time, data capacity, or features.
One highly desirable data manipulation is the calculation for each fixture of the azimuth and elevation settings required for the beam to intersect an absolute location onstage from its current location over it.
By exploiting the communications capabilities of the system, the number of fixtures whose location in space must be reentered when the position of the truss or pipe supporting them changes can may be minimized. While the position of the fixture support structure relative to the stage changes, the relative positions of those fixtures on a common truss or pipe seldom does. Therefore the first and last fixture on an overhead pipe or truss might be "taught" their positions, preferably by means of an input from a position control system or sensor associated with the truss or pipe, but then communicate them to those fixtures mounted inbetween which, having previously been provided with their offsets relative to the "taught" units at the first setup, can calculate their own locations.
Further, it will be apparent that several techniques for controlling the rate at which parameters are changed will be possible. Different rates and start times are extremely complex to produce in prior art systems. It will however be apparent that a control system of the present invention whose local memories contain not only the desired condition for each cue but the desired rate of change could readily allow all units to perform in synchronization, but could equally well be used to produce individually specified rates and start times. The supervisory unit need only provide the Load instruction, and each local control system could start its transitions and vary their rates as instructed with virtually no practical limits on the complexity of the cue. Yet this capability may be provided with little or no impact on system size or cost. Similarly, each local control system can adjust its own rate of parameter change such that all parameter changes start and finish together, regardless of the variations in the amount of adjustment required.
The control system of the present invention thus not only allows any number of local control systems, and as such controlled devices, to be paralleled to the same supervisory unit and its data link, but so long as the local control systems are compatable with the data link, this approach places no limitations on the variety of control systems which can be connected with a common supervisory unit or data link; the number of variables they can maintain; and the number and type of devices they can control. There is, therefore, no reason why the same supervisory unit and buss cannot connect and coordinate color changers, remote yokes, and remote fixtures in any number and combination, each such device employing a local control system optimized for its function.
Further, as many of the same controls are required for the various types of controlled devices, the appeal of the system can be maximized, and its development cost minimized, by designing a "universal" supervisory control unit which is capable of adjusting any automated lighting product accepting the system's communication protocols.
While the simplest embodiment of the system of the present invention provides a corresponding memory location to be provided for each possible setting selection input/cue number, it will be recognized that a linked-list technique can be employed which allows the local control systems to use memory capacity only for cues in which the controlled device is active, maximizing the efficiency with which memory is employed.
It should also be noted that "transparent access" can be provided to the controlled devices for adjustment by direct command from the supervisory level with or without reference to the supervisory memory means in the prior art manner.
A hardware design for the local control unit is also possible which stores the operating program in an electrically-alterable memory accessable in certain modes from the supervisory level, such that an operator need only insert a data carrier containing the most current operating software version for the local system into the supervisory unit and download it to the local control system, such that all local systems, regardless of data of manufacture, thereafter operate on the most current software version and therefore offer the latest features and capabilities.
While the local control system would preferably be made integral with one controlled device, in some low-end applications (such as color-changers and remote yokes) it may prove more economical to locate them at an intermediate level such that one local control system drives, for example, four to eight such devices
Ideally, the hardware design for such a local control system would allow the same printed circuit card to be applied to a number of different applications on an OEM basis with little or no modification. | The application discloses an improved system for the control of a plurality of light projectors each generating a beam suitable for entertainment lighting and each provided with means to vary a plurality of parameters of the beam and with means to conform capable of cooperating to produce a desired adjustment of the beam when provided with a corresponding desired parameter value. The improved system disclosed employs a plurality of local control systems, each with its own local short-term memory, and means are provided for entering desired parameter values, and for storing said values for each of a plurality of desired lighting effects in the short-term memory of the local control system, such that they are each associated with at least one second value which identifies the desired lighting effect. Each of the local control systems has at least one input, and will output a stored parameter value to the means to conform when the second value with which that stored parameter value is associated is provided at said input. A means for selecting, which is capable of producing a plurality of such second values identifying a desired lighting effect to be reproduced, is coupled to said inputs of a plurality of local control systems, preferably by means of a serial data link. Preferably one such local control system is provided for each controlled fixture or device. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to presses, and more particularly to, a method for intermittently punching material with a press.
2. Description of Related Art
Currently, presses are being used to remove or punch material when forming a part from a sheet of material. Typically, the press has a frame, an upper platen with a cutting or punching tool, a lower platen and means for moving the upper platen toward the lower platen. The frame for these presses is rather large in size and height to allow the upper platen to develop enough inertia for the cutting tool such that the cutting tool can stamp or punch the material in a single continuous stroke.
To cut or punch material in a single continuous stroke, the cutting force commonly needed is equal to the yield strength of the material times the length of the cut or punch. Typically, over thirty percent (30%) of the material thickness has to be exceeded in order to allow the material being cut or punched to separate from the remainder of the material. As a result, the frame of the press must be sufficient in size to provide the structural force needed to absorb the cutting pressure. This structural force commonly is equal to the mass of the cutting tool or punch times the inertia thereof.
One problem with conventional presses is that the frame of the press must be rather large in size and height to absorb the required cutting pressure. As a result, a corresponding room must be of large dimensions to contain the press. Another problem is that these presses commonly have a "pit" or cavity disposed below in the support surface to aid in containing the press. This requires the press to be placed in a predetermined position on the support surface. This limits the mobility of the press. A further problem is that heavy equipment is required to move the press. This also reduces the mobility of the press. A still further problem is that a large size and height of the press is required to develop the inertia necessary for punching or removing material in one continuous stroke.
It is, therefore, one object of the present invention to provide a method of removing or punching material that requires a press smaller in size and height than conventional presses.
It is another object of the present invention to reduce the inertia required for the punch or cutting tool.
It is a further object of the present invention to reduce the structural force required for the press when cutting or punching material.
This application is related to another application entitled "APPARATUS FOR PUNCHING MATERIAL" filed on the same date and having similar Specification and drawings.
SUMMARY OF THE INVENTION
Accordingly, the present invention is a method for removing material from a sheet of material with a press having a movable upper platen, a stationary lower platen, and a cutting tool secured to the upper platen. The method includes the steps of establishing a reference point at the surface of the material with the cutting tool and moving the upper platen and cutting tool away from the lower platen a predetermined distance once the reference point is established. The steps also include moving the upper platen and cutting tool toward the lower platen the predetermined distance plus a percentage of the thickness of the material to displace material to be cut with the cutting tool. The steps further include repeating the latter two steps a plurality of times until the material to be cut is removed from the remainder of the material.
One advantage of the present invention is that the inertia required for punching or cutting is reduced by pulsating or intermittently moving the punch or cutting tool into the material. Correspondingly, the structural force needed to absorb the cutting pressure is reduced. This provides the advantage of a press that is smaller in size and height than conventional presses. Another advantage of the present invention is that the press is mobile and may be moved with light equipment such as a fork-lift or the like.
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an apparatus constructed in accordance with the principles of the present invention.
FIG. 2 is a side elevational view of the apparatus of FIG. 1.
FIG. 3 is a front elevational view of the apparatus of FIG. 1.
FIG. 4 is a plan schematic view of the apparatus of FIG. 1.
FIG. 5 is a schematic of the hydraulics for the apparatus of FIG. 1.
FIG. 6 is an enlarged schematic view of a portion of the apparatus for removing material according to the present method.
FIG. 7 is a view similar to FIG. 6 with the cutting tool establishing a reference point with respect to the surface of the material.
FIG. 8 is a view similar to FIG. 7 with the cutting tool penetrating the material in a first stage for the present method.
FIG. 9 is a view similar to FIG. 8 with the cutting tool penetrating the material in a second stage for the present method.
FIG. 10 is a view similar to FIG. 9 with the cutting tool breaking through the material in a third stage for the present method.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 through 3, a progressive die, press system or apparatus 10 is shown. The apparatus 10 includes a lower frame or stand, generally indicated at 12, which is adapted to rest upon a support surface. The lower frame 12 comprises a plurality of vertically extending leg members 14 interconnected by laterally and longitudinally extending support members 16 and 18. The lower frame 12 is generally rectangular in shape and the leg members 14 and support members 16 and 18 may be adjoined at their ends by welding or the like. The lower frame 12 supports at least one, preferably four individual presses, generally indicated at 20, 22, 24 and 26 respectively in series and in spaced relation to the support surface. Since each individual press is similar to each other, only the press 20 will be described.
The press 20 includes a stationary lower platen 28 which is secured to the lower frame 12 by welding or the like. The press 20 also includes a generally rectangular upper frame or housing, generally indicated at 27, comprising a pair of transversely spaced and upwardly extending side support members 30 connected or secured to the lower platen 28 by welding or the like. The upper frame 27 also comprises an upper support member 32 extending generally horizontally between the side support members 30 and connected by welding or the like to the upper end of the side support members 30. The upper frame 27 further comrpises a vertically extending back plate 33 secured by welding or the like to the side and upper support members 30 and 32. The side and upper support members 30 and 32, respectively, and back plate 33 may be connected to one another by suitable means other than welding.
The press 20 also includes a fluid-actuating device, generally indicated at 34, secured to the upper support member 32. The fluid actuating device 34 comprises a fluid cylinder 36 having a movable piston 37 (FIG. 5) disposed therein. The fluid cylinder 36 is secured to the upper support member 32 by any suitable means such as brackets and fasteners, welding or the like. The fluid-actuating device 34 also includes a piston rod 38 having one end connected to the piston 37 and the other end extending outwardly from one end of the fluid cylinder 36 toward the lower platen 28.
The press 20 further includes a movable upper platen 40 secured by brackets 42 and fasteners 44 to the free end of the piston rod 38. It should be appreciated that any suitable means may be used to secure the upper platen 40 to the piston rod 38. The fluid-actuating device 34 is pressurized to support the upper platen 40 in spaced relation to the lower platen 28. As illustrated in FIGS. 4 and 5, the fluid cylinder 36 is connected in a conventional manner by fluid lines 46 to a fluid regulating device or manifold 48 which, in turn, is connected by fluid lines 46 to a source of fluid pressure 50 such as a hydraulic pump and fluid reservoir or the like to move the piston 37 to extend and retract the piston rod 38, thereby moving the upper platen 40 toward and away from the lower platen 28.
The press 20 also includes a punch or cutting tool 52 disposed within and secured to the upper platen 40. The cutting tool 52 is used to cut, punch or remove material from a sheet 82 which is fed into the press 20. It should be appreciated that any suitable means may be used to secure the cutting tool 52 to the upper platen 40.
The press 20 also includes a work plate or tool 56 which rests upon the lower platen 28. The work tool 56 is a generally rectangular plate having a cavity 58 (FIG. 6) formed therein. The work tool 56 is secured to the lower platen 28 by at least one fastener 60 in the front and by a fluid actuated clamp 62 in the back. The fluid actuated clamp 62 includes a fluid cylinder 64 secured by suitable means to the lower platen 28. The fluid cylinder 64 has a movable piston (not shown) disposed therein and connected to one end of a piston rod 66. The piston rod 66 has a horizontally extending T-shaped member 68 connected to the other end of the piston rod 66. The T-shaped member 68 has a first adjustable fastener 70 at one end for engaging and disengaging the work tool 56 and a second adjustable fastener 72 at the other end for engaging and disengaging the lower platen 28. The fluid cylinder 64 is connected by fluid lines 46 to the source of fluid pressure 50 to move the piston, thereby extending and retracting the piston rod 66 to engage and disengage the work tool 56. It should be appreciated that any suitable means could be used to secure the work tool 56 to the lower platen 28.
As illustrated in FIGS. 1 through 3, each press has a chute 74 or the like disposed below the cavity 58 of the work tool 56 to allow removed material to escape the press 20. It should be appreciated that any suitable means could be used to secure the chute 74 to the lower frame 12.
The press 20 also includes a pair of transversely spaced guide rods 76 which are sliding disposed in a corresponding pair of guide bushings 78 extending upwardly from the work tool 56. The guide bars 76 and bushings 78 maintain parallel alignment between the upper platen 40 and the work tool 56 as the upper platen 40 moves in relation to the lower platen 28.
The apparatus 10 also includes a feeding mechanism 80 for feeding a continuous sheet of material 82 through the presses 20, 22, 24 and 26. As the sheet of material 82 moves or feeds through the presses 20 22, 24 and 26, each press removes material from the sheet of material 82. The sheet of material 82 moves as a continuous sheet until the last press 26 removes the part from the remainder of the sheet of material 82. The part produced escapes on chutes 88 and 90 secured to the lower frame 12. It should be appreciated to one skilled in the art that the apparatus 10 is similar to a progressive die.
Referring to FIG. 2, a mechanical stop such as a cam rotator 92 limits the relative distance that the upper platen 40 may move toward the work tool 56. The cam rotators 92 include stops 94 and 96 having a different height relative to each other to stop the upper platen 40 in its movement toward the work tool 56. In other words, the stop 94 may limit the penetration of the cutting tool 52 into the material 82 at a predetermined depth such as ten percent (10%) of the thickness of the material 82 while the stop 96 would allow the cutting tool to penetrate a second predetermined depth such as twenty percent (20%) of the thickness of the material 82. The cam rotator 92 rotates the stops 94 and 96 in and out of the space between the upper platen 40 and work tool 56 each time the piston rod 38 and upper platen 40 are retracted. It should be appreciated that any suitable means may be used to limit or control the position of the cutting tool 52 and upper platen 40 relative to the work tool 56 and lower platen 28.
Referring to FIGS. 2 and 4, the position of the upper platen 40 and cutting tool 52 may be controlled electronically by an electronic control unit 98 or the like as a substitute for the cam rotators 92. The electronic control unit 98 is electrically connected to the fluid regulating device 48 and a pair of position sensors 100 and 102 on the fluid cylinder 36. The position sensors 100 and 102 monitor the position of the piston 37 within the fluid cylinders 36 to control the relative position of the piston 37 within the fluid cylinder 36. In other words, the controlled movement of the piston 37 results in a controlled or finite movement of the cutting tool 52 and upper platen 40 toward the sheet of material 82 and work tool 56. It should be appreciated that any suitable electronic control unit 98 may be used to control the operation of the system 10 according to the method to be described.
Referring to FIG. 5, a hydraulic schematic for the apparatus 10 is shown. The fluid cylinder 36 is connected by fluid lines 46 to the fluid regulating device 48. The fluid regulating devices 48 comprises a plurality of, preferably three, servo-control valves 104 to change or control the directional movement of the piston 37. In other words, the servo-control valves 104 drive the piston 37 one way or the other to provide finite control of the fluid actuating device 34. The fluid regulating device 48 also includes a proportional valve 106 and associated stack 108 which are connected to the servo-control valves 104 to allow fluid flow in and out of the fluid actuating device 34. The proportional valve 106 and stack 108 control the fluid flow and pressure requirements for the fluid actuating device 34. The proportional valve 106 and stack 108 are connected by fluid lines 46 to the pressure source or hydraulic pump 50. It should be appreciated that the servo-control valves 104, porportional valve 106 and stack 108 are conventional.
Referring to FIGS. 6 through 10, a schematic of the method according to the present invention is shown. As illustrated in FIG. 6, the upper platen 40 is moved toward the work tool 56 of the lower platen 28. As illustrated in FIG. 7, the cutting tool 52 touches the surface 110 of the material 82 to establish a zero reference or set point. The piston rod 38 is retracted a predetermined distance and then extended back to the surface 110 plus a predetermined percentage such as ten percent (10%) of the thickness of the material 82 to a point 112 as illustrated in FIG. 8. When this occurs, the material 82 is physically impregnated by the cutting tool 52 which displaces the material 82 but does not exceed the yield strength of the material 82. The piston rod 38 is then retracted and then extended back to the surface 110 plus a second predetermined percentage such as twenty percent (20%) of the original material thickness to point 114 as illustrated in FIG. 9. This also results in displacement of material 82 but does not exceed the yield strength of the material 82. Referring to FIG. 10, the piston rod 38 is retracted a distance and then extended to the surface 110 plus a third predetermined percentage such as thirty percent (30%) of the original material thickness to exceed the yield strength and break or snap through the material 82 such that material is removed from the remaining sheet of material 82. It should be appreciated by one skilled in the art that by pulsating or intermittently moving the cutting tool 52 as described above, less material remains after each displacement resulting in less inertia to break through in the third stage. It should further be appreciated that the entire method occurs in a short or small time period.
The present invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of decription rather than of limitation.
Obviously, many modifications or variations of the present invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described. | The present invention is a method for removing material from a sheet of material with a press having a movable upper platen, a stationary lower platen, and a cutting tool secured to the upper platen. The method includes the steps of establishing a reference point at the surface of the material with the cutting tool and moving the upper platen and cutting tool away from the lower platen a predetermined distance once the reference point is established. The steps also include moving the upper platen and cutting tool toward the lower platen the predetermined distance plus a percentage of the thickness of the material to displace material to be cut with the cutting tool. The steps further include repeating the latter two steps a plurality of times until the material to be cut is removed from the remainder of the material. | 8 |
CROSS REFERENCE TO RELATED APPLICATION AND CLAIM OF PRIORITY
This application is a national phase application under 35 U.S.C. 371 of International Patent Application No. PCT/IB2014/000193 filed on Feb. 24, 2014, which claims priority from U.S. provisional patent application No. 61/773,298 filed on Mar. 6, 2013, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
The invention relates to a system for draining fluids from an aircraft and, more particularly, to a system for expelling leaked or otherwise unwanted fluid from aircraft components to an exterior of the aircraft where the system includes protection against lightning direct strike and attachment.
RELATED ART
Certain aircraft systems and components include drain systems which collect and expel 10 fluids which may leak from the systems or components or which otherwise accumulate in a cavity within the aircraft. The fluids may be flammable liquids such as fuel or oil or non-flammable fluids such as water. The drainage system directs such fluids to the exterior of the aircraft where the fluid is released into the atmosphere.
Traditional drain systems typically consist of one or more drain tubes connected at one end with the aircraft system or component that is susceptible to leakage, a body which extends between the first end and an outer skin of the aircraft, and a second opposite end which extends through the outer skin and protrudes slightly from the aircraft. FIG. 1 , for example, shows a schematic cross-section view of a portion of a conventional drainage system including a plurality of drain tubes 10 , 12 , 14 , and 16 each having first ends (not shown) disposed in fluid communication with an aircraft system or component. The drain tubes 10 , 12 , 14 , and 16 further include respective second ends 18 , 20 , 22 , and 24 which each extend through an outer skin 26 of the aircraft to an exterior where the drain tubes 10 , 12 , 14 , and 16 terminate. The seconds ends 18 , 20 , 22 , and 24 of the drain tubes 10 , 12 , 14 , and 16 typically extend about 0.65 inches or more beyond the aircraft outer skin 26 . The drainage system of FIG. 1 is for an auxiliary power unit (APU) disposed in a tail cone of the aircraft. The drain tubes 10 , 12 , 14 , and 16 are respectively connected to the following APU components: an inlet plenum drain; a fuel control drain; a bearing seal witness drain; and a turbine plenum drain. In use, any excess fluids which leak or are otherwise discharged from these various APU components are driven by gravity through the drain tubes 10 , 12 , 14 , and 16 to the second ends thereof 18 , 20 , 22 , and 24 where the fluids pass through the outer skin 26 are expelled into the atmosphere.
As mentioned, each of the drain tubes 10 , 12 , 14 , and 16 extend from the outer aircraft skin 26 about 0.65 inches or more. That is, the drain tubes protrude into the atmosphere surrounding the aircraft. Additionally, the drain tubes, or at least the second protruding ends thereof, may be composed of a conductive material. As such, the protruding drain tubes may be susceptible to lightning strike and attachment. This is particularly the case with regard to the APU drain tubes illustrated in FIG. 1 which are traditionally disposed on the lower angled surface of the aircraft composite tail cone at the APU access door skin. This is considered to be “zone 2A—swept stroke” and thus lightning effects must be considered.
Accordingly, there is a need for an aircraft drainage system which allows for expulsion of leaked or discharged fluids while at the same time minimizing lightning damage potential.
BRIEF SUMMARY
The disclosure provides a drain for expelling fluids from an interior of an aircraft to an exterior of the aircraft, the drain including a drain tube disposed at the interior of the aircraft having a first end disposed in fluid communication with an aircraft equipment to be drained and an opposite second end, wherein the drain tube terminates at the second end at a location within the interior of the aircraft, a seal which extends between the second end of the drain tube and an outer skin of the aircraft, delimiting a drainage cavity, and a drainage pathway extending from the cavity through the outer skin to the exterior of the aircraft.
The disclosure further provides a drainage system for an aircraft auxiliary power unit disposed in a tail cone of the aircraft, the drainage system including a drain tube having a first end disposed in fluid communication with the APU and configured to receive excess fluid from the APU, the drain tube further including an opposite second end, wherein the drain tube terminates at the second end at a location within the tail cone above a lower angled outer skin of the tail cone, a seal which surrounds and seals the second end of the drain tube, wherein the seal extends downwardly to the angled outer skin of the tail cone and seals thereagainst, delimiting a hermetically sealed drainage cavity, a perforation extending through the angled outer skin to an exterior of the aircraft, and a flange disposed on the outer skin at the exterior of the aircraft and extending over the perforation, the flange being configured to direct drained fluid at the exterior of the aircraft and to cover the perforation at the exterior of the aircraft to prevent lightning from entering the cavity, wherein the perforation is disposed in the angled outer skin at a relative low point of the cavity to facilitate gravity fed drainage of the fluid therethrough.
The above described and other features are exemplified by the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view of a conventional aircraft drain arrangement;
FIG. 2 is a side view of an aircraft;
FIG. 3 is a partial cross section view of a tail cone of the aircraft of FIG. 2 ;
FIG. 4 is perspective view of an access door of the tail cone of FIG. 3 ;
FIG. 5 is a perspective view of a drainage system according to one exemplary embodiment;
FIG. 6 is another perspective view thereof;
FIG. 7 is another perspective view thereof;
FIGS. 8-10 are various cross-sectional views thereof; and
FIG. 11 is a schematic cross sectional view of the drainage system of FIG. 6 .
DETAILED DESCRIPTION
FIG. 2 shows an exemplary aircraft 50 having a tail cone 52 . An auxiliary power unit (APU) is disposed within the tail cone 52 . FIG. 3 shows an enlarged cross-sectional partial view of the tail cone 52 . The tail cone 52 includes an outer skin 54 which extends over the internal aircraft structure which houses the APU 58 . An APU access door 60 is disposed on a lower side 62 of the tail cone 52 . The access door 60 is movable between a closed position (as shown) in which the APU 58 and an interior of the tail cone 52 are inaccessible, and an open position (not shown) in which the door 60 is positioned away from the tail cone such that the APU and tail cone interior may be accessed. The door 60 is typically hinged such that it pivots between the open and closed positions. The lower side 62 of the tail cone 52 is angled with a low point disposed toward the aircraft's front such that the lower side 62 angles upwardly in the aft direction. Thus, the outer skin of the tail cone 52 , including the APU access door 60 , correspondingly angles upwardly in the aft direction such that a low point is located toward the aircraft front.
FIG. 4 shows the APU access door 60 as including an outer skin 64 having an inner side 66 and an outer side 68 . The inner side 66 of the skin 64 is disposed within the tail cone interior; the outer side 68 is on the exterior of the aircraft and is exposed to the atmosphere. A honeycomb structure 70 is disposed on the inner side 66 of the skin 64 and lends strength and reinforcement to the door 60 . The honeycomb structure 70 extends over much of the door 60 but includes a cut away portion 72 which exposes a portion of the inner skin 66 .
A drainage system 100 is shown adjacent to the inner skin 66 of the door 60 at the cutaway portion 72 of the honeycomb structure 70 . The drainage system 100 includes a seal 102 and one or more drain tubes 104 . As will be discussed in detail, the seal 102 is affixed at one side to the internal structure of the aircraft and while an opposite side of the seal 102 engages the inner side 66 of the outer skin 64 of the door 60 when the door is in the closed configuration. FIG. 4 shows the seal 102 engaging the door 60 in the closed position. The drain tubes 104 terminate within the seal 102 , as will be discussed herein in further detail, and extend in an opposite direction away from the seal 102 .
FIG. 5 shows an enlarged view of the drainage system 100 . In this illustrative embodiment, four drain tubes 104 extend into the seal 102 . However, the drainage system 100 may include more or less drain tubes 104 depending upon a specific application and requirements of the system 100 .
FIGS. 6-7 is an enlarged view of the drainage system 100 and a partial view of the door 60 . As shown, the system 100 further includes a bracket 106 and a flange 108 . The flange 108 receives and supports the drain tubes 104 in a generally vertical orientation. The flange 108 is mounted upon the bracket 106 which is connected to an interior structure of the aircraft. In the illustrated example, the bracket 106 is connected to the APU 58 . The bracket 106 includes a mounting surface 110 upon which an upper side 112 of the seal 102 is fixedly mounted. As referenced above, a lower side 114 of the seal 104 is in contact with and engages the inner side 66 of the outer skin 64 of the door 60 . When the door 60 is moved into the opened position, the lower side 114 of the seal 102 disengages from the door 60 thus allowing the door 60 to move to a location remote from the seal 102 and the drain tubes 104 . When the door 60 is moved back into the closed position, the inner side 66 of the door 60 is brought proximate to the seal 102 such that the lower side 114 of the seal 102 contacts and, as discussed further herein, sealingly engages with the door 60 .
FIGS. 8 and 9 are cross-sectional views of the arrangement of FIGS. 6 and 7 taken along the axes Y-Y and X-X, respectively. As shown, the seal 102 delimits a cavity 120 at an interior of the seal 102 . The cavity 120 extends through the seal 102 and is bounded at an upper region by the flange 108 and the drain tubes 104 , and is further bounded at a lower region by the inner side 66 of the skin 64 of the APU access door 60 . This holds when the door 60 is in the closed position, as illustrated. When the door 60 is moved to the open position, the lower side 114 of the seal disengages from the inner side 66 of the door 60 such that the door 60 is free to travel to a position away from the bracket 106 , drain tubes 104 , and seal 102 . In this open position, the cavity 120 is open and exposed to the environment. As discussed above, when the door 60 is brought into the closed position, the seal 102 sealingly engages against the inner side 66 of the skin 64 of the door. In this closed position, the seal cavity 120 is hermetically sealed with respect to the remainder of the interior of the tail cone.
The drain tubes 104 extend through the flange 108 and through the bracket 106 into the cavity 120 . The drain tubes terminate in the upper region of the cavity 120 proximate to the upper side 112 of the seal 102 .
At the lower region of the cavity 120 , the lower portion 114 of the seal is engaged against the outer skin 64 of the door 60 . As such, a portion 65 of the inner side 66 of the door skin 64 is disposed within the cavity 120 . A perforation 122 is formed in this portion 65 of the outer skin 64 of the door 60 . The perforation 122 extends from the cavity 120 , through the outer skin 64 of the door 60 , to an exterior of the aircraft. In the exemplary illustrated embodiment, the perforation 122 is a hole having a circular shape. However, the perforation 122 may assume any desired shape suitable for a particular application of the drainage system 100 . For example, the perforation may curvilinear shaped, rectilinear shaped, or a combination shape having both curvilinear and rectilinear features. In the illustrated embodiment, the system 100 includes a single perforation 122 . In an alternate embodiment, the drainage system may include more than one perforation. Such multiple perforations can be similarly or differently shaped and they can be disposed proximate or distal to one another.
Where the cavity 120 includes a low point, the perforation(s) are preferably positioned proximate to such low point. For example, where the aircraft outer skin 64 is angled relative to a vertical axis of the aircraft and the drainage system is disposed at such angled outer skin 64 , a low point is created within the cavity. In such situation, the seal 102 is affixed perpendicularly to the angled outer skin 64 , as shown in the drawings, thus the cavity itself will be angled and will likely include an area which is lower on the vertical axis than other areas within the cavity. The perforation is preferably disposed within this low area to facilitate gravity induced drainage of any fluids within the cavity 120 .
A scupper flange 124 is disposed at the exterior of the aircraft on the outer side 68 of the skin 64 of the door 60 proximate to the perforation 122 . The scupper flange 124 extends over the perforation 122 and serves to direct expelled fluid in a predetermined direction at the exterior of the aircraft. Also, the scupper flange 124 serves to cover the perforation 122 and protect the cavity 120 and the remainder of the drainage system 100 from lightning which may occur at the exterior of the aircraft. That is, the scupper flange, preferably made of carbon fiber or a similar material, blocks the perforation 122 and the cavity 120 and thus prevents a lightning strike from entering.
FIG. 10 shows another cross-sectional view of the seal 102 and drain tubes 104 in isolation. The exemplary contour and shape of the seal 102 and of the corresponding cavity 120 are illustrated.
As mentioned, the drain tubes 104 of the drainage system 100 terminate at one end in the cavity 120 . The drain tubes 104 extend away from the seal 102 within the aircraft interior and terminate at opposite second ends at an aircraft system or component that is susceptible to fluid leakage or accumulation which requires periodic drainage. In the illustrated example, the drain tubes 104 extend to and are in fluid communication with various components of the APU 58 . For example, the drain tubes may extend to one or more of the APU inlet plenum drain, the fuel control drain, the bearing seal witness drain, and the turbine plenum drain. When fluid enters the drain tubes 104 , it is fed by gravity to the terminal ends of the drain tubes 104 disposed within the cavity 120 within the seal 102 . The fluid descends from the terminal ends of the drain tubes 104 , and flows downward through the cavity 120 to the area 65 of the inner side 66 of the outer skin 66 of the door 60 . As discussed, the perforation 122 is formed at a low point of this area 65 . Therefore, the leaked fluid is drawn by gravity into the perforation 122 , through the outer skin 64 of the door 60 , and into and through the scupper flange 124 from where it is expelled into the atmosphere. Of course, this scenario is with the door in the closed position. With the door in the open position, assuming the aircraft is grounded, liquid descending from the drain tubes 104 would simply fall from the tail cone to the ground.
In the illustrated embodiment, the seal 102 has an oval cross-section and thus the delimited cavity 120 possesses a correspondingly ovoid shape. This is merely exemplary, however. The seal 102 can assume any cross-sectional shape suitable for receiving the drain tubes 104 , for extending to and engaging with the door 60 , and for surrounding the perforation 122 .
The seal 102 , in the instant embodiment, is formed of a flexible material and is configured to absorb movement of the bracket 106 and APU 58 relative to the aircraft outer skin 64 and, vice versa, movement of the outer skin 64 relative to the interior components of the drainage system 100 . FIG. 11 is a schematic cross-section of the drainage system 100 in which the lower side 114 of the seal 102 is compressed against the door 60 . This compression may be a result of the relative motion described above.
Additionally and/or alternatively, the seal 102 may further be formed of a fire resistant material.
As discussed herein, the seal 102 is affixed at the upper side 112 to the mounting surface 110 of the bracket 106 . The seal 102 extends from the bracket 106 toward the APU access door 60 and includes the freely extending lower end 114 which, in the closed position, contacts and seals against the inner side 66 of the door skin 64 . In this configuration, the seal is not affixed to the door 60 , but instead the lower side 114 of the seal 102 sealingly engages the seal surface inner side 66 to hermetically seal the cavity 120 when the door 60 is closed. When the door is moved into the opened position, the engagement of the seal 102 and the door 60 is broken and the cavity 120 is exposed.
In alternate embodiment, the lower side 114 of the seal 102 is affixed to the inner side 66 of the outer skin 64 of the door 60 . In this configuration, the upper side 112 of the seal 102 extends freely towards the bracket 106 which, in this embodiment, includes a sealing surface 110 . In the closed position, the upper side 112 of the seal 102 contacts and sealingly engages the sealing surface 110 of the bracket to thus form and hermetically seal the cavity 120 . When the door is moved to the open position, the upper side 112 of the seal 102 disengages the bracket 106 and, because the seal 102 is affixed to the door 60 , the seal travels with the door 60 as it moves away from the bracket 106 and drain tubes 104 into the open position.
The drainage system 100 creates a drainage pathway 150 as illustrated in FIG. 8 . The pathway 150 extends from the drain tubes 104 , into and through the cavity 120 , into the perforation 122 and through the outer skin 64 of the aircraft, and finally into the scupper flange 124 from which the fluid is expelled into the atmosphere. The fluid is driven along the pathway by gravity and perhaps by a pressure differential created between the stationary air within the cavity and the moving air at the exterior of the aircraft passing around the scupper flange 124 . The drainage pathway 150 is suited for fluid movement only in the direction described, fluid may not move in the opposite direction of the described fluid pathway 150 .
As described, the fluid pathway 150 is suitable for fluid flow but is not a suitable pathway for lightning or movement of lightning energy. The scoop flange 124 inhibits entry of lightning into the cavity 120 . Moreover, the described pathway 150 does not provide any direct pathway for lightning to travel into the aircraft. That is, the seal is an elastic, fire-resistant, non-conductive material which does not offer a pathway for lightning. Furthermore, metallic conductive items such as the bracket 106 and drain tubes 104 are disposed at a distance from the outer skin 64 of the aircraft and from the perforation 122 formed therein. Thus, even if lightning somehow penetrated the cavity 122 or attached to a fluid droplet in scupper flange 124 , further movement of the lightning within the aircraft would be inhibited.
The illustrated embodiment of the aircraft drainage system 100 is described as being disposed at the tail cone of the aircraft to provide drainage to the APU 58 . This is merely exemplary. The system 100 may be utilized at a variety of locations across the aircraft. More specifically, the drainage system 100 may be used at any location on the aircraft where drainage of flammable or non-flammable fluids is desired, and particularly in areas susceptible to lightning exposure.
As used herein the terms “comprising” (also “comprises,” etc.), “having,” and “including” is inclusive (open-ended) and does not exclude additional, unrecited elements or method steps. The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. The term “or” means “and/or.” Reference throughout the specification to “one embodiment”, “another embodiment”, “an embodiment”, and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.
While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | A drain for expelling fluids from an interior of an aircraft to an exterior of the aircraft, the drain including a drain tube disposed at the interior of the aircraft having a first end disposed in fluid communication with an aircraft equipment to be drained and an opposite second end, wherein the drain tube terminates at the second end at a location within the interior of the aircraft, a seal which extends between the second end of the drain tube and an outer skin of the aircraft, delimiting a drainage cavity, and a drainage pathway extending from the cavity through the outer skin to the exterior of the aircraft. | 1 |
FIELD OF THE INVENTION
The present invention relates generally to a drill pipe for an oil or gas well and more particularly to a drill pipe having an internally coated conductive material for providing an electrical pathway for electronic data obtained down hole to be efficiently transmitted to the surface of an oil or gas well.
BACKGROUND OF THE INVENTION
Currently there exist tools in the oil and gas well industry that are specifically designed to obtain drilling and geological parameters downhole, near the drill bit. In some instances, the information obtained by these tools is stored in memory devices. In such cases, the stored information can be retrieved when the memory devices are returned to the surface of the well. This system, however, produces an undesirable lag time between the initial collection and storing of the downhole information and the retrieval of the downhole information at the surface of the well.
As an alternative, the downhole information can be transmitted to the surface of the well using pressure pulses in the drilling fluid. However, this method also produces an undesirable lag time caused by the time a pressure pulse takes to reach the surface. Accordingly, a need exists for a method and a system of transmitting data instantaneously and efficiently to the surface of a well.
SUMMARY OF THE INVENTION
In one embodiment, the present invention includes a drill pipe for an oil or gas well comprising a generally cylindrical hollow drill pipe having an inner diameter, an outer insulative coating is attached to the inner diameter of the drill pipe, a conductive coating is attached to the outer insulative coating, and an inner insulative coating is attached to the conductive coating, wherein the outer insulative coating, the conductive coating and the inner insulative coating together define an insulated electrical pathway from an upper end of the drill pipe to a lower end of the drill pipe.
Another exemplary embodiment of the present invention includes a plurality of the above described drill pipes adjacently connecting to form a drill string, wherein a connector is positioned between each adjacently connected drill pipe to electrically connect the insulated electrical pathway of each drill pipe to the insulated electrical pathway of the corresponding adjacent drill pipe to establish an insulated electrical pathway from an upper end of the drill string to a lower end of the drill string.
A further exemplary embodiment of the present invention includes the above described drill string, wherein each drill pipe inner diameter further comprises, an upper annular recess at an upper end of each drill pipe and a lower annular recess at a lower end of each drill pipe. The outer insulative coating is attached to the inner diameter, the upper annular recess and the lower annular recess of each drill pipe. An upper and a lower conductive sleeve is attached to the outer insulative coating in the upper and lower annular recess, respectively, of each drill pipe. The conductive coating is attached to the outer insulative coating and to the upper and lower conductive sleeves to establish an electrical pathway from the upper end to the lower end of each drill pipe. The inner insulative coating is attached to the conductive coating of each drill pipe, to insulate the electrical pathway of each drill pipe.
Another embodiment of the present invention includes a method of communicating to downhole oil or gas well equipment comprising: providing a generally cylindrical hollow drill pipe having an inner diameter; attaching an outer insulative coating to the inner diameter of the drill pipe; attaching a conductive coating to the outer insulative coating; and attaching an inner insulative coating to the conductive coating, such that the outer insulative coating, the conductive coating and the inner insulative coating together define an insulated electrical pathway from an upper end of the drill pipe to a lower end of the drill pipe.
Another embodiment of the present invention includes a method of communicating to downhole oil or gas well equipment comprising: providing a plurality of generally cylindrical hollow drill pipes wherein each drill pipe comprises an inner diameter; mating each drill pipe with a corresponding adjacent drill pipe to form a drill string; attaching an outer insulative coating to the inner diameter of each drill pipe; attaching a conductive coating to the outer insulative coating of each drill pipe; attaching an inner insulative coating to the conductive coating of each drill pipe, wherein for each drill pipe the outer insulative coating, the conductive coating and the inner insulative coating together define an insulated electrical pathway from an upper end of the drill pipe to a lower end of the drill pipe; and providing a connector that electrically connects the insulated electrical pathway of each drill pipe to the insulated electrical pathway of the corresponding adjacent drill pipe of each drill pipe to establish an insulated electrical pathway from an upper end of the drill string to a lower end of the drill string.
Another embodiment of the present invention includes a method of communicating to downhole oil or gas well equipment comprising: providing a plurality of the above described drill pipes, and forming in the inner diameter of each drill pipe an upper annular recess at an upper end of each drill pipe and a lower annular recess at a lower end of each drill pipe; attaching the outer insulative coating to the inner diameter, the upper annular recess and the lower annular recess of each drill pipe; attaching an upper and a lower conductive sleeve to the outer insulative coating in the upper and lower annular recess, respectively, of each drill pipe; attaching the conductive coating to the outer insulative coating and to the upper and lower conductive sleeves to establish an electrical pathway from the upper end to the lower end of each drill pipe; attaching the inner insulative coating to the conductive coating of each drill pipe, to insulate the electrical pathway of each drill pipe; and providing the connector that electrically connects the insulated electrical pathway of each drill pipe to the insulated electrical pathway of the corresponding adjacent drill pipe of each drill pipe to establish an insulated electrical pathway from an upper end of the drill string to a lower end of the drill string.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
FIG. 1 is a cross-sectional view of a lower end of a first drill pipe and a cross-sectional view of an upper end of a second drill pipe;
FIG. 2 is a cross-sectional view of the drill pipes of FIG. 1 threadingly connected, wherein each drill pipe has a conductive coating electrically connected by a connector;
FIG. 3 is a cross-sectional view of the drill pipes of FIG. 1 threadingly connected, wherein each drill pipe has a first conductive coating and a second conductive coating, and wherein the corresponding first conductive coatings and the corresponding second conductive coatings are electrically connected by a connector;
FIG. 4A is a longitudinal cross-section of the connector of FIG. 2;
FIG. 4B is a transverse cross-section of the connector of FIG. 2, taken from line 4 B— 4 B of FIG. 4A;
FIG. 5 is a cross-sectional view of the drill pipes of FIG. 1 threadingly connected, wherein each drill pipe has a conductive coating electrically connected to an upper and a lower conductive sleeve and wherein a lower conductive sleeve of the fist drill pipe is connected to the upper conductive sleeve of the second drill pipe by the connector of FIGS. 4A and 4B; and
FIG. 6 is a cross-sectional view of the drill pipes of FIG. 1 threadingly connected, wherein each drill pipe has a first conductive coating electrically connected to a first upper and a first lower conductive sleeve and a second conductive coating electrically connected to a second upper and a second lower conductive sleeve, and wherein the first sleeve and the second sleeve are electrically connected by a connector.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 1-6, the present invention is directed a drill pipe having an internally coated conductive material for forming an electrical pathway from an upper end of the drill pipe to a lower end of the drill pipe. The drill pipe of the current invention allows for communication between a well head and downhole equipment in an oil or gas well so that drilling parameters and geological parameters may be obtained downhole and transmitted to the well head for analysis.
FIG. 1 shows a lower end 10 of a first drill pipe 12 and an upper end 14 of a second drill pipe 16 . Although omitted for clarity, the first drill pipe 12 comprises an upper end that is similar to the upper end 14 of a second drill pipe 16 and the second drill pipe 16 comprises an lower end that is similar to the lower end 10 of the first drill pipe 12 . As such, reference to the lower end 10 and the upper end 14 in the following description is to be understood to apply equally to the first drill pipe 12 and to the second drill pipe 16 . In addition, the first drill pipe 12 and the second drill pipe 16 are shaped and formed similarly, such that reference to a drill pipe 22 in the following description is to be understood to apply equally to the first drill pipe 12 and to the second drill pipe 16 .
As depicted in FIG. 1, the drill pipe 22 comprises a body portion 20 that is generally cylindrical in shape and has a hollow center defined by an inner diameter 24 . The upper and lower ends 10 and 14 of the drill pipe 22 each comprise threads 18 . The threads 18 allow the upper end 10 of one drill pipe 22 to be connected to the lower end 14 of another drill pipe 22 . Drill pipes 22 that are connected in this way (as is shown in FIGS. 2-3 and 5 - 6 ) are typically collectively referred to as a drill string 26 . Although FIGS. 2-3 and 5 - 6 show the drill string 26 as having only two drill pipes 22 , the drill string may comprise any number of connected drill pipes 22 .
In an exemplary embodiment, the threads 18 are special tapered threads that, when engaged, provide a connection that is almost as strong as the body portion 20 of the drill pipe 22 and also provides a very reliable pressure seal for drilling fluids that are pumped through the drill string 26 during the drilling process.
In one embodiment, as depicted in FIG. 2, each drill pipe 22 in the drill string 26 comprises an outer insulative coating 28 attached to the inner diameter 24 of the drill pipe 22 , a conductive coating 30 attached to the outer insulative coating 28 , and a inner insulative coating 32 attached to the conductive coating 30 . As such, the outer insulative coating 28 , the conductive coating 30 and the inner insulative coating 32 of each drill pipe 22 together form an insulated electrical pathway from the upper end 14 of the drill pipe 22 to the lower end 10 of the drill pipe 22 , i.e. the outer insulative coating 28 insulates the conductive coating 30 from the body 20 of the drill pipe 22 , which is typically comprised of a metal material, and the inner insulative coating 32 insulates the conductive coating 30 from the drilling fluids.
As shown in FIGS. 2-3 and 5 - 6 when two drill pipes 22 are connected, a small gap 34 exists between the lower end 10 of one drill pipe 22 and the upper end 14 of the adjacent drill pipe 22 . In one embodiment, a connector 36 is attached to the drill string 26 in the small gap 34 between adjacent drill pipes 22 to electrically connect the insulated electrically pathways of the adjacent drill pipes 22 . For example, in the depicted embodiment of FIG. 2, the connector 36 comprises a protruding section 38 that has a larger diameter than the inner diameter 24 of the drill pipes 22 , such that when the connector 36 is disposed between the lower end 10 of one drill pipe 22 and the upper end 14 of the adjacent drill pipe 22 and the drill pipes 22 are connected, the connector 36 is trapped in the small gap 34 between the drill pipes 22 .
In one embodiment, the protruding section 38 of the connector 36 comprises a protruding shoulder 40 that mates with or abuts against a shoulder 42 in the upper end 14 of the drill pipe 22 to secure the connector to the drill string 26 when the connector 36 is disposed between the lower end 10 of one drill pipe 22 and the upper end 14 of the adjacent drill pipe 22 .
To establish the electrical connection between the insulated electrically pathways of the adjacently connected drill pipes 22 , the connector 36 comprises a conducting material 44 that has a body portion 45 , an upper conducting contact 46 and a lower conducting contact 48 . When the connector 36 is disposed between the lower end 10 of one drill pipe 22 and the upper end 14 of the adjacent drill pipe 22 , the upper conducting contact 46 establishes an electrical connection 50 with the conductive coating 30 in the lower end 10 of one drill pipe 22 and the lower conducting contact 48 establishes an electrical connection 52 with the conductive coating 30 in the upper end 14 of the adjacent drill pipe 22 . As such, an electrical pathway is established from the conductive coating 30 in the lower end 10 of one drill pipe 22 , to the upper conducting contact 46 , then to the connector conducting material body portion 45 , then to the lower conducting contact 48 , and then to the upper end 14 of the adjacent drill pipe 22 .
In one embodiment, the connector 36 is comprised of an insulative material, such that the electrical pathway from the upper conducting contact 46 , to the conducing material body portion 45 , to the lower conducting contact 48 , is insulated. For instance, the connector 36 may be formed in a molding process, such as injection molding, with the conducting material 44 being molded into the insulative material of the connector 36 . In one embodiment, the conducting material 44 is elastic, such that the upper conducting contact 46 and the lower conducting contact 48 compress when the electrical connections 50 and 52 are established between the adjacent drill pipes 22 .
The connector 36 may also comprise an upper annular groove 54 and a lower annular groove 56 . For instance, in the embodiment depicted in FIG. 2, the upper annular groove 54 is disposed above the upper conducting contact 46 , and hence above the electrical connection 50 , while the lower annular groove 56 is disposed below the lower conducting contact 48 , and hence below the electrical connection 52 . Disposed within each annular groove 54 and 56 is an elastomeric o-ring 58 . The o-ring 58 in the upper annular groove 54 creates a seal against the conductive coating 30 in the lower end 10 of one drill pipe 22 to prevent the drilling fluids from contaminating the electrical connections 50 and 52 from above, while the o-ring 58 in the lower annular groove 56 creates a seal against the conductive coating 30 in the upper end 14 of the adjacent drill pipe 22 to prevent the drilling fluids from contaminating the electrical connections 50 and 52 from below.
The connector 36 may comprise one conducting material 44 , or, as depicted in FIGS. 4A and 4B, the connector 36 may comprise a plurality of conducting materials 44 . For instance, in the depicted embodiment of FIGS. 4A and 4B, the connector 36 comprises six conducting materials 44 , each attached to the connector 36 and forming the electrical connections 50 and 52 as described above.
The drill string 26 may comprise a plurality of adjacently connected drill pipes 22 , wherein each adjacently connected drill pipe 22 has a the connector 36 disposed therebetween as described above, such that each connector 36 electrically connects the conductive coating 30 of one drill pipe 22 to the conductive coating 30 of its adjacent drill pipe 22 to establish an insulated electrical pathway from an upper end of the drill string 26 to a lower end of the drill string 26 .
As depicted in FIG. 3, each drill pipe 22 in the drill string 26 may comprise a second conductive coating 60 attached to the inner insulative coating 32 , and a second inner insulative coating 62 attached to the second conductive coating 60 , such that the inner insulative coating 32 , the second conductive coating 60 and the second inner insulative coating 62 together form a second insulated electrical pathway.
In such an embodiment, the connector 36 may have an inwardly stepped section 63 , containing a second conducting material 64 having a body portion 65 , an upper conducting contact 66 and a lower conducting contact 68 . The second conducting material 64 may be formed and attached to the conductor 36 as described above with respect to the conducting material 44 .
When the connector 36 is disposed between the lower end 10 of one drill pipe 22 and the upper end 14 of the adjacent drill pipe 22 , the upper conducting contact 66 establishes an electrical connection 70 with the conductive coating 60 in the lower end 10 of one drill pipe 22 and the lower conducting contact 68 establishes an electrical connection 72 with the conductive coating 60 in the upper end 14 of the adjacent drill pipe 22 . As such, an electrical pathway is established from the conductive coating 60 in the lower end 10 of one drill pipe 22 , to the upper conducting contact 66 , then to the connector conducting material body portion 65 , then to the lower conducting contact 68 , and then to the upper end 14 of the adjacent drill pipe 22 . As described above and as shown in FIGS. 4A and 4B, the connector 36 may comprise one second conducting material 64 , or the connector 36 may comprise a plurality of second conducting materials 64 .
The drill string 26 may comprise a plurality of adjacently connected drill pipes 22 , wherein each adjacently connected drill pipe 22 has the connector 36 disposed therebetween as described above, such that each connector 36 electrically connects the conductive coating 60 of one drill pipe 22 to the conductive coating 60 of its adjacent drill pipe 22 to establish a second insulated electrical pathway from an upper end of the drill string 26 to a lower end of the drill string 26 . O-rings may be used, as described above, to prevent the drilling fluids from contaminating the electrical connections 70 and 72 .
Each drill pipe 22 in the drill string 26 may comprise a plurality of conductive coatings and each connector may comprise a corresponding plurality of inwardly stepped sections and conducting materials, such that the drill string 26 comprises a plurality of insulated electrical pathways from an upper end of the drill string 26 to a lower end of the drill string 26 .
In one embodiment, as depicted in FIG. 5, the lower end 10 and the upper end 14 of each drill pipe 22 in the drill string 26 comprises a lower annular recess 76 and an upper annular recess 78 . In such an embodiment, the outer insulative coating 28 is attached to the inner diameter 24 , the upper annular recess 78 and the lower annular recess 76 of each drill pipe 22 . An upper and a lower conducting sleeve 82 and 80 are attached to the outer insulative coating 28 in the upper annular recess 78 and the lower annular recess 76 , respectively. For instance, the upper and lower conducting sleeves 82 and 80 may be press fit into the upper and lower annular recesses 78 and 76 , respectively.
In this embodiment, the conductive coating 30 is attached to the outer insulative coating 28 and to the upper and lower conducting sleeves 82 and 80 to establish an electrical pathway from the upper end 14 to the lower end 10 of each-drill pipe 22 . The inner insulative coating 32 is attached to the conductive coating 30 such that the conductive coating 30 is insulated.
As described above, to establish an electrical connection between the insulated electrically pathways of the adjacently connected drill pipes 22 , the connector 36 is disposed between the lower end 10 of one drill pipe 22 and the upper end 14 of the adjacent drill pipe 22 . When so positioned, the upper conducting contact 46 establishes an electrical connection 90 with the lower conducting sleeve 80 and the lower conducting contact 48 establishes an electrical connection 92 with the upper conducting sleeve 82 , such that an insulated electrical pathway is established from the conductive coating 30 in the lower end 10 of one drill pipe 22 , to the lower conducting sleeve 80 , then to the upper conducting contact 46 , then to the connector conducting material body portion 45 , then to the lower conducting contact 48 , then to the upper conducting sleeve 82 , and then to the upper end 14 of the adjacent drill pipe 22 .
The conducting sleeves 80 and 82 provide a more robust contact surface than the conductive coating. Hence the addition of the conducting sleeves 80 and 82 produces more secure electrical connection 90 and 92 with the connector 36 . O-rings may be used, as described above, to prevent the drilling fluids from contaminating the electrical connections 90 and 92 . In addition, rather than extending the outer insulative coating 28 into the upper and lower annular recesses 78 and 76 , the contact sleeves 82 and 80 may each comprise an insulative material on its outer surface.
In the embodiment depicted in FIG. 6, each drill pipe 22 in the drill string 26 comprises a second lower annular recess 86 and a second upper annular recess 88 . In this embodiment, a second lower conducting sleeve 100 and a second upper conducting sleeve 102 are attached to the second lower annular recess 86 and the second upper annular recess 88 , respectively, such as by press fitting. The second conductive coating 60 is attached to the inner insulative coating 32 and to the second upper and lower conducting sleeves 102 and 100 to establish a second electrical pathway from the upper end 14 to the lower end 10 of each drill pipe 22 . The second inner insulative coating 62 is attached to the second conductive coating 60 such that the second conductive coating 60 is insulated.
In this embodiment, the connector 36 may comprise the inwardly stepped portion 63 comprising the second conducting material 64 , such that the upper conducting contact 66 and a lower conducting contact 68 establish electrical contacts 110 and 112 , respectively, with the second lower conducting sleeve 100 and the second upper conducting sleeve 112 .
Each drill pipe 22 in the drill string 26 may comprise a plurality of conductive coatings and a plurality of corresponding upper and lower conducting sleeves; and each connector may comprise a corresponding plurality of inwardly stepped sections and conducting materials, such that the drill string 26 comprises a plurality of insulated electrical pathways from an upper end of the drill string 26 to a lower end of the drill string 26 .
In each of the embodiments described above, each coating may have a thickness in the range of approximately 0.006 inches to approximately 0.030 inches. In addition, each insulative coating may comprise a plastic polymer such as an epoxy, phenolic, teflon, or nylon. The insulative coatings may be spray applied. The conductive coatings may comprise a metal material, such as copper, aluminum, silver or gold, or a mixture of metal particles and a polymer. The conductive coatings may be applied by plating or spraying.
The preceding description has been presented with references to presently preferred embodiments of the invention. Persons skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structures and methods of operation can be practiced without meaningfully departing from the principle, spirit and scope of this invention. Specifically, although drill strings having only one or two conductive pathways are described herein, it should be understood that the principles of the invention may be applied to form drill pipe and therefore drill strings having any arbitrary number of conductive pathways. Accordingly, the foregoing description should not be read as pertaining only to the precise structures described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope. | A method and apparatus for communicating to downhole oil or gas well equipment are provided. The apparatus includes a drill pipe for an oil or gas well including a generally cylindrical hollow drill pipe having an inner diameter, an outer insulative coating attached to the inner diameter of the drill pipe, a conductive coating attached to the outer insulative coating, and an inner insulative coating attached to the conductive coating, wherein the outer insulative coating, the conductive coating and the inner insulative coating together define an insulated electrical pathway from an upper end of the drill pipe to a lower end of the drill pipe. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to an improved method for the preparation of iodonium salts. More specifically, the present invention relates to an improved method for the production of symmetric or asymmetric diaryliodonium triflate (trifluoromethane sulfonate) salts. The diaryliodonium salts of the present invention are useful as photoacid catalysts for use in acid-sensitive polymerization and in curing systems such as radiation curable release coating compositions.
Iodonium salts and methods for their preparation have been described in the art. For example, Crivello, in U.S. Pat. No. 4,108,747 discloses cationically polymerizable compositions containing an organic material such as epoxides, vinyl ethers, and N-vinyl compounds and an effective amount of aryl onium trifluoromethane sulfonate salts such as triphenyl sulfonium trifluoromethane sulfonate and diphenyliodonium trifluoromethane sulfonate. These curable compositions are disclosed as being polymerizable under ultraviolet radiation.
Reineke, in U.S. Pat. No. 4,125,555, discloses trifluoromethanesulfonate esters which promote char formation in polymer compositions containing a monovinylidene aromatic monomer such as styrene and an ethylenically unsaturated carboxylic anhydride such as maleic anhydride. A method for the preparation of these trifluoromethanesulfonate esters is also described.
Crivello, in U.S. Pat. No. 4,310,469, teaches that epoxy monomers or prepolymers can be cationically polymerized by the use of certain radiationssensitive aromatic halonium salts. The radiation sensitive aromatic salts are disclosed as being diaryliodonium salts, and the radiation curable compositions are taught as being useful as sealants, coating compounds, and encapsulants.
Crivello, in U.S. Pat. No. 4,399,071 discloses a method for making diaryliodonium salts which are useful as photoinitiators for a variety of cationic polymerizable organic materials. In this method an aromatic iodo compound is reacted with an aryl organic aromatic compound in the presence of a peroxy organic acid and an organic sulfonic acid.
Miller, in U.S. Pat. No. 4,786,441 discloses a method for the preparation of iodonium and sulfonium triflates. In this method it is taught that the iodonium or sulfonium triflate is prepared by dissolving or slurring an iodonium or sulfonium halide in an organic solvent such as methylene chloride and reacting it with a trimethylsilyl triflate.
Dektar and Hacker, Journal of Organic Chemistry, 55, 639-647 (1990) discuss the photochemistry of diaryliodonium salts. Specifically, the photochemistry of diphenyl- and bis(4-methylphenyl)iodonium salts was investigated by product analysis, measurement of acid, and determination of the consumption of the iodonium salts. The similarities and differences between diaryliodonium and triarylsulfonium photochemistry is also described.
Umemoto et al. in U.S. Pat. No. 5,066,795 discloses (perfluoroalkyl)dibenzonium salts and a method for their preparation. These compounds are described as being useful as reagents for introducing perfluoroalkyl groups into various organic compounds.
Kitamura et al., Synthesis, 945-946, (1992), discloses a reagent prepared from iodosylbenzene and trifluoromethanesulfonic acid which reacts with aromatic compounds to give diaryliodonium triflates in good yields. The high reactivity of the reagent prepared is also disclosed. In this method a mixture of iodosobenzene and trifluoromethane sulfonic acid is made at 0° C. and is then further contacted with the desired aromatic substrate. However, iodosobenzene can only be prepared by hydrolysis of iodobenzenediacetate. In contrast, the method of the instant invention is easier to practice and employs more available starting materials. Furthermore, the method of the instant invention treats iodoarenedicarboxylates with strong acids such as trifluoromethanesulfonic acid which leads to the formation of bonded dimers however, unexpectedly, these dimers react to form desired monomeric products.
Herzig, in German Patent Publication No. DE 4142327 teaches silane containing iodonium salts and a process for their preparation. These iodonium salts are disclosed as being suitable as photoinitiators for polymerizing cationically polymerizable organic substances such as epoxides, vinyl ethers, epoxy group containing organopolysiloxanes, alkenyloxy group (such as vinyloxy or propenyloxy) containing organopolysiloxanes, and olefins. However, none of the references described hereinabove disclose the unique method of preparing diaryliodonium salts of the instant invention.
SUMMARY OF THE INVENTION
The present invention relates to a method of making diaryliodonium trifluoromethane sulfonate salts which comprises contacting a mixture of iodoaryldicarboxylate with a molar equivalent of trifluormethanesulfonic acid in a non-aromatic solvent to form a homogeneous solution at temperatures of below 0° C. to 100° C. depending on the liquid range of the solvent and mixtures. The method of the instant invention further comprises contacting the homogenous solution prepared above with a molar equivalent of a molecule containing at least one aromatic nucleus being at most pentasubstituted (having at least one unsubstituted hydrogen attached to the aromatic nucleus) at temperatures of below 0° C. to 100° C. depending on the liquid range of the solvent and mixtures. The pure compounds are isolated by removing the reaction solvent and adding a non-solvent to the residue and triturating until solidification occurs.
The compounds prepared by the method of the instant invention are suitable for use with polymerizable or curable compounds such as vinyl ether functional siloxane polymers, vinyl functional siloxanes, organic vinyl ethers, and olefins to afford radiation curable compositions.
It is an object of this invention to provide an improved method for the preparation of diaryliodonium trifluoromethane sulfonate salts.
It is also an object of this invention to provide a method for preparing diaryliodonium trifluoromethane sulfonate salts which is easier to practice and employs more available starting materials.
It is an additional object of this invention to provide a method for preparing diaryliodonium salts which results in improved yields while avoiding stringent reactant requirements and reaction conditions.
It is a further object of this invention to provide diaryliodonuim salt compounds which are advantageously employed with polymerizable or curable compounds such as vinyl ether functional siloxane polymers, vinyl functional siloxanes, organic vinyl ethers, and olefins to afford effective radiation curable compositions.
These and other features, objects and advantages of the present invention will be apparent upon consideration of the following detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a method for the preparation of iodonium salts, the method comprising the steps of: (I) mixing (A) substituted or unsubstituted iodoarene dicarboxylates and (B) a solvent selected from the group consisting of acetic acid, chlorinated hydrocarbons, and polar aprotic solvents, (II) adding to the mixture of (I) an acid (C) selected from the group consisting of perfluoroalkylsulfonic acids, hexahalometallic acids, hexahalometalloidic acids, tetrahaloboronic acids, tetrakis(perfluoroaryl)boronic acids, and tetrakisperfluoroalkylsulfonatoboronic acids at a temperature of at least -20° C. to form a homogenous reaction mixture; (III) reacting with the homogeneous reaction mixture of (II) a compound (D) selected from the group consisting of benzene, alkyl substituted benzenes, aryl substituted benzenes, arylalkyl substituted benzenes, alkoxy substituted benzenes, arylalkoxy substituted benzenes, and halobenzenes for at least 30 minutes; and (IV) stripping off solvent from the mixture of (III).
Compound (A) is a substituted or unsubstituted iodoarene dicarboxylate. The iodoarene dicarboxylate of Step (I) of the method of the instant invention is preferably a compound having the general formula R' a ArI(O 2 CR") 2 wherein R' is selected from the group consisting of monovalent hydrocarbon or halohydrocarbon radicals free of aliphatic unsaturation and having from 1 to 40 carbon atoms, halogens, NO 2 , CN, COOH, SO 3 H, alkoxy radicals, nitro substituted groups, nitrile substituted groups, carboxylic acid substituted groups, sulfonic acid substituted groups, alkoxy substituted groups, R" is a monovalent hydrocarbon or halohydrocarbon radicals free of aliphatic unsaturation and having from 1 to 20 carbon atoms, a has a value of from 0 to 5, and Ar is an arene having from 6 to 40 carbon atoms.
The group R' can be a monovalent hydrocarbon or halohydrocarbon radical free of aliphatic unsaturation having from 1 to 40 carbon atoms. Monovalent hydrocarbon radicals free of aliphatic unsaturation which are suitable as R' include alkyl radicals such as methyl, ethyl, propyl, butyl, hexyl, octyl, and decyl, cycloaliphatic radicals such as cyclohexyl, aryl radicals such as phenyl, tolyl, and xylyl, and arylalkyl radicals such as benzyl and phenylethyl.
Monovalent hydrocarbon radicals suitable as R' also include arene radicals having from 6 to 40 carbon atoms such as naphthyl (C 10 H 7 ), anthracenyl or phenanthracenyl (C 14 H 9 ), pyrenyl (C 16 H 9 ), napthacenyl, 9,10-benzophenanthrenyl, chrysenyl, 1,2-benzanthracenyl, or 3,4-benzophenanthrenyl (C 18 H 11 ), 3,4-benzopyrene or perylenyl (C 20 H 11 ), 1,2,3,4-dibenzanthracenyl, 1,2,5,6-dibenzanthracenyl, 1,2,6,7-dibenzoanthracenyl, 1,2,7,8-dibenzanthracenyl, 1,2,6,7-dibenzophenanthracenyl, 1,2,7,8-dibenzophenanthracenyl, pentacenyl, or picenyl (C 22 H 13 ), coronenyl (C 24 H 11 ), 1,2,4,5-dibenzopyrene (C 24 H 13 ), and hexacenyl (C 26 H 15 ). Arene radicals having up to 40 carbon atoms which are suitable as R' also include combinations of the above radicals attached to one another such as phenylhexadecenyl (C 32 H 19 ) or anthracenylhexacenyl (C 40 H 23 ).
The group R' can also be a halogen atom, or a radical selected from NO 2 , CN, COOH, and SO 3 H. Halogen atoms suitable as R' include fluorine, chlorine, and bromine. Alkoxy radicals suitable as R' include radicals such as methoxy, ethoxy, propoxy, and butoxy radicals. Nitro substituted groups suitable as R' include groups such as 3-O 2 N--C 6 H 4 or 4-Cl,3-O 2 N--C 6 H 3 . Nitrile substituted groups suitable as R' are exemplified by groups such as 4-NC--C 6 H 4 , 1-NC--C 10 H 7 , or 2-NC--C 10 H 7 . Carboxylic acid substituted groups suitable as R' are exemplified by groups such as 4-HOOC--C 6 H 4 or 3-HOOC--C 6 H 4 . Sulfonic acid substituted groups suitable as R' are exemplified by groups such as 4-HO 3 S--C 6 H 4 or 3-HO 3 S--C 6 H 4 . The alkoxy substituted groups suitable as R' include groups such as 4-CH 3 O--C 6 H 4 , 4-C 2 H 5 O--C 6 H 4 , 2-CH 3 O--C 6 H 4 , and 2-C 2 H 5 O--C 6 H 4 .
The group R" is a monovalent hydrocarbon or halohydrocarbon radical free of aliphatic unsaturation having from 1 to 20 carbon atoms. Monovalent hydrocarbon radicals free of aliphatic unsaturation which are suitable as R" include alkyl radicals such as methyl, ethyl, propyl, butyl, hexyl, octyl, and decyl, cycloaliphatic radicals such as cyclohexyl, aryl radicals such as phenyl, tolyl, and xylyl, and arylalkyl radicals such as benzyl and phenylethyl.
Ar in the formula hereinabove denotes an aromatic radical having the formula C n H.sub.(n/2+2) or of formula C m H.sub.(m/2+1), wherein n has a value of 6, 10, 14, 18, 22, 26, 30, 34 or 38 and m has a value of 16, 20, 24, 28, 32, 36, or 40. Ar denotes arene radicals having from 6 to 40 carbon atoms. Arene radicals suitable as Ar are exemplified by phenyl (C 6 H 5 ), naphthyl (C 10 H 7 ), anthracenyl or phenanthracenyl (C 14 H 9 ), pyrenyl (C 16 H 9 ), napthacenyl, 9,10-benzophenanthrenyl, chrysenyl, 1,2-benzanthracenyl, or 3,4-benzophenanthrenyl (C 18 H 11 ), 3,4-benzopyrene or perylenyl (C 20 H 11 ), 1,2,3,4-dibenzanthracenyl, 1,2,5,6-dibenzanthracenyl, 1,2,6,7-dibenzoanthracenyl, 1,2,7,8-dibenzanthracenyl, 1,2,6,7-dibenzophenanthracenyl, 1,2,7,8-dibenzophenanthracenyl, pentacenyl, or picenyl (C 22 H 13 ), coronenyl (C 24 H 11 ), 1,2,4,5-dibenzopyrene (C 24 H 13 ), hexacenyl (C 26 H 15 ), and combinations of these radicals attached to one another such as phenylhexadecenyl (C 32 H 19 ) or anthracenylhexacenyl (C 40 H 23 ).
In step (I) of the method of this invention compound (A) delineated hereinabove is mixed with compound (B) a solvent selected from the group consisting of acetic acid, chlorinated hydrocarbons, and polar aprotic solvents. The chlorinated hydrocarbons are preferably selected from the group consisting of methylene chloride, chloroform, and 1,2-dichloroethane. Preferably the polar aprotic solvents are selected from the group consisting of acetonitrile, dimethylsulfoxide, and benzonitrile.
For purposes of this invention from 40 to 100 percent by weight of solvent (B) can be used, and it is preferred that from 90 to 100 percent by weight of (B) be employed, said percent by weight being based on the total weight of Components (A), (C), and (D).
Step (II) in the method of the present invention comprises adding to the mixture of (I) an acid (C) selected from the group consisting of perfluoroalkylsulfonic acids, hexahalometallic acids, hexahalometalloidic acids, tetrahaloboronic acids, tetrakis(perfluoroaryl)boronic acids, and tetrakisperfluoroalkylsulfonatoboronic acids at a temperature of at least -20° C. to form a homogenous reaction mixture. Perfluoroalkylsulfonic acids are exemplified by perfluorobutanesulfonic acid, perfluoroethanesulfonic acid, perfluoro-octanesulfonic acid, or trifluoromethanesulfonic acid. Hexahalometallic acids include acids such as HSbF 6 , HAsF 6 , HSbCl 6 , and HAsCl 6 , hexahalometalloidic acids include acids such as HPF 6 and HPCl6, tetrahaloboronic acids include acids such as HBF 4 , HBCl 4 , and HBBr 4 , tetrakis perfluoroaryl boronic acids are exemplified by HB(C 6 H 5 ) 4 and HB(C 10 F 7 ) 4 , and tetrakisperfluoroalkylsulfonatoboronic acids include acids such as HB(O 3 SCF 3 ) 4 , HB(O 3 SC 2 F 5 ) 4 , and HB(O 3 SC 4 F 9 ) 4 . Preferably (C) is selected from the group consisting of trifluoromethanesulfonic acid, perfluorobutylsulfonic acid, hexafluoroantimonic acid, hexafluorophosphoric acid, hexafluoroarsenic acid, tetrafluoroboric acid, tetrakis(pentafluorophenyl)boric acid, and tetrakis(trifluoromethanesulfanato)boric acid.
Step (III) in the method of the present invention comprises reacting with the homogeneous reaction mixture of (II) a compound (D) selected from the group consisting of benzene, alkyl substituted benzenes, aryl substituted benzenes, arylalkyl substituted benzenes, alkoxy substituted benzenes, arylalkoxy substituted benzenes, and halobenzenes for at least 30 minutes. Preferably compound (D) is selected from the group consisting of benzene, toluene, xylene, butylbenzene, t-butylbenzene, dodecylbenzene, tetracosyl benzene, octylbenzene, 1-phenyl-5-methylheptane, bisdodecylbenzene, fluorobenzene, anisole, octyloxybenzene, dodecyloxybenzene, octadecyloxybenzene, 1-phenoxy-5-methylheptane, 1,2-bis(phenoxyethane), and 1,3-bis(2-phenylpropyl)-1,1,3,3-tetramethyldisiloxane.
Step (IV) in the method of the present invention comprises stripping off solvent from the mixture of (III). Methods of stripping volatile components are well known in the art and need no extensive delineation herein. Any method of removing volatile components can be used in the present invention, such methods exemplified by, but not limited to, distillation, evaporation, by passage of steam, air, or other gas through the liquid mixture, molecular stills, rotoevaporators, and wiped film evaporators. The preferred method of stripping off the solvent from the mixture of step (III) is by employing a rotoevaporator.
It is preferred for purposes of the present invention that the molar ratio of (A) to (C) to (D) is 0.95 to 1.05 to 0.95 to 1.05 to 0.95 to 1.05. It is preferred for purposes of the instant invention that the molar ratio of (A) to (C) to (D) is 1 to 1 to 1.
The method of the present invention can further comprise the step of adding a mixture of an organic solvent and water prior to step (IV) which results in the formation of an organic layer and an aqueous layer. The organic solvents suitable for the method of the present invention include methylene chloride, acetonitrile, mineral spirits, chlorinated hydrocarbons and the like, benzene, toluene, ethers, and xylene. Preferred organic solvents in the method of this invention include toluene and diethyl ether. The mixture of organic solvent and water can be added in a ratio of 99 weight percent organic solvent to 1 weight percent of water to a ratio of 1 weight percent organic solvent to 99 weight percent of water. It is preferred that the organic solvent make up at least 30 weight percent of this mixture. Addition of this mixture results in the formation of two layers, an organic layer and an aqueous layer. Separation of the organic layer and the aqueous layer comprises allowing the non-miscible layers to phase separate and then drawing the less dense layer of the top and the more dense layer off the bottom of a separation vessel. The manner in which the two layers are mechanically separated is not critical as long as the two layers are isolated. Separation of the two layers may be accomplished by any of the separation methods well known to those skilled in the art. Separation of the two layers may be accomplished by evaporation, distillation, drying, gas absorption, sedimentation, solvent extraction, press extraction, adsorption, and filtration.
The method of the present can further comprise adding water to the separated organic layer. The amount of water added to the organic layer is not critical and may be readily determined through routine experimentation by those of ordinary skill in the art. This can then be followed by stripping of the organic layer. Methods of stripping the organic layer are as delineated above.
The method of the present invention can further comprise heating the mixture after step (III). The mixture in this method of the invention is preferably heated at a temperature of about 20° C. to 100° C. and more highly preferred is that the mixture be heated at a temperature of from about 40° to 70° C. after step (III).
The diaryliodonium salts prepared by the method of the present invention are diaryliodonium salts having the general formula R i a ArI + ArR ii b X - wherein R i is selected from the group consisting of monovalent hydrocarbon or halohydrocarbon radicals free of aliphatic unsaturation having from 1 to 40 carbon atoms, halogen atoms, NO 2 , CN, COOH, SO 3 H, alkoxy radicals, nitro substituted groups, nitrile substituted groups, carboxylic acid substituted groups, sulfonic acid substituted groups, and alkoxy substituted groups, R ii is selected from the group consisting of monovalent hydrocarbon radicals free of aliphatic unsaturation and having from 1 to 40 carbon atoms, alkoxy substituted groups, arylalkoxy radicals, aryloxy radicals, and halogen atoms, Ar denotes arene radicals having from 6 to 40 carbon atoms, a has a value of from 0 to 10, b has value of from 0 to 10, and X - is an anion selected from the group consisting of perfluoroalkylsulfonic acid anions, hexahalometallic acid anions, hexahalometalloidic acid anions, tetrahaloboronic acid anions, tetrakis(perfluoroaryl)boronic acid anions, and tetrakisperfluoroalkylsulfonatoboronic acid anions.
Ar in the formula hereinabove denotes an aromatic radical having the formula C n H.sub.(n/2+2) or of formula C m H.sub.(m/2+1), wherein n has a value of 6, 10, 14, 18, 22, 26, 30, 34 or 38 and m has a value of 16, 20, 24, 28, 32, 36, or 40.
The group R i can be a monovalent hydrocarbon or halohydrocarbon radical free of aliphatic unsaturation having from 1 to 40 carbon atoms. Monovalent hydrocarbon radicals free of aliphatic unsaturation which are suitable as R i include alkyl radicals such as methyl, ethyl, propyl, butyl, hexyl, octyl, and decyl, cycloaliphatic radicals such as cyclohexyl, aryl radicals such as phenyl, tolyl, and xylyl, and arylalkyl radicals such as benzyl, phenylmethyl, phenylethyl, and phenylnaphthyl.
Monovalent hydrocarbon radicals suitable as R i also include arene radicals having from 6 to 40 carbon atoms such as naphthyl (C 10 H 7 ), anthracenyl or phenanthracenyl (C 14 H 9 ), pyrenyl (C 16 H 9 ), napthacenyl, 9,10-benzophenanthrenyl, chrysenyl, 1,2-benzanthracenyl, or 3,4-benzophenanthrenyl (C 18 H 11 ), 3,4-benzopyrene or perylenyl (C 20 H 11 ), 1,2,3,4-dibenzanthracenyl, 1,2,5,6-dibenzanthracenyl, 1,2,6,7-dibenzoanthracenyl, 1,2,7,8-dibenzanthracenyl, 1,2,6,7-dibenzophenanthracenyl, 1,2,7,8dibenzophenanthracenyl, pentacenyl, or picenyl (C 22 H 13 ), coronenyl (C 24 H 11 ), 1,2,4,5-dibenzopyrene (C 24 H 13 ), and hexacenyl (C 26 H 15 ). Arene radicals having up to 40 carbon atoms which are suitable as R i also include combinations of the above radicals attached to one another such as phenylhexadecenyl (C 32 H 19 ) or anthracenylhexacenyl (C 40 H 23 ).
The group R i can also be a halogen atom, or a radical selected from NO 2 , CN, COOH, and SO 3 H. Halogen atoms suitable as R' include fluorine, chlorine, and bromine. Alkoxy radicals suitable as R i include radicals such as methoxy, ethoxy, propoxy, and butoxy radicals. Nitro substituted groups suitable as R i include groups such as 3-O 2 N--C 6 H 4 or 4-Cl, 3-O 2 N--C 6 H 3 . Nitrile substituted groups suitable as R i are exemplified by groups such as 4-NC---C 6 H 4 , 1-NC--C 10 H 7 , or 2-NC--C 10 H 7 . Carboxylic acid substituted groups suitable as R i are exemplified by groups such as 4-HOOC--C 6 H 4 or 3-HOOC--C 6 H 4 . Sulfonic acid substituted groups suitable as R i are exemplified by groups such as 4-HO 3 S--C 6 H 4 or 3-HO 3 S--C 6 H 4 . The alkoxy substituted groups suitable as R i include groups such as 4-CH 3 O--C 6 H 4 , 4-C 2 H 5 O--C 6 H 4 , 2-CH 3 O--C 6 H 4 , and 2-C 2 H 5 O--C 6 H 4 .
The monovalent hydrocarbon radicals free of aliphatic unsaturation having from 1 to 40 carbon atoms (including arene radicals having from 6 to 40 carbon atoms), alkoxy substituted groups, and halogen atoms suitable as R ii are as delineated above for R i including preferred embodiments thereof. Arylalkoxy radicals suitable as R ii include radicals such as benzyloxy and phenylethyloxy. Aryloxy radicals suitable as R ii are exemplified by radicals such as phenoxy and napthoxy.
Ar denotes arene radicals having from 6 to 40 carbon atoms. Arene radicals suitable as Ar are exemplified by phenyl (C 6 H 5 ), naphthyl (C 10 H 7 ), anthracenyl or phenanthracenyl (C 14 H 9 ), pyrenyl (C 16 H 9 ), napthacenyl, 9,10-benzophenanthrenyl, chrysenyl, 1,2-benzanthracenyl, or 3,4-benzophenanthrenyl (C 18 H 11 ), 3,4-benzopyrene or perylenyl (C 20 H 11 ), 1,2,3,4-dibenzanthracenyl, 1,2,5,6-dibenzanthracenyl, 1,2,6,7-dibenzoanthracenyl, 1,2,7,8-dibenzanthracenyl, 1,2,6,7-dibenzophenanthracenyl, 1,2,7,8-dibenzophenanthracenyl, pentacenyl, or picenyl (C 22 H 13 ), coronenyl (C 24 H 11 ), 1,2,4,5-dibenzopyrene (C 24 H 13 ), hexacenyl (C 26 H 15 ), and combinations of these radicals attached to one another such as phenylhexadecenyl (C 32 H 19 ) or anthracenylhexacenyl (C 40 H 23 ).
The anion X - can be an anion selected from the group consisting of perfluoroalkylsulfonic acid anions, hexahalometallic acid anions, hexahalometalloidic acid anions, tetrahaloboronic acid anions, tetrakis(perfluoroaryl)boronic acid anions, and tetrakisperfluoroalkylsulfonatoboronic acid anions. Perfluoroalkylsulfonic acid anions are exemplified by perfluorobutanesulfonic acid anions, perfluoroethanesulfonic acid anions, perfluoro-octanesulfonic acid anions, or trifluoromethanesulfonic acid anions. Hexahalometallic acid anions include anions such as SbF 6 - , AsF 6 - , SbCl 6 - , and AsCl 6 - , hexahalometalloidic acid anions include anions such as PF 6 - and PCl 6 - , tetrahaloboronic acid anions include anions such as BF 4 - , BCl 4 - , and BBr 4 - , tetrakis perfluoroaryl boronic acid anions are exemplified by B(C 6 H 5 ) 4 - and B(C 10 F 7 ) 4 - , and tetrakisperfluoroalkylsulfonatoboronic acid anions include anions such as B(O 3 SCF 3 ) 4 - , B(O 3 SC 2 F 5 ) 4 - , and B(O 3 SC 4 F 9 ) 4 - . It is preferred that X - is trifluoromethanesulfonate.
The following examples are disclosed to further teach, but not limit, the invention which is properly delineated by the appended claims. All amounts (parts and percentages) are by weight unless otherwise indicated.
EXAMPLE 1
To a stirred suspension of 6.44 g (grams) (0.02 mole) of iodobenzene diacetate (from Aldrich, Madison, Wis.) in 20 ml of glacial acetic acid (Solvent) (from FISHER SCIENTIFIC, Pittsburgh, Pa.) was added 3.0 g (0.02 mole) trifluoromethanesulfonic acid (triflic acid, or TfOH, or HOTf) (FC-24 from 3M Co., Minneapolis, Minn.) in dropwise fashion while the solution was at ambient temperature. After all solids were completely dissolved and a clear yellow solution was obtained, there was added to this stirred yellow solution about 2.12 g of 1,3-xylene (Ar) (from Aldrich) in a dropwise fashion, also while the solution was at ambient temperature. The resulting mixture was allowed to stir for about 30 minutes. After this time the solvent was removed by evaporation on a rotary evaporator under an ultimate pressure of less than 1 mm Hg and at a bath temperature of less than 80° C. An oily residue was obtained. The residue was triturated with diethylether (crystallizing solvent) until it solidified, after which it was collected by filtration and washed with more diethyl ether and dried in vacuo. The product was collected in a crystalline form and in a 94% of theoretical yield.
Example 2
To a stirred suspension of 6.44 g (0.02 mole) iodobenzene diacetate (Aldrich, Madison, Wis.) in 20 ml glacial acetic acid (Solvent) (FISHER SCIENTIFIC, Pittsburgh, Pa.) was added 3.0 g (0.02 mole) trifluoromethanesulfonic acid (triflic acid, or TfOH, or HOTf) (FC-24 from 3M Co, Minneapolis, Minn.) in dropwise fashion while the solution was at ambient temperature. After all solids were completely dissolved and a clear yellow solution was obtained, there was added to this stirred yellow solution about 4.92 g of dodecylbenzene (Ar) (from Johnson Matthey Catalog Co., INC, Ward Hill, Mass.) in a dropwise fashion while the solution was at ambient temperature. The resulting mixture was allowed to stir for about 3 hours. Acetic acid was then removed in a rotary evaporator leaving a reaction mixture of oil and acetic acid. After this time there was added to the reaction mixture about 30 ml of toluene (from FISHER) and 30 ml deionized water and the resulting aqueous and organic layers were separated. The organic layer was subsequently repeatedly washed with further portions of deionized water until the pH of the separated water layer was greater than 5. The toluene solvent and residual water was then removed from the separated organic layer by evaporation on a rotary evaporator under an ultimate pressure of less than 1 mm Hg and at a bath temperature of less than 80° C. The product was a residue from this separation process in the form of a viscous liquid oil. The oil was converted to a low-melting solid product, in the case of dodecylbenzene as the substrate, by dissolving the viscous oil in toluene and then adding the solution to an excess of n-pentane and recovering the precipitated solids formed thereby by means of filtration, washing the precipitate with more clean pentane, and then drying in vacuo. However, the viscous oil was a perfectly suitable form of the product.
Example 3
To a stirred suspension of 6.44 g (0.02 mole) iodobenzene diacetate (Aldrich, Madison, Wis.) in 20 ml glacial acetic acid (Solvent) (FISHER SCIENTIFIC, Pittsburgh, Pa.) was added 3.0 g (0.02 mole) trifluoromethanesulfonic acid (triflic acid, or TfOH, or HOTf) (FC-24 from 3M Co, Minneapolis, Minn.) in dropwise fashion while the solution was at ambient temperature. After all solids were completely dissolved and a clear yellow solution was obtained, there was added to this stirred yellow solution about 4.92 g of dodecylbenzene (Ar) (from Johnson Matthey Catalog Co., INC, Ward Hill, Mass.) in a dropwise fashion while the solution was at ambient temperature. The resulting mixture was allowed to stir for about 3 hours. Acetic acid was then removed in a rotary evaporator leaving a reaction mixture of oil and acetic acid. After this time there was added to the reaction mixture about 30 ml of toluene (from FISHER) and 30 ml deionized water and this mixture was agitated to allow the acetic acid to mix with the water phase. The water phase was then drawn off the top and more fresh water was added. The procedure was repeated several times until acetic acid could not be detected in the water phase. The toluene solvent and residual water were then removed from the separated organic layer by evaporation on a rotary evaporator under an ultimate pressure of less than 1 mm Hg and at a bath temperature of less than 80° C. The product was a residue from this separation process in the form of a viscous liquid oil at stripping temperatures but was a solid waxy substance at room temperature. The solid was further purified, in the case of dodecylbenzene as the substrate, by dissolving the solid product in toluene and then adding this solution to an excess of n-pentane and recovering the precipitated solids formed thereby by means of filtration, washing the precipitate with more clean pentane, and then drying in vacuo.
Examples 4-45
In the examples hereinbelow, the above procedure was utilized. In Table I is delineated amount of iodobenzene diacetate, solvent type, solvent amount, amount of trifluoromethanesulfonic acid (denoted FC-24), aromatic compound type (Ar), and amount of Ar. Mixing times ranged from an hour to several hours, and mixing temperatures were at room temperature or ranged from 45° to 70° C. Where a crystallizing solvent was employed, the procedure of Example 1 was followed, where no crystallizing solvent was used, the procedure of Example 2 was employed, and where the oil is reported as being in the form of a solid then the procedure of Example 3 was followed. Table II hereinbelow describes the amount of oil produced (product), oil color, crystallizing solvent (if used), product obtained, and the percent of theoretical yield obtained. In the Examples hereinbelow triflate denotes trifluoromethanesulfonate. The identity of the obtained product was determined by NMR (Nuclear Magnetic Resonance) and IR (Infrared Spectroscopy).
TABLE I__________________________________________________________________________ Iodobenzene Solvent FC-24Diacetate (g) Solvent (ml) (g) Ar Ar (g)__________________________________________________________________________Ex. 4 9.66 HOAc 20 4.51 benzene 2.35 5 6.44 HOAc 20 3.00 benzene 1.56 6 3.24 HOAc 20 1.48 toluene 0.91 7 3.22 HOAc 20 1.51 m-xylene 1.07 8 3.29 HOAc 20 1.52 pentamethylbenzene 1.49 9 6.44 HOAc 20 3.00 n-butylbenzene 2.68 10 3.23 HOAc 20 1.50 sec-butylbenzene 1.37 11 3.25 HOAc 20 1.50 tert-butylbenzene 1.34 12 3.24 HOAc 20 1.51 phenylcyclohexane 1.60 13 6.47 HOAc 20 3.02 1-phenylhexane 3.26 14 9.69 HOAc 20 4.52 dodecylbenzene 7.40 15 6.43 HOAc 20 3.00 dodecylbenzene 4.94 16 9.67 HOAc 20 4.50 dodecylbenzene 7.39 17 9.68 HOAc 20 4.50 dodecylbenzene 7.40 18 9.72 HOAc 20 4.53 dodecylbenzene 7.42 19 9.66 HOAc 20 4.52 dodecylbenzene 7.40 20 9.68 CH2Cl2 20 4.52 dodecylbenzene 7.41 21 6.46 HOAc 20 3.00 dodecylbenzene 4.93 *22 6.75 HOAc 20 3.15 1-phenyldodecane 5.17 23 6.76 HOAc 20 3.02 benzene 1.56 24 6.44 HOAc 20 3.01 fluorobenzene 1.93 25 9.68 HOAc 20 4.51 chlorobenzene 3.38 26 6.44 HOAc 20 3.02 iodobenzene 4.10 27 6.44 HOAc 20 3.02 3-iodotoluene 4.37 28 3.23 HOAc 25 1.49 methylphenylether 1.01 29 3.22 CH3CN 25 1.48 methylphenylether 1.10 30 3.24 CH2Cl2 25 1.51 methylphenylether 1.11 31 3.24 HOAc 20 1.51 methylphenylether 1.09 32 3.22 CH2Cl2 25 1.51 methylphenylether 1.13 33 3.22 CH3CN 25 1.50 methylphenylether 1.10 34 3.22 HOAc 20 1.51 butylphenylether 1.50 35 12.88 HOAc 50 6.47 octylphenylether 8.65 36 3.24 HOAc 20 1.50 octadecylphenylether 3.46 37 6.44 HOAc 20 3.01 4-phenoxybutyl bromide 4.58 38 6.43 CH2Cl2 20 3.00 2-phenoxyethanol 2.77 39 6.45 HOAc 20 3.00 2-phenoxyethanol 2.76 40 6.46 CH2Cl2 20 3.00 2-phenoxyethanol 2.77 41 12.89 HOAc 20 6.01 2-phenoxyethanol 5.54 42 12.86 HOAc 50 6.00 2-phenoxyethanol 5.53 43 6.46 HOAc 20 3.02 thiophene 1.68 44 9.73 HOAc 20 4.52 dodecylbenzene 7.41 45 10.08 HOAc 20 4.50 dodecylbenzene 7.39__________________________________________________________________________ *3-Iodotoluene Diacetate was substituted for Iodobenzene Diacetate
*-3-Iodotoluene Diacetate was substituted for Iodobenzene Diacetate
TABLE II__________________________________________________________________________ CrystallizingEx. Oil (g) Oil Color Solvent % Yield Product Obtained__________________________________________________________________________ 4 10.80 orange ether 59.5 Diphenyliodonium triflate 5 8.69 yellow ether 50.0 Diphenyliodonium triflate 6 4.92 yellow ether 51.6 4-methylphenylphenyl iodonium triflate 7 5.35 white ether 93.3 dimethylphenylphenyl iodonium triflate 8 4.44 dark purple ether 23.5 pentamethylphenylphenyl iodonium triflate 9 10.45 brown ether 58.4 butylphenylphenyl iodonium triflate10 5.72 yellow ether 58.2 s-butylphenylphenyl iodonium triflate11 5.49 yellow ether 45.8 t-butylphenylphenyl iodonium triflate12 6.15 yellow ether 51.6 cyclohexylphenylphenyl iodonium triflate13 10.68 brown none 73.8 hexylphenylphenyl iodonium triflate14 20.01 yellow none 80.6 dodecylphenylphenyl iodonium triflate15 12.57 brown none 80.2 dodecylphenylphenyl iodonium triflate16 18.61 brown none 79.2 dodecylphenylphenyl iodonium triflate17 20.10 yellow none 78.8 dodecylphenylphenyl iodonium triflate18 19.45 yellow none 78.6 dodecylphenylphenyl iodonium triflate19 18.97 orange none 72.0 dodecylphenylphenyl iodonium triflate20 18.61 orange none 69.0 dodecylphenylphenyl iodonium triflate21 12.30 orange none 47.5 dodecylphenylphenyl iodonium triflate22 12.08 brown none 76.3 dodecylphenylphenyl iodonium triflate23 8.32 yellow-orange ether 53.2 3-methylphenylphenyl iodonium triflate24 8.86 orange ether 68.8 4-fluorophenylphenyl iodonium triflate25 13.27 orange ether 40.2 4-chlorophenylphenyl iodonium triflate26 8.66 orange ether 52.8 4-iodophenylphenyl iodonium triflate27 10.96 orange ether 50.9 iodotolylphenyl iodonium triflate28 4.15 red-brown CH2Cl2- 56.3 methoxyphenylphenyl ether iodonium triflate29 3.19 brown ether 54.5 methoxyphenylphenyl iodonium triflate30 3.39 brown ether 53.5 methoxyphenylphenyl iodonium triflate31 5.75 dark brown ether 50.9 methoxyphenylphenyl iodonium triflate32 2.37 red-brown CH2Cl2- 21.7 methoxyphenylphenyl ether iodonium triflate33 1.79 red-brown CH2Cl2- 15.4 methoxyphenylphenyl ether iodonium triflate34 5.14 black-green ether 61.1 butyloxyphenylphenyl iodonium triflate35 18.98 brown none 67.0 octyloxyphenylphenyl iodonium triflate36 12.79 dark brown ether 73.0 3bromopropoxyphenylphenyl iodonium triflate37 11.93 brown ether 82.6 4-(4'-bromobutoxy) phenylphenyl iodonium triflate38 10.88 brown ether 71.8 4-(2-hydroxyethoxy) phenylphenyl iodonium triflate39 11.42 dark brown ether 71.3 4-(2-hydroxyethoxy) phenylphenyl iodonium triflate40 13.45 brown ether 71.3 4-(2-hydroxyethoxy) phenylphenyl iodonium triflate41 20.40 brown ether 58.3 4-(2-hydroxyethoxy) phenylphenyl iodonium triflate42 20.97 brown ether 7.1 4-(2-hydroxyethoxy) phenylphenyl iodonium triflate43 10.35 dark blue ether 8.2 2-thiophenylphenyl iodonium triflate44 solid yellow none 93.0 Dodecylphenyphenyl iodonium triflate45 solid yellow none 94.8 (Dodecylphenyl) (3-methylphenyl) iodonium triflate__________________________________________________________________________
It should be apparent from the foregoing that many other variations and modifications may be made in the compounds, compositions and methods described herein without departing substantially from the essential features and concepts of the present invention. Accordingly it should be clearly understood that the forms of the invent/on described herein are exemplary only and are not intended as limitations on the scope of the present invention as defined in the appended claims. | The present invention relates to an improved method for the preparation of iodonium salts. More specifically, the present invention relates to an improved method for the production of symmetric or asymmetric diaryliodonium triflate (trifluoromethane sulfonate) salts. The diaryliodonium salts of the present invention are useful as photoacid catalysts for use in acid-sensitive polymerization and in curing systems such as radiation curable release coating compositions. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to Application No. EP 07107174.0 filed on Apr. 27, 2007, entitled “Tire Pressure Measurement System Having Reduced Current Consumption,” the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a tire pressure measurement system (TPMS) where a wheel module, including a measurement unit, is located inside the tire, and is supplied from a power source of limited capacity. Examples of such power sources are electrochemical batteries, piezoelectric power generators or inductive power generators.
BACKGROUND
[0003] Wheel modules include one or more integrated circuits to perform measurement and signal processing tasks required by the system. The integrated circuit is programmed to wake up for less than a second at intervals of typically 10-30 seconds, to perform measurements and transmit data. The rest of the time is spent in the sleep (powerdown) mode, where only a timer circuit is active. Since more than 99% of the time may be spent in sleep mode, the power consumption of the device in this mode is obviously of importance.
[0004] When produced in the currently used technologies, such integrated circuits have a maximum limit for the internal supply voltage of the digital core circuits which is less than the voltages provided by the energy sources mentioned above. A voltage regulator or converter is therefore required to adapt the supply voltage to a level that is compatible with the digital core of the integrated circuits.
[0005] It is often the case that the integrated circuit includes special higher voltage elements, so that the voltage regulator can be provided on the same chip as the low voltage digital core.
[0006] Due to the limited capacity of the power sources, it is important that the power consumption of the wheel module is minimized. Typically, voltage regulators are used for voltage conversion. The voltage regulator requires a certain bias current to operate, and this current constitutes a significant part of the sleep mode power consumption.
SUMMARY
[0007] A tire pressure measurement system (TPMS) is described herein. The system comprises: a capacitor; and an integrated circuit configured to receive a supply voltage, the integrated circuit comprising: a voltage regulator; and a measurement unit; wherein the voltage regulator is configured to be turned on and off for predetermined periods of time and arranged such that the capacitor is charged and discharged, respectively. The voltage regulator and the capacitor are connected to the measurement unit in order to selectively provide the measurement unit electric charge at a voltage between predetermined upper and lower limits. The average bias current of the voltage regulator is reduced by turning it on and off at fixed intervals. While the regulator is turned off, current is supplied from the capacitor.
[0008] The above and still further features and advantages of the present invention will become apparent upon consideration of the following definitions, descriptions and descriptive figures of specific embodiments thereof, wherein like reference numerals in the various figures are utilized to designate like components. While these descriptions go into specific details of the invention, it should be understood that variations may and do exist and would be apparent to those skilled in the art based on the descriptions herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Examples of the present invention will now be described with reference to the accompanying drawings, in which:
[0010] FIG. 1 a shows an integrated circuit of a tire pressure measurement system (TPMS);
[0011] FIG. 1 b shows an integrated circuit of a TPMS according to an embodiment;
[0012] FIG. 2 shows a comparison of the various voltages of the circuit according to an embodiment;
[0013] FIG. 3 shows an example of a voltage regulator of the integrated circuit of FIG. 1 b; and
[0014] FIG. 4 shows an example of an arrangement of a TMPS according to an embodiment.
DETAILED DESCRIPTION
[0015] With reference to FIG. 1 a, a TPMS wheel module comprises an integrated circuit 1 that is supplied with an external supply voltage V in which varies between the voltages V in — max and V in — min . The integrated circuit 1 comprises a voltage regulator 2 configured to receive the external supply voltage, in the range between V in — max to V in — min , inclusive, and produces a regulated output voltage V reg within the limits V reg — max and V reg — min . The integrated circuit 1 further comprises a digital core 3 requiring a supply voltage between the levels V core — max and V core — min , inclusive.
[0016] When V in — max >V core — max , the digital core 3 cannot be connected directly to the external supply voltage, and a voltage regulator 2 must be inserted between the external supply voltage and the digital core 3 . The voltage regulator 2 creates a voltage drop between the external supply voltage and the digital core 3 , ensuring that V core — max >V reg — max . For proper operation of the device, it is also necessary to have V in — min >V core — min , and V reg — min >V core — min .
[0017] For earlier semiconductor technologies using batteries as a power source, the voltage regulator was in many cases not needed since V core — max >V in — max (i.e., the supply voltage range included the battery voltage). For designs using current semiconductor technologies, or using other types of power generators, this is in general not the case, and a voltage regulator is required. This problem also arises in the field of energy harvesting devices, as these frequently generate relatively high voltages. In order to operate correctly, the voltage regulator draws a certain amount of current in its control circuits. This current, called the regulator bias current, is drawn from the battery in addition to the current required by the digital core. Several design techniques are available to obtain sufficient circuit performance with very low current consumption. Nevertheless, the voltage regulator bias current is of the same order of magnitude as the supply current to the digital core when in sleep mode.
[0018] Thus, the regulator increases the load on the power source, which in turn means that the power source must be increased, leading to added size, weight, and cost. Since TPMS systems must minimize all these parameters in order to be efficient, a way to minimize or eliminate the voltage regulator bias current is desirable.
[0019] FIG. 1 b shows an example of the present invention in which a voltage regulator 2 is turned on for brief periods to charge a capacitor 4 . When the voltage regulator 2 is in an off state, a digital core 3 (e.g., measurement unit) is supplied by the charge stored on the capacitor 4 . By correctly choosing the on and off times of the voltage regulator 2 , the V core voltage can be maintained between the limits V core — max and V core — min , while at the same time reducing the average bias current of the voltage regulator 2 . Additionally, a switch 5 is closed and opened under control of the digital core. Typically, the present invention reduces the average bias current by 75% or more, resulting in a significant battery saving over the lifetime of the device.
[0020] FIG. 2 shows how the V core voltage will vary between V core — max and V core — min as the voltage regulator is turned on and off (i.e., duty cycled) and the switch 5 is closed and opened, respectively. The switch 5 on (closed) time must be sufficient to charge the capacitor to the V reg voltage while the voltage regulator 2 is in the on state, and the switch 5 off (open) time must be short enough to ensure that the V core voltage will never fall below V core — min while the voltage regulator 2 is in the off state and the capacitor 4 is discharging.
[0021] The purpose of the switch is to avoid leakage of charge from the capacitor back into the voltage regulator when the latter is turned off. Therefore, the switch can be dispensed with if the voltage regulator presents a high impedance in the off state. However, if the switch is needed, then the switch must be closed (conducting) when the regulator is on, and open (isolating) when the regulator is off. The control signal(s) from the digital core must change the state of the switch and the voltage regulator in synchronism.
[0022] The voltage regulator can be realized in a number of ways, for example, by a conventional linear regulator with a fixed output voltage, or a combination of a comparator and a switch.
[0023] An example of a voltage regulator 2 is shown in FIG. 3 . The two exemplary types of regulator mentioned above share the majority of the circuit elements, such as a voltage reference V ref , a comparator/error amplifier 6 , and a switch/pass transistor 7 . The main difference is in the type of regulation. The linear regulator must be designed to be stable, while the switching circuit is by design unstable.
[0024] In the case of a comparator, when turned on, the switch passes current to the capacitor, until the comparator decides that the capacitor voltage has reached its upper limit and turns off the switch. While the comparator is used to turn off the charging current to the capacitor, the turn-on time has to be determined by the control logic, as previously described.
[0025] There are several possible solutions to control the on and off timing to ensure a V reg between V core — max and V core — min .
[0026] The on and off times can be calculated based on simulations or measurement data, and fixed in the digital core 3 . By using fixed timing, the need for a circuit to detect if V core is close to V core — min is avoided, thus avoiding another potential current consumer.
[0027] To optimize for lowest possible charge consumption, several different timing schedules can be selected by the digital core 3 before it enters the sleep mode based on, for example, the expected current load in sleep mode. The timing schedule can be influenced by parameters (e.g., calculated current consumption based on activated modules during sleep mode, measured temperature, and measured battery voltage).
[0028] Those skilled in the art will take proper design practice into account, such as allowing for temperature variation of current, considering the effect of the capacitor on the stability of the voltage regulator 2 , and considering the effect of timing difference between the turn-on of the voltage regulator 2 and the closing of the switch 5 . It should also be appreciated that other types of voltage regulators may be employed to implement the invention.
[0029] FIG. 4 shows an implementation of a TPMS according to an embodiment of the present invention in a vehicle wheel. The system comprises a wheel module 8 that houses the integrated circuit 1 that performs measurements for determining the tire pressure and transmits data by RF electromagnetic waves 9 to an external receiver 10 .
[0030] While the invention has been described in detail with reference to specific embodiments thereof, it will be apparent to one of ordinary skill in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. Accordingly, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A tire pressure measurement system (TPMS) includes a capacitor and an integrated circuit configured to receive a supply voltage. The integrated circuit includes a voltage regulator and a measurement unit. The voltage regulator is configured to be turned on and off for predetermined periods of time such that the capacitor is charged and discharged, respectively. The voltage regulator and the capacitor are connected to the measurement unit in order to selectively provide electric charge at a voltage between predetermined upper and lower limits. | 1 |
This is a national stage of PCT/IE12/000037 filed Jul. 20, 2012 and published in English, which has a U.S. priority of No. 61/510,628, filed Jul. 22, 2011, hereby incorporated by reference.
This invention relates to new compounds for use in the treatment of inflammatory bowel disease.
INTRODUCTION
Inflammatory bowel disease (IBD) consists of two idiopathic inflammatory diseases, ulcerative colitis (UC) and Crohn's disease (CD). The greatest distinction between UC and CD is the range of inflamed bowel tissue. Inflammation in CD is discontinuously segmented, known as regional enteritis, while UC is superficial inflammation extending proximally and continuously from the rectum. At present, the exact cause of IBD is unknown. The disease seems to be related to an exaggerated mucosal immune response to infection of the intestinal epithelium because of an imbalance of pro-inflammatory and immune-regulatory molecules. The inheritance patterns of IBD suggest a complex genetic component of pathogenesis that may consist of several combined genetic mutations. Currently no specific diagnostic test exists for IBD, but as an understanding of pathogenesis is improved so will our testing methods. Treatment of IBD consists of inducing and maintaining remission. IBD patients may be maintained on remission by use of a 5-aminosalycilate. However, while the use of aminosalycilates in UC provides considerable benefit, both in inducing remission in mild to moderate disease and in preventing relapse, the usefulness of these drugs to maintain remission in CD is questionable and is no longer recommended. The mainstay of treatment of active disease is a corticosteroid, commonly used for limited periods to return both UC and CD patients to remission, though budesonide, designed for topical administration with limited systemic absorption, has no benefit in maintaining remission. Alternatives, such as the immunosuppressive drugs azathioprine and mercaptopurine, together with methotrexate and cyclosporine have limited efficacy and the capability of inducing grave adverse effects. Anti-TNFα antibodies, such as infliximab and adalimubab, may be used in those patients unresponsive to standard immunosuppressive therapy. However, many patients fail to respond to anti-TNFα therapy, either due to their particular phenotype or by the production of autoantibodies.
STATEMENTS OF INVENTION
In accordance with the present invention there are provided compounds for use in the treatment of inflammatory bowel disease including Crohn's disease and ulcerative colitis.
In particular, the present invention provides compounds of the structural formula I:
Also provided are pharmacologically acceptable isomers and salts of the compound of formula (I)—compound 1.
In particular, the present invention provides compounds of relative stereochemistry as demonstrated in structural formula II:
Also provided are pharmacologically acceptable salts of the compound of formula (II)—compound 2.
The active enantiomers have been characterised, spectroscopically, by their physical and chemical properties and by normal and chiral HPLC retention data.
A specific enantiomeric form has been found to be particularly useful for the treatment of IBD.
The invention also provides the N-Methyl-(D)-Glucamine salt of the compound of formula III:
The compounds of the invention may crystallize in more than one form. This characteristic is referred to as polymorphism, and such polymorphic forms (“polymorphs”) are within the scope of the invention. Polymorphism generally can occur as a response to changes in temperature, pressure, or both. Polymorphism can also result from variations in the crystallization process. Polymorphs can be distinguished by various physical characteristics known in the art such as x-ray diffraction patterns, solubility, and melting point.
Certain of the compounds described herein are capable of existing as stereoisomers. The scope of the present invention includes mixtures of stereoisomers as well as purified or enriched mixtures. Also included within the scope of the invention are the individual isomers of the compounds of the invention as well as any wholly or partially equilibrated mixtures thereof. Certain compounds of the invention contain one or more chiral centers. Therefore the present invention includes racemates, purified enantiomers, and enantiomerically enriched mixtures of the compounds of the invention. The compounds of the present invention include racemic and chiral indane dimers.
Salts encompassed within the term pharmaceutically acceptable salts refer to non-toxic salts of the compounds of this invention. Salts of the compounds of the present invention may comprise acid addition salts.
The invention includes a solvate of any of the compounds of the invention. The term solvate refers to a complex of variable stoichiometry formed by a solute (in this invention, a compound of the invention, or a salt or physiologically functional derivative thereof) and a solvent. Such solvents, for the purpose of the invention, should not interfere with the biological activity of the solute. Non-limiting examples of suitable solvents include, but are not limited to water, methanol, ethanol, and acetic acid. Preferably the solvent used is a pharmaceutically acceptable solvent. Non-limiting examples of suitable pharmaceutically acceptable solvents include water, ethanol, and acetic acid. Most preferably the solvent used is water.
The invention includes a prodrug of any of the compounds of the invention. The term prodrug refers to any pharmaceutically acceptable derivative of a compound of the present invention that, upon administration to a mammal, is capable of providing (directly or indirectly) a compound of the present invention or an active metabolite thereof. Such derivatives, for example, esters and amides, will be clear to those skilled in the art.
The invention further provides a pharmaceutical composition comprising any of the compounds described above.
The active compound may be present in the medicament for use in man at a suitable dose to achieve the desired effect. For example, the final dose may be between 0.1 and 10 mg/kg.
It may be possible to administer the compounds of the invention in the form of a bulk active chemical. It is however, preferred that the compounds be administered in the form of a pharmaceutical formulation or composition. Such formulations may comprise one or more pharmaceutically acceptable excipient, carrier or diluent.
The compounds of the invention may be administered in a number of different ways. The compounds may be administered orally. Preferred pharmaceutical formulations for oral administration include tablets, capsules, caplets, solutions, suspensions or syrups.
The pharmaceutical formulations may be provided in a form for modified release such as a time release capsule or tablet.
The medicament may be administered orally, parenterally, intra-nasally, trans-cutaneously or by inhalation.
Pharmaceutical formulations may be adapted for administration by any appropriate route, for example by an oral (including buccal or sublingual), rectal, nasal, topical (including buccal, sublingual or transdermal), vaginal, or parenteral (including subcutaneous, intramuscular, intravenous or intradermal) route. Such formulations may be prepared by bringing into association the active ingredient with the carrier(s) or excipient(s).
Pharmaceutical formulations adapted for oral administration may be presented as discrete units such as capsules or tablets; powders or granules; solutions or suspensions, each with aqueous or non-aqueous liquids; edible foams or whips; or oil-in-water liquid emulsions or water-in-oil liquid emulsions. For oral administration in the form of a tablet or capsule, the active drug component can be combined with an oral, non-toxic pharmaceutically acceptable inert carrier such as ethanol, glycerol, water, and the like. Powders may be prepared by comminuting the compound to a suitable fine size and mixing with an appropriate pharmaceutical carrier such as an edible carbohydrate such as starch or mannitol. Flavorings, preservatives, dispersing agents, and coloring agents and the like may also be included.
Capsules may made by preparing a powder, liquid, or suspension mixture and encapsulating within gelatin or other suitable shell material. Lubricants such as colloidal silica, talc, magnesium stearate, calcium stearate, or solid polyethylene glycol may be added to the mixture. A disintegrating or solubilizing agent such as calcium carbonate or sodium carbonate can also be added to improve the availability of the medicament when the capsule is ingested. Other agents such as binders, lubricants, disintegrating agents, and coloring agents can also be incorporated into the mixture. Examples of suitable binders include starch, gelatin, natural sugars, corn sweeteners, natural and synthetic gums, tragacanth, or sodium alginate, carboxymethylcellulose, polyethylene glycol and the like. Suitable lubricants for these dosage forms include, for example, sodium oleate, sodium stearate, magnesium stearate, sodium benzoate, sodium acetate, sodium chloride, and the like. Suitabel disintegrators include, without limitation, starch, methyl cellulose, agar, bentonite, xanthan gum, and the like.
Tablets may be formulated by preparing a powder mixture, granulating the mixture, adding a lubricant and disintegrant, and pressing into tablets. A powder mixture may be prepared by mixing the compound, suitably comminuted, with a diluent or base as described above. Optional ingredients include binders such as carboxymethylcellulose, aliginates, gelatins, or polyvinyl pyrrolidone, solution retardants such as paraffin, resorption accelerators such as a quaternary salt, and/or absorption agents such as bentonite, kaolin, or the like. The powder mixture can be wet-granulated with a binder such as syrup, starch paste, or solutions of cellulosic or polymeric materials, and pressing through a screen.
The compounds of the present invention can also be combined with a free flowing inert carrier and compressed into tablets directly without going through other steps such as granulating. A clear or opaque protective coating consisting of a sealing coat of a suitable material such as shellac, sugar or polymeric material, and a polish coating for example of wax can be provided. If appropriate colourants be added to these coatings to distinguish different unit dosages.
Oral fluids such as solutions, syrups, and elixirs can be prepared in dosage unit form so that a given quantity contains a predetermined amount of the compound. Syrups can be prepared, for example, by dissolving the compound in a suitably flavored aqueous solution, while elixirs are prepared through the use of a non-toxic alcoholic vehicle. Suspensions can be formulated by dispersing the compound in a non-toxic vehicle. Solubilisers and emulsifiers such as ethoxylated isostearyl alcohols and polyoxy ethylene sorbitol ethers, preservatives; flavor additives such as peppermint oil, or natural sweeteners, saccharin, or other artificial sweeteners; and the like can also be added.
Where appropriate, dosage unit formulations for oral administration can be microencapsulated. The formulation can also be prepared to prolong or sustain the release as for example by coating or embedding particulate material in suitable polymers, wax, or the like.
The compounds described herein and salts, solvates, and physiological functional derivatives thereof, can also be administered in the form of liposome delivery systems, such as small unilamellar vesicles, large unilamellar vesicles, and multilamellar vesicles. Liposomes can be formed from a variety of phospholipids, such as cholesterol, stearylamine, or phosphatidylcholines.
The compounds of the invention and salts, solvates, and physiologically functional derivatives thereof may also be delivered by the use of monoclonal antibodies as individual carriers to which the compound molecules are coupled.
The compounds may also be coupled with soluble polymers as targetable drug carriers. Such polymers can include, for example, polyvinylpyrrolidone (PVP). The compounds may also be coupled to a biodegradable polymer achieve controlled release of a drug. Such polymers include polylactic acid, polycyanoacrylates, and block copolymers of hydrogels.
Pharmaceutical formulations adapted for transdermal administration may be presented as discrete patches intended to remain in intimate contact with the skin/epidermis of a patient for a prolonged period of time. For example, the active ingredient may be delivered from the patch by iontophoresis.
Pharmaceutical formulations adapted for topical administration may be formulated as ointments, creams, suspensions, lotions, powders, solutions, pastes, gels, sprays, aerosols, or oils. For treatments of external tissues the formulations may be applied as a topical ointment or cream.
For topical administration in the mouth the formulation may include lozenges, pastilles, and mouthwashes.
For nasal administration, a powder having a particle size for example in the range 20 to 500 microns may be used. The powder may be administered by rapid inhalation through the nasal passage from a container of the powder held close up to the nose. Suitable formulations wherein the carrier is a liquid, for administration as a nasal spray or as nasal drops, include aqueous or oil solutions of the active ingredient.
Pharmaceutical formulations adapted for administration by inhalation include fine particle dusts or mists, which may be generated by means of metered dose pressurized aerosols, nebulizers, or insufflators and the like.
For rectal administration the formulation may be presented as suppositories or as enemas.
For vaginal administration the formulation may be in the form of pessaries, tampons, creams, gels, sprays or the like.
For parenteral administration the formulation may be aqueous and non-aqueous sterile injection solutions which may contain various additives such as anti-oxidants, buffers, bacteriostats, and solutes that render the formulation isotonic with the blood of the intended recipient; and aqueous and non-aqueous sterile suspensions which may include suspending agents and thickening agents. The formulations may be presented in unit-dose or multi-dose containers, for example sealed ampules and vials, and may be stored in a freeze-dried (lyophilized) condition requiring only the addition of the sterile liquid carrier, for example water for injections, immediately prior to use. Extemporaneous injection solutions and suspensions may be prepared from sterile powders, granules, and the like.
The compounds of the present invention and their salts, solvates, and physiologically functional derivatives thereof, may be employed alone or in combination with other therapeutic agents. The compound of the invention and the other pharmaceutically active agent(s) may be administered together or separately. If administered separately, administration may occur simultaneously or sequentially, in any order. The amounts of the compound of the invention and the other pharmaceutically active agent(s) and the relative timings of administration will be selected in order to achieve the desired combined therapeutic effect. The administration in combination of a compound of the invention salts, solvates, or physiologically functional derivatives thereof with other treatment agents may be in combination by administration concomitantly in either a single pharmaceutical composition including both compound or in separate pharmaceutical compositions each including one of the compounds. In some cases the combination of drugs may be administered separately in a sequential manner in which one agent is administered first and a second agent is administered second or the other way around. Such administration may be in a similar time frame or over longer time.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood from the following description thereof given by way of example only, in which:
FIG. 1 is the X-ray crystal structure showing the absolute stereochemistry for the enantiomer compound 4 (R)-(+)-methylbenzylamine salt (compound 9);
FIG. 2 is the X-ray crystal structure showing the absolute stereochemistry for the enantiomer compound 2 (S)-(−)-methylbenzylamine salt (compound 8);
FIG. 2A is a view of a molecule of compound 8 from the crystal structure showing the numbering scheme employed. Anisotropic atomic displacement ellipsoids for the non-hydrogen atoms are shown at the 50% probability level. Hydrogen atoms are displayed with an arbitrarily small radius. Only the major disorder component is shown;
FIG. 3 is a graph of the effect of compounds 2, 3, 4 and 5 at 30 mg/kg on disease activity index (DAI) over 7 days in 5% DSS colitis;
FIG. 4 is a bar chart of the effect of compounds 2, 3, 4 and 5 at 30 mg/kg on disease activity index (DAI) at day 7 in 5% DSS colitis;
FIG. 5 is a graph of the effect of compounds 5, 7, 2 and 6 at 10 mg/kg on disease activity index (DAI) over 7 days in 5% DSS colitis;
FIG. 6 is a bar chart of the effect of compounds 5, 7, 2 and 6 at 10 mg/kg on disease activity index (DAI) at day 7 in 5% DSS colitis. Asterisks indicate a significant (P<0.05) difference (1 way ANOVA) from the vehicle control group.
FIG. 7 Is a graph showing the effect of compound 6 on weight loss in 5% DSS-treated mice. Data are Mean±SEM from 6-7 mice per group;
FIG. 8 Is a graph showing the effect of compound 6 on DAI in 5% DSS-treated mice. Data are Mean±SEM from 6-7 mice per group;
FIG. 9 Is a bar chart showing the effect of compound 6 on DAI in 5% DSS-treated mice on day 7. Data are Mean±SEM. Asterisks indicate a significant (P<0.05) difference (1 way ANOVA) from the vehicle control group;
FIG. 10 Is a bar chart showing the effect of compound 6 on Colon length of 5% DSS-treated mice on day 7. Asterisks indicate a significant (P<0.05) difference (1 way ANOVA) from the vehicle control group;
FIG. 11 Shows representative haematoxylin and eosin-stained sections from distal colons of mice. Higher magnifications (×10) are shown;
FIG. 12 Is a bar chart showing the effect of compound 6 on histology scores of colons from DSS-treated mice. Data are Mean±SEM from 5-6 mice. Asterisks indicate a significant (P<0.05) difference (1 way ANOVA) from the vehicle control group. Note, maximum score 10;
FIG. 13 Is a bar chart showing myeloperoxidase (MPO) activity in the colons of untreated or vehicle, prednisolone and compound 6 treated mice exposed to 5% DSS. Data are Mean±SEM from 5-6 mice. Asterisks indicate a significant (P<0.05) difference (1 way ANOVA) from the vehicle control group;
FIG. 14(A) to (C) are bar charts showing the effect of compound 6 on levels of cytokines (IL1β, TNFα and IL6) in mice treated with DSS. Data are Mean±SEM from 5-6 mice. Asterisks indicate a significant (P<0.05) difference (1 way ANOVA) from the vehicle control group;
FIG. 15 Is a grph showing weight loss in IL10 --/-- mice treated with vehicle or compound 6. Mice were administered compound 6 (300 mg/kg/week) or vehicle orally on a Monday/Wednesday/Friday (MWF) dosing schedule. Mice were ˜4 weeks of age at start of experiment and were treated for 9 weeks. Mice were weighed weekly and data are presented as Mean±SEM from 9-12 mice per group. Mice were monitored for overt disease, rectal prolapse, and moribund animals were humanely killed;
FIG. 16 Is a scatter graph representing Serum Amyloid A (SAA) levels of individual mice, and Mean (bar), from surviving animals at week 9 (11 and 9 mice in compound 6 or vehicle-treated groups, respectively). Student's t-test was used to test for statistical differences between groups;
FIG. 17 Are representative hematoxylin and eosin-stained sections from distal colons from IL10 --/-- mice treated for 9 weeks with vehicle or compound 6; and
FIG. 18 Is a scatter graph showing histology scores of distal colons of IL10 -/-- mice treated with vehicle or compound 6. Scatter graph representing histology score of individual mice, and Mean (bar), from surviving animals at week 9 (11 and 9 mice in compound 6 or vehicle-treated groups, respectively). Student's t-test was used to test for statistical differences between groups.
DETAILED DESCRIPTION OF THE INVENTION
Compound 1 represents a pair of diastereoisomers that result from the reduction and demethylation of the ketone compound A which has a chiral centre at C-2, and is, as a result, a pair of enantiomers.
Reduction of this compound with LiAlH 4 yields a compound of the formula
This compound comprises two diastereoisomers:
Hydrolysis of Diastereoisomer B gives rise to compounds 2 and 3
Hydrolysis of Diastereoisomer C gives rise to compounds 4 and 5.
The diastereoisomers can be resolved chemically or chromatographically into their constituent enantiomers.
The absolute stereochemistry of compound 4 has been established by single crystal X-ray of compound 4 (R)-(+)-methylbenzylamine salt (compound 9) ( FIG. 1 ).
The absolute stereochemistry of compound 2 was confirmed by single crystal X-ray of compound 2 (S)-(−)-methylbenzylamine salt (compound 8) ( FIGS. 2 and 2A ).
General Reaction Procedures
General synthetic procedures for the coupling of enantiomeric mixtures as exemplified below are described in WO9720806A, the entire contents of which are herein incorporated by reference.
General Preparation of Acid Derivative Compound A
To a stirred solution of the coupled product (4 mmol, 1.00 g) in tert-butanol (5 mL) and diethyl ether (30 mL) under nitrogen was added methyl (4-bromomethyl)benzoate (6 mmol, 1.41 g). To this was added a solution of potassium tert-butoxide in tert-butanol (30 mL) and diethyl ether (5 mL), slowly drop wise. With each drop, the mixture turned a yellow colour and it then reverted to its original grey colour. The mixture was stirred for a further 3 hours until the TLC (80:20, hexane:ethyl acetate) showed no more starting material. The reaction was quenched by the addition of sat. NH 4 Cl. The layers were separated and the aqueous layer extracted with diethyl ether (2×120 mL). The combined organic layers were washed with water, brine, dried over MgSO 4 and evaporated. The solid product precipitated from the crude on removal of most of the solvent. This was filtered off and washed with cold diethyl ether to give 0.98 g (62%) of a cream solid.
Reduction of Methyl Benzoate Compound
To a stirred solution of the methyl benzoate compound (1.27 mmol; 0.50 g) in THF (15 mL) was added lithium tri-tert-butoxyaluminohydride (1.9 mmol, 0.48 g), slowly portion wise. The reaction was monitored by TLC (80:20, hexane:ethyl acetate) and after 3 h, all of the starting material had been consumed.
The reaction was quenched by pouring onto ice and the crude product extracted into ethyl acetate by stirring the aqueous mixture for 10-15 min with ethyl acetate then pouring into a separatory funnel and then allowing it to separate. The combined organic layers were washed with water, brine, dried over MgSO 4 and evaporated to give 0.34 g (68%) of a cream-tan solid. The product was isolated as a mixture of two diastereoisomers in an approximately 2:1 ratio.
Analytical Results for the Mixture of Two Diastereoisomers
Purity (HPLC): 94.9% (as a 2:1 ratio of diastereoisomers)
δ H (300 MHz, CDCl 3 ): 2.77-3.60 (6H, m, 3×C H 2 ) 3.85 (3H, s, C H 3 ), [5.02 (1H, s, C —OH)] 5.18 (1H, s, C —OH), [6.23 (1H, s, C ═C] 6.43 (1H, s, C ═C), 6.90-6.98 (2H, m, Ar— H ), 7.11-7.21 (1H, m, Ar— H ), 7.22-7.31 (5H, m, Ar— H ), 7.36-7.42 (2H, m, Ar— H ), 7.78-7.84 (2H, m, Ar— H ).
Where possible, the value for the minor diastereoisomer is given in brackets.
δ C (75.5 MHz, CDCl 3 ): 38.3 ( C H 2 ), 38.4 ( C H 2 ), 38.6 ( C H 2 ), 39.9 ( C H 2 ), 40.3 ( C H 2 ), 43.4 ( C H 2 ), 51.9 (COO C H 3 ), 52.0 (COOCH 3 ), 55.9 (quat. C ), 56.3 (quat. C ), 82.0 ( C H—OH), 82.8 ( C H—OH), 120.5 (tert. C ), 120.7 (tert. C ), 123.5 (tert. C ), 123.6 (tert. C ), 124.0 (tert. C ), 124.2 (tert. C ), 124.5 (tert. C ), 124.6 (tert. C ), 124.8 (tert. C ), 124.9 (tert. C ), 125.1 (tert. C ), 125.2 (tert: C ), 126.1 (tert. C ), 126.4 (tert. C ), 127.0 (quat. C ), 127.1 (quat. C ), 128.0 (tert. C ), 128.2 (tert. C ), 128.5 (tert. C ), 128.8 (tert. C ), 129.0 (tert. C ), 129.2 (tert. C ), 129.5 (tert. C ), 2×130.0 (2×tert. C ), 2×130.2 (2×tert. C ), 130.7 (tert. C ), 140.4 (quat. C ), 141.5 (quat. C ), 142.8 (quat. C ), 143.2 (quat. C ), 143.5 (quat. C ), 143.6 (quat. C ), 143.7 (quat. C ), 144.2 (quat. C ), 144.3 (quat. C ), 144.5 (quat. C ), 150.4 (quat. C ), 152.6 (quat. C ), 167.0 ( C ═O), 167.2 ( C ═O).
Hydrolysis of Methyl Benzoate Moiety
The ester was placed in a round-bottomed flask and 10% aq. NaOH (1 mL) was added to it followed by sufficient methanol to form a solution (6 mL). The solution was heated at 40° C. and monitored by TLC (80:20, hexane:ethyl acetate). After ca. 4 h, no further ester was seen.
The mixture was cooled and sat. NH 4 Cl added (solution at pH 12). Dilute HCl was added to acidic pH (pH 2). The product was extracted from the cloudy solution into ethyl acetate (3×10 mL). The combined extracts were dried over MgSO 4 and evaporated in vacuo to give 0.15 g (quantitative) of a cream solid. The product was isolated as a mixture of two diastereoisomers in an approximately 2:1 ratio.
Analytical Results for the Mixture of Two Diastereoisomers
Purity (HPLC): 95.2% (as a 2:1 ratio of diastereoisomers)
δ H (400 MHz, CDCl 3 ): 2.81-3.59 (6H, m, 3×C H 2 ), [5.05 (1H, s, C —OH)], 5.23 (1H, s, C —OH), 6.46 (1H, s, C ═C), [6.66 (1H, s, C ═C)], 6.95-7.03 (2H, m, Ar— H ), 7.12-7.17 (1H, m, Ar— H ), 7.21-7.29 (5H, m, Ar— H ), 7.37-7.43 (2H, m, Ar— H ), 7.85-7.91 (2H, m, Ar— H ).
Where possible, the value for the minor diastereoisomer is given in brackets.
δ C (100 MHz, CDCl 3 ): 37.9 ( C H 2 ), 38.1 ( C H 2 ), 38.2 ( C H 2 ), 39.5 ( C H 2 ), 39.9 ( C H 2 ), 43.1 ( C H 2 ), 55.5 (quat. C ), 55.9 (quat. C ), 81.6 ( C H—OH), 82.4 ( C H—OH), 120.2 (tert. C ), 120.3 (tert. C ), 123.1 (tert. C ), 123.2 (tert. C ), 123.5 (tert. C ), 123.9 (tert. C ), 124.1 (tert. C ), 124.4 (tert. C ), 124.5 (tert. C ), 124.7 (tert. C ), 125.9 (tert. C ), 126.0 (tert. C ), 126.5 (tert. C), 2×126.7 (quat. C & tert. C ), 126.9 (quat. C ), 128.1 (tert. C ), 128.2 (tert. C ), 128.4 (tert. C ), 2×129.2 (2×tert. C ), 2×129.4 (2×tert. C ), 2×129.8 (2×tert. C ), 2×129.9 (2×tert. C ), 130.4 (tert. C ), 140.0 (quat. C ), 141.0 (quat. C ), 142.3 (quat. C ), 142.7 (quat. C ), 143.0 (quat. C ), 143.2 (quat. C ), 143.8 (quat. C ), 144.0 (quat. C ), 144.1 (quat. C ), 144.7 (quat. C ), 150.0 (quat. C ), 152.0 (quat. C ), 170.8 ( C ═O), 171.1 ( C ═O).
Chemical Separation of Enantiomers
Preparation of N—BOC D-phenylalanine derivative of methyl benzoate diastereoisomer and/or separation of subsequent diastereoisomers α1 and α2 (or β1 and β2)
Note: procedure applicable to both diastereoisomers but the example given is for the first diastereoisomer.
Diastereoisomer A (2.5 mmol, 1.0 g) and N—BOC D-phenylalanine (3.1 mmol, 0.8 g) were placed in a round bottom flask fitted with a condenser and suspended in CH 3 CN (25 mL) under nitrogen. To this suspension was added pyridine (3.1 mmol, 0.3 mL) followed by a solution of DCC (3.1 mmol, 0.7 g) and DMAP (10% mol, 0.25 mmol, 0.05 g) in CH 3 CN (2 mL). The mixture was stirred for 20 h at 50° C., and then allowed to reach room temperature.
The white solid was filtered off and the solvent removed in vacuo. Ethyl acetate was added and the solution obtained was washed with 10% H 2 SO 4 , sat. NaHCO 3 , dried over MgSO 4 and evaporated to give 2.1 g of a yellow oil (83% pure by HPLC, yield: quantitative).
The diastereoisomers α1 and α2 were separated by flash chromatography (90 g of silica/g of product) using hexane/MTBE 90:10. From 4.17 g of mixture, 1.3 g of α2, derivative was obtained (as well as 1.71 g of the α1 derivative and 0.3 g as a mixture of both).
Hydrolysis of N—BOC D-phenylalanine Derivative of Methyl Benzoate Compound (α1, α2, β1 or β2)
The diastereoisomer α2 (2.3 mmol, 1.45 g) was dissolved in methanol (25 mL) and NaOH (11.5 mmol, 0.45 g) was added and the mixture stirred at reflux temperature and monitored by TLC. After 20 h, the starting material was consumed.
The reaction was cooled to room temperature and quenched by addition of sat. NH 4 Cl. The methanol was removed in vacuo and the aqueous solution acidified to pH 1 with conc. HCl. The product was extracted with ethyl acetate, dried over MgSO 4 and evaporated to give 1.6 g of a yellow gum, which was purified by a short silica column with hexane:MTBE 80:20 as eluent. 0.44 g of acid derivative compound 5 (50% yield) was obtained which was 97.2% pure by HPLC.
Note: An alternative hydrolysis was also carried out using 10% aqueous NaOH in methanol at 40-50° C. This procedure took almost 5 days to go to completion.
Analytical Results for Enantiomers α1, α2, β1, β2
Enantiomer β1 from Diastereoisomer B-Compound 3
Description: Cream amorphous solid
Melting point 195-196° C.
[α] D : +98.51 (1.07%, MeOH)
Purity: 99.0% δ H (400 MHz, CDCl 3 ): 2.87 (1H, d, J=13.28 Hz, C H 2 ), 3.00-3.09 (2H, m, C H 2 ), 3.29 (1H, d, J=13.36 Hz, C H 2 ), 3.43-3.61 (2H, m, C H 2 ), 5.27 (1H, s, C H —OH), 6.49 (1H, s, C H ═C), 7.00 (2H, d, J=7.88 Hz, Ar— H ), 7.16-7.32 (6H, m, Ar— H ), 7.44 (2H, d, J=7.24 Hz, Ar— H ), 7.90 (2H, d, J=7.92 Hz, Ar— H ).
Enantiomer β2 from Diastereoisomer B—Compound 2
Description: Cream amorphous solid
Melting point 184-185° C.
[α] D : −114.44 (0.18%, MeOH)
Purity: 99.8% δ H (400 MHz, CDCl 3 ): 2.87 (1H, d, J=13.32 Hz, C H 2 ), 3.00-3.09 (2H, m, C H 2 ), 3.29 (1H, d, J=13.28 Hz, C H 2 ), 3.46 (1H, d, J=22.64 Hz, C H 2 ), 3.58 (1H, d, J=22.56 Hz, C H 2 ), 5.27 (1H, s, C H —OH), 6.49 (1H, s, C H ═C), 7.00 (2H, d, J=8.04 Hz, Ar— H ), 7.15-7.34 (6H, m, Ar— H ), 7.44 (2H, d, J=7.20 Hz, Ar— H ), 7.90 (2H, d, J=8.04 Hz, Ar— H ).
Enantiomer α1 from Diastereoisomer C-Compound 4
Description: Cream solid
Melting point 136-140° C.
[α] D : −39.3 (0.66%, MeOH)
Purity: 94.0%
δ H (400 MHz, CDCl 3 ): 2.90-3.59 (6H, m, 3×C H 2 ), 5.08 (1H, s, C H —OH), 6.70 (1H, s, C H ═C), 7.05 (2H, d, J=8.08 Hz, Ar— H ), 7.19 (1H, t, J=7.34 Hz, Ar— H ), 7.26-7.47 (7H, 2×m, Ar— H ), 7.93 (2H, d, J=8.08 Hz, Ar— H ).
Enantiomer α2 from Diastereoisomer C-Compound 5
Description: Cream amorphous solid
Melting point 195-196° C.
[α] D : +32.1 (1.18%, MeOH)
Purity: 97.2%
δ H (400 MHz, CDCl 3 ): 2.94-3.59 (6H, m, 3×C H 2 ), 5.08 (1H, s, C H —OH), 6.70 (1H, s, C H ═C), 7.05 (2H, d, J=8.12 Hz, Ar— H ), 7.19 (1H, t, J=7.34 Hz, Ar— H ), 7.26-7.47 (7H, 2×m, Ar— H ), 7.93 (2H, d, J=8.12 Hz, Ar— H ).
HPLC Method
Achiral and Chiral HPLC methods were established for the qualitative and quantitative separation of enantiomers compounds 2, 3, 4, 5.
HPLC Resolution of Enantiomers
Reverse phase method Column Hypersil BDS C18, 5 μ, 250 × 4.6 mm Phenomenex Luna C18, 5μ, 250 × 4.6 mm, N: 32 Wavelength 210 nm Flow rate 1 mL/min (for ketone and esters) 0.6 mL/min (for acids and salts) Mobile phase 70:30 CH 3 CN:0.1% aq. Acetic acid Sample 1 mg/mL, made up in mobile phase (or CH 3 CN:dIW = 50:50 for acids/salts) Retention times Compound 1 - 20 min Diastereoisomers C (compounds 4/5) 9 min Diastereoisomers B (compounds 2/3) 10 min Chiral method Column ChiralPack IC, 5μ, 250 × 4.6 mm Wavelength 210 nm Temperature 25° C. Flow rate 0.35 mL/min Mobile phase n-Heptane/IPA/HOAc (or TFA) = 90/10/0.1 Sample 1 mg/mL, made up in mobile phase (or nHeptane/IPA/MeOH = 81/9/10 for salts) Retention times Compound A 54 min and >60 min Compound 4 - 30 min Compound 5 - 37 min Compound 3 - 18 min Compound 2 - 19 min
Salt Formation
Salts were prepared by dissolving the free acid of compounds 2, 3, 4 and 5 in aqueous or aqueous organic solvent in the presence of the appropriate base and isolating the salt by evaporation of solvent.
Compound 6: The N-Methyl-(D)-Glucamine salt (NMDG) of compound 2.
Compound 6 Physiochemical Properties:
Appearance: Off-white solid
Molecular Weight: 577 (free acid: 382)
Molecular Formula: C 33 H 39 O 8 N (free acid: C 26 H 22 O 3 )
Melting Point: 165-167° C.
Compound 6: [α] D : −76.5 (sample concentration: 200 mg/10 ml in Water)
Mass (Da): ES+ only [NMDG+Na] was visible
Elemental analysis: Calc: C (68.61), H (6.80), N (2.42), O (22.16). Found: C (68.44), H (6.80), N (2.50), O (21.98).
δ H (400 MHz, DMSO): 2.48 (3H, apparent s, NC H 3 ), 2.65 (1H, d, J=13.56 Hz, HC H ), 2.84-3.02 (4H, m), 3.16 (1H, d, J=13.60 Hz, HC H ), 3.40-3.70 (7H, m), 3.85-3.92 (1H, in), 5.06 (1H, s, C H —OH), 5.93 (1H, broad s, CH—O H ), 6.41 (1H, s, C H ═C), 6.80 (2H, d, J=7.92 Hz, Ar— H ), 7.06-7.41 (8H, m, Ar— H ), 7.64 (2H, d, J=7.80 Hz, Ar— H ).
δ C (100 MHz, DMSO): 33.8 ( C H 3 ), 37.9 ( C H 2 ), 38.2 ( C H 2 ), 39.5 ( C H 2 ), 51.6 ( C H 2 —N), 55.8 (quat. C ), 63.5 ( C H 2 —O), 69.0 ( C H—O), 70.3 ( C H—O), 70.6 ( C H—O), 71.3 ( C H—O), 81.1 ( C H—OH), 120.1 (tert. C ), 123.4 (tert. C ), 123.7 (tert. C ), 124.3 (tert. C ), 124.4 (tert. C ), 126.1 (tert. C ), 126.3 (tert. C ), 127.0 (tert. C ), 127.5 (tert. C ), 2×128.5 (2×tert. C ), 2×129.1 (2×tert. C ), 140.4 (quat. C ), 141.1 (quat. C ), 142.9 (quat. C ), 144.5 (quat. C ), 145.2 (quat. C ), 154.3 (quat. C ), 170.4 ( C ═O).
X-Ray Studies
The absolute stereochemistry of compound 2 was established by single crystal X-ray analysis of its (S)-(−)-methylbenzylamine salt (compound 8). The results are given in Appendix 2. The results were in agreement with the stereochemistry shown in FIG. 2 . The absolute stereochemistry of compounds 4 and 5 were established by conversion of the alcohols (compounds 2-5) to their ketenes and by correlation of their optical rotations.
Inflammatory Bowel Disease (IBD)
Inflammatory Bowel Disease (IBD) consists of two idiopathic inflammatory diseases, Ulcerative Colitis (UC) and Crohn's Disease (CD). The greatest distinction between CD and UC is the range of inflamed bowel tissue. Inflammation in CD is discontinuously segmented, known as regional enteritis, while UC is superficial inflammation extending proximally and continuously from the rectum. At present the cause of IBD is unknown. The disease seems to be related to an exaggerated mucosal immune response to infection of the intestinal epithelium because of an imbalance of pro-inflammatory and immune-regulatory molecules. The inheritance of patterns of IBD, suggest a complex genetic component of pathogenesis that may consist of several combined genetic mutations. Currently no specific diagnosis exists for IBD, but as an understanding of pathogenesis improves so will testing methods. Treatment of IBD consists of inducing and maintaining remission. IBD patients may be maintained on remission by use of a 5-aminosalycilate. However, while the use of aminosalycilates in UC provides considerable benefit, both in inducing remission in mild to moderate disease and in preventing relapse, the usefulness of these drugs to maintain remission in CD is questionable and is no longer recommended. The mainstay of treatment of active disease is a corticosteroid, commonly used for limited periods to return both UC and CD patients to remission, though budesonide, designed for topical administration with limited systemic absorption, has no benefit in maintaining remission. Alternatives, such as the immunosuppressive drugs azathioprine and mercaptopurine, together with methotrexate and cyclosporine have limited efficacy and the capability of inducing grave adverse effects. Anti-TNFα antibodies such as infliximab and adalimubab may be used in those patients unresponsive to standard immunosuppressive therapy. However, many patients fail to respond to anti-TNFα therapy, either due to their particular phenotype or by the production of autoantibodies.
Acute Murine DSS Colitis Model
The dextran sodium sulphate (DSS) colitis model is an experimental mouse model that exhibits many of the symptoms observed in human UC, such as diarrhoea, bloody faeces, mucosal ulceration, shortening of the colon, weight loss and alterations in certain colon cytokines. The study is widely used as a model for studying the pathogenesis of UC and also for screening new therapeutic interventions for the treatment of UC.
In these studies, an acute colitis model was used, with 5% DSS administered in the drinking water of BALB/c mice. This dosage regime induces severe acute colitis, by days 7-8 mice had overt rectal bleeding and marked weight loss; unless sacrificed beforehand, all mice would have died by days 10-12.
Mice
Specific Pathogen-Free BALB/c mice, 6-8 weeks of age, were obtained from a commercial supplier (Harlan UK). Mice were fed irradiated diet and housed in individually ventilated cages (Tecniplast UK) under positive pressure.
DSS Treatment
DSS (5%) was dissolved in drinking water. Compounds were administered orally at a dose of 10 mg/kg or 30 mg/kg on days 0-7, and mice were culled on day 8 or day 9, depending on the severity of the disease. The mice were checked each day for morbidity and the weight of individual mice was recorded. Induction of colitis was determined upon autopsy, length of colon and histology. Colons were recovered and stored at −20° C. for immunological analysis. All of the compounds and experimental groups are randomly alphabetically labelled. Throughout experiments all data recording was performed in a blind manner. The codes on boxes/groups were not broken until after the data was analysed i.e. boxes labelled A, B, C etc were identified as untreated, DSS-treated, or DSS+compound-treated.
To quantify the extent of colitis, a disease activity index (DAI) was determined based on weight loss, faecal blood and stool consistency. A score was given for each parameter, with the sum of the scores used as the DAI. For each treatment group n=8.
Description of DAI Score Weight loss % Stool consistency Faecal blood 0 None Normal None 1 1-3 2 3-6 Loose stool 1 Visible in stool 3 6-9 4 >9 Diarrhea 2 Gross bleeding 3 Definitions: 1 Loose stool - stool not formed, but becomes a paste on handling. 2 Diarrhea - no stool formation, fur stained around the anus. 3 Gross bleeding - fresh blood on fur around the anus with excessive blood in the stool.
Administration of Compounds
All compounds were prepared for oral gavage (0.1 mL per os (p.o.) per 10 g body weight) as a suspension in 0.5% carboxymethyl cellulose/2% Tween 80, at a dose of 3-30 mg/Kg. Compounds as free acid were initially dissolved in absolute alcohol and diluted with 14+1 with 0.5% carboxymethyl cellulose/2% Tween 80; this resulted in a fine precipitate in suspension while N-Methyl-(D)-Glucamine salts were soluble in the vehicle alone.
Effect of Individual Enantiomers Compounds 2, 3, 4 and 5 in 5% DSS Murine Colitis
BALB/c given 5% DSS in drinking water were administered compounds 2, 3, 4 and 5 at 30 mg/kg p.o. as a suspension in 0.5% carboxymethyl cellulose/2% Tween 80 daily for 7 days. DAI measures the extent of the disease in this model. Compound 4 was without activity on this variable, there not being any significant (P>0.05) difference in DAI at any time point ( FIG. 3 ). At day 7, both compound 2 and compound 5 significantly (P<0.5) reduced DAI by a considerable margin, from 9.0+0.53 for vehicle controls to 3.2±0.73 for compound 5 and 2.5±0.71 for compound 2, there being no significant difference between the two ( FIG. 4 ). In comparison, compound 3 reduced DAI to only 5.3±0.6. This was significantly (P>0.05) less potent than either compound 2 or compound 5. Further, while the DAI in compound 3-treated mice was statistically (P<0.05) less than vehicle controls at day 7 ( FIG. 4 ), at day 6 there was no statistical (P>0.05) difference between compound 3 and vehicle ( FIG. 3 ). In conclusion, of the four enantiomers, compounds 2, 3, 4 and 5 both compounds 2 and 5 are highly active in this model at 30 mg/kg. Compound 3 has minimal activity which is significantly (P<0.05) less than compound 2 and compound 5. Compound 4 is almost devoid of activity in this 5% DSS murine colitis model.
Selection of a Salt of Compounds 2 and 5
As a consequence of the limited aqueous solubility of the enantiomers compound 2 and compound 5, we attempted the synthesis of five salts of compound 5. The sodium salt, potassium salt, calcium salt, α-methylbenzylamine salt and N-Methyl-(D)-Glucamine salt were synthesised. The sodium and calcium salt were unsuccessful. The three salts of compound 5, named potassium salt, α-methylbenzylamine salt and N-Methyl-(D)-Glucamine salt were used for solubility and partition coefficient (log P) studies.
The solubility of the four compounds was determined:
Milli-RO H 2 0
pH 4.0 Buffer
pH 7.0 Buffer
pH 9.0 Buffer
Compound
μg/mL
μg/mL
μg/mL
μg/mL
Compound 5
1.38
0.33
320.1
369.6
Compound 5 Potassium salt
217.0
0.15
54.71
340.3
Compound 5 Methyl-
413.9
0.20
227.4
311.0
benzylamine salt
Compound 5 N-Methyl-D-
>60,000*
0.14
>60,000*
>60,000*
Glucamine salt
*Estimated value
Compound 5 N-Methyl-(D)-Glucamine salt (compound 7) was determined, surprisingly, to be the most soluble compound from this group of analogous compounds by a considerable margin, with a solubility of >60,000 μg/mL in Milli-RO water, 0.14 μg/mL in pH 4 buffer, >60,000 μg/mL in pH 7.0 and >3,000 μg/mL in pH 9.0 buffer. Almost identical values were obtained with compound 2 N-Methyl-(D)-Glucamine (compound 6) with a solubility of >60,000 μg/mL in Milli-RO water, 0.5 μg/mL in pH4 buffer, >60,000 μg/mL in pH 7.0 and >3,000 μg/mL in pH 9.0 and buffer.
The partition coefficient of compound 5 and related analogous compounds was investigated using the HPLC method (reverse phase C18 HPLC column) at neutral, acidic and alkaline pH.
The partition coefficient of the four compounds was determined:
Neutral
Basic
Acid
Compound
Log10 POW
Log10 POW
Log10 POW
Compound 5
3.7
3.7
3.9
Compound 5 Potassium salt
3.7
3.7
3.9
Compound 5 Methyl-
3.6
3.6
3.9
benzylamine salt
Compound 5 N-Methyl-D-
3.5
3.5
3.8
Glucamine salt
The partition coefficient of each salt of compound 5 was found to be similar. It is suggested that this is happening because when the salt is in solution the compound dissociates into the parent compound 5 and the associated salt ion. As a result of this the measured partition coefficient was from the parent ion rather than the salt molecules.
The partition coefficient (Log 10 POW) of compound 2 N-Methyl-D-Glucamine salt (compound 6) was successfully determined in neutral, basic and acidic conditions as 3.5, 4.3 and 2.6 respectively.
N-Methyl-(D)-Glucamine was chosen as the salt candidate for both compound 2 and compound 5.
Effect of Enantiomers Compound 2 and Compound 5 and their N-Methyl-(D)-Glucamine Salts (Compounds 6 and 7) at 10 mg/kg in 5% DSS Murine Colitis
Given that both compounds 2 and 5 show considerable activity in the 5% DSS model at 30 mg/kg, we then re-examined their activity, together with their N-Methyl-(D)-Glucamine salts at the lower dose of 10 mg/kg, given daily for 7 days as a suspension or solution in 0.5% carboxymethyl cellulose/2% Tween 80. No adjustment was made in the dosages of the salts to compensate for their increased molecular weight. Both compounds 5 and 7, at 10 mg/kg, had no significant (P>0.05) effect on DAI in the 5% DSS murine colitis model when compared to vehicle control (see FIG. 5 ). In contrast, at day 7, both compound 2 and compound 6, the N-Methyl-(D)-Glucamine salt, at 10 mg/kg significantly (P<0.05) and potently reduced DAI from 9.3±0.51 (vehicle) to 2.1±0.7 and 3.3±0.52 respectively ( FIG. 6 ).
In conclusion, compound 2 (and its N-Methyl-(D)-Glucamine salt, compound 6) is the most potent of the four enantiomers by a considerable margin, and the only enantiomer to retain activity at the lower dose level of 10 mg/kg.
Effect of a Range of Doses of Compound 6 and a Comparison with Prednisolone on 5% DSS Murine Colitis
Compound 6 was selected as the most favoured enantiomer. The activity of compound 6 in the 5% DSS murine model of colitis at varying dose levels was tested to ascertain if there was a dose/response relationship and to make a comparison with a potent oral steroid, Prednisolone, commonly used to return patients suffering from acute exacerbations of IBD to remission.
Mice were administered compound 6 at dose levels 3, 10 and 30 mg/Kg (equivalent to 6.6-20 mg/Kg of the compound 2). A group of DSS-treated mice was also treated with prednisolone, 5 mg/Kg. Prednisolone is a corticosteroid in clinical use in the treatment of human IBD and the quantity used in this study is the optimal dose of prednisolone for this model. After 3 days of treatment of BALB/c mice with 5% DSS in the drinking water signs of colitis were apparent. This was manifested as weight loss ( FIG. 7 ) and an increase in the disease DAI ( FIG. 8 ). However, following oral administration daily for 7 days, compound 6 at three doses (3, 10 and 30 mg/Kg) caused no overt reactions in mice. Compound 6 ameliorated the severity of colitis following acute DSS treatment in multiple parameters of disease examined. The capacity of compound 6 to ameliorate disease in the DSS model was dose-dependent. Compound 6 at 30 mg/Kg was therapeutic in the DSS model at a comparable, or better, efficacy relative to prednisolone at 5 mg/Kg.
The severity of these symptoms are progressive; by day 7 the DSS-treated mice have lost up to 15% of their body weight and all mice have perfuse rectal bleeding. The DAI values on the day of autopsy showed that mice treated with compound 6 3-30 mg/kg had at each dose level, a significantly (P<0.05−P<0.01) lower DAI than vehicle controls. Prednisolone (5 mg/kg) also significantly (P<0.01; ANOVA; Dunnett Multiple Comparison Test), reduced DAI scores ( FIG. 9 ).
At autopsy on day 7, there was significant shortening of colon length (P<0.05−P<0.01; ANOVA; Dunnett Multiple Comparison Test) in all DSS treated groups compared to colons from mice not treated with DSS ( FIG. 10 ). The lowest dose of 3 mg/kg of compound 6 did not have a significant effect in inhibiting colon shortening when compared to vehicle controls whereas the 10 and 30 mg/kg groups and the Prednisolone group did have a significant effect. Compound 6 at 30 mg/kg was significantly better than Prednisolone (P<0.05; ANOVA; Dunnett Multiple Comparison Test) ( FIG. 10 ).
Following DSS treatment histology sections of the distal colon showed extensive crypt damage and cell infiltration ( FIG. 11 ).
The extent of colon damage was quantified using an arbitrary scoring system. Compound 6 at both 10 and 30 mg/Kg, caused a dose-dependent and highly statistically significant reduction (P<0.01; Kruksal-Wallis ANOVA; Dunnett Multiple Comparison Test) in colon pathology relative to the vehicle group. In contrast, there was no significant improvement in histology scores with the prednisolone (5 mg/Kg) treated group relative to vehicle-treated mice ( FIG. 12 ).
Consistent with the histology results showing inflammation in the colons of mice, there was a significant (P<0.001; Kruksal-Wallis ANOVA; Dunnett Multiple Comparison Test) elevation in colon myeloperoxidase (MPO) activity in DSS-treated mice administered vehicle only. Colonic myeloperoxidase activity (MPO), representing the level of inflammatory neutrophil cell infiltration into the gut wall which was increased by almost 8-fold by DSS treatment but was significantly (P<0.05) reduced by both compound 6 at 30 mg/kg and Prednisolone, at 63% and 54% respectively by day 7 ( FIG. 13 ).
Quantification of levels of colon cytokines showed that DSS-treatment induces elevated IL1β ( FIG. 14( a ) ), TNFα ( FIG. 14( b ) ) and IL6 ( FIG. 14( c ) ), to 0.744±0.076 ng/mg, 1.478±0.378 ng/mg and 1.057±0.1784 ng/mg respectively. In each case, compound 6 caused a significant (P<0.05, 30 mg/kg) and dose-dependant reduction in these cytokine levels. Prednisolone (5 mg/kg) also reduced (p<0.05) these increases in cytokine levels; for each cytokine there was no significant difference between the effect of prednisolone 5 mg/kg and compound 6 at the higher dose level of 30 mg/kg at day 7
In summary, following oral administration daily for 7 days, compound 6 at three doses (3, 10 and 30 mg/Kg) caused no overt reactions in mice. Compound 6 ameliorated the severity of colitis following acute 5% DSS treatment by multiple parameters of disease examined and the capacity to ameliorate the disease is dose-dependent. Further, compound 6 at 30 mg/Kg was therapeutic in the DSS model at a comparable or better efficacy, relative to prednisolone (5 mg/Kg).
Chronic IL10 --/-- Model
Mice with a deletion in the IL10 --/-- gene spontaneously develop chronic colitis, with the age of onset and the severity of the disease being dependent on background mouse strain and the conditions in which the animals are housed. The onset of colitis in IL10 --/-- mice housed under the conditions used in this study was also strain dependent, with an earlier onset and greater severity, in terms of mortality, in BALB/c strain mice relative to C57BL/6 strain animals. In this experiment, animals received oral treatment on a MWF regime over 9 weeks. Initially, both groups of mice progressively gain weight ( FIG. 15 ). Vehicle treated mice stopped gaining weight from week 5 of treatment, whereas compound 6-treated mice maintained weight gain until week 8. By week 9 animals had marked weight loss, with one moribund animal humanely killed on day 60 in each group. As other mice were losing weight and developing clinical symptoms of disease, both groups were culled at week 9 (day 63) and analysed. While there were greater mortalities in the vehicle-treated group (25%) relative to compound 6 treated mice (9.2%) by Kaplan-Meier analysis, there was no statistical difference in survival of IL10 -/- mice over the 9 weeks. Serum was recovered from mice and Serum Amyloid A (SAA) and was analysed as a marker for severity of colitis. There were significantly (P<0.05; Student's t-test) reduced SAA levels in compound 6 treated mice relative to vehicle treated IL10 --/-- mice ( FIG. 16 ).
Histology sections of colons from IL10 --/-- mice treated with vehicle or compound 6 are shown in FIG. 17 .
Histology sections of colons from IL10 --/-- mice treated with vehicle or compound 6 were scored. The extent of colon pathology was significantly reduced (P<0.05; Student's t-test) in IL10 --/-- mice receiving compound relative to mice treated with vehicle ( FIG. 18 ).
In summary, oral treatment with compound 6 (300 mg/kg/week) in IL10 --/-- BALB/c strain mice, using a MWF regime over 9 weeks, delayed weight loss and reduced deaths from colitis relative to vehicle-treated mice. In this model of chronic colitis, compound 6 significantly reduced disease indices with respect to a serum marker of colon inflammation and the degree of inflammation and damage to the colon. This is particularly noteworthy in view of the fact that the plasma half-life (t 1/2 ) for compound 6 is 3 hours in the rat. With the standard MWF dosing schedule, mice will have been unexposed to compound 6 for substantial periods during the experiment.
The invention is not limited to the embodiments hereinbefore described which may be varied in detail.
APPENDIX 1
List of Abbreviations Used
aq aqueous
b.p. boiling point
CDCl 3 chloroform-d
CH(OCH 3 ) 3 trimethylsilyl orthoformate
CO 2 carbon dioxide
DCM dichloromethane
dIW distilled ionized water
DMSO dimethyl sulphoxide
Et 2 O ether
EtOH ethanol
H 2 O water
HCl hydrochloric acid
IR infra red
IPA isopropyl alcohol
KCl potassium chloride
M molar
min minutes
microliters
mM milli-molar
m.p. melting point
N 2 nitrogen
NaBH 4 sodium borohydride
NaOH sodium hydroxide
Na 2 SO 4 sodium sulphate
NMR nuclear magnetic resonance
O 2 oxygen
RT room temperature
t BuOH tert butanol
t BuOK potassium tert butoxide
S.E.M. standard error of mean
THF tetrahydrofuran
TLC thin layer chromatography
μl microliters
Triflic Acid trifluoromethanesulfonic acid
TMS Triflate trimethyl silyl trifluoromethanesulfonate
v/v volume per volume
w/v weight per volume
λ em emission wavelength
λ exc excitation wavelength
APPENDIX 2
X-Ray Studies
A single crystal X-ray analysis was carried out on compound 2 (S)-(−)-methylbenzylamine salt (compound 8), using a SuperNova, Dual, Cu at zero, Atlas Diffractometer and the parameters outlined in Table 1.
TABLE 1 Data collection and structure refinement for compound 8, the (S)-(−)- methylbenzylamine salt of compound 2. Diffractometer SuperNova, Dual, Cu at zero, Atlas Radiation source SuperNova (Cu) X-ray Source, Cu Kα Data collection method Omega scans Theta range for data collection 3.74 to 76.22° Index ranges −13 ≦ h ≦ 13, −11 ≦ k ≦ 12, −14 ≦ l ≦ 14 Reflections collected 12753 Independent reflections 5263 [R(int) = 0.0196] Coverage of independent 99.4% reflections Variation in check reflections N/A Absorption correction Semi-empirical from equivalents Max. and min. transmission 1.00000 and 0.90238 Structure solution technique direct Structure solution program Bruker SHELXTL Refinement technique Full-matrix least-squares on F 2 Refinement program Bruker SHELXTL Function minimized Σw(F o 2 − F c 2 ) 2 Data/restraints/parameters 5263/1/363 Goodness-of-fit on F 2 1.007 Δ/σ max 0.001 Final R indices 5161 data; I > 2σ(I) R1 = 0.0321, wR2 = 0.0857 all data R1 = 0.0327, wR2 = 0.0865 Weighting scheme w = 1/[σ 2 (F o 2 ) + (0.0600P) 2 + 0.2200P] where P = (F o 2 + 2F c 2 )/3 Absolute structure parameter 0.04(14) Extinction coefficient 0.0035(5) Largest diff. peak and hole 0.214 and −0.154 e Å −3
Refinement Summary:
Ordered Non-H atoms, XYZ Freely refining
Ordered Non-H atoms, U Anisotropic
H atoms (on carbon), XYZ Idealized positions riding on attached atoms
H atoms (on carbon), U Appropriate multiple of U(eq) for bonded atom
H atoms (on heteroatoms), XYZ Freely refining
H atoms (on heteroatoms), U Isotropic
Disordered atoms, OCC Refined with a two part model constrained to a total of unity
Disordered atoms, XYZ freely refining
Disordered atoms, U freely refining
The single crystal X-ray data establishes that the structure of compound 6 is monoclinic, space group P2 1 , with one molecule of compound 6 in the asymmetric unit (Table 2).
TABLE 2
Sample and crystal data for compound 8
Crystallization solvents
Diethyl ether, MeOH, THF
Crystallization method
Slow evaporation
Empirical formula
C 34 H 33 N 1 O 3
Formula weight
503.61
Temperature
100(1) K
Wavelength
1.54178 Å
Crystal size
0.50 × 0.50 × 0.50 mm
Crystal habit
Colourless Block
Crystal system
Monoclinic
Space group
P2 1
Unit cell dimensions
a = 11.0344(2) Å
α = 90°
b = 10.1727(2) Å
β = 93.682(2)°
c = 11.8532(2) Å
γ = 90°
Volume
1327.77(4) Å 3
Z
2
Density (calculated)
1.260 Mg/m 3
Absorption coefficient
0.627 mm −1
F(000)
536
The absolute stereochemistry was determined as S, S at C9 and C10 for compound 2 and S at C33 for the methylbenzylamine cation. The assignment was made from consideration of both the Flack parameter which was determined to be 0.04 (14) and from the a priori knowledge of the stereochemistry of the salt former.
The absolute stereochemistry was also determined using Bayesian statistics on the Bijvoet pair differences which resulted in a probability of the stereochemistry at the chiral centers C9, C10 and C33 being S, S and S respectively as 1.000 and R, R and R as 0.000. This supports the assignment of S, S and S for C9, C10 and C33 respectively from the Flack parameter measurement.
The calculated X-ray powder diffraction pattern from the single crystal X-ray structure was in agreement with the stereochemistry shown in FIG. 2 (or the following).
TABLE 3
Atomic coordinates and equivalent isotropic, atomic displacement
parameters, (Å 2 ), for compound 8. U(eq) is defined as one third of the
trace of the orthogonalised U ij tensor.
x/a
y/b
z/c
U(eq)
O1
0.02763(10)
0.17316(11)
1.16556(8)
0.0228(2)
O2
0.07430(9)
−0.03465(10)
1.12294(7)
0.0194(2)
O3
0.10561(8)
0.01057(10)
1.90142(8)
0.0184(2)
C1
0.08315(12)
−0.12167(14)
1.47373(12)
0.0198(3)
C2
0.07248(13)
−0.09752(14)
1.35802(12)
0.0192(3)
C3
0.08014(11)
0.02912(13)
1.31666(11)
0.0158(3)
C4
0.05975(11)
0.05851(14)
1.19195(11)
0.0164(3)
C5
0.10196(12)
0.13219(14)
1.39262(11)
0.0184(3)
C6
0.11261(13)
0.10790(14)
1.50817(11)
0.0197(3)
C7
0.10101(11)
−0.01884(14)
1.55106(10)
0.0164(3)
C8
0.09988(12)
−0.04205(14)
1.67717(10)
0.0177(3)
C9
0.22568(11)
−0.05199(14)
1.74191(10)
0.0160(3)
C10
0.20981(12)
−0.06390(14)
1.87231(10)
0.0173(3)
C11
0.32285(12)
−0.00001(14)
1.92450(11)
0.0183(3)
C12
0.36695(13)
−0.00323(15)
2.03747(11)
0.0217(3)
C13
0.46523(13)
0.07703(16)
2.07062(12)
0.0263(3)
C14
0.51796(13)
0.15733(16)
1.99312(13)
0.0271(3)
C15
0.47368(13)
0.16061(15)
1.87974(13)
0.0237(3)
C16
0.37476(12)
0.08173(14)
1.84684(11)
0.0188(3)
C17
0.30303(12)
0.07486(14)
1.73362(11)
0.0189(3)
C18
0.29536(12)
−0.17122(14)
1.70380(10)
0.0170(3)
C19
0.24493(13)
−0.29849(15)
1.68674(11)
0.0224(3)
C20
0.34284(13)
−0.38466(15)
1.64945(10)
0.0202(3)
C21
0.34340(15)
−0.51740(16)
1.62093(12)
0.0279(3)
C22
0.45250(18)
−0.57426(17)
1.59308(13)
0.0363(8)
C23
0.55837(16)
−0.50075(18)
1.59165(13)
0.0317(4)
C24
0.55735(14)
−0.36697(17)
1.61785(12)
0.0269(3)
C25
0.44911(13)
−0.31016(15)
1.64729(11)
0.0212(3)
C26
0.42215(14)
−0.17370(16)
1.68241(12)
0.0238(3)
C18A
0.29536(12)
−0.17122(14)
1.70380(10)
0.0170(3)
C19A
0.24493(13)
−0.29849(15)
1.68674(11)
0.0224(3)
C20A
0.34284(13)
−0.38466(15)
1.64945(10)
0.0202(3)
C21A
0.34340(15)
−0.51740(16)
1.62093(12)
0.0279(3)
C22A
0.45250(18)
−0.57426(17)
1.59308(13)
0.0279(3)
C23A
0.55837(16)
−0.50075(18)
1.59165(13)
0.0317(4)
C24A
0.55735(14)
−0.36697(17)
1.61785(12)
0.0269(3)
C25A
0.44911(13)
−0.31016(15)
1.64729(11)
0.0212(3)
C26A
0.42215(14)
−0.17370(16)
1.68241(12)
0.0238(3)
N1
−0.09024(11)
−0.21952(13)
1.02800(10)
0.0194(2)
C27
−0.18541(12)
0.06679(15)
0.92258(12)
0.0220(3)
C28
−0.19466(13)
0.15069(16)
0.82981(13)
0.0256(3)
C29
−0.23606(14)
0.10317(17)
0.72421(13)
0.0273(3)
C30
−0.26855(15)
−0.02757(18)
0.71195(13)
0.0301(3)
C31
−0.26063(14)
−0.11089(16)
0.80481(13)
0.0255(3)
C32
−0.21928(12)
−0.06417(15)
0.91135(11)
0.0200(3)
C33
−0.21444(12)
−0.15827(15)
1.01084(12)
0.0205(3)
C34
−0.24587(14)
−0.09613(16)
1.12172(13)
0.0256(3)
TABLE 4
Selected bond lengths, (Å), for compound 8
O1—C4
1.2528(18)
O2—C4
1.2688(17)
O3—C10
1.4373(16)
O3—H3A
0.88(2)
C1—C2
1.3909(19)
C1—C7
1.3964(19)
C2—C3
1.383(2)
C3—C5
1.3929(19)
C3—C4
1.5108(17)
C5—C6
1.3893(18)
C6—C7
1.395(2)
C7—C8
1.5141(16)
C8—C9
1.5457(17)
C9—C18
1.5203(19)
C9—C17
1.5537(19)
C9—C10
1.5713(16)
C10—C11
1.5040(18)
C11—C16
1.391(2)
C11—C12
1.3953(17)
C12—C13
1.394(2)
C13—C14
1.385(2)
C14—C15
1.401(2)
C15—C16
1.390(2)
C16—C17
1.5152(18)
C18—C19
1.418(2)
C18—C26
1.4380(19)
C19—C20
1.481(2)
C20—C21
1.392(2)
C20—C25
1.398(2)
C21—C22
1.394(2)
C22—C23
1.388(3)
C23—C24
1.396(2)
C24—C25
1.391(2)
C25—C26
1.485(2)
N1—C33
1.5073(18)
N1—H1B
0.91(2)
N1—H1C
0.93(2)
N1—H1D
0.90(2)
C27—C32
1.388(2)
C27—C28
1.390(2)
C28—C29
1.391(2)
C29—C30
1.383(3)
C30—C31
1.387(2)
C31—C32
1.398(2)
C32—C33
1.5172(19)
C33—C34
1.518(2)
TABLE 5
Selected bond angles, (°), for compound 8
C10—O3—H3A
107.0(15)
C2—C1—C7
120.96(13)
C3—C2—C1
120.72(13)
C2—C3—C5
118.95(12)
C2—C3—C4
121.50(12)
C5—C3—C4
119.48(12)
O1—C4—O2
125.44(12)
O1—C4—C3
116.78(12)
O2—C4—C3
117.77(12)
C6—C5—C3
120.23(13)
C5—C6—C7
121.32(13)
C6—C7—C1
117.75(12)
C6—C7—C8
120.71(12)
C1—C7—C8
121.43(13)
C7—C8—C9
115.87(10)
C18—C9—C8
111.09(11)
C18—C9—C17
110.70(11)
C8—C9—C17
113.19(11)
C18—C9—C10
108.74(10)
C8—C9—C10
109.89(10)
C17—C9—C10
102.86(10)
O3—C10—C11
109.18(11)
O3—C10—C9
109.69(10)
C11—C10—C9
103.26(10)
C16—C11—C12
121.07(13)
C16—C11—C10
110.61(11)
C12—C11—C10
127.84(13)
C13—C12—C11
118.29(14)
C14—C13—C12
120.72(13)
C13—C14—C15
120.99(14)
C16—C15—C14
118.34(14)
C15—C16—C11
120.58(13)
C15—C16—C17
129.14(13)
C11—C16—C17
110.16(12)
C16—C17—C9
103.90(11)
C19—C18—C26
109.64(13)
C19—C18—C9
124.70(12)
C26—C18—C9
125.65(13)
C18—C19—C20
107.21(12)
C21—C20—C25
120.31(14)
C21—C20—C19
131.41(14)
C25—C20—C19
108.27(13)
C20—C21—C22
118.51(15)
C23—C22—C21
121.31(15)
C22—C23—C24
120.24(15)
C25—C24—C23
118.68(15)
C24—C25—C20
120.94(14)
C24—C25—C26
130.48(14)
C20—C25—C26
108.57(13)
C18—C26—C25
106.29(13)
C33—N1—H1B
108.3(13)
C33—N1—H1C
112.0(13)
H1B—N1—H1C
107.4(18)
C33—N1—H1D
111.6(13)
H1B—N1—H1D
112.5(18)
H1C—N1—H1D
105.0(17)
C32—C27—C28
120.51(14)
C27—C28—C29
120.09(15)
C30—C29—C28
119.78(14)
C29—C30—C31
120.10(14)
C30—C31—C32
120.61(15)
C27—C32—C31
118.89(14)
C27—C32—C33
122.36(13)
C31—C32—C33
118.74(13)
N1—C33—C32
110.61(11)
N1—C33—C34
108.16(11)
C32—C33—C34
114.30(12)
TABLE 6
Selected torsion angles, (°), for compound 8
C7—C1—C2—C3
0.4(2)
C1—C2—C3—C5
1.7(2)
C1—C2—C3—C4
−175.50(12)
C2—C3—C4—O1
156.41(13)
C5—C3—C4—O1
−20.75(18)
C2—C3—C4—O2
−22.38(18)
C5—C3—C4—O2
160.46(12)
C2—C3—C5—C6
−1.7(2)
C4—C3—C5—C6
175.57(12)
C3—C5—C6—C7
−0.5(2)
C5—C6—C7—C1
2.5(2)
C5—C6—C7—C8
−173.65(12)
C2—C1—C7—C6
−2.52(19)
C2—C1—C7—C8
173.64(12)
C6—C7—C8—C9
−83.92(16)
C1—C7—C8—C9
100.03(15)
C7—C8—C9—C18
−64.43(16)
C7—C8—C9—C17
60.83(15)
C7—C8—C9—C10
175.19(12)
C18—C9—C10—O3
−155.49(11)
C8—C9—C10—O3
−33.70(15)
C17—C9—C10—O3
87.10(12)
C18—C9—C10—C11
88.22(13)
C8—C9—C10—C11
−149.99(11)
C17—C9—C10—C11
−29.19(13)
O3—C10—C11—C16
−96.36(13)
C9—C10—C11—C16
20.29(15)
O3—C10—C11—C12
75.67(18)
C9—C10—C11—C12
−167.68(14)
C16—C11—C12—C13
−0.5(2)
C10—C11—C12—C13
−171.75(13)
C11—C12—C13—C14
−0.3(2)
C12—C13—C14—C15
0.3(2)
C13—C14—C15—C16
0.4(2)
C14—C15—C16—C11
−1.2(2)
C14—C15—C16—C17
174.32(14)
C12—C11—C16—C15
1.2(2)
C10—C11—C16—C15
173.88(13)
C12—C11—C16—C17
−175.05(12)
C10—C11—C16—C17
−2.40(16)
C15—C16—C17—C9
167.34(14)
C11—C16—C17—C9
−16.79(15)
C18—C9—C17—C16
−88.09(12)
C8—C9—C17—C16
146.44(11)
C10—C9—C17—C16
27.92(13)
C8—C9—C18—C19
−44.46(16)
C17—C9—C18—C19
−171.10(11)
C10—C9—C18—C19
76.60(15)
C8—C9—C18—C26
137.25(13)
C17—C9—C18—C26
10.60(17)
C10—C9—C18—C26
−101.70(15)
C26—C18—C19—C20
−1.81(14)
C9—C18—C19—C20
179.67(11)
C18—C19—C20—C21
−179.77(14)
C18—C19—C20—C25
1.34(15)
C25—C20—C21—C22
1.5(2)
C19—C20—C21—C22
−177.24(14)
C20—C21—C22—C23
−1.1(2)
C21—C22—C23—C24
−0.3(2)
C22—C23—C24—C25
1.2(2)
C23—C24—C25—C20
−0.7(2)
C23—C24—C25—C26
177.73(14)
C21—C20—C25—C24
−0.6(2)
C19—C20—C25—C24
178.39(12)
C21—C20—C25—C26
−179.41(12)
C19—C20—C25—C26
−0.38(15)
C19—C18—C26—C25
1.57(15)
C9—C18—C26—C25
−179.92(11)
C24—C25—C26—C18
−179.32(14)
C20—C25—C26—C18
−0.71(15)
C32—C27—C28—C29
−1.2(2)
C27—C28—C29—C30
0.3(2)
C28—C29—C30—C31
0.4(2)
C29—C30—C31—C32
−0.3(2)
C28—C27—C32—C31
1.2(2)
C28—C27—C32—C33
−178.07(13)
C30—C31—C32—C27
−0.5(2)
C30—C31—C32—C33
178.85(14)
C27—C32—C33—N1
−86.99(16)
C31—C32—C33—N1
93.72(15)
C27—C32—C33—C34
35.36(18)
C31—C32—C33—C34
−143.93(14)
TABLE 7
Anisotropic atomic displacement parameters, (Å 2 ), for compound 8 The anistropic atomic
displacement factor exponent takes the form: −2π 2 [h 2 a* 2 U 11 + . . . + 2hka* b* U 12
U 11
U 22
U 33
U 23
U 13
U 12
O1
0.0325(5)
0.0206(5)
0.0153(4)
0.0025(4)
0.0015(4)
0.0044(4)
O2
0.0255(5)
0.0206(5)
0.0123(4)
−0.0017(4)
0.0024(3)
−0.0014(4)
O3
0.0205(4)
0.0232(5)
0.0116(4)
−0.0002(4)
0.0027(3)
0.0016(4)
C1
0.0257(7)
0.0179(7)
0.0159(6)
0.0017(5)
0.0018(5)
−0.0028(5)
C2
0.0267(7)
0.0171(7)
0.0139(6)
−0.0035(5)
0.0024(5)
−0.0019(5)
C3
0.0160(6)
0.0187(7)
0.0128(6)
−0.0004(5)
0.0017(4)
0.0011(5)
C4
0.0166(5)
0.0193(7)
0.0134(6)
0.0000(5)
0.0014(4)
−0.0018(5)
C5
0.0234(6)
0.0155(7)
0.0159(6)
−0.0001(5)
−0.0011(5)
0.0020(5)
C6
0.0251(6)
0.0175(7)
0.0158(6)
−0.0030(5)
−0.0024(5)
0.0028(5)
C7
0.0150(5)
0.0213(7)
0.0129(6)
0.0000(5)
0.0009(4)
0.0028(5)
C8
0.0188(6)
0.0217(7)
0.0124(6)
−0.0007(5)
0.0000(4)
0.0018(5)
C9
0.0186(6)
0.0177(7)
0.0117(5)
0.0004(5)
0.0007(4)
−0.0002(5)
C10
0.0206(6)
0.0190(7)
0.0121(6)
0.0000(5)
0.0005(4)
0.0022(5)
C11
0.0201(6)
0.0185(7)
0.0163(6)
−0.0030(5)
0.0004(5)
0.0033(5)
C12
0.0234(6)
0.0249(8)
0.0166(6)
−0.0018(5)
−0.0015(5)
0.0056(5)
C13
0.0237(7)
0.0322(9)
0.0216(7)
−0.0074(6)
−0.0074(5)
0.0074(6)
C14
0.0196(7)
0.0284(8)
0.0324(8)
−0.0099(6)
−0.0049(6)
0.0015(6)
C15
0.0199(6)
0.0229(7)
0.0282(7)
−0.0035(6)
0.0008(5)
0.0012(6)
C16
0.0186(6)
0.0198(7)
0.0178(6)
−0.0023(5)
0.0007(5)
0.0028(5)
C17
0.0213(6)
0.0203(7)
0.0151(6)
0.0004(5)
0.0018(5)
−0.0008(5)
C18
0.0200(6)
0.0206(7)
0.0101(5)
0.0011(5)
−0.0009(4)
0.0004(5)
C19
0.0245(7)
0.0249(8)
0.0176(6)
−0.0024(5)
0.0008(5)
0.0029(5)
C20
0.0256(7)
0.0227(7)
0.0124(6)
0.0001(5)
0.0015(5)
0.0027(5)
C21
0.0392(8)
0.0237(8)
0.0215(6)
−0.0032(6)
0.0059(6)
−0.0017(7)
C22
0.063(2)
0.0236(16)
0.0226(13)
−0.0024(11)
0.0090(13)
0.0165(15)
C23
0.0359(8)
0.0356(9)
0.0240(7)
−0.0034(6)
0.0049(6)
0.0140(7)
C24
0.0253(7)
0.0331(9)
0.0225(7)
−0.0050(6)
0.0034(5)
0.0047(6)
C25
0.0253(7)
0.0253(8)
0.0129(5)
0.0003(5)
0.0016(5)
0.0035(5)
C26
0.0277(7)
0.0248(8)
0.0197(6)
−0.0005(6)
0.0069(5)
0.0012(6)
C18A
0.0200(6)
0.0206(7)
0.0101(5)
0.0011(5)
−0.0009(4)
0.0004(5)
C19A
0.0245(7)
0.0249(8)
0.0176(6)
−0.0024(5)
0.0008(5)
0.0029(5)
C20A
0.0256(7)
0.0227(7)
0.0124(6)
0.0001(5)
0.0015(5)
0.0027(5)
C21A
0.0392(8)
0.0237(8)
0.0215(6)
−0.0032(6)
0.0059(6)
−0.0017(7)
C22A
0.0392(8)
0.0237(8)
0.0215(6)
−0.0032(6)
0.0059(6)
−0.0017(7)
C23A
0.0359(8)
0.0356(9)
0.0240(7)
−0.0034(6)
0.0049(6)
0.0140(7)
C24A
0.0253(7)
0.0331(9)
0.0225(7)
−0.0050(6)
0.0034(5)
0.0047(6)
C25A
0.0253(7)
0.0253(8)
0.0129(5)
0.0003(5)
0.0016(5)
0.0035(5)
C26A
0.0277(7)
0.0248(8)
0.0197(6)
−0.0005(6)
0.0069(5)
0.0012(6)
N1
0.0248(6)
0.0191(6)
0.0143(5)
−0.0013(5)
0.0005(4)
−0.0007(5)
C27
0.0216(6)
0.0233(7)
0.0213(7)
−0.0001(5)
0.0017(5)
−0.0030(5)
C28
0.0250(7)
0.0228(8)
0.0293(7)
0.0035(6)
0.0038(6)
−0.0021(6)
C29
0.0265(7)
0.0298(9)
0.0254(7)
0.0087(6)
−0.0001(5)
−0.0017(6)
C30
0.0326(8)
0.0357(9)
0.0214(7)
0.0019(6)
−0.0041(6)
−0.0050(7)
C31
0.0286(7)
0.0238(8)
0.0234(7)
0.0001(6)
−0.0034(6)
−0.0053(6)
C32
0.0169(6)
0.0233(7)
0.0198(6)
0.0024(5)
0.0007(5)
−0.0024(5)
C33
0.0196(6)
0.0205(7)
0.0212(6)
0.0023(5)
0.0001(5)
−0.0031(5)
C34
0.0280(7)
0.0264(8)
0.0232(7)
0.0029(6)
0.0065(6)
0.0024(6)
APPENDIX 3
Compound 1 4-((−1-hydroxy-2,3-dihydro-1H,1′H-2,2′-biinden-2-yl)methyl)benzoic acid
Compound 2 4-(((1S,2S)-1-hydroxy-2,3-dihydro-1H,1′H-2,2′-biinden-2-yl)methyl)benzoic acid
Compound 3 4-(((1R,2R)-1-hydroxy-2,3-dihydro-1H,′1′H-2,2′-biinden-2-yl)methyl)benzoic acid
Compound 4 4-(((1R,2S)-1-hydroxy-2,3-dihydro-1H,1′H-2,2′-biinden-2-yl)methyl)benzoic acid
Compound 5 4-(((1S,2R)-1-hydroxy-2,3-dihydro-1H,1′H-2,2′-biinden-2-yl)methyl)benzoic acid
Compound 6 6-(Methylamino)hexane-1,2,3,4,5-pentanol 4-(((1S,2S)-1-hydroxy-2,3-dihydro-1H,1′H-2,2′-biinden-2-yl)methyl)benzoate
Compound 7 6-(Methylamino)hexane-1,2,3,4,5-pentanol 4-(((1S,2R)-1-hydroxy-2,3-dihydro-1H,1′H-2,2′-biinden-2-yl)methyl)benzoate
Compound 8 (S)-1-Phenylethylammonium 4-(((1S,2S)-1-hydroxy-2,3-dihydro-1H,-1′H-2,2′-biinden-2-yl)methyl)benzoate
Compound 9 (R)-1-Phenylethylammonium 4-(((1R,2S)-1-hydroxy-2,3-dihydro-1H,1′H-2,2′-biinden-2-yl)methyl)benzoate | Described are compounds of the structural formula (I): Also provided are pharmacologically acceptable isomers and salts of the compound of (I). The compounds are useful in the treatment of inflammatory bowel disease. | 0 |
CROSS REFERENCE
[0001] This application is a continuation-in-part of U.S. Non-provisional application Ser. No. 13/211,817 filed on Aug. 17, 2011. The parent application is incorporated by reference herein in its entirety.
BACKGROUND
[0002] Isolation of downhole environments depends on the deployment of a downhole tool that effectively seals the entirety of the borehole or a portion thereof, for example, an annulus between a casing wall and production tube. Swellable packers, for example, are particularly useful in that they automatically expand to fill the cross-sectional area of a borehole in response to one or more downhole fluids. Consequently, swellable packers can be placed in borehole locations that have a smaller inner diameter than the cross-sectional area of the fully expanded swellable packer. However, certain downhole conditions, such as the presence of monovalent and polyvalent cations (e.g., Ca 2+ , Zn 2+ , etc.) in the aqueous downhole fluids contacting the swellable packer, tend to decrease both the amount of swelling and the rate at which the packer swells, and may also accelerate degradation of the packer. In order to overcome these issues and to continually improve upon swelling efficiency under a variety of conditions, the industry is always desirous of new and alternate swelling systems.
SUMMARY
[0003] A swellable system reactive to a flow of fluid, including an article including a swellable material operatively arranged to swell upon exposure to a flow of fluid, the flow of fluid containing ions therein; and a filter material disposed with the swellable material and operatively arranged to remove the ions from the flow of fluid before exposure to the swellable material.
[0004] A method of operating a swellable system including filtering ions from a flow of fluid with a filter material; and swelling a swellable material responsive to the flow of fluid upon exposure to the fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0006] FIG. 1 is a cross-sectional view of a swellable article in an initial configuration;
[0007] FIG. 2 is a cross-sectional view of the swellable article of FIG. 1 in a swelled configuration;
[0008] FIG. 3 is a swellable system according to an embodiment disclosed herein where a swellable article is disposed with a filter material in a shell covering a swellable core; and
[0009] FIG. 4 is a swellable system according to another embodiment disclosed herein where a filter material is separately disposed from a swellable article.
DETAILED DESCRIPTION
[0010] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0011] Referring now to FIG. 1 , a system 10 including a tubular or string 12 and a downhole article 14 , e.g., a packer or sealing element, disposed thereon is illustrated. The downhole article 14 includes, for example, a base composition and a filter component, discussed in more detail below. The base composition comprises an elastomeric material and/or an absorbent material. Due to fluid absorption by the absorbent material, e.g. absorption of water, brine, hydrocarbons, etc., the article 14 expands or swells to a second configuration shown in FIG. 2 . Various absorbent materials are known and used in the art. For example, with respect to water swellable embodiments any so-called Super Absorbent Polymer could be used, or those marketed by Nippon Shokubai Co., Ltd. under the name AQUALIC® CS-6S. The elastomeric material is included, for example, to provide a seal against a downhole structure 16 , e.g., a borehole in a subterranean formation 18 , shown in FIG. 2 . Of course, the structure 16 could be any other tubing, casing, liner, etc. located downhole and engagable by the article 14 . The elastomeric material could be any swellable or non-swellable material. In some embodiments, the elastomeric material is absorbent with respect to one or more downhole fluids thus also encompassing the absorbent material. In this way, for example, the article 14 can be run-in having an initially radially compressed configuration, exposed to fluids once located downhole, and expanded to engage between the tubular 12 and the structure 16 . In one embodiment, the structure 16 is isolated by expansion of the article 14 such that fluids (e.g., from the formation 18 ) are substantially prevented from flowing past the article 14 once the article 14 is expanded.
[0012] Downhole fluids typically comprise an aqueous component, which more accurately is a brine containing various ions, e.g., metal cations from dissolved salts. As noted above, monovalent and polyvalent cations can interact with the absorbent material, and decrease the overall rate and ratio of expansion of the absorbent material, thereby hindering the sealing efficacy of the article. It has been generally found that polyvalent cations such as Ca 2+ , Zn 2+ , etc. have a more profound effect on the performance of swellable materials, particularly in water swellable articles, than monovalent cations and are thus usually more desirable to be removed. It is to be appreciated that while water-swellable materials are discussed as an exemplary embodiment that is adversely affected by the presence of cations, other materials may be swellable in response to different fluids and/or adversely affected by anions. For example, in one embodiment the swellable material is adversely affected (e.g., reduced swelling, shorter life span, slower swelling rate, etc.) by the presence of anions. For this reason, the term “ions” as used herein will refer to any cation or anion that has a negative effect on the performance of a corresponding swellable material.
[0013] To mitigate the deleterious effect of such ions on the absorbent material, the filter material acts to remove or filter ions from the downhole fluids before they interact with the swellable material. By remove or filter, it is meant that the filter material captures or holds the ions in, at, or proximate a capture site or location proximate to the filter material, or otherwise neutralizes the ions such that the flow of fluid is at least partially relatively devoid of ions downstream of the filter material. Thus, while the ions are still technically in the fluid, they are prevented from adversely affecting the swelling of the swellable material and therefore considered to be removed or filtered. The removal, filtering, or capture may be done by chemical or physical bonding between the filter material and the ions, physisorption or chemisorption at or by the filter material or a surface thereof, electrostatic and/or van der Waals attraction between the filter material or an atomic structure thereof (e.g., functionalized group) and the ions, etc., examples of which are discussed in more detail below.
[0014] In the embodiment of FIGS. 1 and 2 , the filter material, the elastomeric material, and/or the absorbent material can all be mixed together, e.g., homogeneously, then formed into the article 14 . An alternate embodiment for a system 22 is shown in FIG. 3 , the system 22 including an article 24 on a tubular or string 26 . The article 24 is formed from a core 28 and a shell 30 . In this embodiment, the core 28 includes the aforementioned swellable material, while the shell 30 includes the filter material. The core 28 and the shell 30 may both, for example, include suitable elastomeric and/or filler materials to provide sealing for the article 24 and to impart chemical and physical properties to the article 24 . In this way, the flow of fluid to which the swellable material in the core 28 is reactive will first be filtered of ions by the filter material in the shell 30 .
[0015] A system 32 according to another embodiment is shown in FIG. 4 in which a swellable article 34 is disposed with a tubular or string 36 . In this embodiment, a formation 38 is separated from the article 34 by a radially disposed tubular or string 40 , e.g., a casing, liner, tubing, etc. The tubular/string 40 includes at least one port or opening 42 for enabling a flow of fluid, generally designated by an arrow 44 , to encounter the article 34 . The filter material can be arranged in a plug 46 positioned in the opening 42 , in a membrane or film 48 positioned over the opening 42 , etc. The plug 46 can be formed as any suitable fluid permeable member for creating a passageway for communicating fluid to the swellable material. In this way, the flow of fluid is filtered by the filter material before it reaches the article 34 . The plug 46 and/or the membrane 48 could be formed from any suitable permeable material, e.g., a porous foam, fibers, with the filter material disposed in or with the permeable material, e.g., in pores of the permeable material.
[0016] In another embodiment, essentially a combination of the above, the shell 30 could be a protective or elastomeric shell impermeable to downhole fluids and resistant to corrosion and degradation. A permeable plug, such as discussed with respect to the plug 46 could be included in the shell 30 as opposed the an outer tubular 40 . In this way, the swellable article will benefit from an outer shell made of an elastomeric or other material that can be selected to provide beneficial properties such as corrosion resistance, fluid impermeability, etc., while also maintaining the advantageous ion filtering properties provided by the current invention as discussed herein.
[0017] In one embodiment, the filter material comprises one or more graphene-based compounds. By graphene-based it is meant a compound that includes or is derived from graphene, such as graphene itself, graphite, graphite oxide, graphene oxide, etc. The compounds could take any form used with such graphene-based compounds, such as sheets or nanosheets, particles, flakes, nanotubes, etc. Advantageously, the unique properties of graphene enable effective donor—acceptor interactions between both the anions and the cations and the graphene flakes or particles. The graphene-based materials, associated oxides, or other derivatives or functionalized compounds thereof may contain a corresponding relatively large number of capture sites for attracting and binding ions via van der Waals and/or Coulombic interactions. Of course, other materials with electron-rich surfaces can be used for similarly filtering cations, while highly electron deficient materials may be utilized with respect to anions.
[0018] To further increase the ability of graphene-based filter materials to capture the aforementioned polyvalent cations, the filter materials can be functionalized to include one or more functional groups. The process of forming graphite or graphene oxide, for example, results in the inclusion of various functional groups that are relatively negatively charged (e.g., carboxylic acid groups) or polar (e.g., carbonyl groups). Polyvalent cations will be attracted to and captured by these groups. In one embodiment the filter material is covalently modified with thiol groups according to known diazonium chemistry procedures. Thiol groups are naturally excellent at capturing positively charged ions, notably doubly charged mercury cations, although other metallic cations ions such as the aforementioned Ca 2+ , Zn 2+ , etc., contained in downhole brines will also be readily captured by thiol groups. Other functional groups such as disulfide groups, carboxylic acid, sulfonic acid groups may also be used for their ability to capture polyvalent cations, particularly doubly charged cations. Other functional groups include chelating ligand groups, such as iminodiacetic acid, iminodiacetic acid group, N-[5-amino-1-carboxy-(t-butyl)pentyl]iminodi-t-butylacetate) group, N-(5-amino-1-carboxypentyl)iminodiacetic acid group, N-(5-amino-1-carboxypentyl)iminodiacetic acid tri-t-butyl ester group, aminocaproic nitrilotriacetic acid group, aminocaproic nitrilotriacetic acid tri-tert-butylester group, 2-aminooxyethyliminodiacetic acid group, and others that would be recognized by those of ordinary skill in the art in view of the disclosure herein.
[0019] The graphene-based materials could also be functionalized to filter anions, e.g., with quaternary ammonium, quaternary phosphonium, ternary sulfonium, cyclopropenylium cations, or primary, secondary, ternary amino, or other groups. These groups are either positively charged or become protonated in acidic environments and thus require anions to compensate for the charge. In some situations, the anion can be exchanged with another anion while preserving charge. For example, in one embodiment, the graphene-based material is functionalized with a quaternary ammonium group, the positive charge of which is balanced by hydroxide anions. In this example, in brine containing SO 4 2− anions, one SO 4 2− anion will be captured and two hydroxide anions (OH − ) will be released. In an embodiment, a mixture of graphene-based material functionalized with sulfonic acid groups and graphene-based material functionalized with quarternary ammonium groups balanced by hydroxide anions is used to neutralize a CaCl 2 brine. In the cation-exchange process, Ca 2+ cations are captured with a simultaneous release of two H + ions for each Ca 2+ cation. In the anion-exchange process, Cl − ions are captured by the quaternary ammonium group with a simultaneous release of OH − anion for each Cl − ion. Recombination of released H + and OH − ions results in the formation of water molecules, which may contribute to the swelling process of water-swellable materials.
[0020] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. | A swellable system reactive to a flow of fluid including an article having a swellable material operatively arranged to swell upon exposure to a flow of fluid containing ions therein. A filter material is disposed with the swellable material and operatively arranged to remove the ions from the flow of fluid before exposure to the swellable material. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. National Stage of International Application No. PCT/EP2013/001273, filed Apr. 29, 2013, which designated the United States and has been published as International Publication No. WO 2013/164081 and which claims the priority of German Patent Application, Serial No. 10 2012 207 206.3, filed Apr. 30, 2012, pursuant to 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The invention relates to an adhesive application device for applying an adhesive to a material which is moved along a direction of transport x, comprising a nozzle unit having a number of nozzles for applying the adhesive to the material, and to a method for applying adhesive to a material which is moved along a direction of transport x.
Adhesive application devices of this type are used for example in the production of window envelopes. In this case, as a rule first of all a web of paper is guided through a roller system having a number of cutter rollers or similar cutting implements in order to produce an envelope blank. In this case, in a separate cutting process the envelope blank is provided with a cutout for a window. Around this cutout, in a subsequent method step, an adhesive agent is then applied, and a window material is glued on. In this case, as a rule a roller system is also resorted to for applying the adhesive agent. A gumming roller comprising adhesive stamp or a format part for applying the adhesive agent to the envelope blank or to a window film which is adapted to the height and width of the window is rolled onto the envelope blank or the window film, so that the edges of the cutout are provided with sufficient adhesive agent. What is disadvantageous about this method is that a variation in the size of the window, but also a variation in the positioning of the window, always results in the gumming roller being replaced. Thus not only does a separate gumming roller have to be provided and held available for each desired format, they even have to be changed in a costly manner and with production being stopped upon each change of format.
In the case of gluing of paper or cardboard blanks over a large surface area, in addition to the above-mentioned gumming rollers also strips comprising a number of metering nozzles, through which an adhesive agent or an adhesive is applied to the blank, are used. A nozzle system of this type is known for example from the document DE 10 2007 002 980 A1. The metering strip in this case extends over the entire width of the paper web and comprises a number of individual nozzles which are arranged at fixed distances from one another and can be activated individually. Fixed systems of this type are, however, suitable only to a limited extent for use in gluing window elements and, furthermore, are very costly to clean. Owing to the only slight gap between the nozzles and the paper blanks or the roller which transports these paper blanks, cleaning of the nozzles is impeded, which again results in relatively long downtimes of the installation.
SUMMARY OF THE INVENTION
It is therefore the object of the invention to provide an adhesive application device of the above-mentioned type and a method for operating an adhesive device which can process gluing patterns of different sizes particularly flexibly and efficiently in a very simple manner.
With respect to the device, this object is achieved according to the invention in that the nozzle unit is arranged to be displaceable transversely to the direction of transport x along a first guide, spindle.
With respect to the method, this object is achieved according to the invention in that the nozzle unit comprising a number of nozzles is moved along a first guide spindle, transversely to the direction of transport, to the desired gluing position, the application of a first adhesive taking place via these nozzles.
Advantageous configurations are the subject matter of the dependent claims.
The invention is based on the concept that particularly flexible adaptation to different dimensions of the region which is to be provided with adhesive is possible when a fixed adhesive template or a format template can be dispensed with. For this reason, a nozzle unit comprising a number of nozzles was used. As has now been shown, the provision of very widely varying formats of gluing surfaces is made possible in particular when this nozzle unit is arranged to be movable and the gluing always takes place in the optimum gluing position. For this reason, the nozzle unit is arranged to be displaceable along a first guide spindle which runs transversely to the direction of transport of the material. Thus it is possible for the entire width of the material to be reached by the nozzle unit via the shortest paths possible. The nozzle unit in this case designates a system consisting of a plurality of gluing heads which can be displaced along a common guide spindle. These units can be connected together at fixed intervals, for example as a nozzle block, or alternatively be constructed to be individually movable.
For an arrangement of the individual gluing heads and the nozzles on the nozzle unit which is as space-saving as possible, and at the same time in order to provide gluing surfaces which are as large as possible, in an advantageous configuration these heads and nozzles are arranged in a row and transversely to the direction of transport. By means of this arrangement, as large a width of the gluing surface as possible can be reached using a fixed number of nozzles.
In order to further increase the flexibility of the adhesive application device for different gluing formats and also in order to provide the possibility of being able to resort to different adhesive agents, in a particularly advantageous configuration a further nozzle unit is provided which comprises a number of individual gluing heads which are displaceable relative to one another. This further nozzle unit or these individual gluing heads in this case are likewise arranged to be displaceable transversely to the direction of transport of the material along one guide spindle in each case.
In order to achieve particularly rapid and high strength, in this case the individual gluing heads are designed for applying hot glue, while the nozzles in the nozzle unit are designed for applying cold glue. The consequence of this is that, owing to the dot-wise application of hot glue at selected points of the gluing format, for example in the corners of a rectangular cutout in the material, a rapid adhesive action can occur and thus, for example when gluing windows, the second material which is placed on top in a subsequent production process produces a basic adhesion as quickly as possible which prevents initial slipping or detachment. The cold glue which is applied over a larger surface area by the nozzle unit hardens substantially more slowly, and thus ensures the permanent, long-lasting adhesive action.
For a particularly efficient and also flexible distribution of the adhesive, the application of the adhesive by the individual nozzles of the nozzle unit and also by the nozzles of the individual gluing heads in a preferred configuration of the adhesive application device can be activated individually and separately from one another. This results in rectangular gluing surfaces, such as are required for example when gluing windows, also being possible in a very simple, adhesive-saving manner. In the case of a rectangular gluing surface, for example in a first step, corresponding to the width of the rectangle, a specific number of adjacent nozzles would apply an adhesive before, in a number of further steps, only the outermost two nozzles of the above specific number of nozzles release adhesive, until the length of the rectangle is reached, before in a final step again all the above-specified nozzles apply adhesive to the web of material. In parallel with this method, the nozzles of the individual gluing heads may apply additional adhesive at selected points of the rectangle.
Owing to residual glue sticking to the nozzles and hence a clogging thereof, regular cleaning of said nozzles becomes necessary. For particularly simple cleaning of the nozzles on the nozzle unit or alternatively on the individual gluing heads, therefore, in an advantageous configuration cleaning stations are provided which are arranged in each case along the guide spindle in question. The nozzle unit or the individual gluing heads can thus be displaced along the guide spindle into the cleaning stations which, in order to have the shortest paths possible, are preferably located directly next to the transport roller for the material or to the conveyor. If production is interrupted, or alternatively during individual production stages in which no gluing is required, the nozzles can thus be pushed particularly easily out of the gluing position into a cleaning position in the cleaning station.
For automation of the cleaning operation or alternatively in order to generate cleaning instructions, the adhesive application device in a particularly preferred configuration comprises a signal unit, which comprises a measuring unit and an evaluation unit. The measuring unit in this case measures a cleaning parameter, for example by means of a sensor in the region of the nozzles, the time since the last cleaning of the nozzles or the number of gluing operations by the nozzles, and transmits this continually to an evaluation unit. This evaluation unit compares the measured value with a corresponding limit value stored in the evaluation unit. Exceeding of the limit value in this case is reported to the signal unit, which thereupon, depending on the result of the evaluation unit, emits a signal for automatic cleaning of the nozzles at the next interruption in the gluing process, or alternatively generates only a visual or acoustic warning signal for manual initiation of the cleaning process. In this case, a large number of rules and limit values for automatic cleaning of the nozzles can be stored in the evaluation unit.
The advantages achieved by the invention are in particular that, owing to the flexible positioning of the nozzle unit transversely to the direction of transport of the material and to the individual activation of the nozzles, a space-saving adhesive application device can be provided which can reproduce virtually any shape of a gluing surface without replacing format parts. Owing to the combination of the nozzle unit with a plurality of individual gluing heads and the operation with different glue types, both a rapid, initial and a secure, long-lasting adhesive action can thus be achieved. Furthermore, particularly simple cleaning of the nozzles which sometimes is conceivable even during operation of the installation is possible.
BRIEF DESCRIPTION OF THE DRAWING
An embodiment of the invention will be explained in greater detail with reference to drawings in which:
FIG. 1 is a detail of an adhesive application device,
FIG. 2 is a detail of an adhesive application device comprising a cleaning station and drive units.
Identical parts are provided with the same reference numerals in all the figures.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A detail of an embodiment of an adhesive application device 1 is illustrated in FIG. 1 . A material 2 —what is shown is by way of example a web of material 2 which has already been cut laterally in a preceding operating step—in this case is guided along a direction of transport x. What is illustrated in this case is flat transport of the material 2 , as might for example be realised by a belt conveyor. It is, however, conceivable also to transport the material 2 via a transport roller. When transporting the material 2 it is also possible to effect the application of the adhesive horizontally, that is to say that the material 2 is guided vertically downwards or upwards, while the adhesive application device is arranged such that the nozzle unit 8 and the individual gluing heads 14 spray the adhesive on horizontally.
The material 2 already has a number of cutouts 4 which, in the case of the production of envelopes, form the window element. One of these window elements 4 in the present embodiment has already passed the nozzle unit 8 and the individual gluing heads 14 for applying the adhesive, and is provided with a gluing pattern 6 which is arranged around the cutout 4 . The gluing pattern 6 illustrated in this case consists of a number of individual adhesive dots, which consist of hot glue or cold glue, according to the activation of the nozzle unit 8 and the individual gluing heads 14 . Alternatively, however, adhesive strips, in particular parallel to the direction of transport, are also conceivable. In particular when producing envelopes comprising window elements, in this case the application of the adhesive both to the window film and to the envelope blank is conceivable.
The application of the adhesive dots of cold glue takes place in this case via a nozzle unit 8 arranged directly above the web of material 2 , which unit is formed as a nozzle block 8 . This nozzle block 8 comprises a number of nozzles 10 —in the present embodiment eight nozzle heads comprising one nozzle 10 each are provided on the nozzle block 8 —by means of which the cold glue can be applied to the material 2 . The nozzles 10 of the nozzle block 8 in the embodiment are in this case arranged at a fixed, unchangeable distance from one another. It is however likewise conceivable for the distance between the nozzles 10 in the nozzle unit 8 to be able to be varied individually. The nozzle block 8 in this case is arranged transversely to the direction of transport x of the material and can be moved or displaced over the entire width along three guide spindles 12 which are arranged mutually parallel. In this case, the outer two guide spindles 12 serve merely to guide and stabilise the nozzle block 8 . Only the middle guide spindle has a thread for positioning the nozzle block 8 . In addition to the nozzle block 8 for applying the cold glue, two individual gluing heads 14 are provided by which a hot glue can be applied to the material 2 . The hot glue in this case ensures rapid initial adhesion when subsequently gluing to a second material or to a window element. The individual gluing heads 14 for applying the hot glue in this case are likewise arranged on separate guide spindles 16 , 18 in each case and thus can be oriented individually transversely to the direction of transport x. The nozzles 10 , both those of the nozzle block 8 and of the individual gluing heads 14 , may in this case be activated individually by a control unit (not shown) in relation to the application of adhesive. In order to control the individual gluing heads 14 , therefore, a line 20 is provided for each individual gluing head 14 , via which line both the power is supplied and the control signals for the application of the adhesive are routed. The control and supplying of power to the nozzle unit 8 also take place via such a line (not shown).
The edge of the window elements on the web of material 2 , upon passing through the gluing station, is thus first of all provided with a number of individual hot glue dots or lines before a cold glue gluing pattern is applied by the nozzle block 8 .
A larger detail of an embodiment of an adhesive application device 1 is illustrated in Hg. 2 , viewed from a different angle. In this case, likewise the cleaning station 22 is illustrated, which is arranged next to the web of material 2 (not shown), such that upon displacement of the nozzle block 8 and the individual gluing heads 14 along the guide spindles 12 , 16 , 18 next to the web of material 2 said nozzle blocks and heads are guided into the cleaning station 22 . Both the gluing position of the nozzle unit 8 and of the individual gluing heads 14 and the cleaning position of the nozzle unit 8 and the individual gluing heads 14 thus lie along the guide spindles 12 , 16 , 18 , so that it is possible to switch particularly simply and rapidly between the two positions. The cleaning station 22 in this case comprises a flushing chamber 24 and a cleaning chamber 26 . In the cleaning chamber 26 there is arranged a rotatably mounted cleaning roller 28 , in particular a foam roller, which in the case of cleaning the nozzles 10 is in direct contact with the nozzles 10 and frees the nozzles 10 from adhesive residues by means of a rotary movement of the cleaning roller 28 . In this case, the cleaning roller 28 can be provided with a cleaning fluid, in particular a solvent, so that the adhesive residues can be removed particularly simply. The width of the cleaning roller 28 in this case is adapted to the width of the nozzle block 8 , in order to be able to clean all the nozzles 10 of the nozzle block 8 in one operating step. In an alternative embodiment, the cleaning roller 28 may also be made smaller. In this case, it is then expedient if the nozzles 10 do not remain in the cleaning position, but are guided past the cleaning roller 28 . The nozzles 10 are thus cleaned while they are passing by the rotating cleaning roller 28 .
After the adhesive residues in the cleaning chamber 26 have been eliminated, the nozzle unit 8 and the individual gluing heads 14 can be pushed, again along the guide spindles 12 , 16 , 18 , into a flushing chamber 24 . In this flushing position, a short test run is carried out, during which adhesive is briefly released through the nozzles 10 into a collecting container 30 . This spray burst with adhesive frees the nozzles 10 from dried adhesive residues in their interior. Then the nozzle unit 8 and/or the individual gluing heads 14 are pushed back into the cleaning position, where final cleaning is performed by the moistened cleaning roller 28 .
These cleaning cycles in this case are monitored and checked by a signal unit (not shown). In this case, the time which has elapsed since the last cleaning of the nozzle unit 8 and the individual gluing heads 14 is measured continuously by a measuring unit. As soon as this measured time exceeds a first limit value, cleaning of the nozzle unit 8 and the individual gluing heads 14 corresponding to the cleaning sequence described above is initiated automatically at the next stoppage of the machine. If no stoppage of the machine is intended or effected and the measured time also exceed a second limit value, a warning, for example in the form of a visual or acoustic signal, is emitted, which indicates that it is urgently required to clean the nozzle unit 8 and the individual gluing heads 14 . Then the machine can be stopped manually, so that the cleaning process can be carried out automatically or likewise manually. It is likewise conceivable for the installation automatically to stop and carry out the cleaning process if the second (or a third) limit value is exceeded. Once the cleaning operation has concluded, the time measurement is restarted.
In addition to measuring the time since the last cleaning, it is likewise possible to monitor further parameters for the state of the gluing heads or their nozzles by appropriate sensors, and, if they exceed or fall below a limit value, to initiate cleaning accordingly.
The adhesive application device 1 according to the embodiment of FIG. 2 furthermore comprises a number of drive units 32 for moving the nozzle unit 8 and the individual gluing heads 14 along the respective guide spindle 12 , 16 , 18 . In the embodiment illustrated, the movement takes place automatically by means of an electric motor and a toothed-belt system (not shown). However, manual displacement of the nozzle unit 8 and the individual gluing heads 14 by crank handles is likewise conceivable. | An adhesive application device for applying, includes a nozzle unit having a number of nozzles for applying an adhesive to a material which is moved along a direction of transport, said nozzles being displaceable transversely to the direction of transport along a first guide spindle; and plural individual gluing heads, each being arranged separately from each other on respective second separate guide spindles, so as to be displaceable transversely to the direction of transport. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to surface controlled subsurface safety valves for controlling fluid flow in a well.
2. Prior Art
Valves are positioned at various subsurface locations in well flow conductors to control flow through the conductor. Many subsurface valves are surface controlled. One or more control conduits extend between the subsurface valve and the wellhead surface. Fluid is pressurized or depressurized and pumped into the control conduit. Generally, the subsurface valves are normally closed. Pressurization of control fluid above a minimal value is required to open the valve. Upon depressurization of control fluid, the valve returns to its normally closed position.
Closure of present surface controlled subsurface safety valves is resisted and delayed by various control fluid forces. When such a valve is positioned at a great depth in a well, valve closure may take as long as one hour. When a disaster occurs and time is of the essence for shutting in and controlling the well, an hour delay between initiation of valve closure and complete closure is too long.
For a surface controlled subsurface safety valve having a single control conduit, as disclosed in U.S. Pat. No. 3,703,193, three control fluid forces resist valve closure. First, a hydrostatic pressure force, proportional to valve depth, is created due to the presence of control fluid within the control conduit. Second, a fluid frictional force is created due to the required displacement of a relatively large volume of control fluid from the safety valve into the small diameter control conduit during valve closure. Third, the inertia of the control fluid, which was initially at rest, and which must be displaced back into the control conduit also resists valve closure. Utilizing dual control conduits, as disclosed in U.S. Pat. No. 3,696,868, permits the first, hydrostatic pressure force to be counterbalanced and, in effect, nullified. However, valve closure is still resisted by fluid frictional forces and the inertia of the mass of control fluid at rest. Additionally, there are extra equipment costs and handling problems whenever a well installation incorporates dual control conduits for a single subsurface valve.
U.S. Pat. No. 4,005,751 discloses controlling communication of control fluid to a main valve with a pilot valve. For the disclosed main valve control fluid pressure in excess of well fluid pressure is required to both close the main valve and open the main valve. If a disaster occurred at the wellhead and the control fluid pressure dropped, the main valve disclosed in U.S. Pat. No. 4,005,751 may not close.
U.S. Pat. No. 3,292,706 discloses a subsurface main valve and an auxiliary valve. The auxiliary valve does not increase the responsiveness of the main valve to decreases in control pressure and does not permit the closure speed of the main valve to be increased.
U.S. application Ser. No. 798,180 now U.S. Pat. No. 4,119,146 filed May 18, 1977 discloses utilizing a pilot valve to control communication of control fluid to a main valve. In a first position of the pilot valve, control fluid communicates to the main valve and may be effective to open the main valve. In a second position of the pilot valve, control fluid is prevented from communicating to the main valve and the pressure responsive actuator of the main valve becomes pressure balanced. In certain of the embodiments disclosed in that application leakage in the pilot valve would permit communication between the control conduit and the tubing bore. In other embodiments disclosed in the application dual control conduits are utilized, with their inherent disadvantages of extra costs and extra handling problems. Finally, the pilot valves disclosed in the application include two seal bores and two seal means. An imperfection in any of these four elements could result in the disclosed main valve and pilot valve being rendered inoperative.
OBJECTS OF THE INVENTION
An object of this invention is to enable a subsurface safety valve having a single control conduit to be positioned at a much greater depth in a well than has heretofore been possible without subjecting the control conduit to possible communication with the tubing bore.
Another object of this invention is to enable a single conduit surface controlled subsurface safety valve to obtain the advantages of a dual conduit surface controlled subsurface safety valve without the disadvantages of extra cost and extra handling problems normally associated with dual conduit surface controlled subsurface safety valves, and without valve closure being resisted by the two fluid forces normally resisting such closure for dual conduit controlled valves.
Another object of this invention is to simplify the structure of a pilot valve for controlling communication of control fluid between a control conduit and a surface controlled subsurface safety valve.
Another object of this invention is to eliminate fluid flow around the valve of a pilot valve which controls communication of control fluid between a control conduit and a surface controlled subsurface safety valve.
These and other objects and features of advantage of this invention will be apparent in the drawings, detailed description, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like numerals indicate like parts, and wherein an illustrative embodiment of this invention is shown:
FIG. 1 is a schematic illustration of a well installation having a surface controlled subsurface safety valve in accordance with this invention;
FIGS. 2A and 2B are continuation views of a subsurface safety valve useable in the well installation of FIG. 1 with the safety valve closed; and
FIGS. 3A and 3B are continuation views of the subsurface safety valve of FIGS. 2A and 2B with the safety valve open.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A well flow conductor, such as the tubing string 10, conducts fluids from the producing formation (not shown) to the surface. One or more well pipes, such as the casing string 12, surround the tubing string 10. Between the tubing string 10 and the casing string 12 is defined an annulus 14. Packing means 16 seals off the annulus 14 at a subsurface location in the well above the producing formation. Fluids from the producing formation are thereby confined to the bore of the tubing string 10. Subsurface flow through the tubing string 10 is controlled by a subsurface safety valve 18. Control conduit means 20 extend between the subsurface safety valve 18 and the surface. Through control conduit means 20, hydraulic control fluid is communicated to the subsurface safety valve 18 to render the valve 18 responsive to surface controls. At the surface, operating manifold 22 pressurizes and depressurizes hydraulic control fluid and pumps control fluid into control conduit means 20. When hydraulic control fluid is pressurized at least to a minimal valve by operating manifold 22, the subsurface safety valve 18 opens the subsurface flow path. When the pressure of fluid within control conduit means 22 is relieved, the subsurface safety valve 18 closes the subsurface flow path. At the surface, flow through the tubing string is controlled by surface valves 24 and 26.
Heretofore, the depth to which a single conduit surface controlled subsurface safety valve could be positioned in a well has been limited. With minor modifications, of the type that can be made in any standard machine shop, an existing valve can be transferred into a valve 18 structured in accordance with this invention and positioned at a well depth much greater than has heretofore been possible. Once so modified and positioned at an increased depth in the well, the single conduit, surface controlled subsurface safety valve 18 closes with minimal resistance due to fluid forces. Closure is relatively swift. Once valve closure is initiated, the large volume of control fluid, which presently retards valve closure, is dumped into the annulus 14. That large volume of control fluid is not forced into a small diameter control conduit 20 against the resistive action of the hydrostatic pressure force, fluid frictional forces, and the inertia of the mass of fluid in the control conduit 20. The likelihood of communication between the control conduit 20 and the subsurface flow path is substantially nil. If desired, the annulus 14 may be pressurized and the subsurface safety valve 18 may be operated with all the advantages of a dual conduit controlled subsurface safety valve. Furthermore, the advantages of a dual conduit subsurface valve are obtained without the disadvantages of extra control conduit cost and handling problems. Finally, a simplified pilot valve controls the communication between the subsurface safety valve 18 and either the control conduit 20 or the annulus 14.
The details of a surface controlled subsurface safety valve structured in accordance with this invention are illustrated in FIGS. 2A and 2B and 3A and 3B. The illustrated valve is a tubing retrievable surface controlled subsurface safety valve. Those skilled in the art could easily adapt this invention for use with wire line retrievable surface controlled subsurface safety valves and with pumpdown surface controlled subsurface safety valves.
The subsurface safety valve 18 includes housing means 28 for defining the controlled subsurface flow path 30, closure means 32 for controlling the subsurface flow path 30, and pressure responsive actuator means for actuating movement of the closure means 32.
Valve housing means 28 is adapted to be positioned within the tubing string 10. Once so positioned, subsurface flow through the tubing string bore is confined to the flow path 30 extending longitudinally through housing means 28. For the illustrated subsurface safety valve 18, housing means 28 is formed from interconnected tubular sections 28a, 28b and 28c. The uppermost tubular section 28a is interconnected with the tubing string 10 extending upwardly from the subsurface valve 18 as at threaded connection 34. Likewise, the lower tubular section 28c would be interconnected to the tubing string 10 extending downwardly from the subsurface valve 18 by another threaded connection (not shown in FIGS. 2B and 3B).
Closure means 32 controls fluid flow through the flow path 30. Closure means 32 is movable between a first position closing the flow path 30 to fluid flow (see FIG. 2B) and a second full open position opening the flow path 30 to fluid flow (see FIG. 3B). The illustrated closure means 32 is an axially movable and rotatable ball valve element. The ball valve element closure means 32 includes passage means 36 extending therethrough and a spherical sealing surface 38 formed on the outer surface thereof. When the closure means 32 is in its first position, the spherical sealing surface 38 sealingly engages a complementary seat means 40. Additionally, passage means 36 is not aligned with the flow path 30. Fluid flow through the flow path 30 is thereby prevented. When the ball valve element closure means 32 is in its second position, passage means 36 is aligned with the flow path 30 and a straight, full open bore exists through the valve 18. Axial movement of the ball valve element closure means 32 with respect to housing means 28 imparts a moment arm thereto. The moment arm rotates the ball valve element closure means 32 between its first position and its second position.
Pressure responsive actuator means moves the closure means 32 between its first position and its second position by moving the closure means 32 axially with respect to housing means 28. The pressure responsive actuator means normally assumes a first position wherein the closure means 32 is in its first position (see FIGS. 2A and 2B). Control fluid from control conduit means 20 is communicated to a first pressure affected means of actuator means. The first pressure affected means may be pressure affected surface. When the pressure of control fluid affecting said first pressure affected means is at least a minimal value, actuator means moves to a second position and closure means is moved thereby to its second position (see FIGS. 3A and 3B).
The actuator means includes axially movable operator means 42, yieldable urging means 44 for yieldably urging operator means 42 to its first position, a first pressure affected means for moving operator means 42 to a second position when affected by fluid pressurized to at least a minimal value, and a second pressure affected means for offsetting said first pressure affected means.
Operator means 42 is disposed within housing means 28 and is movable axially therein. Axial movement of operator means 42 imparts a corresponding axial movement to the closure means 32. In the first position of operator means 42, closure means 32 is in its first position. In the second position of operator means 42, closure means 32 is in its second position. Operator means 42 includes interconnected tubular sections 42a and 42b.
Yieldable urging means 44 yieldably urges operator means 42 to its first position. Yieldable urging means 44 may be the coil compression spring means 44 shown. The spring means 44 is disposed between a stationary stop shoulder 46 associated with housing means 28 and shoulder means 48 carried by operator means 42. In the absence of a net pressure force affecting operator means 42, yieldable urging means 44 is powerful enough to push and maintain operator means 42 in its first position. The closure means 32 is thereby moved and maintained in its first position so that the valve 18 is truly a safety valve.
A first pressure affected means produces a pressure force tending to urge operator means 42 towards its second position. Seal means 50 is carried by operator means 42 and seals between operator means 42 and housing means 28. Seal means 52 is carried by housing means 28 and seals between operator means 42 and housing means 28. The seal means 50 and 52 are sized relative to each other to form a first pressure responsive area. Fluid admitted to a first, upper, chamber means 54, defined between operator means 42 and housing means 28 by seal means 50 and 52, affects that first pressure responsive area and produces a pressure force tending to urge operator means 42 towards its second position.
A second pressure affected means offsets the first pressure affected means when both of the first and second pressure affected means are affected by the same fluid pressure. Housing means 28 carries seal means 56 and 58 which seal between housing means 28 and operator means 42. Seal means 56 and 58 are sized relative to seal means 50 so that a second pressure responsive area is thereby defined. Preferably, the first pressure responsive area is substantially equal to the second pressure responsive area. Fluid within a second, lower, chamber means 60 formed between operator means 42 and housing means 28 and defined by seal means 50 and 56, affects this second pressure responsive area and produces a pressure force tending to urge operator means 42 towards its first position. Whenever the fluid pressure within the first and second chamber means 54 and 60 are equal, due to the equal pressure responsive areas for each pressure affected means, the net fluid pressure force affecting operator means 42 is zero.
The pressure of fluid within the annulus 14 surrounding the subsurface safety valve 18 is continuously communicated to the second pressure affected means of the valve actuator means. For the illustrated valve 18, housing means 28 includes lateral extending port means 62 which open in the second, lower, chamber means 60. Fluids communicate through the port means 62 between the second, lower, chamber means 60 and the region surrounding housing means 28 (e.g. the annulus 14).
Means 64 selectively control fluid communication between the first pressure affected means of the actuator means and one of control conduit means 20 and the annulus 14. In a first operative position of the selective communicating means 64, fluid communication between the annulus 14 and the first, upper, chamber means 54 is permitted and fluid communication between control conduit means 20 and the first chamber means 54 is prevented. In a second operative position of the selective communicating means 64, fluid communication between control conduit means 20 and the first chamber means 54 is permitted and fluid communication between the annulus and the first chamber means 54 is prevented. The selective communicating means 64 normally assumes its first operative position. Movement of the selective communicating means 64 to its second operative position occurs whenever control fluid within control conduit means 20 is pressurized at least to a selected value. The selective communicating means is designed to swiftly reassume its first operative position whenever the pressure of control fluid drops below that selected value. The selective communicating means 64 is located at a subsurface location in the well in close proximity to the subsurface safety valve 18. In the illustrated embodiment, the selective communicating means 64 is positioned adjacent to chamber means 54. However, the selective communicating means 64 could be positioned elsewhere within the well installation as long as it is in close proximity to the subsurface valve 18 and the hydrostatic fluid pressure forces due to the difference in elevation between the selective communicating means 64 and the subsurface safety valve 18 are substantially zero.
The selective communicating means may comprise the pilot valve means 64 or single value means (illustrated in FIGS. 2A and 3A). Pilot valve means 64 in turn comprises a two-way valve means and has a simplified structure. A valve plug means 66 is resiliently urged to and normally maintained in a first position. Valve plug means 66 is movable across port means 68. Movement of valve plug means 66 depends upon the pressure of control fluid within control conduit means 20. Fluids do not flow across valve plug means 66. Therefore, sealing components of pilot valve means 64 are not affected by flow cutting.
Pilot valve means 64 also includes body means 70 in which valve plug means 66 is movable. Body means 70 defines longitudinal chamber means 72. Chamber means 72 has a seal bore means 74 extending along at least a portion of its length. Fluid from control conduit means 20 communicates between one end portion of pilot valve chamber means 72 and control conduit means 20 through orifice means 76. Orifice means 76 opens in said one end portion of chamber means 72. Fluid communicates between the other end portion of pilot valve chamber means 72 and the annulus 14 through aperture means 78. Aperture means 78 opens in said other end portion of chamber means 72. Port means 68 opens in the seal bore means 74 and between the opening of orifice means 76 and aperture means 78 into pilot valve chamber means 72. Through port means 68, fluids communicate between pilot valve chamber means 72 and the first upper chamber means 54 of the subsurface safety valve 18.
Valve plug means 66 carries seal means 80. Seal means 80 seals between valve plug means 66 and the seal bore means 74 of valve body means 70. Therefore, depending upon whether valve plug means 66 is between port means 68 and orifice means 76 or between port means 68 and aperture means 78, fluid flow between the first, upper, chamber means 54 of the safety valve 18 and one of control conduit means 20 and the annulus 14 is permitted and fluid flow between chamber means 54 and the other of control conduit means 20 and the annulus 14 is prevented.
Coil compression spring means 82 resiliently urges valve plug means 66 to its first position (see FIG. 2A). Whenever valve plug means 66 is in its first position, the selective communicating means is in its first operative position.
Valve plug means 66 moves to its second position (see FIG. 3A) whenever fluid within control conduit means 20 is pressurized at least to a selected value. Due to the continuous sealing action of seal means 80, valve plug means 66 is pressure responsive. The pressure of fluid within control conduit means 20 creates a first pressure force which tends to urge valve plug means 66 towards its second position. Countering that pressure force is a second pressure force created by pressure of fluid within the annulus 14 and which tends to urge valve plug means 66 towards its first position. Movement of valve plug means 66 towards its second position depends upon the control fluid pressure force affecting valve plug means 66 being greater than the sum of the annulus fluid pressure force affecting valve plug means 66 and the resilient urging force of spring means 82. The selected value to which control fluid is pressurized to move valve plug means 66 therefore varies proportionally with the annulus fluid pressure.
In operation, the surface controlled subsurface safety valve of this invention responsively controls subsurface flow through a well. The valve 18 is normally closed. The valve 18 will remain closed as long as the pressure of control fluid within control conduit means 20 is less than a minimal value. The valve plug means 66 of pilot valve means 64 and the operator means 42 and closure means 32 of the subsurface safety valve 18 are in their respective first positions (see FIGS. 2A and 2B).
Control fluid within control conduit means 20 is pressurized to open the subsurface safety valve 18. Operating manifold 22 pumps fluid into control conduit means 20 and pressurizes that control fluid. The pressurized control fluid exerts a pressure force upon valve plug means 66. That pressure force tends to move valve plug means 66 towards its second position. The pressure force created by the pressurized hydraulic control fluid is resisted by the resilient urging force of spring means 82 and the pressure force acting upon valve plug means 66 due to the presence of fluids within the annulus 14. The pressure of fluid within control conduit means 20 is increased at least to a selected value wherein the control fluid pressure force is greater than the sum of the resilient urging spring force and the annulus fluid pressure force. The force of the pressurized control fluid moves valve plug means 66 to its second position. During the movement of valve plug means 66 it moves across port means 68.
Once valve plug means 66 has moved across port means 68, control fluid communicates between control conduit means 20 and the first, upper chamber means 54 of the subsurface safety valve 18. The first pressure affected means of the actuator means is thereafter affected by pressurized control fluid. Pressurized control fluid within chamber means 54 produces a pressure force upon operator means 42. The control fluid pressure force tends to move operator means 42 towards its second position and is resisted by the yieldable urging force of spring means 44 and an annulus fluid pressure force due to communication of annulus fluid to the second, lower, chamber means 60. Operating manifold 22 continues to increase the pressure of fluid within control conduit means 20. Once the control fluid pressure force affecting operator means 42 reaches a minimal value and exceeds the yieldable urging force and the annulus fluid pressure force, operator means 42 is moved from its first position towards its second position. Movement of operator means 42 results in axial and rotational movement of closure means 32. The passage means 36 of closure means 32 becomes aligned with the flow path 30 through housing means 28. When operator means 42 is in its second position, closure means 32 is also in its second position and the flow path 30 through housing means 28 is fully opened.
The flow path 30 through housing means 28 will remain opened as long as the control fluid within control conduit means 20 remains pressurized. If the control fluid pressure should drop below a selected value, for whatever reason, closure of the subsurface safety valve 18 will be initiated. In accordance with this invention, closure of the subsurface safety valve 18 is swifter and much more easily obtainable, even though the valve 18 is positioned at a great depth within a well installation, than has heretofore been possible.
Reduction of control fluid pressure below a selected value causes spring means 82 to move valve plug means 66 to its first position. Valve plug means 66 moves across port means 68. Thereafter, communication of control fluid between control conduit means 20 and the first, upper, chamber means 54 of the safety valve 18 is prevented. Additionally, communication between the first, upper, chamber means 54 and the annulus 14 is now permitted. The pressure of fluids in the annulus 14 therefore affect the first pressure affected means of the safety valve 18. Since the second pressure affective means of the safety valve is also affected by annulus fluid pressure, these two pressure affected means are pressure equalized. In other words, substantially the same fluid pressure is present within the first, upper, chamber means 54 and tends to move operator means 42 downwardly towards its second position and is present within the second, lower, chamber means 60 and tends to move operator means upwardly towards its first position. The two pressure forces cancel each other out. The force of the yieldable urging spring means 44 moves operator means upwardly to its first position. Upon such movement, closure means 32 returns to its first position. The passage means 36 becomes non-aligned with the flow path 30 through valve housing means 28. Spherical seating surface 38 seats with and sealingly engages seat means 40. Upward flow through the flow path 30 is prevented.
During upward movement of operator means 42 towards its first position, control fluid within the first, upper, control chamber means 54 is dumped into the annulus 14 after passage through port means 68, pilot valve chamber means 72 and aperture means 78. Displacement of control fluid from the first upper chamber means 54 occurs with much less fluid force resistance than has heretofore been possible. Presently, such displacement of control fluid out of a safety valve's control pressure chamber is exceedingly difficult. A large volume of fluid presently must be moved into a relatively small diameter control conduit. The hydrostatic pressure force of the column of fluid within the conduit resists that movement, the frictional force of the fluid in contact with the wall of the conduit resists that movement, and the inertia of the mass fluid within that conduit resists that movement. With the safety valve 18 and pilot valve means 64 structured in accordance with this invention, none of these forces resist displacement of control fluid from the first, upper, chamber means 54. The control fluid within the chamber means 54 may be readily displaced into the annulus 14. Only relatively minor fluid forces will resist such displacement. The yieldable urging spring means 44 will easily be able to store the energy required to move operator means 42 and closure means 32 from their second position to their first position.
Pilot valve means 64 will be somewhat sensitive to fluid forces due to the presence of fluid within control conduit means 20. However, due to the small incremental volume of control fluid which will be displaced during movement of the pilot valve's valve plug means 66 and due to the small pressure responsive area of the valve plug means 66, the resilient urging spring means 82 can be designed to store sufficient energy and create a force that will move valve plug means 66. For example, under the worst possible conditions, there will be zero fluid pressure in the annulus 14. Therefore, the only forces affecting movement of operator means 42 and valve plug means 66 will be the fluid pressure force of control fluid and the respective forces of yieldable urging spring means 44 and resilient urging spring means 82. Assume the safety valve 18 is positioned at a depth of 5,000 feet. If the hydraulic control fluid is oil, the hydrostatic control line pressure increases at a rate of 0.35 pounds per square inch per linear foot. At 5,000 feet, the hydrostatic control line pressure would be 1,750 psi. If the valve plug means had an area of 0.05 square inches, (approximately a 0.25 inch diameter), the hydrostatic pressure force affective upon valve plug means 66 would be 87.5 pounds. Approximately 0.125 cubic inches of fluid would be displaced upwardly in the control conduit 20 during movement of pilot valve plug means 66 from its second position to its first position. The frictional fluid forces and force due to the inertia of the fluid would be relatively small. Therefore, approximately 100 pounds of force would be required to assure that the pilot valve plug means 66 returned to its first position. Such a force may easily be provided with known coil compression springs.
If desired, the annulus 14 may be pressurized and the valve 18 may be operated with all the advantages presently obtainable when dual conduits are used to communicate control fluid to a subsurface valve. The annulus 14 may be filled with fluid and the pressure of fluid within the annulus regulated from the surface by known techniques. The subsurface safety valve 18 will be opened by pressurizing fluid within the control conduit 20 in the manner previously described. To return the subsurface safety valve to its closed position, the pressure of control fluid within control conduit means 20 would be decreased and the pressure of fluid within the annulus 14 may be increased. The annulus fluid will create a pressure force tending to assist the force of the resilient urging spring means 82. Movement of valve plug means 66 to its first position from its second position will therefore only be resisted by fluid frictional forces and the inertia of the column of fluid within control conduit means 20. Again, those forces will be relatively small. Once valve plug means 66 has moved to its first position, the pressure responsive actuator means of the safety valve 18 will again be pressure equalized. Annulus fluid pressure will communicate with both of the upper chamber means 54 and the lower chamber means 60. Control fluid in the upper chamber means 54 will be displaced into the annulus 14. Since the annulus has a relatively large cross-sectional area, the displacement of fluid from the upper pressure chamber means 54 into the annulus will occur without substantial resistance due to fluid frictional forces and fluid inertia. Although the volume of fluid within the upper chamber means 54 is relatively large when that fluid has to be displaced into a small diameter control conduit, that volume is relatively small when it can be displaced into the annulus 14. The force required to displace the fluid out of the upper chamber means 54 may easily be provided by the yieldable urging spring means 44.
From the foregoing, it can be seen that the objects of this invention have been obtained. A single conduit surface controlled subsurface safety valve has been modified to enable swift closure and placement of the valve at an increased depth in the well. The annulus surrounding the valve may be pressurized and the valve may operate with all the advantages of a dual surface controlled subsurface safety valve without the inherent disadvantages of such a dual conduit valve. During valve closure, minimal fluid forces resist displacement of control fluid out of the valve's control fluid pressure chamber. That control fluid is displaced and dumped into the annulus surrounding the valve. During such displacement of control fluid, the pressure responsive actuator of the valve is pressure equalized. Therefore, the normal coil compression spring for such a safety valve may easily generate the force required to return the valve to its closed position. Communication of control fluid between the control conduit and the valve is controlled by a pilot valve. The pilot valve includes a valve plug which simply moves across a controlled port. There is no fluid flow across the valve plug itself. Thus, the possibility of flow cutting around the valve plug is eliminated.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof. Various changes in the size, shape, and materials, as well as the details of the illustrated construction, may be made within the scope of the appended claims without departing from the spirit of the invention. | Disclosed is a surface controlled subsurface safety valve for deep well service. Communication of control fluid to the subsurface safety valve is controlled at a subsurface location in close proximity to the valve. Responsiveness of the subsurface safety valve to decreases in control pressure is thereby increased and the valve's closure speed is also increased. This abstract of the disclosure is neither intended to define the scope of the invention, which, of course, is measured by the claims, nor is it intended to limit the invention in any way. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present disclosure relates generally to the field of telemetry systems for transmitting information through a flowing fluid. More particularly, the disclosure relates to the field of signal detection in such a system.
[0002] Sensors may be positioned at the lower end of a well drilling string which, while drilling is in progress, continuously or intermittently monitor predetermined drilling parameters and formation data and transmit the information to a surface detector by some form of telemetry. Such techniques are termed “measurement while drilling” or MWD. MWD may result in a major savings in drilling time and improve the quality of the well compared, for example, to conventional logging techniques. The MWD system may employ a system of telemetry in which the data acquired by the sensors is transmitted to a receiver located on the surface. Fluid signal telemetry is one of the most widely used telemetry systems for MWD applications.
[0003] Fluid signal telemetry creates pressure signals in the drilling fluid that is circulated under pressure through the drill string during drilling operations. The information that is acquired by the downhole sensors is transmitted by suitably timing the formation of pressure signals in the fluid stream. The pressure signals are commonly detected by a pressure transducer tapped into a high pressure flow line at the surface. Access to, and penetration of, the high pressure flow line may be restricted due to operational and/or safety issues.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] A better understanding of the present invention can be obtained when the following detailed description of example embodiments are considered in conjunction with the following drawings, in which:
[0005] FIG. 1 shows schematic example of a drilling system;
[0006] FIG. 2 shows an example block diagram of the acquisition of downhole data and the telemetry of such data to the surface in an example drilling operation;
[0007] FIGS. 3A-3D show examples of pressure signal transmitter assemblies suitable for use in a fluid telemetry system;
[0008] FIG. 4 shows an example embodiment of an optical interferometer system used to detect downhole transmitted pressure signals;
[0009] FIG. 5 shows an example of a measurement section fiber adhered to a pliant substrate;
[0010] FIG. 6 is a block diagram showing an example of the processing of a received optical signal; and
[0011] FIG. 7 is a chart of laboratory test data showing raw interferometer data and integrated interferometer data compared to conventional pressure sensor data for pressure signal detection.
[0012] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION
[0013] Referring to FIG. 1 , a typical drilling installation is illustrated which includes a drilling derrick 10 , constructed at the surface 12 of the well, supporting a drill string 14 . The drill string 14 extends through a rotary table 16 and into a borehole 18 that is being drilled through earth formations 20 . The drill string 14 may include a kelly 22 at its upper end, drill pipe 24 coupled to the kelly 22 , and a bottom hole assembly 26 (BHA) coupled to the lower end of the drill pipe 24 . The BHA 26 may include drill collars 28 , an MWD tool 30 , and a drill bit 32 for penetrating through earth formations to create the borehole 18 . In operation, the kelly 22 , the drill pipe 24 and the BHA 26 may be rotated by the rotary table 16 . Alternatively, or in addition to the rotation of the drill pipe 24 by the rotary table 16 , the BHA 26 may also be rotated, as will be understood by one skilled in the art, by a downhole motor (not shown). The drill collars add weight to the drill bit 32 and stiffen the BHA 26 , thereby enabling the BHA 26 to transmit weight to the drill bit 32 without buckling. The weight applied through the drill collars to the bit 32 permits the drill bit to crush the underground formations.
[0014] As shown in FIG. 1 , BHA 26 may include an MWD tool 30 , which may be part of the drill collar section 28 . As the drill bit 32 operates, drilling fluid (commonly referred to as “drilling mud”) may be pumped from a mud pit 34 at the surface by pump 15 through standpipe 11 and kelly hose 37 , through drill string 14 , indicated by arrow 5 , to the drill bit 32 . The drilling mud is discharged from the drill bit 32 and functions to cool and lubricate the drill bit, and to carry away earth cuttings made by the bit. After flowing through the drill bit 32 , the drilling fluid flows back to the surface through the annular area between the drill string 14 and the borehole wall 19 , indicated by arrow 6 , where it is collected and returned to the mud pit 34 for filtering. The circulating column of drilling mud flowing through the drill string may also function as a medium for transmitting pressure signals 21 carrying information from the MWD tool 30 to the surface. In one embodiment, a downhole data signaling unit 35 is provided as part of MWD tool 30 . Data signaling unit 35 may include a pressure signal transmitter 100 for generating the pressure signals transmitted to the surface.
[0015] MWD tool 30 may include sensors 39 and 41 , which may be coupled to appropriate data encoding circuitry, such as an encoder 38 , which sequentially produces encoded digital data electrical signals representative of the measurements obtained by sensors 39 and 41 . While two sensors are shown, one skilled in the art will understand that a smaller or larger number of sensors may be used without departing from the principles of the present invention. The sensors 39 and 41 may be selected to measure downhole parameters including, but not limited to, environmental parameters, directional drilling parameters, and formation evaluation parameters. Such parameters may comprise downhole pressure, downhole temperature, the resistivity or conductivity of the drilling mud and earth formations, the density and porosity of the earth formations, as well as the orientation of the wellbore.
[0016] The MWD tool 30 may be located proximate to the bit 32 . Data representing sensor measurements of the parameters discussed may be generated and stored in the MWD tool 30 . Some or all of the data may be transmitted in the form of pressure signals by data signaling unit 35 , through the drilling fluid in drill string 14 . A pressure signal travelling in the column of drilling fluid may be detected at the surface by a signal detector unit 36 employing optical fiber loop 230 . The detected signal may be decoded in controller 33 . The pressure signals may be encoded binary representations of measurement data indicative of the downhole drilling parameters and formation characteristics measured by sensors 39 and 41 . Controller 33 may be located proximate the rig floor. Alternatively, controller 33 may be located away from the rig floor. In one embodiment, controller 33 may be incorporated as part of a logging unit.
[0017] FIG. 2 shows a block diagram of the acquisition of downhole data and the telemetry of such data to the surface in an example drilling operation. Sensors 39 and 41 acquire measurements related to the surrounding formation and/or downhole conditions and transmit them to encoder 38 . Encoder 38 may have circuits 202 comprising analog circuits and analog to digital converters (A/D). Encoder 38 may also comprise a processor 204 in data communication with a memory 206 . Processor 204 acts according to programmed instructions to encode the data into digital signals according to a preprogrammed encoding technique. One skilled in the art will appreciate that there are a number of encoding schemes that may be used for downhole telemetry. The chosen telemetry technique may depend upon the type of pressure signal transmitter 100 used. Encoder 38 outputs encoded data 208 to data signaling unit 35 . Data signaling unit 35 generates encoded pressure signals 21 that propagate through the drilling fluid in drill string 14 to the surface. Pressure signals 21 are detected at the surface by signal detector 36 and are transmitted to controller 33 for decoding. In one example embodiment, signal detector 36 may be a fiber optic signal detector, described below. Controller 33 may comprise interface circuitry 65 and a processor 66 for decoding pressure signals 21 into data 216 . Data 216 may be output to a user interface 218 and/or an information handling system such as logging unit 220 . Alternatively, in one embodiment, the controller circuitry and processor may be an integral part of the logging unit 220 .
[0018] FIGS. 3A-3D show example embodiments of pressure signal transmitter 100 . FIG. 3A shows a pressure signal transmitter 100 a disposed in data signaling unit 35 a . Pressure signal transmitter 100 a has drilling fluid 5 flowing therethrough and comprises an actuator 105 that moves a gate 110 back and forth against seat 115 allowing a portion of fluid 5 to intermittently pass through opening 102 thereby generating a negative pressure signal 116 that propagates to the surface through drilling fluid 5 .
[0019] FIG. 3B shows a pressure signal transmitter 100 b disposed in data signaling unit 35 b . Pressure signal transmitter 100 b has drilling fluid 5 flowing therethrough and comprises an actuator 122 that moves a poppet 120 back and forth toward orifice 121 partially obstructing the flow of drilling fluid 5 thereby generating a positive pressure signal 126 that propagates to the surface through drilling fluid 5 .
[0020] FIG. 3C shows a pressure signal transmitter 100 c disposed in data signaling unit 35 c . Pressure signal transmitter 100 c has drilling fluid 5 flowing therethrough and comprises an actuator 132 that continuously rotates a rotor 130 in one direction relative to stator 131 . Stator 131 has flow passages 133 allowing fluid 5 to pass therethrough. Rotor 130 has flow passages 134 and the movement of flow passages 134 past flow passages 133 of stator 131 generates a continuous wave pressure signal 136 that propagates to the surface through drilling fluid 5 . Modulation of the continuous wave pressure signal may be used to encode data therein. Modulation schemes may comprise frequency modulation and phase shift modulation.
[0021] FIG. 3D shows a pressure signal transmitter 100 d disposed in data signaling unit 35 d . Pressure signal transmitter 100 d has drilling fluid 5 flowing there through and comprises an actuator 142 that rotates a rotor 140 back and forth relative to stator 141 . Stator 141 has flow passages 143 allowing fluid 5 to pass therethrough. Rotor 140 has flow passages 144 and the alternating movement of flow passages 144 past the flow passages 143 of stator 141 generates a continuous wave pressure signal 146 that propagates to the surface through drilling fluid 5 . Modulation of the continuous wave pressure signal may be used to encode data therein. Modulation schemes may comprise frequency modulation and phase shift modulation.
[0022] FIG. 4 shows an example of signal detector 36 configured as an optical interferometer 200 for detecting pressure signals in conduit 211 . Interferometer 200 comprises a light source 202 , an optical fiber loop 230 , an optical coupler/splitter 215 , and an optical detector 210 . Light source 200 may be a laser diode, a laser, or a light emitting diode that emits light into optical coupler/splitter 215 where the light is split into two beams 231 and 232 . Beam 231 travels clockwise (CW) through loop 230 , and beam 232 travels counter-clockwise (CCW) through loop 230 .
[0023] Loop 230 has a length, L, and comprises measurement section 220 and delay section 225 . In one embodiment, measurement section 220 may be 2-10 meters in length. In this example, measurement section 220 is wrapped at least partially around conduit 211 , which may be standpipe 11 of FIG. 1 . Alternatively, measurement section 220 may be wrapped around any section of flow conduit that has pressure signals travelling therein. The length of measurement section 220 is designated by X in FIG. 4 , and represents the length of fiber that reacts to hoop strains in standpipe 11 caused by the pressure signals therein. The optical fibers of measurement section 220 may be physically adhered to conduit 211 . Alternatively, see FIG. 5 , measurement section 220 may comprise a length, X, of optical fiber 302 adhered in a folded pattern to a pliant substrate 300 that is attachable to a conduit. In one embodiment, pliant substrate 300 may be a biaxially-oriented polyethylene terephthalate material, for example a Mylar® material manufactured by E.I. Dupont de Nemours & Co. Pliant substrate 300 may be adhesively attached, for example, to standpipe 11 of FIG. 1 using any suitable adhesive, for example an epoxy material or a cyanoacrylate material.
[0024] Delay section 225 may be on the order of 500-3000 meters in length. The small diameter of optical fibers contemplated (on the order of 250 μm) allows such a length to be wound on a relatively small spool. As shown in FIG. 4 , delay section 225 comprises a length identified as L−X. It will be seen that L is a factor in the sensitivity of the sensor.
[0025] Counter-propagating beams 231 , 232 traverse loop 230 and recombine through coupler/splitter 215 , and detected by photo-detector 210 . Under uniform (constant in time) conditions, beams 231 , 232 will recombine in phase at the detector 210 because they have both traveled equal distances around loop 230 . Consider counter-propagating beams 231 , 232 and a time varying pressure P(t) in standpipe 11 . Beams 231 , 232 will be in phase after they have traveled the distance X in their two paths, and they will be in phase after they have continued through the distance L−X as well. Now, let the pressure within the pipe be changing at a rate of dP/dt during the time Δt while beams 231 , 232 travel the distance L−X, then
[0000] Δ t= ( L−X ) n/c,
[0026] where c is the speed of light, and n is the refractive index of the optical fiber. During this time interval, the pressure within the pipe changes by an amount ΔP, which acts to radially expand standpipe 11 . This expansion results in a change ΔX in the length, X, of the measurement section 220 of optical fiber 230 wrapped around conduit 211 . Although at the end of the interval Δt the two beams are in phase, they will go out of phase for the last portion of the circuit before they recombine, because the length of measurement section 220 has changed during the previous interval Δt. For the final leg of the trip around the loop, the counter-clockwise beam 232 will travel a distance that is different by an amount ΔX from the clockwise rotating beam 231 . When the beams combine at detector 210 , they will be out of phase by a phase difference, Δφ, where
[0000] Δφ=2π(Δ X )/ nλ,
[0027] where λ is the wavelength of the light emitted by source 202 . As beams 231 , 232 are combined, it can be shown that a factor in the signal will be cos(Δφ/2). Thus, counter propagating beams 231 , 232 will be out of phase when ΔX=λ.
[0028] The change of the pressure in the pipe during the interval Δt is given by
[0000] Δ P =( dP/dt )Δ t =( dP/dt )( L−X )( n/c ).
[0000] Let K be the sensitivity of the pipe to internal pressure; that is, the change in circumference of the pipe ΔC due to a change in pressure ΔP given by,
[0000] Δ C=K (Δ P )
[0000] K can be computed from dimensions and material properties of the pipe materials. For example, for a thin-walled pipe, where D pipe >10*pipe thickness, t, it can be shown that
[0000] K=πD pipe 2 /2 Et
[0029] where E is the modulus of elasticity of the pipe material.
[0000] For a thick walled pipe, where D pipe ≦10*pipe thickness, t, it can be shown that
[0000] K= 2 πD o D i 2 /E ( D o 2 −D i 2 )
[0030] where D o and D i are the outer and inner pipe diameters, respectively.
[0000] If N coil is the number of turns of fiber around the pipe, then
[0000] Δ X=N (Δ C )= N coil K ( dP/dt )( L−X )( n/c ).
[0000] Thus, the change in length indicated by the interferometer is a function of the time derivative of the pressure signal, the number of turns N coil of fiber on the pipe, and the length L of the delay portion of the fiber.
[0031] FIG. 6 is a block diagram showing an example of the processing of a received optical signal using interferometer 200 . Counter propagating beams 231 , 232 travel through optical fiber 230 comprising measurement section 220 and delay section 225 . In this example, delay section 225 comprises multiple loops of optical fiber around a spool. Pressure signal 21 causes a lengthening of measurement section 220 which produces a phase shift in the recombined beams at detector 210 , as described previously. Detector 210 outputs a phase shift signal that is conditioned by signal conditioner 312 and outputs as an analog signal proportional to the time derivative of pressure dp/dt at 314 . The signal 314 is transmitted to A/D in block 316 where the dp/dt signal is digitized. The digitized dp/dt signal is integrated in block 318 to produce a digital signal similar to the original pressure signal P(t). The P(t) signal is then decoded in block 320 to produce data 216 . Data 216 may be used in log modules 324 to produce logs 326 . In one embodiment, optical source 202 , optical detector 210 , and signal conditioner 312 may be physically located close to conduit 211 in signal detector 36 . Alternatively, some of these items may be located away from conduit 211 , for example in controller 33 . The functional modules 316 , 318 , 320 , 324 , and 326 may comprise hardware and software and may be located in controller 33 . In one embodiment, controller 33 may be a stand alone unit located in a separate location, for example a logging unit. Alternatively, controller 33 may be an integral part of a logging unit using shared hardware and software resources. While described above with reference to a single optical signal detector on a conduit, it is intended that the present disclosure cover any number of such detectors space out along such a conduit.
[0032] FIG. 7 is a chart of laboratory test data showing raw interferometer data and integrated interferometer data compared to conventional pressure sensor data for pressure signal detection. Pressure signals are generated in a flowing fluid in a flow loop. A pressure signal transmitter generates pressure signals into the flowing fluid. An interferometer similar to interferometer 200 is installed on a section of conduit. A conventional strain gauge pressure sensor is mounted within 2 m of the interferometer. FIG. 7 shows the raw interferometer data proportional to dp/dt in curve 700 . The raw data is processed as described above to produce an integrated interferometer curve 710 . Curve 705 is the reading from the conventional pressure transducer. As shown in FIG. 7 , integrated interferometer curve 710 is substantially similar to conventional pressure transducer curve 705 .
[0033] Numerous variations and modifications will become apparent to those skilled in the art. It is intended that the following claims be interpreted to embrace all such variations and modifications. | An apparatus for detecting data in a fluid pressure signal in a conduit comprises an optical fiber loop comprises a measurement section and a delay section wherein the measurement section is disposed substantially circumferentially around at least a portion of the conduit, and wherein the measurement section changes length in response to the fluid pressure signal in the conduit. A light source injects a first optical signal in a first direction into the measurement section and a second optical signal in a second direction opposite the first direction into the delay section. An optical detector senses an interference phase shift between the first optical signal and the second optical signal and outputs a first signal related thereto. | 6 |
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/437,277 filed Jan. 28, 2011.
FIELD
[0002] The present disclosure is related to drying and gas or vapor contact with solids, by continuous processing with centrifugal force and heating; cleaning and liquid contact with solids with means for collecting escaping material; classifying, separating and assorting solids, with heat treatment; classifying, separating and assorting solids with fluid suspension with grading deposition of gaseous feed with fluidically induced, unidirectional swirling; or classifying, separating and assorting solids, with a liquid feed grading deposition including rotational hydrodynamic extraction; and pumps where one fluid is pumped by contact or entrainment with another within a rotary impeller, or by a jet.
BACKGROUND
[0003] The separation of the products of a reaction taking place within a feedstock is currently done in several ways. Examples include batch processing, gravity separation, and centrifugal separation. A new approach is a radial counterflow reactor, which uses a feedstock in a workspace with controlled turbulence patterns created by the rotation of one or more disk impellers, and is described in several disclosures by the present applicants.
[0004] There are currently a variety of vessels for the growth or other processing of biological material. The current approaches do not allow for the efficient application of energy throughout the material within the vessel, while simultaneously stripping out exceptionally beneficial or harmful components within the vessel in a continuous process which lends itself to high volume.
[0005] Two examples will be used here to illustrate this. The first is the promotion of algae growth for the production of biofuels from CO 2 . Typically the algae is placed with sterilized water and nutrients in clear vessels such as tubes to allow sunlight to shine in, and CO 2 is bubbled up in the tubes to mix with the algae. There is inefficiency in the application of the sunlight energy to the tube, where much of the algae in the interior of the column are shielded from the sun while that on the exterior may get too much. A need exists for improved access of light for photosynthesis to algae in a bioreactor or in a pond.
[0006] The distribution of the CO 2 in the tube also tends to be uneven because there is not enough mixing. When the algae has had time to create oils and other hydrocarbons, which here will be generally called lipids, then the algae has to be extracted, dried, and processed to remove the lipids. This is a wasteful and energy intensive extra step, and because this is a batch process, there is not a continuous stream that would lend itself to high volume.
[0007] It would be preferable to have a continuous lipid production process that did not depend on killing the algae. A goal of research has been to engineer a “lipid trigger” in the algae to make it extrude lipids, instead of storing them internally, and to do so continuously, instead of only producing them intermittently during periods when there is no cell division. But if a live algae colony were able to be continuously producing lipids in this way, there is no efficient way to extract the lipids to keep them from contaminating the algae environment. There is also no way to, at the same time, continuously separate the dead algae from the live ones, to keep the most productive members flourishing. Also, there is a need to strip out the oxygen produced by the algae to favor the forward photosynthesis reaction for enhancing algae growth.
[0008] Where algae is in a pond, oxygen is produced by photosynthesis and released to the atmosphere, but dissolved oxygen in the water is consumed by the decay of dead algae, and the depletion of oxygen in the water leads to dead zones where fish cannot live.
[0009] In shrimp and fish aquaculture, oxygen is desired, instead of carbon dioxide, but the same need exists for continuous stripping of waste gases and circulation of water to extract feces and other waste material.
[0010] To use another example, the combustion of material to create biochar is typically done in furnaces in a batch process. There is a need for continuous mixing that ensures that heat energy will be evenly applied throughout the feedstock, and for an efficient mechanism for continuously stripping out volatile gases or liquids to aid the forward reaction.
[0011] The applicants have described a variety of variations on the design of a radial counterflow reactor comprising one or more rotating disk impellers, which has many benefits in establishing a radial counterflow pattern with lighter elements continuously migrating toward the axis, and heavier elements toward the periphery. This radial counterflow reactor idea has been described through its application to the continuous processing of gases, liquids and sludge.
SUMMARY
[0012] A radial counterflow reactor is described featuring radiant energy, from among the wavelengths from infrared to ultraviolet, applied to the workspace. The reactor typically comprises two approximately parallel counter-rotating disk impellers, defining a turbulent workspace between them. The workspace can also be defined by a single impeller approximately parallel to a static casing. The disk impellers are conductive to the radiant energy, allowing at least some portion of the radiant energy to pass through them into the workspace to transform the feed. The radiant energy can come from emitting elements which are outside of the impellers and the workspace, or the radiant energy can come from elements embedded in the impellers.
[0013] One example design is a photobioreactor with two counter-rotating disk impellers, defining a turbulent workspace between them. The disk impellers are transparent to radiant energy, to allow an applied radiant energy, from infrared to ultraviolet, to be transmitted through them into the workspace to transform the feed. This type of photobioreactor reactor is especially useful for the growth and processing of biological and organic material, including in aquaculture.
[0014] For example, algae can be grown between transparent disk impellers in an axenic closed photobioreactor system, with improved means for extraction of products such as lipids for oil production. The impellers can be oppositely rotating solid disks, or moving liquid disk layers created by an array of jets. The algae feedstock, together with water, CO 2 and nutrients, is fed into the workspace and slowly sheared by the impellers, creating a fractal network of branching vortices where controlled turbulence and centrifugal force spins heavier components toward the periphery of the vortices and toward the periphery of the disks. At the same time, suction applied to the axial port in the upper disk impeller by a suction pump draws the lighter products such as lipids inward in a sink flow through the cores of the vortices, to be exhausted out of the axial port. The transparent disk impellers can be solid or liquid. If moving liquid disk layers form the impellers, they can contain dissolved nutrients or gases to be supplied by diffusion to the workspace, and they can also carry away wastes through drains in the impeller layers. In addition, the liquid impeller layers can supply hot or cool water as needed. Dead algae sink and are swept to the periphery of the photobioreactor where they are extracted as a sludge. Continuous gentle churning of the algae in this way exposes more of them to the light and extracts the waste products.
[0015] In an embodiment for shrimp farming, algae and shrimp may coexist in the photobioreactor such that the shrimp eat the algae. Dead shrimp and feces are spun out by the disk impellers while live shrimp thrive among the live algae being nourished at the center. Methane and other waste gases are stripped out continuously and oxygen is introduced along with the recycled water.
[0016] In an embodiment for fish farming, feces and dead fish are spun to the periphery of the photobioreactor where they can be easily collected at a wall, while the water is extracted, clarified, degassed, and aerated prior to being reintroduced to the tank.
[0017] In another example design, biological and organic material is processed by radiant energy coming out of the solid impellers in a biochar reactor where wood or other organic waste is pyrolyzed by heat applied through heated impellers, with biochar accumulating at the periphery, and bio-oil and gases exhausted out of the axis.
DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows a cross section of a radial counterflow reactor utilizing absorbed energy applied into a feedstock, showing the basic components, as well as the flow of a feedstock and energy into it, and the flow of byproducts out.
[0019] FIG. 2 shows a closeup of a portion of the reactor shown in FIG. 1 , with more detail for the workspace.
[0020] FIG. 3 shows a schematic side view of the flow patterns in the workspace.
[0021] FIG. 4 shows a head-on view of the flow patterns in the workspace, featuring nested vortices.
[0022] FIG. 5 shows a top view of the bottom disk impeller, showing the ports, vanes and other components.
[0023] FIG. 6 shows a side cross section view of the bottom disk impeller shown in FIG. 5 .
[0024] FIG. 7 shows the superimposed patterns of the vanes for the top and bottom impellers, at a starting point in their counter-rotation.
[0025] FIG. 8 shows the superimposed patterns of the vanes for the top and bottom impellers, rotated by 10° in opposite directions.
[0026] FIG. 9 shows the superimposed patterns of the vanes for the top and bottom impellers, rotated by 20° in opposite directions.
[0027] FIG. 10 shows the superimposed patterns of the vanes for the top and bottom impellers, rotated by 30° in opposite directions.
[0028] FIG. 11 shows the superimposed patterns of the vanes for the top and bottom impellers, rotated by 40° in opposite directions.
[0029] FIG. 12 shows the superimposed patterns of the vanes for the top and bottom impellers, rotated by 50° in opposite directions.
[0030] FIG. 13 shows the superimposed patterns of the vanes for the top and bottom impellers, rotated by 60° in opposite directions.
[0031] FIG. 14 shows the superimposed patterns of the vanes for the top and bottom impellers, rotated by 70° in opposite directions.
[0032] FIG. 15 shows the superimposed patterns of the vanes for the top and bottom impellers, rotated by 80° in opposite directions.
[0033] FIG. 16 shows a set of flows for a radial counterflow algae photobioreactor.
[0034] FIG. 17 shows a set of flows for a radial counterflow biochar bioreactor.
[0035] FIG. 18 shows a top view of an array of jets to create a moving liquid disk impeller.
[0036] FIG. 19 shows a cross section of two liquid impellers in a photobioreactor for aquaculture.
DRAWING REFERENCE NUMERALS
[0000]
1 —feed source
2 —feed transfer
3 —axial feed conduit
4 —axial feed port
5 —baffle
6 —bottom disk impeller
7 —top disk impeller
8 —rotation of top disk impeller
9 —rotation of bottom disk impeller
10 —axis of rotation
11 —workspace
12 —periphery of the workspace
13 —heavy products exhaust port
14 —heavy products collection
15 —heavy products transfer
16 —heavy products storage
17 —sink flow
18 —axial exhaust port
19 —axial suction pump
20 —lighter products transfer
21 —lighter products receptacle
22 —axial support shaft
23 —upper exhaust conduit
24 —upper disk bearing and seal
25 —lower intake conduit
26 —lower disk bearing and seal
27 —base support
28 —prime mover
30 —lower drive track
31 —upper drive track
32 —support wheel
33 —sleeper wheel
34 —sleeper wheel support
35 —drive shield wall
36 —output deflector wall
37 —output vent
38 —heavy product screw conveyor
39 —pinch section
40 —pinch opening
41 —radiant energy source
42 —absorption into feed
45 —axial feed pump
46 —feed flow
47 —sink flow
48 —heavy products flow
50 —vortex in shear layer
51 —vane on lower disk
52 —vane on baffle
53 —vane on upper disk impeller
54 —crossflow filter inset into bottom disk impeller
55 —liquid flow through crossflow filter
56 —rugose ridges on bottom disk impeller
56 a —gas vent on top disk impeller
57 —rugose ridges on top disk impeller
60 —boundary layer
61 —direction of flow of boundary layer
62 —flow from boundary layer to shear layer
63 —shear layer
64 —outer part of vortex
65 —direction of flow of outer vortex
66 —movement from shear layer to boundary layer
67 —inner part of vortex
68 —direction of flow of inner vortex
69 —inward sink flow
70 —vortex with counterclockwise rotation
71 —vortex with counterclockwise rotation
72 —centrifugal separation
73 —bottom impeller
74 —first vane
75 —second vane
76 —third vane
77 —fourth vane
78 —edge of baffle
79 —conical apex of screw feed conveyor
80 —vane crossing intersection
81 —corresponding inverted vane on top disk impeller
82 —first intersection axis
83 —second intersection axis
84 —third intersection axis
85 —fourth intersection axis
86 —fifth intersection axis
87 —sixth intersection axis
88 —seventh intersection axis
89 —eighth intersection axis
90 —rugose ridge on bottom disk impeller
91 —example of corresponding inverted rugose ridge on top disk impeller
92 —gas vent
93 —drive shield wall brace
96 —straight vane on bottom impeller
97 —straight vane on top impeller
98 —heavy products flow
99 —light products sink flow
100 —vortex network
101 —main supply pipe
102 —branch supply pipe
103 —liquid jet nozzle
104 —area of jet
105 —direction of flow
106 —drain inlet
107 —drain pipe
108 —central drain
109 —central supply pipe
110 —axial exhaust
111 —support frame
112 —support float
113 —peripheral wall
114 —upper liquid impeller
115 —lower liquid impeller
116 —turbulence flow
117 —nutrients
118 —waste products in liquid impeller
119 —supply inlet
120 —drain outlet
DETAILED DESCRIPTION
[0150] Three examples will be given of a radial counterflow reactor with radiant energy applied to the feed. Each comprises a closed vessel with one or more feed stock input ports, one or more output ports for lighter products, and one or more output ports for heavier products, plus a source of radiant energy, in wavelengths selected from infrared to ultraviolet, to be to be absorbed by the feedstock. The first example will describe a photobioreactor with solid impellers. The second example describes a more simplified photobioreactor with liquid impellers. Both of these examples use radiant energy transmitted through transparent impellers. The third example is a biochar processor which also uses solid impellers, which are heated, either by the application of external heat or internal heating elements.
Algae Processor
[0151] This reactor will first be described in an exemplary configuration as a photobioreactor for growing lipid-producing algae. It will be appreciated by the skilled practitioner that this example is not meant to restrict the possible applications of this description to the solution of other types of problems. Similarly, the design disclosed here is exemplary, and is not meant to preclude any modified design to suit a particular purpose.
[0152] A feed source 1 comprises storage for a transportable feed, such as algae, combined with water, CO 2 , and nutrients. A feed transfer 2 brings the feed into the photobioreactor, by means such as pumps, conveyors or a gravity feed, into an axial feed conduit 3 , leading to an axial feed port 4 , where the feed enters the photobioreactor in a space underneath a baffle 5 , which is located between a bottom disk impeller 6 and top disk impeller 7 . These two disk impellers, which act as centrifugal pumps, rotate in opposite directions, such as those shown at 8 and 9 , about an axis of rotation 10 . A workspace 11 is defined in the space between the disk impellers. The workspace has boundary layers along the surfaces of the impellers, and a shear zone between the boundary layers, where amplified centrifugal force in organized vortex turbulence creates separation between the heavy and lighter products.
[0153] After the algae is introduced into the photobioreactor, it is expected to multiply and grow there within it, and the primary feed from then on will be water along with CO 2 and nutrients to promote proper growth.
[0154] The heavier products, such as an algae sludge, move toward the periphery of the workspace 12 where they are extruded, falling through a heavy products exhaust port 13 to be collected, in this case into an annular heavy products collection trough 14 , where the heavy products transfer means 15 convey the heavy products to the heavy products storage 16 . Meanwhile, while the heavy products migrate outward, an inward sink flow 17 is set up above the baffle, leading inward to an axial exhaust port 18 . The sink flow is forced by an axial suction pump 19 , in this case a screw conveyor. This pump can also be a mechanical pump or any other kind of appropriate pump to draw out the light products axially so a lighter products transfer 20 can convey them to a lighter products receptacle 21 . These lighter products include anything with a lower specific gravity than the heavier products. For example, the lighter products can include lipids extruded by the algae and oils as well as gases including oxygen produced by photosynthesis.
[0155] The disks and the conveyor pumps in this design are supported by an axial support shaft 22 , which extends downward through the upper exhaust conduit casing 23 . This casing has the support for the upper disk bearing and seal 24 , which preferably contains a combination thrust bearing and rotary seal. A similar disk bearing and seal is in the casing for the lower disk. If the disk bearing and seal 24 is made to be movable up and down, such as by a telescoping upper exhaust conduit casing 23 and/or a similar one for the bottom disk impeller, then the separation between the top and bottom disk impellers 7 and 6 can be changed if needed. For instance, in the example of algae, a relatively wide separation could be used for an algae growth process, and a narrower one could be used to concentrate and dewater a resulting algae sludge. The axial support shaft 22 preferably also extends down through the axial feed conduit 3 , which has an axial feed pump 25 , in this case a screw conveyor, and lower disk bearing and seal 26 . Because these screw conveyors are tied to the disk impeller motion and the disk impellers have opposite rotation 8 and 9 , the screw conveyors in this design have an opposite slope in order to make a consistent movement of material upward in both cases. A base support 27 anchors the assembly.
[0156] On the periphery of the disks is a prime mover 28 to turn the disk impellers in counter-rotation. This prime mover 28 can be a motor or another source of motive power such as wind or water power. The motor can be coupled to the hub or another part of the disk impellers in order to turn them. In this instance, the prime mover is coupled to a peripheral drive wheel 29 which simultaneously contacts the bottom disk impeller 6 at a bottom drive track 30 , and the top disk impeller 7 at a top drive track 31 . The rotation of the drive wheel 29 would therefore turn the two disk impellers in opposite directions. The drive wheel would preferably be a straight or spiral bevel gear, and the drive tracks would be compatible gear tracks. Support wheels such as at 32 contacting the opposite side of the disk impeller from the drive tracks will help to maintain a consistent engagement of the drive wheel 29 with the drive track such as at 30 . Sleeper wheels such as at 33 also maintain a consistent separation of the disks, and are supported by sleeper wheel supports such as at 34 .
[0157] Inboard of the drive wheels are barrier walls to shield the drive components from the products inside, and to direct their flow. The drive shield wall 35 is an annular wall attached to the top disk impeller, and is a backup barrier to prevent the products from the interior of the photobioreactor from clogging the drive system. Inboard of the drive shield wall 35 is the output deflector wall 36 , which is also an annular wall, but this time attached to the bottom disk impeller, and angled inward so that the outward flow from the periphery is deflected downward to the heavy products exhaust port 13 and the heavy products collection trough 14 . On the top of this output space, an output vent 37 allows remaining gases from the heavy product to escape. The collection trough 14 for the heavy product can contain a conveyor to further collect it, such as an annular heavy product screw conveyor 38 in the bottom of the trough, ending in a tangential branch for dumping the product into a hopper.
[0158] Inboard of these barrier walls, the separation of the disks narrows to the pinch section 39 , where heavy output products are squeezed and concentrated, beginning with the pinch opening 40 , where the workspace narrows.
[0159] The passage of feed into the workspace, while the disk impellers are in motion, creates a fractal network of vortices in the shear layer, with lighter products converging in a sink flow 17 into the axial exhaust port 18 . At the same time, radiant energy, selected from the range of wavelengths from infrared to ultraviolet, is transmitted by a radiant energy source 41 , so that it is absorbed into the feed 42 in the workspace.
[0160] This radiant energy transmission is done by making the disk impellers transparent or conductive to the radiant energy. For this example of an algae photobioreactor, the transparent disks allow the energy from sunlight or other artificial light energy to pass through them into the feed to be absorbed, including the wavelengths most beneficial for algae growth.
[0161] If the algae can benefit from the maximum amount of exposure to light, it is preferable for both disk impellers 6 and 7 to be transparent, and for there to be a light source both above and below the disks. This can be done with a reflector for a single light source such as the sun, or with duplicate artificial light sources above and below the disks. If the photobioreactor described here is duplicated in a stack, then the light source for the bottom of one photobioreactor can serve as the light source for the top of another. As an alternative, a single light source can be reflected back into the feed from a mirror finish on the disk impeller opposite the transparent disk impeller.
[0162] As the disk impellers slowly turn, the algae in the workspace are slowly swirled and rotated in the vortex flows, being exposed to light from every side, and continuously absorbing energy, like a roast being rotated on a spit. Heat flux due to forced convection sweeping the heat transfer surfaces is 50 W/cm2 which is better than static heating (pool boiling) at only 20, Controlled agitation of the algae maximizes the energy flux into them. This controlled agitation also provides radially inward pathways for the extraction of oxygen from photosynthesis, ammonia, H2S, oil, and clean water through the axial exhaust port 18 , here shown as an opening at the center of the top disk. The axial extraction of light fractions enables a continuous process which favors photosynthesis by extracting the products.
[0163] The disk impellers may be solid transparent disks, screens, radial arms, or other configurations and materials permitting flux of radiant energy into the workspace. Ultraviolet radiant energy can thus have enhanced disinfecting by churning the feed so that microbes are exposed and killed by UV because suspended solids offer them no effective shade.
[0164] FIG. 2 shows a closeup of the left side of the workspace 11 in FIG. 1 . The feed flow into the photobioreactor is shown at 46 , and the sink flow for light products to axial extraction out of the photobioreactor is shown at 47 , as well as the peripheral flow outward for heavy products 48 . The feed in the axial feed conduit 3 comes through the axial feed port 4 and enters the photobioreactor in the space underneath the baffle 5 , which is located between the bottom disk impeller 6 and the top disk impeller 7 . The feed flow is enhanced by vanes attached to the impellers, such as those shown in FIGS. 7-15 . The vanes on the bottom impeller are indicated by 51 , the vanes on the baffle are at 52 , and the vanes on the upper impeller are shown at 53 . In this example, the baffle is assumed to be attached to the bottom disk impeller so they co-rotate, so the vane pattern of the vanes on the top of the baffle 52 will resemble the vanes on the bottom impeller 51 .
[0165] An optional crossflow filter 54 inset into the bottom disk impeller can be used to remove fluid from a sludge in a fluid flow 55 , by making use of the force produced when the sludge is forced outward by centrifugal force while being squeezed by the pinch section 40 where the disks impellers have a narrower separation. The crossflow filter is a sintered metal or plastic screen, made flush to the interior surface of the disk impeller facing the workspace, and usually backed by a watertight plug to close it when it is not in use. This crossflow filter would be used for dewatering an algae sludge, with the disk impellers spinning much faster than they normally would for general algae growth. This faster rotation would tend to spin all of the algae outward from the workspace, to clear the way for a fresh batch. The dewatered algae sludge concentrate would then proceed outward into the pinch section 40 .
[0166] A similar perforated opening gas vent 56 a in the top disk impeller could be used to vent gases that would tend to accumulate in bubbles on its interior surface, and be swept out toward the periphery by the vanes. There would be a smaller net area of opening needed for the vent in this case. The vented gases should be monitored as to their composition, as part of the sensors which would monitor the condition of the feed in the workspace, measuring factors such as temperature, pH, density, nutrients and mass flow.
[0167] Optional rugose ridges, such as 56 on the bottom impeller and 57 on the top impeller, can interrupt and constrict the outward flow 48 flow still further, causing pressure waves for osmotic shock at low speed or cavitation in fluids at high speed, as another way to transform the feed. These rugose ridges are described more fully in the discussion of FIG. 5 .
[0168] FIG. 3 shows a cross section closeup of the flows in the workspace. Next to each disk impeller 6 and 7 is a boundary layer 60 , characterized by a laminar flow 61 of the feed, some of which flows inward 62 to the shear layer 63 , which is located between the boundary layers. The shear layer contains a branching area-preserving network of vortices, with larger vortices toward the axis collecting the products of smaller vortices toward the periphery. The outer region of a typical vortex is shown at 64 , with its flow at 65 . Heavier products are spun out by amplified centrifugal force in the photobioreactor and migrate outward, first to the outer regions of the vortex and then to the boundary layer in an outward flow 66 . Meanwhile, the inner part of the vortex 67 has a flow 68 that collects the lighter parts, which are drawn inward toward the axis of rotation in a sink flow 69 .
[0169] In the case of algae, under normal growth conditions the boundary layers would comprise mostly a water, CO 2 and nutrient feed, and the algae would concentrate in the vortices in the shear layer, where they would divide and grow.
[0170] FIG. 4 shows an orthogonal cross section of the workspace, with a flow pattern of vortices, where the clockwise flow of a larger vortex 70 may be surrounded by counterclockwise flows 71 in the overall turbulence pattern. Both of these types of vortices contribute to the overall sink flow network by creating centrifugal separation 72 of the feed. For algae, the rotations of the algae in these vortices would expose all of them more completely to the light coming through the disk impellers, while at the same time the centrifugal separation 72 would strip out the products with a lower specific gravity, such as extruded lipids, into the sink flow. Recent work by VG Energy has shown how the lipid trigger can be manipulated to make algae overproduce and extrude lipids, instead of storing them in their bodies. If these extruded lipids can be continuously stripped away from the algae, they will not contaminate the environment of the algae and inhibit their growth. The live algae are typically kept apart by electrical repulsion, and kept buoyant by their motility as well as internal gas vacuoles or gas bubbles on their membranes, but as they die they would become less buoyant and would migrate into the heavier products flow outward. Thus, the dead algae would tend to collect on the periphery of the reactor, and the lighter products such as lipids would be continuously collected in the axial sink flow.
[0171] If the goal of the photobioreactor is the mass production of algae, then the excess algae be extruded at the periphery, leaving a constantly growing and dividing stock in the workspace. This separation could be assisted by the clumping of algae by autoflocculation. As the algae consume the carbon dioxide being introduced axially, the outer regions of the workspace grow to have a higher pH, which, together with flocculants in the solution such as calcium carbonates and calcium phosphates, cause the algae to clump together. This increases the centrifugal force on the clumps, and causes them to spin outward to the periphery. Using ports in the disk impellers for introducing flocculant chemicals directly into the solution at a given radial distance from the axis of rotation 10 can allow more precise control of this process.
[0172] In FIG. 5 is a top view of the bottom impeller 73 , which has a clockwise rotation 9 . It can be made of any suitable material, such as plastic, glass, ceramic, metal or any practical material. In the case of transparent disk impellers for algae, the material used should not block the most beneficial wavelengths. There are, in this example, four vanes 74 , 75 , 76 and 77 , attached to the impeller and made of a suitable material, shaped in this case according to a spiral. The edge of the baffle 5 is indicated at 78 . In the center, at the axis of rotation, is the apex of the screw feed conveyor 79 , which preferably should be conical to produce a more lateral feed underneath the baffle.
[0173] The vanes form crossing intersections such as 80 with the corresponding but inverted vanes on the underside of top impeller, such as 81 , which is here seen as if looking down through the top impeller at a moment when the vanes are crossing. These moving intersections form a rhythmical flow along eight well-defined intersection axes: 82 , 83 , 84 , 85 , 86 , 87 , 88 and 89 . This rhythmical flow is shown in FIGS. 7-15 . The mass flow along these eight axes is the basis for the organized turbulence of the flow of the shear layer between the disks. This mass flow through the boundary layers also prevents the formation of biofilm which can coat the disk impellers and block light. The vanes push the feed outward as the disk impellers turn, and the intersection points moving outward along the intersection axes form moving zones of increased shear and vorticity which reinforce the sink flow moving inward toward the axis of rotation.
[0174] A pattern of rugose ridges 90 can be part of the peripheral section, as also seen in FIG. 2 . They are designed to intersect the corresponding rugose ridges from the top impeller, such as shown by a sample at 91 . These rugose ridges are for causing osmotic pressure waves at low speeds or cavitation in liquids at high speeds, or to aid in the comminution of a more solid feed. In the case of algae, the rugose ridges would produce osmotic shock, and, at high speed, cavitation bubbles in the water, which would explode the algae cell membranes and release the contents, allowing a better interaction with digestive enzymes for more complete recovery of any stored lipids.
[0175] The output deflector wall is shown at 36 . This barrier, which can be made part of the impeller or separately attached, deflects the processed heavy products downward into the heavy products outlets 13 , which are here shown partially covered because of the overhang of the output deflector wall 36 . The drive shield wall is shown at 35 . This wall is actually attached to the top disk impeller, but is added here for clarity. A gas vent 92 and a drive shield wall brace 93 are also shown. The drive shield wall brace 93 aids in the attachment of the drive shield wall to the top disk impeller. If a similar brace and attachment is also built into the disk impeller for the output deflector wall 36 , then the disk impeller design can be made to be interchangeable; usable for either the top or the bottom disk impeller.
[0176] The optional annular crossflow filter inset into the bottom disk impeller is shown at 54 , which can be used to remove fluid from a sludge as discussed and shown in cross section in FIG. 2 . A fuller description of this annular crossflow filter in a radial counterflow reactor can be found in the applicant's U.S. Pat. No. 7,757,866 entitled “Rotary Annular Crossflow Filter, Degasser and Sludge Thickener.”
[0177] At the periphery of the disk, a drive track 30 engages the gear teeth of the drive wheel 29 which is driven by a motor 28 , or a sleeper wheel such as 33 which has a sleeper wheel support 34 . The drive can be a gear drive, a belt drive, a chain drive, or a friction drive, as needed for the application requirements, including noise, speed, and torque.
[0178] FIG. 6 shows a side view cross section of the bottom disk impeller 73 of FIG. 5 , drawn to the same scale, as also shown in FIG. 1 . The bottom disk impeller 6 has an axial feed conduit 3 and an axial feed port 4 where the feed enters underneath the baffle 5 . A motor 28 drives a drive wheel 29 which engages a drive track 30 to rotate the disk impeller 6 around the axis of rotation 10 , stabilized by sleeper wheels such as 33 and other supports such as sleeper wheel support 34 and a base support 27 . The heavy products exhaust port is shown at 13 . The disk impeller vanes 51 and the baffle vanes 52 as well as the crossflow filter 54 are also shown in FIG. 2 . In the peripheral pinch section b are the rugose ridges 56 . Further toward the periphery are the output deflector wall 36 and the drive shield wall 35 with optional gas vents 92 . A drive shield wall brace 93 can be built into a generic disk impeller design to enable attachment of the disk shield wall to the top disk impeller.
[0179] FIGS. 7-15 show the successive rotation positions of a set of four straight vanes on two counter-rotating disk impellers. Each figure represents a rotation of 10°, so they make a repeating cycle of 90°. The direction of rotation for the top disk impeller is at 8 , and the direction of rotation for the bottom disk impeller is shown at 9 . The location of the edge of the baffle is at 78 . A straight vane on the bottom disk impeller is shown at 96 , and a straight vane on the top disk impeller is at 97 . The successive positions for these vanes are shown in each figure, and the parts representative of the top disk impeller are shown with dashed lines. The intersection points of the vanes form eight radial axes, such as at 82 , which are the organizing axes for the sink flow.
Liquid Impellers
[0180] FIGS. 18-19 show another example of a photobioreactor, featuring liquid impellers, which is especially useful for aquaculture and for UV disinfection. FIG. 18 shows a top view of an array of jets to create a moving liquid disk impeller. Preferably this array is static, and only the liquid moves. The liquid is fed through a network of supply pipes. An example of a main supply pipe is shown at 101 , and 102 shows a branch supply pipe. An example of a liquid jet nozzle is at 103 . When liquid such as water is forced through this nozzle, it makes a jet area of water pressure 104 which, in combination with the flow from the other jets, creates an overall direction of flow 105 for the liquid layer, forming a liquid impeller disk. Preferably the jets should be in a planar arrangement, parallel to the surface of the water, and the jet nozzles are configured to spray a pattern which spreads more horizontally than vertically, to fill in the liquid impeller layer more completely and to keep it from becoming too thick.
[0181] In addition to the supply pipes spraying into the liquid impellers, preferably there are also drain pipes. Drain inlets 106 feed into drain pipes 107 which lead back to a central drain 108 , which is distinct from the central supply pipe 109 . An axial exhaust pipe 110 takes out the sink flow products from the workspace. Support frame members 111 keep the pipes and jets from becoming distorted or out of place, and support floats 112 can relieve their weight. A peripheral wall 113 sets a boundary for the photobioreactor.
[0182] FIG. 19 shows a cross section of two liquid impellers in the photobioreactor. The top liquid impeller 114 is created by jets from fluid such as water carried by main supply pipes such as at 101 , fed by a central supply flow 119 , creating an overall direction of flow 8 . In this case the upper boundary of the upper impeller is equal to the surface of the water. The bottom liquid impeller 115 is created by a similar array of pipes and jets, but pointing in the opposite direction, so as to produce an opposite direction of rotation 9 in the liquid impeller. Oppositely flowing turbulence 116 extending from the boundary layer into the shear layer in the workspace 11 creates a vortex network, with a sink flow of lighter products 17 being drawn into the central exhaust, while a flow of heavier products 15 flows from the periphery. A network of drain pipes 107 is preferably also present, leading into a central drain outlet 120 . A support float 112 helps manage the weight of the pipes, and the peripheral wall is shown at 113 . The liquid impellers can be used within a cylindrical tank or in a pond or lake which is larger than the width of the array of jets. One liquid impeller can also be used by itself at some distance below the surface, allowing the surface of the water and the liquid impeller to define the workspace.
[0183] Radiant energy 41 is applied in this case by sunlight shining through the transparent water to encourage growth in the workspace. The liquid impellers can introduce nutrients such as food and beneficial gases into the workspace, by first dissolving these components into the water carried in through the supply pipes. The drain pipes can help draw out any waste products that find their way into the liquid impeller layer. The liquid impellers can also help regulate temperature in the workspace. For example, on a hot day, the upper impeller layer can be supplied with colder water, which will diffuse downward and cool the workspace.
[0184] Aquaculture can include the cultivation of many different types of organisms, such as algae, shrimp, fish, oysters, and seaweed, either alone or in combination. The younger or weaker organisms would be more likely to be passively carried by the vortices created in the workspace, but the larger or stronger mobile organisms would be able to be actively able to swim into the disk impellers themselves, where they could have more direct access to food in the liquid impeller layer, with less competition than in the workspace. This self-separation of organisms could aid in the harvesting of the more mature individuals.
Biochar Processer
[0185] Another example of a radial counterflow reactor with applied radiant energy is used for the processing of biomass for biochar, bio-oil, and combustible gas. In this case the feed 1 is different, but the general design of FIG. 1 is the same, with the applied energy 41 absorbed into the feed 42 in the workspace 11 being infrared or heat energy heating the disk impellers 6 , 7 , which are made of a refractory material that can resist heat, pressure and wear. The heating can be done by external means, such as flames heating a portion of the disk impeller as it passes, or internal means, such as heating coils built into the rotating disk impellers. The combustible gas output of the process can be burned to help supply this heat.
[0186] A wide variety of cellulosic biomass feed stocks can be used, including wood chips, sawdust, switchgrass, bagasse, corn stover, plant cuttings, seaweed, and algae cake, and other biodegradable waste. The feed should be ground before it is input into the bioreactor to enable it to be churned by the turbulence in the workspace, and dried to reduce the energy needed to convert it.
[0187] The biomass feedstock is churned and heated in the workspace 11 of the radial counterflow reactor, where it undergoes thermal decomposition in an oxygen-starved environment, forming biochar and gaseous products that comprise bio-oil and syngas. The pyrolysis of triglycerides and other organic compounds in the feedstock forms carboxylic acids, alkans, alkenes, aromatics, and other volatile compounds that can be condensed into bio-oil. Syngas is comprised of hydrogen and carbon monoxide. In addition, there will be steam and other gaseous. The biochar may contain potash and other compounds, depending on the feed. More applied energy 41 applied to the bioreactor for higher temperatures will create more gasification and less char. The infrared energy can come from heated disk impellers, or heated sand mixed with the feed, such as is used by BTG-BTL in their design for a rotating cone reactor. The pyrolysis can be fast pyrolysis, for a higher proportion of bio-oil output, or slow pyrolysis, for more biochar out. The present design for a bioreactor will be more efficient in the processing because of the high turbulence and rapid stripping of the light products from the feed.
[0188] In the workspace 11 , the pyrolysis of triglycerides and other organic compounds in the feedstock forms carboxylic acids, alkans, alkenes, aromatics, and other volatile compounds, which comprise the light products stream 99 . Producer gas, a more complete gasification product created by even more heat and pressure, is comprised of carbon monoxide, steam, hydrogen and other compounds, and is useful for producing fuel and chemicals. The biochar product is useful for soil remediation and carbon sequestration, and also can be burned as a fuel.
[0189] FIGS. 16 and 17 shows examples of sets of flows for a radial counterflow reactor, showing the outline of a disk impeller 7 , the axial exhaust port 18 , the heavy products flow 98 toward the periphery, and the inward light products sink flow 99 , as separated by a vortex network 100 . In FIG. 16 , for a radial counterflow algae photobioreactor, the heavy products flow 98 comprises heavy products with more specific gravity than water in the feed, such as algogenic organic matter (AOM), senescent algae, and flocculated algae. The light flows would be the components with less specific gravity, such as gases, including oxygen and excess CO 2 and extruded lipids. Increasing the rotation speed of the disk impellers as well as the suction at the axial exhaust port 18 would increase the radial counterflow separation effects, to make healthy excess algae that is crowding the workspace also move outward. When the central suction is decreased and the rotation speed is increased, the net effect is to clear out the workspace, for cleaning or restocking. In FIG. 17 , the heavy products for a biochar reactor would include biochar, and the light products would include bio-oil, volatile organic compounds (VOCs) and steam.
[0190] The radial counterflow reactor with applied radiant energy of this disclosure has here been described for its use as an algae churn, in aquaculture and as a biochar oven. However, it will be appreciated by those skilled in the art that a continuous separator of this type, making use of applied energy to transform the feed while simultaneously separating the byproducts, can find use in other applications, such as chemical engineering, refining, and food processing.
[0191] For example, radiant energy in radial counterflow can aid in drying, cleaning or processing solids while simultaneously extracting vapors and gases, or other continuous processing with centrifugal force and heating. It can also be of use in classifying, separating and assorting solids with heat treatment, or with separating or classifying gases and liquids by induced swirl and rotational hydrodynamic extraction. The radial counterflow reactor with applied radiant energy is also of use as a pump where one fluid is pumped by contact or entrainment with another within a rotary impeller, or by using one or more jets.
[0192] While the embodiments of the present invention have been particularly shown and described above, it will be understood by one of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims. | An improvement is described for the processing of biological material in a continuous stream by the application of radiant energy taken from the wavelengths from infrared to ultraviolet, and its absorption by a feedstock in a workspace of featuring controlled turbulence created by one or more counter-rotating disk impellers. The absorbed energy and the controlled turbulence patterns create a continuous process of productive change in a feed into the reactor, with separated light and heavy product output streams flowing both inward and outward from the axis in radial counterflow. The basic mechanism of processing can be applied to a wide range of feedstocks, from the promotion of the growth of algae to make biofuel or other forms of aquaculture, to a use in the controlled combustion of organic material to make biochar. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for reducing disturbances induced in a signal measurement or recording, in particular, but not exclusively, by movement of the electrodes or changes in the pressure applied to the electrodes.
2. Brief Description of the Prior Art
Oesophageal recording of diaphragm electromyogram (EMG) has traditionally been problematic due to the low amplitude of the EMG signal relative to the artifactual disturbances such as, in particular, the so-called electrode motion artifacts. At high gain settings, large electrode motion artifacts lead to saturation of the output of the preamplifier, thereby causing a temporary loss of the EMG signal. This problem of the prior art makes EMG recording very difficult during dynamic manoeuvres, such as for example rapid shallow breathing or panting.
OBJECTS AND SUMMARY OF THE INVENTION
A first object of the present invention is to provide a technology capable of reducing disturbances induced in a measurement or recording by:
movements of detecting electrodes;
changes in the pressure applied to these electrodes; or
other mechanical influence on the electrodes, generally referred to as motion artifacts.
Another object of the present invention is to reduce the amplitude of motion artifacts relative to the amplitude of the EMG signal to thereby reduce the possibility for saturation of the preamplifier.
A third object of the present invention is to overcome the problems of the prior art related to low signal-to-artifact ratio.
A further object of the present invention is to improve bipolar electrode measurements of diaphragm electromyogram (EMG).
In a preferred embodiment of the invention, there is provided a measurement apparatus for detecting an electrical signal produced by a muscle while reducing signal disturbances caused by motion artifacts, the measurement apparatus comprises:
a) a probe;
b) at least one electrode mounted on said probe; and
c) a disturbance reducing interface attached to said probe and covering said at least one electrode, the interface being ion permeable and segregating said at least one electrode from the muscle.
The objects, advantages and other features of the present invention will become more apparent upon reading of the following non restrictive description of preferred embodiments thereof, given by way of example only with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the appended drawings:
FIG. 1 is a schematic representation of a set-up of an EMG analysis system;
FIG. 2 is a side elevation view of the free end section of an oesophageal catheter on which an array of electrodes of the EMG analysis system of FIG. 1 is mounted;
FIG. 3 is a longitudinal, partial cross sectional view of the free end section of the oesophageal catheter of FIG. 2, showing an individual matrix of permeable material applied to each separate electrode of the array;
FIG. 4 is a longitudinal, partial cross sectional view of the free end section of the oesophageal catheter of FIG. 2, showing a continuous matrix of permeable material applied to and spanning the entire electrode array;
FIG. 5 is a partial perspective view of the free end section of an oesophagpal catheter, showing an array of semicircular electrodes and a continuous matrix of permeable material applied to and spanning the entire array of semicircular electrodes;
FIG. 6 is a partial perspective view of the free end section of an oesophageal catheter, showing an array of button electrodes which can be circular, square, rectangular, or of any other shape, and a continuous matrix of permeable material applied to and spanning the entire array of button electrodes;
FIG. 7 is a longitudinal, partial cross sectional view of the free end section of an oesophageal catheter, showing an electrode embedded in the material of the catheter, and a matrix of permeable material applied to the embedded electrode;
FIG. 8 is a longitudinal, partial cross sectional view of the free end section of an oesophageal catheter, showing a stud electrode and a matrix of permeable material applied to the stud electrode;
FIG. 9 is a partial perspective view of the free end section of the oesophageal catheter of FIG. 7, showing an array of electrodes such as shown in FIG. 7, embedded into the material of the catheter;
FIG. 10 is a partial perspective view of the free end; section of an oesophageal catheter, showing an array of button electrodes covered by a matrix of permeable material applied to the outer surface of the oesophageal catheter;
FIG. 11 is a partial perspective view of the free end section of an oesophageal catheter, showing an array of button electrodes as well as an array of grounding electrodes; and
FIG. 12 is an end cross sectional view of the array of button electrodes of FIG. 10 covered by the matrix applied to the outer surface of the oesophageal catheter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a technology capable of reducing disturbances induced in an electrical signal measurement and/or recording by movement of detecting electrodes or changes in the pressure applied to these electrodes. The electrodes are conductive elements used to detect electrical activity. The range of applications of the present invention includes electrical signal measurement and/or recording wherein electrodes are immersed in an eleclectrolyte (so-called wet electrodes). A typical example is the measurement and/or recording of diaphragm electromyogram (EMG), oesophageal peristalsis, or ECG with electrodes positioned on a catheter which in turn is introduced in the oesophagus.
Although the preferred embodiments will be described hereinafter with reference to oesophageal catheters and an application to the measurement of diaphragm electromyogram (EMG), it should be kept in mind that it is within the scope of the present invention to envisage other applications for this technology using other types of catheters or probes.
Referring to FIGS. 1 and 2, to measure EMG activity of the diaphragm 11 of a human patient 14 , an array of electrodes such as 12 are mounted on the free end section 15 of an oesophageal catheter 13 , with an inter-electrode distance d (FIG. 2 ). The distance d is adjusted in relation to body size; distance d will be larger for an adult than for an infant. The catheter 13 is a hollow tube having a diameter related to body size; the diameter will be smaller for infants than for adults. The catheter diameter, electrode size as well as the inter-electrode distance d may also vary in relation to the purpose of the catheter use.
As shown in FIG. 1, the catheter 13 is introduced into the patient's oesophagus through one nostril or the mouth until the array of electrodes 12 is situated at the level of the gastro-oesophageal junction. Of course, positioning of the electrode array comprising a series of differentially and axially arranged electrode pairs (for example electrode, pairs 1 - 7 of FIG. 2) is guided by the electrocardiographic (ECG) recordings and the diaphragm EMG. Alternatively, the electrodes 12 are monopolar electrodes differentiated in a computer, for example computer 19 of FIG. 1 . When required, ground is obtained through a separate, grounding electrode structure 25 (FIG. 1 ).
Positioning of an electrode at the oesophageal hiatus (where the oesophagus passes through the diaphragm is guided by visual inspection and/or computer algorithms studying the intensity, shape and polarity of ECG and diaphragm EMG signals. When the electrode is close to the oesophageal hiatus, i.e. next to the heart, ECG signal amplitude is high. If the electrode array is positioned close to the mouth (away from the heart), ECG signals present lower amplitudes at the proximate electrodes, and higher amplitudes at the distal electrodes. If the electrode array is positioned too far in the stomach, ECG has a high amplitude at the proximate electrodes of the array and a low amplitude at the distal electrodes. If the electrode array spans the region of the heart, ECG signals will show a time shift along the electrode array. If the electrodes are positioned away from the heart, ECG signals show no time lag. Diaphragm EMG signals obtained through electrode pairs located above and below the diaphragm have opposite polarities (with no time shift). EMG signals obtained on the same side of the diaphragm show the same polarity (and no time shift). The characteristics described in this paragraph will help the operator to adequately position the array of electrodes.
According to a preferred embodiment, an electrode 12 is mounted on the free end section 15 of the catheter 13 by winding stainless steel wire (not shown) around catheter 13 . The wound stainless steel wire presents a rough surface smoothed out by solder, which in turn is electroplated with nickel, copper and then gold or silver. Use of other metallic elements such as semicylindrical electrodes 21 (FIG. 5 ), button electrodes 22 and 23 (FIG. 6 ), etc., could be contemplated. The button electrodes can be arranged into a longitudinal linear array (electrodes 22 ), or at least one button electrode (see 23 ) can be angularly offset from the electrodes 22 about the longitudinal axis of the catheter section 15 .
For larger diameter feeding tubes or catheters, electrodes such as electrode 26 in FIG. 7 can be embedded into the material 27 of the feeding tube or catheter 28 . FIG. 9 shows a longitudinal array of electrodes 26 embedded into the material 27 of the free end section of the oesophageal catheter 28 . FIG. 9 also shows the electric wires such as 30 , embedded in the material 27 of the catheter 28 , and individually connecting each electrode 26 to the amplifiers 16 of FIG. 1 . In the example of FIGS. 7 and 9, the electrodes 26 are oval. The electric wires such as 30 in FIG. 9 individually connect each electrode such as 26 with a respective input of the monopolar or differential (depending on the monopolar or differential arrangement of the electrodes 12 or 26 ) amplifiers 16 (FIG. 1 ). Obviously, these electric wires 30 follow the catheter such as 28 from the respective electrodes such as 26 to the corresponding amplifiers 16 ; the electric wires 30 can be embedded in the material such as 27 of the catheter such as 28 or passed separately outside (see for example 45 in FIG. 10) or inside (see for example 46 in FIG. 10) the catheter lumen 47 depending on the intended application. The electric wires such as 30 transmitting the EMG signals collected by the various electrodes such as 26 are necessarily electrically insulated from each other and preferably surrounded by a conductive mesh constituting a shield against external disturbances.
Referring now to FIG. 8, a stud electrode 31 is illustrated. Each stud electrode 31 is mounted in a hole 32 made through the wall of an oesophageal catheter 33 .
The electrodes such as 34 in FIG. 10 can also be applied by means of glue or any other suitable adhesive material or compound, including double adhesive tape.
In the example of FIGS. 10 and 12, a linear array of oval electrodes 34 is mounted on the outer surface 44 of a catheter 36 comprising two longitudinal lumens 47 and 48 . Referring to FIG. 12, each electrode 34 is applied to the catheter surface 44 . As described in the foregoing description, the electric wires (see 45 and 46 ) for individually connecting the electrodes 34 to the amplifiers 16 will extend either inside lumen 47 (see 46 in FIG. 10 ), inside lumen 48 , outside the catheter 36 (see 45 in FIG. 10 ), or embedded in the material of the catheter 36 .
FIG. 11 is a partial perspective view the free end section of an oesophageal catheter 37 , comprising a longitudinal, linear array of button electrodes 38 . FIG. 11 also shows an example of grounding electrode structure (see 25 in FIG. 1 ). In the example of FIG. 11, the grounding electrode structure comprises a helical array of grounding electrodes 39 mounted on the outer surface 40 of the catheter 37 . Of course, the array of grounding electrodes 39 is centered on the longitudinal axis of the catheter 37 and presents the general configuration of a cylindrical helix.
Pressure sensors, pH sensors, thermistors and other detector devices can be added onto the catheter in accordance with the requirements of the intended application.
Referring back to FIG. 1, the group of amplifiers 16 amplifies and band-pass filters each EMG signal. The amplified EMG signals are sampled by a personal computer 19 through respective isolation amplifiers of a unit 18 , to form signal segments of fixed duration. Unit 18 supplies electric power to the various electronic components of the amplifiers 16 and isolation amplifiers while ensuring adequate isolation of the patient's body from such power supply. The unit 18 also incorporates bandpass filters included in the respective EMG signal channels to eliminate the effects of aliasing. The successive EMG signal segments are then digitally processed into the personal computer 19 after analog-to-digital conversion thereof. This analog-to-digital conversion is conveniently carried out by an analog-to-digital converter implemented in the personal computer 19 . The personal computer 19 includes a monitor 40 and a keyboard 41 .
It is believed to be within the capacity of those of ordinary skill in the art to construct suitable amplifiers 16 and an adequate isolation amplifiers and power supply unit 18 . Accordingly, the amplifiers 16 and the unit 18 will not be further described in the present specification.
To eliminate the problems related to motion of the electrode, changes in the pressure applied to the electrode, and/or intermittent contact with surrounding tissue, a motion artifact reducing interface is applied to the electrode surface. The problems listed above can grouped as disturbances; the motion artifact reducing interface may therefore also be referred to as a disturbance reducing interface. The motion artifact reducing interface advantageously consists of a matrix of permeable material comprising, for example, a mesh, foam or other porous material, e.g. a fine filament matrix of nylon. The principle of operation is that the matrix of permeable material creates an interface that hosts ions and electrodes and prevents direct contact between the metal surface of the electrode and the surrounding body tissue. The type of permeable material and thickness thereof is not crucial for performance as long as it forms an ion saturated interface producing no direct contact between the electrode and body tissue. However, excessive thickness may cause increased distance between the electrode and muscle, which will weaken the signal strength and lower the frequency content of this signal.
As illustrated in FIGS. 3-8 and 10 , the matrix of permeable material is applied to the exposed surface of the electrodes where the ion concentration gradients are largest to reduce mechanically-caused movements of ions.
The matrix can be formed by separate single matrices 17 (FIG. 3 ), 29 (FIG. 7) or 42 (FIG. 8) individually applied to or integrated in the exposed surface of each electrode 12 (FIG. 3 ), 26 (FIG. 7) or 31 (FIG. 8 ). For example, each individual matrix 17 , 29 or 42 can be glued on, or adhere to by other means, the outer surface of the catheter to cover the associated electrode. However no adhesive material may cover the electrode surface.
The matrix can also take the form of a continuous matrix 20 (FIGS. 4, 5 and 6 ) or 35 (FIGS. 10 and 12 ). For example, the continuous matrix may form a tube that can be pulled over the catheter to cover the entire span of the array of electrodes 12 (FIG. 4 ), 21 (FIG. 5 ), 22 and 23 (FIG. 6 ), and 34 (FIGS. 10 and 12 ). In the case of a continuous matrix spanning the entire electrode array, the conductivity of the material constituting the matrix, when dry, has to present a conductivity lower than the conductivity of the metal forming the electrodes, whereby electrical conduction is carried out across the matrix, i.e., through the electrolyte. These matrices provide a much more stable voltage with a reduction of the so-called electrode motion induced artifacts on the diaphragm EMG signal.
Also, the matrix can either cover the entire circumference of the catheter (see matrices 20 and 17 of FIGS. 3-6) or a portion of the circumference of the catheter (see matrices 29 , 42 and 35 of FIGS. 7, 8 , 10 and 12 ). Again these matrices can be adhered to the outer surface of the catheter to cover the electrodes; no adhesive material may cover the electrode surface.
Other alternatives (not shown) are (a) to wind or wrap the matrix around the catheter and the electrodes, and (b) to host or embed the electrodes into the matrix.
The electrode structure according to the invention can be applied to measurement of the diaphragm electromyogram (EMG) exclusively or in combination with a device for providing feeding/medication/liquid supply to the patient, and emptying of gastric liquids, common to the treatment of patients in need of ventilatory support. The electrode structure is usable to provide diaphragm EMG signals from a plurality of conductive elements which in turn can be used to:
monitor diaphragm EMG (frequency, amplitude or power);
trigger and control gas flow, gas volume or gas pressure delivered by a mechanical lung ventilator; and
control a closed loop ventilator system that will automatically adjust the level of inspiratory support in proportion to changes in the neuro-ventilatory efficiency such that the neural drive remains stable at a desired target level.
The closed loop ventilator system control can further use the intensity of the diaphragm electromyogram (EMG) obtained immediately before inspiratory flow occurs to quantify pre-inspiratory breathing efforts.
The catheter including the array of electrodes is aimed to be disposed of after a single use; however, when desired, conventional sterilization techniques can be applied in view of re-using the catheter. The catheter can stay in the same patient for extensive periods of time; it is therefore important that the electrodes and matrix be made out of a non-allergen material.
Retrocardiac recording of electrocardiogram and oesophageal peristalsis are other possible applications.
The electrode structure according to the invention is applicable in all patients on ventilatory support and will enhance the possibility of obtaining spontaneous breathing and of optimizing patient ventilator interaction. There exists also a utility for this electrode structure during anaesthesia for monitoring vital fonctions of the patient. The electrode structure can be used in connection with all kinds of ventilator systems in intensive care unit settings or other wards where assisted ventilation is required.
Although the present invention has been described hereinabove with reference to preferred embodiments thereof, these embodiments can be modified at will, within the scope of the appended claims, without departing from the spirit and nature of the subject invention. | A myographic probe for detecting an electrical signal produced by a muscle and for reducing the influence of electrode disturbances. The probe includes electrodes and a disturbance reducing interface covering each electrode thereby segragating the electrodes from the muscle. Electrode disturbances include problems such as those related to the motion of the electrodes, changes in the pressure applied to the electrode, and/or intermittent contact with sourrounding tissue. The disturbance reducing interface is ion permeable and is, when dry, less conductive than the electrodes. The disturbance reducing interface may comprise a matrix of permeable material such as a mesh, foam, or other porous materials. The probe may be in the form of a catheter and be advantageously used in a human cavity such as the oesophagus. Another advantage of the invention is the possibility of using electrodes which are different from conventional wound wire electrodes. | 0 |
RELATED APPLICATIONS
This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Nos. 61/126,862, filed May 7, 2008; 61/054,261, filed May 19, 2008; 61/130,240, filed May 28, 2008; 61/073,219, filed Jun. 17, 2008; 61/081,570, filed Jul. 17, 2008; 61/082,754, filed Jul. 22, 2008; 61/088,918, filed Aug. 14, 2008; 61/091,633, filed Aug. 25, 2008; 61/092,635, filed Aug. 28, 2008; 61/102,068, filed Oct. 2, 2008; 61/109,382, filed Oct. 29, 2008; 61/200,665, filed Dec. 1, 2008; 61/153,442, filed Feb. 18, 2009; 61/163,720 filed, Mar. 26, 2009; 61/053,465, filed May 15, 2008; 61/054,935, filed May 21, 2008; and 61/091,992, filed Aug. 26, 2008, each of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The invention encompasses new polymorphs of lapatinib ditosylate, and processes for preparation thereof.
BACKGROUND OF THE INVENTION
Lapatinib ditosylate, N-[3-chloro-4-[(3-fluorophenyl)methoxy]phenyl]-6-[5-[(2-methylsulfonylethylamino)methyl]-2-furyl]quinazolin-4-amine ditosylate, has the following chemical structure:
Lapatinib ditosylate is currently marketed in the United States under the tradename TYKERB® by GlaxoSmithKline. It was approved by the FDA as a drug for use in patients with advanced metastatic breast cancer.
Lapatinib ditosylate is described in PCT publications WO1999/035146, WO2002/002552, WO2005/046678, WO2006/113649, WO1998/002437, WO2001/004111, WO1996/009294, WO2002/056912, WO2005/105094, WO2005/120504, WO2005/120512, WO2006/026313, and WO2006/066267.
Two polymorphs of lapatinib ditosylate, anhydrous and monohydrate forms are described in U.S. Pat. No. 7,157,466 (WO 2002/002552).
The present invention relates to the solid state physical properties of lapatinib ditosylate. These properties can be influenced by controlling the conditions under which lapatinib ditosylate is obtained in solid form. Solid state physical properties include, for example, the flowability of the milled solid. Flowability affects the ease with which the material is handled during processing into a pharmaceutical product. When particles of the powdered compound do not flow past each other easily, a formulation specialist must take that fact into account in developing a tablet or capsule formulation, which may necessitate the use of glidants such as colloidal silicon dioxide, talc, starch or tribasic calcium phosphate.
Another important solid state property of a pharmaceutical compound is its rate of dissolution in aqueous fluid. The rate of dissolution of an active ingredient in a patient's stomach fluid can have therapeutic consequences since it imposes an upper limit on the rate at which an orally-administered active ingredient can reach the patient's bloodstream. The rate of dissolution is also a consideration in formulating syrups, elixirs and other liquid medicaments. The solid state form of a compound may also affect its behavior on compaction and its storage stability.
These practical physical characteristics are influenced by the conformation and orientation of molecules in the unit cell, which defines a particular polymorphic form of a substance. These conformational and orientation factors in turn result in particular intramolecular interactions such that different polymorphic forms may give rise to distinct spectroscopic properties that may be detectable by powder X-ray diffraction, solid state 13 C NMR spectrometry and infrared spectrometry. A particular polymorphic form may also give rise to thermal behavior different from that of the amorphous material or another polymorphic form. Thermal behavior is measured in the laboratory by such techniques as capillary melting point, thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) and can be used to distinguish some polymorphic forms from others.
The discovery of new polymorphic forms of a pharmaceutically useful compound provides a new opportunity to improve the performance characteristics of a pharmaceutical product. It enlarges the repertoire of materials that a formulation scientist has available for designing, for example, a pharmaceutical dosage form of a drug with a targeted release profile or other desired characteristic. There is a need in the art for additional polymorphic forms of lapatinib ditosylate.
SUMMARY OF THE INVENTION
The present invention encompasses novel solid crystalline forms of lapatinib ditosylate referred to herein as Form I, Form II, Form III, Form IV, Form V, Form VI, Form VII, Form VIII, Form IX, Form XI, Form XII, Form XIII, Form XIV, Form XV, Form XVI, Form XVII, Form XVIII, and Form XIX; processes for preparing thereof, and pharmaceutical compositions containing one or more of these forms.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a powder X-ray diffraction pattern for Form I of lapatinib ditosylate, as obtained in Example 1.
FIG. 2 shows a powder X-ray diffraction pattern for Form I of lapatinib ditosylate, as obtained in Example 9.
FIG. 3 shows a powder X-ray diffraction pattern for Form II of lapatinib ditosylate, as obtained in Example 3, experiment no. 6.
FIG. 4 shows a powder X-ray diffraction pattern for Form II of lapatinib ditosylate, as obtained in Example 3, experiment no. 5.
FIG. 5 shows a powder X-ray diffraction pattern for Form III of lapatinib ditosylate.
FIG. 6 shows a powder X-ray diffraction pattern for Form IV of lapatinib ditosylate.
FIG. 7 shows a powder X-ray diffraction pattern for Form V of lapatinib ditosylate.
FIG. 8 shows a powder X-ray diffraction pattern for Form VI of lapatinib ditosylate, as obtained in Example 3.
FIG. 9 shows a powder X-ray diffraction pattern for Form VI of lapatinib ditosylate, as obtained in Example 63.
FIG. 10 shows a powder X-ray diffraction pattern for Form VI of lapatinib ditosylate, as obtained in Example 74.
FIG. 11 shows a powder X-ray diffraction pattern for Form VI of lapatinib ditosylate, as obtained in Example 79.
FIG. 12 shows a powder X-ray diffraction pattern for Form VII of lapatinib ditosylate, as obtained in Example 4.
FIG. 13 shows a powder X-ray diffraction pattern for Form VII of lapatinib ditosylate, as obtained in Example 15.
FIG. 14 shows a powder X-ray diffraction pattern for Form VIII of lapatinib ditosylate, as obtained in Example 3
FIG. 15 shows a powder X-ray diffraction pattern for Form VIII of lapatinib ditosylate, as obtained in Example 71.
FIG. 16 shows a powder X-ray diffraction pattern for Form VIII of lapatinib ditosylate, as obtained in Example 77.
FIG. 17 shows a powder X-ray diffraction pattern for Form IX of lapatinib ditosylate.
FIG. 18 shows a powder X-ray diffraction pattern for Form XI of lapatinib ditosylate, as obtained in Example 11.
FIG. 19 shows a powder X-ray diffraction pattern for Form XI of lapatinib ditosylate, as obtained in Example 12.
FIG. 20 shows a powder X-ray diffraction pattern for Form XI of lapatinib ditosylate, as obtained in Example 14.
FIG. 21 shows a powder X-ray diffraction pattern for Form XII of lapatinib ditosylate.
FIG. 22 shows a powder X-ray diffraction pattern for Form XIII of lapatinib ditosylate.
FIG. 23 shows a powder X-ray diffraction pattern for Form XIII of lapatinib ditosylate, as obtained in Example 76.
FIG. 24 shows a powder X-ray diffraction pattern for Form XIII of lapatinib ditosylate, as obtained in Example 78.
FIG. 25 shows a powder X-ray diffraction pattern for Form XIV of lapatinib ditosylate.
FIG. 26 shows a powder X-ray diffraction pattern for Form XIX of lapatinib ditosylate.
FIG. 27 shows a powder X-ray diffraction pattern for Form XVI of lapatinib ditosylate.
FIG. 28 shows a powder X-ray diffraction pattern for Form XVII of lapatinib ditosylate, as obtained in Example 82.
FIG. 29 shows a powder X-ray diffraction pattern for Form XVII of lapatinib ditosylate, as obtained in Example 83.
FIG. 30 shows a powder X-ray diffraction pattern for Form XV of lapatinib ditosylate, as obtained in Example 86.
FIG. 31 shows a powder X-ray diffraction pattern for Form XIX of lapatinib ditosylate, as obtained in Example 87.
FIG. 32 shows a powder X-ray diffraction pattern for Form XV of lapatinib ditosylate.
FIG. 33 shows a powder X-ray diffraction pattern for Form XVIII of lapatinib ditosylate.
FIG. 34 shows a powder X-ray diffraction pattern for Form XVIII of lapatinib ditosylate, as obtained in Example 92.
FIG. 35 shows a solid-state 13 C NMR spectrum of lapatinib ditosylate Form I in the 0-200 ppm range.
FIG. 36 shows a solid-state 13 C NMR spectrum of lapatinib ditosylate Form I in the 100-200 ppm range.
FIG. 37 shows a solid-state 13 C NMR spectrum of lapatinib ditosylate Form XIII in the 0-200 ppm range.
FIG. 38 shows a solid-state 13 C NMR spectrum of lapatinib ditosylate Form XIII in the 100-200 ppm range.
FIG. 39 shows a solid-state 13 C NMR spectrum of lapatinib ditosylate Form XV in the 0-200 ppm range.
FIG. 40 shows a solid-state 13 C NMR spectrum of lapatinib ditosylate Form XV in the 100-200 ppm range.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the term “lapatinib ditosylate” includes any solid state composition of lapatinib base and p-toluenesulfonic acid. For example: a salt, a co-crystal, or a solid mixture of base and acid.
As used herein, the terms “slurry”, or “suspension” refer to a mixture of suspended solids in liquid (solvent). Typically, the solvent is used in an amount that does not result in the full dissolution of the substance.
As used herein, the term “neat condition” refers to a reaction which is carried out without the presence of a solvent.
As used herein, a “wet crystalline form” refers to a polymorph that was not dried using any conventional techniques.
As used herein, a “dry crystalline form” refers to a polymorph that was dried using any conventional techniques.
As used herein, drying is carried out at elevated temperature under reduced pressure. Preferably, the crystalline form is dried at about 40° C. to about 90° C., more preferably, between about 60° C. and about 70° C., and, most preferably, about 60° C. Preferably the drying is carried out under reduced pressure (for example less than 1 atmosphere, more preferably, about 10 mbar to about 100 mbar, more preferably, about 10 mbar to about 25 mbar). Preferably the drying takes place over a period of about 8 hours to about 36 hours, more preferably, about 10 hours to about 24 hours, and, most preferably, about 12 hours.
As used herein, the term “overnight” refers to a period of about 12 hours to about 24 hours.
As used herein, an antisolvent is a liquid that when added to a solution of a solute in a solvent, induces, enhances or facilitates precipitation of the solute. Precipitation of lapatinib ditosylate (also referred to as “lapatinib-DTS”), for example, may be induced by an antisolvent when addition of the antisolvent causes lapatinib ditosylate to precipitate from the solution, or to precipitate more rapidly, or to precipitate to a greater extent than lapatinib ditosylate would precipitate out of the solvent without the antisolvent. As used herein, the term volume (“V”) refers to ml per gram. For example, 30 V means 30 ml solvent per one gram of compound.
As used herein, the term “room temperature” refers to a temperature of about 20° C. to about 30° C.
As used herein, lapatinib base Form X refers to a crystalline lapatinib base characterized by a data selected from the group consisting of: a PXRD pattern having peaks at about 20.0, 21.3, 24.0, 24.6 and 27.0±0.2 degrees 2-theta; and a PXRD pattern having peaks at about 6.8, 11.4, 16.0, 16.9, 18.0, 20.0, 21.3, 24.0, 24.6 and 27.0±0.2 degrees 2-theta. Lapatinib base Form X can be obtained using any method known in the art, for example, by forming a slurry of lapatinib ditosylate and acetonitrile; and adding an inorganic base to obtain Lapatinib base Form X.
Unless stated otherwise, wherever p-toluenesulfonic acid is used, at least two equivalents of the acid are added, more preferably about 2-4 equivalents, even more preferably about 2-3 equivalents, and most preferably about 2-2.5 equivalents are added.
The present invention relates to novel solid crystalline forms of lapatinib ditosylate referred to herein as Form I, Form II, Form III, Form IV, Form V, Form VI, Form VII, Form VIII, Form IX, Form XI, Form XII, Form XIII, Form XIV, Form XVI, Form XVII, Form XVIII, and Form XIX.
In one embodiment, the invention encompasses Form I of lapatinib ditosylate characterized by data selected from the group consisting of a PXRD pattern having peaks at about 4.4, 20.0, and 21.5±0.2 degrees 2-theta, and at least two peaks selected from the group consisting of 10.2, 18.1, 24.0, 24.6, 26.0 and 27.1±0.2 degrees 2-theta; a solid state 13 C NMR spectrum with signals at about 110.2, 127.1 and 137.4±0.2 ppm; and a solid-state 13 C NMR spectrum having chemical shifts differences between the signal exhibiting the lowest chemical shift and another in the chemical shift range of 100 to 180 ppm of about 0.0, 16.9 and 27.2±0.1 ppm, wherein the signal exhibiting the lowest chemical shift in the chemical shift area of 100 to 180 ppm is typically at about 110.2±1 ppm.
Preferably, the peaks at about 4.8 or at about 6.6±0.2 degrees two-theta are absent wherein the analysis is done at a scan rate slow enough, according to the common knowledge of the skilled in the art. The scan rate used may vary from instrument to instrument, and sample preparation.
In another embodiment, the present invention encompasses Form I of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIGS. 1-2 .
In another embodiment, the present invention encompasses Form I of lapatinib ditosylate as characterized by a solid state 13 C NMR spectrum illustrated in FIGS. 33 and 34 .
In another embodiment, the invention encompasses crystalline Form II of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 8.5, 12.8, and 15.1±0.2 degrees 2-theta, and at least two peaks selected from the group consisting of 4.3, 19.4, 19.8, 21.5, and 30.5±0.2 degrees 2-theta.
In another embodiment, the present invention encompasses crystalline Form II of lapatinib ditosylate as characterized by PXRD patterns illustrated in FIGS. 3-4 .
In another embodiment, the invention encompasses crystalline Form III of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 4.7, 14.2, and 15.3±0.2 degrees 2-theta, and at least two peaks selected from the group consisting of 3.8, 7.6, 19.2, 19.7, and 23.1±0.2 degrees 2-theta.
In another embodiment, the present invention encompasses crystalline Form III of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 5 .
In another embodiment, the invention encompasses crystalline Form IV of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 8.6, 11.7, and 13.4±0.2 degrees 2-theta, and at least two peaks selected from the group consisting of 4.6, 15.3, 15.6, 18.9, 19.5, 22.4, and 23.5±0.2 degrees 2-theta.
In another embodiment, the present invention encompasses crystalline Form IV of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 6 .
In another embodiment, the invention encompasses crystalline Form V of lapatinib ditosylate characterized by data selected from the group consisting of: a PXRD pattern having peaks at about 12.8, 15.5, and 18.5±0.2 degrees 2-theta, and at least two peaks selected from the group consisting of 4.2, 8.7, 20.5, 21.4, 26.4 and 30.0±0.2 degrees 2-theta; a PXRD pattern having peaks at about 4.3, 5.7, 6.5, 8.6 and 16.6±0.2 degrees 2-theta; and a PXRD pattern having peaks at about 4.3, 5.7, 6.5, 8.6, 15.6, 16.6, 18.5, 20.2, 21.0 and 23.1+0.2 degrees 2-theta.
In another embodiment, the present invention encompasses crystalline Form V of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 7 .
In another embodiment, the invention encompasses crystalline Form VI of lapatinib ditosylate characterized by data selected from the group consisting of: a PXRD pattern having peaks at about 5.6, 6.5, and 17.2±0.2 degrees 2-theta, and at least two peaks selected from the group consisting of 4.3, 8.6, 15.5, 16.5, 21.0, 23.1, 27.6 and 28.8±0.2 degrees 2-theta; a PXRD pattern having peaks at about 4.3, 5.7, 6.5, 8.6 and 16.6±0.2 degrees 2-theta; and a PXRD pattern having peaks at about 4.3, 5.7, 6.5, 8.6, 15.6, 16.6, 18.5, 20.2, 21.0 and 23.1±0.2 degrees 2-theta.
In another embodiment, the invention encompasses crystalline Form VI of Lapatinib ditosylate characterized by a PXRD pattern having peaks at about 4.3, 5.7, 6.5, 8.6 and 16.6±0.2 degrees 2-theta.
In another embodiment, the invention encompasses crystalline Form VI of Lapatinib ditosylate characterized by a PXRD pattern having peaks at about 4.3, 5.7, 6.5, 8.6, 15.6, 16.6, 18.5, 20.2, 21.0 and 23.1±0.2 degrees 2-theta.
In another embodiment, the present invention encompasses crystalline Form VI of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 11 .
In another embodiment, the invention encompasses crystalline Form VII of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 15.3, 19.0, and 25.2±0.2 degrees 2-theta, and at least two peaks selected from the group consisting of 20.0, 21.5, 23.0, 24.6 and 29.0±0.2 degrees 2-theta.
In another embodiment, the invention encompasses crystalline Form VII of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 15.3, 19.0, and 25.2±0.2 degrees 2-theta, and at least two peaks selected from the group consisting of 20.0, 21.5, 23.0, 24.6 and 29.0±0.2 degrees 2-theta, wherein the crystalline form is substantially free of a peak at about 4.8, or at about 6.6±0.2 degrees two-theta.
In one embodiment, the present invention encompasses crystalline Form VII of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIGS. 12-13 .
Preferably, the peaks at about 4.8 or at about 6.6±0.2 degrees two-theta are absent wherein the analysis is done at a scan rate slow enough, according to the common knowledge of the skilled in the art. The scan rate used may vary from instrument to instrument, and sample preparation.
In another embodiment, the invention encompasses crystalline Form VIII of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 8.8, 15.1 and 16.1±0.2 degrees 2-theta, and at least two peaks selected from the group consisting of 5.5, 6.5, 16.6, 18.1, 21.9, and 27.1±0.2 degrees 2-theta.
In another embodiment, the present invention encompasses crystalline Form VIII of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 14 .
In another embodiment, the invention encompasses Form IX of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 4.1, 5.4, and 8.1±0.3 degrees 2-theta, and at least two peaks selected from the group consisting of 16.2, 18.0, 19.7 and 22.7+0.2 degrees 2-theta.
In one embodiment, the present invention encompasses Form IX of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 17 .
In another embodiment, the invention encompasses Form XI of lapatinib ditosylate characterized by a PXRD pattern with broad peaks with a maxima at about 4.1 to about 4.3 and a maxima at about 19.0 to about 19.2, and two additional very broad peaks defined by angle ranges of about 21.5 to about 24.5, and about 24.5 to about 27.0 in degrees 2-theta. Preferably, Form XI is substantially amorphous.
In one embodiment, the present invention encompasses Form XI of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIGS. 18-20 .
In another embodiment, the invention encompasses Form XII of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 5.4, 18.3, 19.1, 24.7, and 25.8±0.3 degrees 2-theta. Preferably, Form XII is substantially amorphous.
In another embodiment, the present invention encompasses Form XII of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 21 .
In another embodiment, the invention encompasses crystalline Form XIII of lapatinib ditosylate characterized by data selected from the group consisting of a PXRD pattern having peaks at about 5.9, 6.8, and 8.9±0.2 degrees 2-theta, and at least two peaks from the following list: 12.2, 13.5, 16.0, 18.7 and 22.9±0.2 degrees 2-theta; a PXRD pattern having peaks at about 5.9, 6.8, 8.9, 12.2 and 13.6±0.2 degrees 2-theta; a PXRD pattern having peaks at about 5.9, 6.8, 8.9, 12.2, 13.6, 14.6, 16.0, 19.0, 20.4 and 22.9±0.2 degrees 2-theta; a solid-state 13 C NMR spectrum with signals at about 125.1, 129.6 and 150.7±0.2 ppm; a solid-state 13 C NMR spectrum having chemical shifts differences between the signal exhibiting the lowest chemical shift and another in the chemical shift range of 100 to 180 ppm of about 17.2, 21.7 and 42.8±0.1 ppm, wherein the signal exhibiting the lowest chemical shift in the chemical shift area of 100 to 180 ppm is typically at about 107.9+1 ppm.
In another embodiment, the present invention encompasses crystalline Form XIII of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 23 .
In another embodiment, the present invention encompasses crystalline Form XIII of lapatinib ditosylate as characterized by a solid-state 13 C NMR spectrum illustrated in FIGS. 35 , and 36 .
In another embodiment, the invention encompasses crystalline Form XIV of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 6.0, 16.9, and 17.5±0.2 degrees 2-theta, and at least two peaks from the following list: 18.7, 19.6, 21.5, 23.3 and 24.0±0.2 degrees 2-theta.
In another embodiment, the present invention encompasses crystalline Form XIV of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 25 .
In another embodiment, the invention encompasses crystalline Form XV of lapatinib ditosylate characterized by data selected from the group consisting of: a PXRD pattern having peaks at about 6.2, 7.0, 8.9, 12.9, and 16.1+0.2 degrees 2-theta; a PXRD pattern having peaks at about 6.2, 7.0, 8.9, 12.9, 16.1, 17.0, 18.9, 19.9, 23.7 and 26.0; a solid-state 13 C NMR spectrum with signals at about 125.1, 128.3 and 137.1+0.2 ppm; and a solid-state 13 C NMR spectrum having chemical shifts differences between the signal exhibiting the lowest chemical shift and another in the chemical shift range of 100 to 180 ppm of about 17.2, 20.3 and 29.2±0.1 ppm, wherein the signal exhibiting the lowest chemical shift in the chemical shift area of 110 to 180 ppm is typically at about 107.9±1 ppm.
In another embodiment, the present invention encompasses crystalline Form XV of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 32 .
In another embodiment, the present invention encompasses crystalline Form XV of lapatinib ditosylate as characterized by a solid-state 13 C NMR spectrum illustrated in FIGS. 39 , and 40 .
The crystalline form of lapatinib ditosylate, Form XV, is also substantially free of any other polymorphic forms. By “substantially free” is meant 20% (w/w) or less, preferably 10% (w/w) or less, more preferably 5% (w/w) or less, most preferably 2% (w/w) or less, particularly 1% (w/w) or less, more particularly 0.5% (w/w) or less, and most particularly 0.2% (w/w) or less.
In another embodiment, the invention encompasses Form XVI of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 5.3, and 6.3±0.2 degrees 2-theta, and at least three peaks selected from the group consisting of 8.5, 17.0, 18.4, 21.2 and 25.0±0.2 degrees 2-theta.
In another embodiment, the present invention encompasses Form XVI of lapatinib ditosylate as characterized by PXRD patterns illustrated in FIG. 27 .
In another embodiment, the invention encompasses Form XVII of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 3.3, 4.8, and 7.9±0.2 degrees 2-theta, and a broad peak with maximum at about 22.7 degrees 2-theta.
In another embodiment, the present invention encompasses Form XVII of lapatinib ditosylate as characterized by PXRD patterns illustrated in FIGS. 28 and 29 .
In another embodiment, the invention encompasses crystalline Form XVIII of lapatinib ditosylate characterized by a PXRD pattern having peaks at about 5.6, 13.1, 16.0, 16.9 and 23.6±0.2 degrees 2-theta. Form XVIII is further characterized by a PXRD pattern having peaks at about 5.6, 7.4, 13.1, 14.7, 15.2, 16.0, 16.9, 19.8, 20.4 and 23.6±0.2 degrees 2-theta.
In another embodiment, the present invention encompasses crystalline Form XVIII of lapatinib ditosylate as characterized by PXRD patterns illustrated in FIG. 33 .
In another embodiment, the invention encompasses crystalline Form XIX of lapatinib ditosylate characterized by data selected from the group consisting of: a PXRD pattern having peaks at about 6.3, 7.1, and 9.0±0.2 degrees 2-theta, and at least two peaks from the following list: 17.5, 19.0, 20.0, 22.5 and 26.0±0.2 degrees 2-theta; a PXRD pattern having peaks at about 6.3, 7.1, 9.0, 17.5, 19.0, and 22.5±0.2 degrees 2-theta; a PXRD pattern having peaks at about 6.3, 7.1, 9.0, 17.5, 18.5, 19.0, 19.4, 20.0, 22.5, and 26.0±0.2 degrees 2-theta.
In another embodiment, the present invention encompasses crystalline Form XIX of lapatinib ditosylate as characterized by a PXRD pattern illustrated in FIG. 26 .
In one embodiment, the present invention encompasses a process for preparing Form I of lapatinib ditosylate comprising combining lapatinib base, preferably Form X, with p-toluenesulfonic acid (PTSA) under neat conditions to obtain Form I of lapatinib ditosylate.
The mixture is preferably maintained at a temperature of about 0° C. to about 60° C., more preferably about room temperature to about 40° C., most preferably about room temperature, preferably for about 16 hours to about 66 hours, more preferably about 16 hours to about 24 hours, and most preferably about 16 hours. Recovering the product may be carried out by any known method such as filtration.
In another embodiment, the invention encompasses another process for preparing Form I of lapatinib ditosylate comprising combining lapatinib base, p-toluenesulfonic acid, and a solvent selected from the group consisting of heptane and hexane to form a slurry; recovering the obtained precipitate.
The slurry is preferably maintained at about room temperature to about 40° C., most preferably about room temperature, preferably for about 2 hours to about 66 hours, more preferably about 16 hours to about 24 hours, and most preferably about 16 hours. Recovering the product may be carried out by any known method such as filtration.
The obtained precipitate may be further heated to about 40° C. to about 70° C., under reduced pressure.
In another embodiment, the invention encompasses a process for preparing Form iI of lapatinib ditosylate comprising forming a solution of lapatinib ditosylate with an organic solvent selected from the group consisting of dimethylacetamide (DMA), and dimethylformamide (DMF); adding an antisolvent selected from the group consisting of toluene, methyl-tert butyl ether (MTBE), and heptane; and recovering of the crystalline form.
In one specific embodiment, the pair of solvents and antisolvents can be selected from the group consisting of: DMA/toluene, DMA/MTBE, DMA/heptane, and DMF/toluene.
The mixture is preferably maintained at a temperature of about 0° C. to about 60° C., more preferably about 20° C. to about 40° C., even more preferably, about 20° C. to about 30° C., most preferably about 25° C., preferably, for about 1 hour to about 18 hours, more preferably about 1 hour to about 6 hours. Recovering the product may be carried out by any known method such as filtration.
Preferably, lapatinib ditosylate is prepared in situ comprising combining lapatinib base and p-toluenesulfonic acid.
In another embodiment, the present invention encompasses another process for preparing Form iI of lapatinib ditosylate comprising combining lapatinib ditosylate with dimethylformamide to form a slurry; and recovering the crystalline form.
Typically, the mixture is maintained at a temperature of about room temperature, preferably for about 30 minutes to about 24 hours, more preferably for about 30 minutes to about 12 hours, even more preferably for about 30 minutes to about 6 hours, and most preferably for about 2 hours.
In another embodiment, the invention encompasses a process for preparing Form III of lapatinib ditosylate comprising forming a solution of lapatinib ditosylate and dimethylformamide; adding an antisolvent selected from the group consisting of acetone, and tetrahydrofuran (THF); and recovering the precipitate.
The mixture is preferably maintained at a temperature of about 0° C. to about 65° C., more preferably about 20° C. to about 40° C., even more preferably about 20° C. to about 30° C., preferably, for about 1 hour to about 18 hours, and more preferably for about 1 hour to about 6 hours. Recovering the product may be carried out by any known method such as filtration.
Preferably, lapatinib ditosylate is prepared in situ comprising combining lapatinib base and p-toluenesulfonic acid.
In another embodiment, the invention encompasses a process for preparing Form IV of lapatinib ditosylate comprising forming a solution of lapatinib ditosylate and dimethylformamide; adding acetonitrile; and recovering the product.
The mixture is preferably maintained at a temperature of about 0° C. to about 90° C., more preferably about 20° C. to about 50° C., even more preferably about 20° C. to about 30° C., preferably, for about 1 hour to about 18 hours, more preferably for about 1 hour to about 6 hours. Recovering the product may be carried out by any known method such as filtration.
Preferably, lapatinib ditosylate is prepared in situ comprising combining lapatinib base and p-toluenesulfonic acid.
In another embodiment, the invention encompasses a process for preparing Form V of lapatinib ditosylate comprising forming a solution of lapatinib ditosylate and an organic solvent selected from the group consisting of N-methylpyrrolidone (NMP), and DMF; adding an antisolvent selected from the group consisting of hexane, acetone, tetrahydrofuran, acetonitrile, isopropanol (IPA), and methyl-tert butyl ether; and recovering the product. The pair of solvents and antisolvents can be selected from the group consisting of: N-methylpyrrolidone/hexane, N-methylpyrrolidone/isopropanol, N-methylpyrrolidone/acetone, N-methylpyrrolidone/tetrahydrofuran, N-methylpyrrolidone/MTBE, and N-methylpyrrolidone/acetonitrile.
Preferably, lapatinib ditosylate is prepared in situ comprising combining lapatinib base and p-toluenesulfonic acid.
The mixture is preferably maintained at a temperature of about 0° C. to about 60° C., more preferably about 20° C. to about 40° C., even more preferably about 20° C. to about 30° C. for about 1 hour to about 18 hours. Recovering the product may be carried out by any known method such as filtration.
In another embodiment, the present invention encompasses another process for preparing Form V of lapatinib ditosylate comprising combining lapatinib ditosylate with N-methylpyrrolidone to form a slurry; and recovering the precipitate.
Typically, the mixture is maintained at a temperature of about 0° C. to about 90° C., more preferably about 20° C. to about 50° C., even more preferably about 20° C., to about 30° C., preferably for about an hour to about 6 hours, more preferably for about 30 minutes to about 24 hours, more preferably for about 30 minutes to about 12 hours, even more preferably for about 30 minutes to about 6 hours, and most preferably for about 2 hours.
In another embodiment, the present invention encompasses a process for preparing Form VI of lapatinib ditosylate comprising forming a solution of lapatinib ditosylate in dimethylformamide; and precipitating Form VI. Precipitation can be carried out comprising: cooling the solution, or concentrating the solution, or by seeding with lapatinib ditosylate Form VI, or by adding an antisolvent selected from the group consisting of MTBE, hexane, and heptane.
In one specific example, lapatinib ditosylate is prepared in situ comprising dissolving lapatinib base and p-toluenesulfonic acid in dimethylformamide.
Preferably, the solution of lapatinib base in dimethylformamide is heated to about 40° C. to about 60° C., more preferably to about 40° C., prior to the addition of the acid. When cooling is applied in order to induce precipitation, preferably, the obtained mixture is cooled to about −10° C. to about 25° C., more preferably to about −10° C. to about 15° C., and most preferably to about 0° C. to about 10° C.
The obtained Form VI can be further recrystallized comprising forming a slurry of the obtained Form VI of lapatinib ditosylate in dimethylformamide. Slurrying the obtained Form VI results with higher chemichal purity of the lapatinib ditosylate Form VI. Preferably, the chemichal purity of the lapatinib ditosylate Form VI before slurrying in dimethylformamide is at least 98%. Preferably, the chemichal purity of the lapatinib ditosylate Form VI after slurrying in dimethylformamide is at least 99%.
Form VI can be further dried to obtain Form XV of lapatinib ditosylate. Preferably, Form VI is dried at a temperature of about 40° C. to about 90° C., more preferably, at about 60° C. to about 70° C., and most preferably about 60° C., preferably under reduced pressure. Preferably the drying is carried out, more preferably, for about 12 hours to about 20 hours, and, most preferably, for 12 hours.
The mixture is preferably maintained at a temperature of about 0° C. to about 60° C., more preferably about 20° C. to about 40° C., even more preferably about 20° C. to about 30° C. for about 2 hours to about 16 hours, preferably about 2 hours to about 7 hours. Recovering the product may be carried out by any known method such as filtration.
In another embodiment, the present invention encompasses a process for preparing Form VII of lapatinib ditosylate comprising drying Form XI of lapatinib ditosylate, preferably under reduced pressure, or drying Form I of lapatinib ditosylate, preferably, under reduced pressure.
Preferably, drying is carried out at a temperature of about 40° C. to about 80° C., more preferably 40° C. to about 70° C., and most preferably about 40° C. to about 60° C., preferably, for about 8 hours to about 36 hours, more preferably for about 10 hours to about 20 hours, and most preferably for about 12 hours.
In another embodiment, the present invention encompasses a process for preparing Form VII of lapatinib ditosylate comprising combining lapatinib base, preferably Form X, with p-Toluenesulfonic acid in the presence of organic solvent selected from the group consisting of heptane, and methyl tert butyl ether to form a slurry; and drying the obtained precipitate to obtain Form VII of lapatinib ditosylate.
The mixture is preferably maintained at a temperature of about 0° C. to about 60° C., more preferably about 20° C. to about 40° C., even more preferably about 20° C. to about 30° C., preferably, for about 30 minutes to about 24 hours, more preferably for about 30 minutes to about 12 hours, even more preferably for about 30 minutes to about 6 hours, and most preferably for about 2 hours. Recovering the product may be carried out by any known method such as filtration.
Preferably, the obtained Form VII is dried at a temperature of about 40° C. to about 60° C., more preferably for about 40° C. to about 50° C., preferably for about 8 hours to about 36 hours, more preferably, for about 10 hours to about 20 hours, and most preferably for about 12 hours.
In another embodiment, the present invention encompasses a process for preparing Form VIII of lapatinib ditosylate comprising forming a solution of lapatinib base in DMA; adding p-toluenesulfonic acid; and recovering the obtained precipitate.
Preferably, lapatinib ditosylate is prepared in situ comprising combining lapatinib base and p-toluenesulfonic acid.
Preferably, the solution of lapatinib base in DMA is heated to about 40° C. to about 60° C., more preferably to about 40° C., prior to the addition of the acid. Preferably, after the addition of the acid, the obtained mixture is cooled to about −10° C. to about 25° C., more preferably to about −10° C. to about 15° C., and most preferably to about 0° C. to about 10° C.
Form VIII can be further dried to obtain Form XIII of lapatinib ditosylate. Preferably, Form VIII is dried at a temperature of about 60° C. to about 90° C., more preferably about 70° C. to about 90° C., preferably under reduced pressure. Preferably the drying is carried out overnight, more preferably, for about 12 hours to about 20 hours, and, most preferably, for 12 hours.
In another embodiment, the invention encompasses a process for preparing Form VIII of lapatinib ditosylate comprising forming a solution of lapatinib ditosylate and dimethylacetamide; adding hexane; and recovering the product.
The mixture is preferably maintained at a temperature of about 0° C. to about 70° C., more preferably about 20° C. to about 50° C., and most preferably about 20° C. to about 30° C., preferably, for about 1 hour to about 18 hours, more preferably, for about an hour to about 6 hours. Recovering the product may be carried out by any known method such as filtration.
Preferably, lapatinib ditosylate is prepared in situ comprising combining lapatinib base and p-toluenesulfonic acid.
In another embodiment, the present invention encompasses a process for preparing Form IX of lapatinib ditosylate comprising combining lapatinib base, preferably, lapatinib base Form X, with p-toluenesulfonic acid in the presence of diethyl ether; and drying the obtained precipitate to obtain Form IX of lapatinib ditosylate.
The mixture is preferably maintained at a temperature of about 0° C. to about 35° C., more preferably about 20° C. to about 30° C., and most preferably about 25° C., preferably, for about 1 hour to about 18 hours. Recovering the product may be carried out by any known method such as filtration.
Preferably, the obtained Form IX is dried at a temperature of about 30° C. to about 60° C., more preferably 40° C. to about 60° C., and most preferably about 40° C. to about 50° C., preferably for about 8 hours to about 36 hours, more preferably, for about 10 hours to about 20 hours, and most preferably for about 12 hours.
In another embodiment, the present invention encompasses a process for preparing Form XI of lapatinib ditosylate comprising melting lapatinib ditosylate by heating; and cooling the lapatinib ditosylate to obtain Form XI.
Preferably, the lapatinib is heated to about 100° C. to about 120° C. for about 0.5 hour. Preferably, the lapatinib ditosylate is cooled to about room temperature.
In another embodiment, the present invention encompasses a process for preparing Form XI of lapatinib ditosylate comprising grinding lapatinib ditosylate, preferably lapatinib ditosylate Form I, in the presence of a solvent (about one drop) selected from the group consisting of ethanol, and isopropanol.
The term “grinding” broadly refers to crushing a compound, typically using a mortar and pestle.
In another embodiment, the present invention encompasses a process for preparing Form XI of lapatinib ditosylate comprising dissolving lapatinib ditosylate in dimethyl sulfoxide; and removing the solvent by lyophilization.
Preferably, lapatinib ditosylate is prepared in situ comprising combining lapatinib base and p-toluenesulfonic acid.
Typically, lyophilization is done by a process comprising cooling the solution to obtain a cooled mixture, and evaporating the solvent while maintaining the mixture cooled at low temperature.
Preferably, the solution is cooled to a temperature of about −30° C. to about −40° C., providing the cooled mixture, which is a frozen mass.
Typically, the frozen mass is then subjected to a pressure of less than about one atmosphere, to remove the solvent.
In another embodiment, the present invention encompasses another process for Form XI of lapatinib ditosylate comprising forming a slurry of lapatinib base, PTSA, and methyl tert butyl ether; and recovering Form XI of lapatinib ditosylate.
Typically, the mixture is maintained at about 0° C. to about 60° C., more preferably about 20° C. to about 40° C., and most preferably about 20° C. to about 30° C., preferably, for about 30 minutes to about 24 hours, more preferably for about 30 minutes to about 12 hours, even more preferably for about 30 minutes to about 6 hours, and most preferably for about 2 hours.
In another embodiment, the present invention encompasses a process for preparing Form XII of lapatinib ditosylate comprising grinding Form I of lapatinib ditosylate in the presence of water (about one drop).
The precipitate is preferably dried at the elevated temperature for about 16 hours.
In another embodiment, the invention encompasses a process for preparing Form XIII of lapatinib ditosylate comprising forming a solution of lapatinib ditosylate, and dimethylacetamide; adding hexane; and drying the obtained precipitate to obtain Form XIII.
Optionally, lapatinib ditosylate can be prepared in situ comprising combining lapatinib base, and p-toluenesulfonic acid in DMA.
The mixture is preferably maintained at a temperature of about 0° C. to about 70° C., more preferably about 20° C. to about 40° C., and most preferably about 20° C. to about 30° C. for about 2 hours to about 72 hours, more preferably about 2 hours to about 48 hours, and most preferably about 2 hour to about 5 hours. The precipitate is dried at a temperature of about 40° C. to about 90° C., more preferably about 50° C. to about 80° C., even more preferably about 50° C. to about 70° C., and most preferably about 60° C., preferably, for about 10 hours to about 96 hours, more preferably about 10 hours to about 72 hours, and most preferably about 10 hours to about 24 hours to obtain Form XIII.
In another embodiment, the invention encompasses a process for preparing Form XIII of lapatinib ditosylate comprising drying lapatinib ditosylate Form VIII, or lapatinib ditosylate Form VI.
Preferably, Form VIII, or Form VI are dried at a temperature of about 40° C. to about 90° C., more preferably about 40° C. to about 60° C., for about 10 hours to about 96 hours, more preferably about 10 hours to about 72 hours, and most preferably about 30 hours to about 40 hours.
In another embodiment, the invention encompasses a process for preparing Form XIV comprising dissolving lapatinib ditosylate in DMA; adding methanol; and drying the obtained precipitate.
Optionally, lapatinib ditosylate can be prepared in situ comprising combining lapatinib base, preferably Form X, and p-toluenesulfonic acid.
The mixture is preferably maintained at a temperature of about 0° C. to about 70° C., more preferably about 20° C. to about 50° C., and most preferably about 20° C. to about 30° C. for about 1 hour to about 18 hours. Recovering the product may be carried out by any known method such as filtration.
In another embodiment, the invention encompasses a process for preparing lapatinib ditosylate Form XV comprising forming a solution of lapatinib ditosylate in dimethylformamide; adding heptane; and drying the obtained precipitate to obtain Form XV. In one embodiment, the addition of heptane results in a suspension of crystalline lapatinib ditosylate Form VI, and drying the crystalline lapatinib ditosylate Form VI results in crystalline lapatinib ditosylate Form XV. The present invention therefore also encompasses a process for preparing Form XV of lapatinib ditosylate comprising drying Form VI of lapatinib ditosylate. Preferably, after addition of heptane, the obtained suspension is stirred for a suitable period of time to facilate production of lapatinib ditosylate Form XV. The stirring time suitable for production of lapatinib ditosylate Form XV can be determined by a person skilled in the art using routine experimentation. In a preferred embodiment, the suspension is stirred for a period from about 4 hours to about 12 hours, more preferably from about 4 hours to about 8 hours, and most preferably about 5 hours. Preferably, the suspension is stirred at room temperature. Preferably, the drying is carried out at a temperature of about 40° C. to about 90° C., more preferably about 50° C. to about 80° C., even more preferably about 50° C. to about 70° C., and most preferably at about 50° C. under reduced pressure (less than 1 atmosphere).
Optionally, lapatinib ditosylate can be prepared in situ by combining lapatinib base and p-toluenesulfonic acid in dimethylformamide.
The obtained mixture is preferably maintained at about room temperature, preferably for about 2 hours to about 8 hours, more preferably for about 5 hours to about 6 hours.
In another embodiment, the present invention encompasses a process for preparing Form XVI of lapatinib ditosylate comprising forming a suspension of lapatinib base Form X and p-toluenesulfonic acid with methyl isobutyl ketone; and recovering the crystalline form.
The suspension may be stirred at about room temperature for about 20 hours.
In another embodiment, the present invention encompasses a process for preparing Form XVII of lapatinib ditosylate comprising drying lapatinib ditosylate Form XVI.
Preferably, the drying is carried out at elevated temperature, preferably under reduced pressure (less than about 1 atmosphere). Typically, Form XVI is dried at a temperature of about 40° C. for about 120 hours.
In another embodiment, the present invention encompasses a process for preparing Form XVIII of lapatinib ditosylate comprising slurrying lapatinib ditosylate in dimethylformamide; adding tetrahydrofuran; and adding heptane to obtain Form XVIII.
Preferably, the obtained slurry is maintained at about 0° C. to about 70° C., more preferably about 20° C. to about 50° C., and most preferably about 20° C. to about 30° C., preferably for about 10 hours to about 20 hours, more preferably for about 14 hours to about 20 hours, and most preferably for about 16 hours.
In another embodiment, the present invention encompasses a process for preparing Form XIX of lapatinib ditosylate comprising drying Form VI of lapatinib ditosylate at a temperature of about 40° C. to about 90° C., more preferably about 50° C. to about 80° C., even more preferably about 50° C. to about 70° C., and most preferably at about 60° C. under reduced pressure (less than 1 atmosphere). Preferably, the process further comprises forming a solution of lapatinib ditosylate in dimethylformamide; adding heptane to produce a suspension of Form VI of lapatinib ditosylate. Preferably, the obtained suspension is stirred for a suitable period of time to facilate production of lapatinib ditosylate Form XIX. The stirring time suitable for production of lapatinib ditosylate Form XIX can be determined by a person skilled in the art using routine experimentation. In a preferred embodiment, the suspension is stirred for a period from about 18 hours to about 30 hours, more preferably from about 18 hours to about 24 hours, and most preferably about 24 hours. Preferably, the suspension is stirred at 25° C.
The mixture is preferably maintained at a temperature of about 0° C. to about 80° C., more preferably about 20° C. to about 50° C., and most preferably about 20° C. to about 30° C. for about 1 hour to about 18 hours. Recovering the product may be carried out by any known method such as filtration.
In another embodiment, the present invention encompasses a new process for preparing lapatinib ditosylate monohydrate comprising slurrying Lapatinb ditosylate in methanol, water, or a mixture of water and an organic solvent selected from the group consisting of acetone, acetonitrile, methanol, ethanol, and isopropanol; and drying the obtained precipitate. Preferably, the water/solvent ratio is about 40:60 to about 60:40, more preferably about 50:50.
Typically, the mixture is maintained at a temperature of about 0° C. to about 70° C., more preferably about 20° C. to about 50° C., and most preferably about 20° C. to about 25° C., preferably, for about 2 hours to about 18 hours. Preferably, the obtained precipitate is dried at a temperature of about 40° C. to about 70° C., more preferably about 40° C. to about 60° C., and most preferably about 40° C. Preferably, drying is carried out overnight, and most preferably, for about 16 hours.
In another embodiment, the present invention encompasses another process for preparing lapatinib ditosylate monohydrate comprising dissolving lapatinib ditosylate in an organic solvent selected from the group consisting of dimethylacetamide, dimethylformamide, and dimethylsulfoxide; and adding an anti solvent selected from the group consisting of hexane, tetrahydrofuran, ethyl acetate, acetonitrile, isopropanol, and acetone, wherein, if dimethylformamide or dimethylsulfoxide are used as the organic solvent, the precipitate is dried at elevated temperature under reduced pressure. The pair of solvents and antisolvents can be selected from the group consisting of: DMA/tetrahydrofuran, DMA/ethyl acetate, DMA/acetone, DMA/acetonitrile, DMA/isopropanol.
Preferably the reaction mixture is maintained at about 0° C. to about 70° C., more preferably about 20° C. to about 40° C., and most preferably at about room temperature, preferably, for about an hour to about 16 hours. The precipitate is preferably dried at an elevated temperature, preferably under reduced pressure. For example, drying can be carried out at a temperature of about 40° C. to about 90° C., more preferably about 50° C. to about 80° C., even more preferably about 50° C. to about 70° C., and most preferably about 60° C., preferably for about 16 hours.
In another embodiment, the present invention encompasses a new process for preparing anhydrous lapatinib ditosylate comprising slurrying lapatinib ditosylate in an organic solvent selected from the group consisting of methyl ethyl ether, acetone, isopropanol, n-butanol, methanol, tetrahydrofuran, ethyl acetate, dimethyl carbonate, dichloromethane, chloroform, acetonitrile, and a mixture of tetrahydrofuran/water; and drying the obtained precipitate.
Preferably, the slurry is maintained at a temperature of about 0° C. to about 50° C., more preferably about 20° C. to about 50° C., and most preferably about 20° C. to about 30° C., preferably for about an hour to about 24 hours, more preferably for about 2 hours to about 8 hours, and most preferably for about 2 hours. The precipitate is then dried at an elevated temperature, preferably under reduced pressure. For example, the precipitate can be dried at about 40° C. to about 70° C., and more preferably about 40° C.
In another embodiment, the invention encompasses a process for preparing anhydrous lapatinib ditosylate comprising forming a slurry of lapatinib base, and p-toluenesulfonic acid, in toluene; and drying the obtained precipitate.
Preferably, the slurry is maintained at a temperature of about 0° C. to about 50° C., more preferably about 20° C. to about 50° C., and most preferably about 20° C. to about 30° C., preferably for about an hour to about 24 hours, more preferably for about 2 hours to about 8 hours, and most preferably for about 2 hours.
In another embodiment, the present invention encompasses a process for preparing anhydrous lapatinib ditosylate comprising dissolving lapatinib ditosylate in an organic solvent selected from the group consisting of dimethylacetamide, dimethylformamide, and dimethylsulfoxide; and adding an anti solvent selected from the group consisting of isopropanol, acetonitrile, MTBE, acetone, tetrahydrofuran, methanol, and ethanol. The pair of solvents and antisolvents can be selected from the group consisting of: DMF/isopropanol, DMF/acetonitrile, DMF/MTBE, DMF/acetone, DMA/MTBE, DMSO/tetrahydrofuran, DMSO/acetone, DMSO/methanol, and DMSO/ethanol. When DMF/acetonitrile, DMF/acetone, and DMA/MTBE are used, the precipitate is further dried.
Preferably, the mixture is maintained at about 0° C. to about 70° C., preferably about 20° C. to about 30° C. for about 2 hours. The precipitate can be further dried. For example at about 40° C. to about 90° C., more preferably about 50° C. to about 80° C., and most preferably about 60° C., preferably, under reduced pressure.
The present invention provides a pharmaceutical formulation comprising one or more of the above described lapatinib ditosylate Forms I, II, III, IV, V, VI, VII, VIII, IX, XI, XII, XIII, XIV, XV, XVI, XVII, XVIII, or XIX. This pharmaceutical composition may additionally comprise at least one pharmaceutically acceptable excipient.
Alternatively, pharmaceutical formulations of the present invention may also contain one of the novel crystalline forms of lapatinib ditosylate disclosed herein in a mixture with other forms of lapatinib ditosylate.
In another embodiment, the invention encompasses a pharmaceutical formulation comprising one or more of the above described lapatinib ditosylate Forms I, II, III, IV, V, VI, VII, VIII, IX, XI, XII, XIII, XIV, XV, XVI, XVII, XVIII, or XIX for the treatment of patients with advanced metastatic breast cancer.
In addition to the active ingredient(s), the pharmaceutical formulations of the present invention may contain one or more excipients. Excipients may be added to the formulation for a variety of purposes.
Having described the invention with reference to certain preferred embodiments, other embodiments will become apparent to one skilled in the art from consideration of the specification. The invention is further defined by reference to the following examples describing in detail the preparation of the composition and methods of use of the invention. It will be apparent to those skilled in the art that many modifications, both to materials and methods, may be practiced without departing from the scope of the invention.
EXAMPLES
X-Ray Power Diffraction
X-Ray powder diffraction data was obtained by using methods known in the art using a SCINTAG powder X-Ray diffractometer model X'TRA equipped with a solid-state detector. Copper radiation of 1.5418 Å was used. A round aluminum sample holder with zero background was used. The scanning parameters included: range: 2-40 degrees two-theta; scan mode: continuous scan; step size: 0.05 deg.; and a rate of 3 deg/min. All peak positions are within ±0.2 degrees two theta.
Figure no. 32 was obtained by using methods known in the art using a Bruker X-Ray powder diffractometer model D8 advance equipped with lynxeye.
Scan range: 2-40°. Step size: 0.05°. Time per step: 5.2 seconds.
Example 1
To 0.1 gr solid lapatinib base Form X sample, 0.065 gr of p-toluenesulfonic acid was added to obtain a yellow solid. The resulting dry solid was stirred over 16 h at 25° C. The cake thus obtained, identified as Form I of lapatinib ditosylate.
Example 2
To 50 mg of crystalline anhydrous lapatinib ditosylate sample, a solvent was added and the resulting suspension was stirred and filtered. The various conditions are summarized in the following table:
stirring
Experiment
stirring time
temperature
no.
solvent
amount (V)
(h)
(° C.)
result
1
DMF
5
2
25
II
2
NMP
5
2
25
V
Example 3
To 50 mg of crystalline anhydrous lapatinib ditosylate sample, a solvent was added and a yellow solution was obtained. To the resulting solution an antisolvent was added, to obtain a yellow suspension. The resulting suspension was stirred and filtered. The various conditions are summarized in the following table:
stirring
Experiment
amount
amount
stirring
temperature
no.
solvent
(V)
antisolvent
(ml)
time (h)
(° C.)
result
3
DMA
30
hexane
1507.5
1
25
VIII
4
DMA
30
Toluene
603
1
25
II
5
DMA
30
MTBE
1206
1
25
II
6
DMF
10
Toluene
100.5
2
25
II
7
DMF
10
Acetone
100.5
2
25
III
8
DMF
10
THF
100.5
2
25
III
9
DMF
10
Acetonitrile
100.5
2
25
IV
10
NMP
30
hexane
1507.5
1
25
V
11
NMP
30
IPA
1809
1
25
V
12
NMP
30
Acetone
1206
1
25
V
13
NMP
30
THF
1206
1
25
V
14
NMP
30
MTBE
1206
1
25
V
15
NMP
30
Acetonitrile
1206
1
25
V
16
DMF
10
MTBE
100.5
2
25
VI
Example 4
To the mixture of 0.1 gr solid lapatinib-base Form X and 0.065 gr PTSA (p-toluenesulfonic acid), 3 ml (30V) Heptane was added to obtain yellow suspension. The resulting suspension was stirred over 18 h at 25° C. The obtained cake was analyzed and was identified as Form I. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as Form VII of lapatinib ditosylate.
Example 5
To the mixture of 0.5 gr solid lapatinib-base Form X and 0.33 gr PTSA, 15 ml (30V) diethyl ether was added to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as Form IX of lapatinib ditosylate.
Example 6
To the mixture of 0.5 gr solid lapatinib-base Form X and 0.33 gr PTSA, 15 ml (30V) hexane was added to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as Form I of lapatinib ditosylate.
Example 7
To the mixture of 0.5 gr solid lapatinib-base Form X and 0.33 gr PTSA, 15 ml (30V) methyl tert butyl ether was added to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as Form VII of lapatinib ditosylate.
Example 8
To 0.5 gr solid lapatinib-base Form X sample, 0.33 gr PTSA was added to obtain a yellow solid. The resulting solid was stirred over 66 h at 25° C. The cake thus obtained, identified by PXRD as Form I of lapatinib ditosylate.
Example 9
To 0.5 gr solid lapatinib-base Form X sample, 0.33 gr PTSA was added to obtain a yellow solid. The resulting solid was stirred over 24 h at 40° C. The cake thus obtained, identified by PXRD as Form I of lapatinib ditosylate.
Example 11
To the mixture of 0.3 gr solid lapatinib-base Form X and 0.198 gr PTSA, 9 ml (30 V) of hexane was added to obtain a yellow suspension. The resulting suspension was stirred over 24 h at 40° C., then filtered. The cake thus obtained was dried for 16 h, 40° C. in a vacuum oven and identified by PXRD as Form I of lapatinib ditosylate.
Example 12
Lapatinib ditosylate Form I was heated to 100-120° C. for 30 minutes and cooling to about 25° C. The product of the heating was identified by PXRD as Form XI of lapatinib ditosylate.
Example 13
A drop of ethanol was added to about 50 mg of lapatinib ditosylate Form I that was placed in a mortar. The powder and the ethanol were strongly ground together with a pestle for 1 minute. The product of the grinding was identified by PXRD as Form XI of lapatinib ditosylate.
Example 14
A drop of isopropanol was added to about 50 mg of lapatinib ditosylate Form I that was placed in a mortar. The powder and the isopropanol were strongly ground together with a pestle for 1 minute. The product of the grinding was identified by PXRD as Form XI of lapatinib ditosylate.
Example 15
1.14 g of lapatinib ditosylate was dissolved in 55 ml (50V) of DMSO. The solution was lyophilized at temperature of −40° C. under vacuum for 4 days. The cake thus obtained was identified as Form XI of lapatinib ditosylate.
Example 16
To the mixture of 0.5 gr solid lapatinib-base Form X and 0.33 gr PTSA, 15 ml (30V) MTBE was added to obtain a yellow suspension. The resulting suspension was stirred over 2 h at 25° C. The cake thus obtained was identified by PXRD as Form XI of lapatinib ditosylate.
Example 17
The cake obtained by the procedure described in example 14 was dried for 16 h, 40° C. in a vacuum oven and identified by PXRD as Form VII of lapatinib ditosylate.
Example 18
A drop of water was added to about 50 mg of lapatinib ditosylate Form I that was placed in a mortar. The powder and the water were strongly ground together with a pestle for 1 minute. The product of the grinding was identified by PXRD as Form XII of lapatinib ditosylate.
Example 19
To 0.5 g solid lapatinib ditosylate, 30V dimethylacetamide was added and a yellow solution was obtained. To the resulting solution 150V hexane was added, to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 60° C. in a vacuum oven, identified as Form XIII of lapatinib-ditosylate.
Example 20
To a solid 1 g lapatinib ditosylate sample, 30V dimethylacetamide was added and a yellow solution was obtained. To the resulting solution 100V MeOH was added, to obtain a yellow suspension. The resulting suspension was stirred over 16 h at 25° C. The cake thus obtained was dried for 16 h, 60° C. in a vacuum oven, identified as Form XIV of lapatinib ditosylate.
Example 22
To a solid lapatinib-DTS sample, 12V methyl ethyl ether was added and the resulting yellow suspension was stirred over 2 h at 50° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 23
To a solid lapatinib-DTS sample, 12V acetone was added and the resulting yellow suspension was stirred over 2 h at 30° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 24
To a solid lapatinib-DTS sample, 12V isopropanol was added and the resulting yellow suspension was stirred over 2 h at 50° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 25
To a solid lapatinib-DTS sample, 12V n-butanol was added and the resulting yellow suspension was stirred over 2 h at 50° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 26
To a solid lapatinib-DTS sample, 12V methanol was added and the resulting yellow suspension was stirred over 2 h at 30° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 28
To a solid lapatinib-DTS sample, 12V tetrahydrofuran was added and the resulting yellow suspension was stirred over 2 h at 30° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 29
To a solid lapatinib-DTS sample, 12V ethyl acetate was added and the resulting yellow suspension was stirred over 2 h at 30° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 30
To a solid lapatinib-DTS sample, 12V dimethyl carbonate was added and the resulting yellow suspension was stirred over 2 h at 50° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 31
To a solid lapatinib-DTS sample, 12V dichloromethane was added and the resulting yellow suspension was stirred over 2 h at 30° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 32
To a solid lapatinib-DTS sample, 12V chloroform was added and the resulting yellow suspension was stirred over 2 h at 30° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 34
To a solid lapatinib-DTS sample, 12V acetonitrile was added and the resulting yellow suspension was stirred over 2 h at 50° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 35
To a solid lapatinib-DTS sample, 10V dimethylformamide was added. To the resulting solution 10V isopropanol was added, to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C., whereupon it was filtered. The cake thus obtained identified as anhydrous lapatinib-DTS.
Example 36
To a solid lapatinib-DTS sample, 10V dimethylformamide was added. To the resulting solution 10V acetonitrile was added, to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 60° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 38
To a solid lapatinib-DTS sample, 10V dimethylformamide was added. To the resulting solution 10V acetone was added, to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 60° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 40
To a solid lapatinib-DTS sample, 30V dimethylacetamide was added. To the resulting solution 120V methyl tert butyl ether was added, to obtain yellow suspension. The resulting suspension was stirred over 1 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 60° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 41
To a solid lapatinib-DTS sample, 5V dimethylsulfoxide was added. To the resulting solution 5V tetrahydrofuran was added, to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as anhydrous lapatinib-DTS.
Example 42
To a solid lapatinib-DTS sample, 5V dimethylsulfoxide was added. To the resulting solution 5V acetone was added, to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as anhydrous lapatinib-DTS.
Example 43
To a solid lapatinib-DTS sample, 5V dimethylsulfoxide was added. To the resulting solution 5V acetonitrile was added, to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as anhydrous lapatinib-DTS.
Example 44
To a solid lapatinib-DTS sample, 10V dimethylsulfoxide was added. To the resulting solution 100V methanol was added, to obtain yellow suspension. The resulting suspension was stirred over 16 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 60° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 45
To a solid lapatinib-DTS sample, 10V dimethylsulfoxide was added. To the resulting solution 100V ethanol was added, to obtain yellow suspension. The resulting suspension was stirred over 16 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 60° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 46
To a solid lapatinib-DTS sample, a mixture of 5/5V tetrahydrofuran/H2O was added and the resulting yellow suspension was stirred over 2 h at 30° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 47
To the mixture of 0.5 gr solid lapatinib-base and 0.33 gr PTSA, 15 ml (30V) Toluene was added and the resulting yellow suspension was stirred over 2 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as anhydrous lapatinib-DTS.
Example 48
To a solid lapatinib-DTS sample, 10V water was added and the resulting yellow suspension was stirred over 2 h at 50° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as lapatinib-DTS monohydrate.
Example 49
To a solid lapatinib-DTS sample, a mixture of 5V water/5V acetone was added and the resulting yellow suspension was stirred over 2 h at 30° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as lapatinib-DTS monohydrate.
Example 50
To a solid lapatinib-DTS sample, a mixture of 5V H 2 O/5V methanol was added and the resulting yellow suspension was stirred over 2 h at 30° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as lapatinib-DTS monohydrate.
Example 51
To a solid lapatinib-DTS sample, a mixture of 5V H 2 O/5V ethanol was added and the resulting yellow suspension was stirred over 2 h at 30° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as lapatinib-DTS monohydrate.
Example 52
To a solid lapatinib-DTS sample, a mixture of 5V H 2 O/5V isopropanol was added and the resulting yellow suspension was stirred over 2 h at 50° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as lapatinib-DTS monohydrate.
Example 53
To a solid lapatinib-DTS sample, 5V H 2 O/5V acetonitrile was added and the resulting yellow suspension was stirred over 2 h at 50° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 40° C. in a vacuum oven, identified as lapatinib-DTS monohydrate.
Example 55
To a solid lapatinib-DTS sample, 30V dimethylacetamide was added. To the resulting solution 120V THF was added, to obtain yellow suspension. The resulting suspension was stirred over 1 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as lapatinib-DTS monohydrate.
Example 56
To a solid lapatinib-DTS sample, 30V dimethylacetamide was added. To the resulting solution 120V ethyl acetate was added, to obtain yellow suspension. The resulting suspension was stirred over 1 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as lapatinib-DTS monohydrate.
Example 57
To a solid lapatinib-DTS sample, 30V dimethylacetamide was added. To the resulting solution 120V acetone was added, to obtain yellow suspension. The resulting suspension was stirred over 1 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as lapatinib-DTS monohydrate.
Example 58
To a solid lapatinib-DTS sample, 30V dimethylacetamide was added. To the resulting solution 120V acetonitrile was added, to obtain yellow suspension. The resulting suspension was stirred over 1 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as lapatinib-DTS monohydrate.
Example 59
To a solid lapatinib-DTS sample, 30V dimethylacetamide was added. To the resulting solution 90V isopropanol was added, to obtain yellow suspension. The resulting suspension was stirred over 16 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as lapatinib-DTS monohydrate.
Example 61
To a solid lapatinib-DTS sample, 5V dimethylsulfoxide was added. To the resulting solution 5V IPA was added, to obtain yellow suspension. The resulting suspension was stirred over 2 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 60° C. in a vacuum oven, identified as lapatinib-DTS monohydrate.
Example 62
To the mixture of 0.5 gr solid lapatinib-base and 0.33 gr PTSA, 15 ml (30V) methanol was added and the resulting yellow suspension was stirred over 18 h at 25° C., whereupon it was filtered. The cake thus obtained was, identified as lapatinib-DTS monohydrate.
Example 63
To a solid lapatinib-DTS (0.5 gr) sample, 10V Dimethylformamide was added and yellow solution was obtained. To the resulting solution 150V heptane was added, to obtain yellow suspension. The resulting suspension was stirred over 6 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as Form VI of lapatinib-DTS.
Example 64
To a solid lapatinib-DTS sample, 10V dimethylformamide was added and yellow solution was obtained. To the resulting solution 150V heptane was added, to obtain yellow suspension. The resulting suspension was stirred over 6 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 60° C. in a vacuum oven, identified as Form XIX of lapatinib-DTS.
Example 65
To a solid lapatinib-DTS sample, 20V dimethylacetamide was added and yellow solution was obtained. To the resulting solution 150V hexane was added, to obtain yellow suspension. The resulting suspension was stirred over 16 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as Form VIII of lapatinib-DTS.
Example 69
To a solid lapatinib-DTS sample, 10V dimethylformamide was added and yellow solution was obtained. To the resulting solution 150V hexane was added, to obtain yellow suspension. The resulting suspension was stirred over 5 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 60° C. in a vacuum oven, identified as a mixture of Forms XIX and XIII of lapatinib-DTS.
Example 71
To 0.5 g solid lapatinib ditosylate, 30V dimethylacetamide was added and a yellow solution was obtained. To the resulting solution, 150V hexane was added to obtain a yellow suspension. The resulting suspension was stirred over 2 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as Form VIII of lapatinib-DTS.
Example 73
The cake obtained at example 72 was dried for 40 h at 60° C. in a vacuum oven, identified as Form XIII of lapatinib-DTS.
Example 74
To 0.5 g of solid anhydrous lapatinib-DTS, 10V dimethylformamide was added and a yellow solution was obtained. To the resulting solution, 150V hexane was added to obtain a yellow suspension. The resulting suspension was stirred over 7 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as Form VI of lapatinib-DTS.
Example 75
The cake obtained at example 74 was dried for 16 h at 60° C. in a vacuum oven, identified as a polymorphic mixture of Forms XIX and XIII of lapatinib-DTS.
Example 76
To the mixture of 0.31 gr solid lapatinib-base Form X and 0.186 gr PTSA in 30V (15 ml) dimethylacetamide, 75 ml (150V) hexane was added to obtain a yellow suspension. The resulting suspension was stirred over 5 h at 25° C. The cake thus obtained was dried for 16 h at 60° C. in a vacuum oven, identified as Form XIII of lapatinib-DTS.
Example 77
To the mixture of 1 gr solid lapatinib-base Form X and 0.6 gr PTSA, 48 ml (30V) dimethylacetamide was added to obtain a yellow solution. 120 ml (75V) hexane was added dropwise into the prepared solution over 5 h and the resulting suspension was stirred over 24 h at 25° C., then filtered. The cake thus obtained was identified as Form VIII of lapatinib-DTS.
Example 78
The cake obtained at example 77 was dried for 36 h at 60° C. in a vacuum oven, identified as Form XIII of lapatinib-DTS.
Example 79
To 5 gr of solid anhydrous lapatinib-DTS sample, 50 ml (10V) dimethylformamide was added and a yellow solution was obtained. To the resulting solution, 750 ml (150V) heptane was added to obtain a yellow suspension. The resulting suspension was stirred over 16 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as Form VI of lapatinib-DTS.
Example 81
To 1.03 g solid lapatinib-base Form X suspension in 50 ml methyl isobutyl ketone, 0.63 g p-toluenesulfonic acid in 16 ml methyl isobutyl ketone solution was added, to obtain yellow-brownish suspension. The resulting suspension was stirred over 20 h at 25° C., then filtered. The cake thus obtained, identified as Form XVI of lapatinib-ditosylate.
Example 82
The cake thus obtained according to example 81 was dried for 120 h at 40° C. in a vacuum oven, identified as Form XVII of lapatinib-ditosylate.
Example 83
1.03 g solid lapatinib-base Form X suspension in 50 ml methyl isobutyl ketone was added into solution of 0.63 g p-toluenesulfonic acid in 16 ml methyl isobutyl ketone to obtain yellow-brownish suspension. The resulting suspension was stirred over 20 h at 25° C., then filtered. The cake thus obtained was dried for 120 h at 40° C. in a vacuum oven, identified as Form XVII of lapatinib-ditosylate.
Example 85
To 0.5 gr solid lapatinib-ditosylate sample 5V dimethylformamide was added and yellow suspension was obtained. To the resulting suspension 5V THF was added, to obtain yellow suspension. To resulting suspension 10V heptane was added, than it was stirred over 16 h at 25° C., whereupon it was filtered. The cake thus obtained was identified as Form XVIII of lapatinib-ditosylate
Example 86
To the mixture of 2 gr solid lapatinib-base, 1.2 gr PTSA, 15V dimethylformamide was added to obtain brownish solution. To the resulting solution 150V heptane was added, to obtain yellow suspension. The resulting suspension was stirred over 5 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 48 h, 50° C. in a vacuum oven, identified as Form XV of lapatinib-DTS.
Example 87
To the mixture of 2.5 gr solid lapatinib-base, 1.64 gr PTSA, 15V dimethylformamide was added to obtain orange solution. To the resulting solution 150V heptane was added, to obtain yellow suspension. The resulting suspension was stirred over 24 h at 25° C., whereupon it was filtered. The cake thus obtained was dried 48 h, 50° C. in a vacuum oven, identified as Form XIX of lapatinib-DTS.
Example 88
To a solid lapatinib-DTS sample 5V dimethylformamide was added and yellow suspension was obtained. To the resulting suspension 10V heptane was added. The resulting suspension was stirred over 3 h at 25° C., 1 h at 5° C., whereupon it was filtered. The cake thus obtained was dried 16 h, 70° C. in a vacuum oven, identified as a mixture of Forms XV and XIII of lapatinib-DTS.
Example 89
A drop of acetone was added to about 50 mg of lapatinib ditosylate Form XV that was placed in a mortar. The powder and the acetone were strongly ground together with a pestle for 1 minute. The product of the grinding was identified by PXRD as mixture of Forms XIII and XV of lapatinib ditosylate.
Example 90
50 mg of mixture of Forms XIII and XV of lapatinib ditosylate was heated to 100° C. for 30 minutes. The product of the heating was identified by PXRD as Form XV of lapatinib ditosylate.
Example 91
PTSA was added to a solution of lapatinib-base in 5V dimethylformamide, 8.03 gr (2 eq) to obtain a brownish solution.
The solution was seeded with Form VI at 40° C., than it was stirred over 1 hour, to obtain a yellow suspension. Then, it was cooled to 0° C. over 6 hours, and stirred over 10 hours. The resulting suspension was deep-cooled to −10° C. over 2 hours, and stirred over 2 hours. The obtained cake was filtered and identified as Form VI of lapatinib-DTS.
Example 92
Lapatinib ditosylate Form XIII (150 mg) were stored under DMF vapors at room temperature for 48 hours. It was then analyzed by PXRD and identified as Form XVIII of lapatinib ditosylate. After 6 hours at ambient conditions the material was retested and identified as Form XIII of lapatinib ditosylate.
Example 93
Lapatinib ditosylate Form XV (150 mg) was stored under acetone vapors at 25° C. for 48 hours. It was then analyzed by PXRD and identified as Form XIII of lapatinib ditosylate. | The present invention provides novel polymorphs of lapatinib ditosylate, processes for preparing them, and pharmaceutical compositions comprising one or more of these polymorphs. | 2 |
CROSS REFERENCE
[0001] The present application claims priority to U.S. provisional application Ser. No. 61/968,435, which was filed on Mar. 21, 2014, entitled Pressure Actuated Flow Control in an Abrasive Jet Perforating Tool, the disclosure of which is incorporated by reference herein in its entirety.
FIELD OF INVENTION
[0002] This invention relates generally to the field of treating wells to stimulate fluid production. More particularly, the invention relates to the field of high pressure abrasive fluid injection in oil and gas wells.
BACKGROUND OF THE INVENTION
[0003] Abrasive jet perforating uses fluid slurry pumped under high pressure to perforate tubular goods around a wellbore, where the tubular goods include tubing, casing, and cement. Since sand is the most common abrasive used, this technique is also known as sand jet perforating (SJP). Abrasive jet perforating was originally used to extend a cavity into the surrounding reservoir to stimulate fluid production. It was soon discovered, however, that abrasive jet perforating could not only perforate, but cut (completely sever) the tubular goods into two pieces. Sand laden fluids were first used to cut well casing in 1939. Abrasive jet perforating was eventually attempted on a commercial scale in the 1960s. While abrasive jet perforating was a technical success (over 5,000 wells were treated), it was not an economic success. The tool life in abrasive jet perforating was measured in only minutes and fluid pressures high enough to cut casing were difficult to maintain with pumps available at the time. A competing technology, explosive shape charge perforators, emerged at this time and offered less expensive perforating options.
[0004] Consequently, very little work was performed with abrasive jet perforating technology until the late 1990's. Then, more abrasive-resistant materials used in the construction of the perforating tools and jet orifices provided longer tool life, measured in hours or days instead of minutes. Also, advancements in pump materials and technology enabled pumps to handle the abrasive fluids under high pressures for longer periods of time. The combination of these advances made the abrasive jet perforating process more cost effective. Additionally, the recent use of coiled tubing to convey the abrasive jet perforating tool down a wellbore has led to reduced run time at greater depth. Further, abrasive jet perforating did not require explosives and thus avoids the accompanying danger involved in the storage, transport, and use of explosives. However, the basic design of abrasive jet perforating tools used today has not changed significantly from those used in the 1960's.
[0005] Abrasive jet perforating tools and casing cutters were initially designed and built in the 1960's. There were many variables involved in the design of these tools. Some tool designs varied the number of jet locations on the tool body, from as few as two jets to as many as 12 jets. The tool designs also varied the placement of those jets, such, for example, positioning two opposing jets spaced 180° apart on the same horizontal plane, three jets spaced 120° apart on the same horizontal plane, or three jets offset vertically by 30°. Other tool designs manipulated the jet by orienting it at an angle other than perpendicular to the casing or by allowing the jet to move toward the casing when fluid pressure was applied to the tool.
[0006] Abrasive jet perforating may be used in combination with various steps during well completion, stimulation, and intervention to reduce a number of trips in and out of the well, which can lower completion costs. Costs may be further decreased when equipment, in a single trip downhole, may accomplish multiple functions.
[0007] Abrasive jet perforating tools may include multiple openings into which threaded ports, referred to as jets, may be inserted or screwed. Having the ability to selectively open fluid flow to certain jet locations may aid in allowing an abrasive jet perforating tool to perform multiple functions, such as setting a plug/packer or using a fluid pulse type data delivery system. According to the state of the art, selective opening of various jets on a perforating tool is accomplished by sliding a sleeve across the fluid opening inside the inner diameter of the tool. The sliding sleeve is actuated to open a fluid path through the tool to particular jets. Sliding sleeves, however, present numerous drawbacks. First, the overall inner diameter of the tool is decreased, which can cause problems with pressure loss through the tool due to friction. Second, it could prevent a drop ball from being used in a tool located below the perforator. Third, it requires the complete disassembly of the tool to reset the sleeve. With rupture pins, the jet can be removed from the tool and another pin inserted without removing the tool from the assembly.
[0008] As disclosed herein, there is a method and apparatus for using rupture pins to selectively open jets on a perforating tool.
SUMMARY
[0009] Abrasive jet perforating tools introduce abrasive slurry at high pressures through one or more jets located in the tool. In certain situations, it may be advantageous to open different jets at different times in a perforating job. Conventional methods of opening jets can be complex, expensive, and prone to failure. Therefore, disclosed herein is a method and apparatus for using rupture pins to selectively opening jets on a perforating tool.
[0010] Rupture pins, inserted in the jet of a perforating jet tool are configured to break when a threshold fluid pressure is applied to the jet perforating tool, according to one embodiment presented. Multiple jets are contemplated, with multiple rupture pins. Rupture pins may be configured to rupture at different pressures, thereby giving tool operator the means to selectively open jets.
[0011] According to one embodiment, rupture pins are inserted from the inside annulus of a jet perforating tool through the jet toward the external surface. The rupture pins may be held in the tool by positive pressure, by chemical bonding, or by affixing a pin fastener or a mating piece designed to hold the rupture pins in the jet perforating tool. As disclosed herein, when the rupture pin ruptures, a lower portion of the rupture pin is ejected from the jet perforating tool, where it can fall down in the wellbore out of the way of the perforation or fracking operation. For embodiments containing a mating piece or pin faster, the mating piece and/or fastener is ejected with the lower portion of the rupture pin.
[0012] According to one embodiment, there is provided an apparatus comprising a jet perforating tool comprising a plurality of jets, and a first rupture pin inserted in a first jet of the plurality of jets to seal the first jet, wherein the first rupture pin is configured to rupture when a fluid pressure greater than a first threshold pressure is applied to the jet perforating tool. In one embodiment, the rupture pin is attached to the jet through a chemical compound. In another, the rupture pin is mechanically attached to the first jet. In another, the rupture pin is mechanically attached to the first jet by a pin fastener. It can also be attached by a mating piece.
[0013] In one embodiment, the apparatus further comprises a second rupture pin inserted in a second jet of the plurality of jets to seal the second jet, wherein the second rupture pin is configured to rupture when a fluid pressure greater than a second threshold pressure is applied to the jet perforating tool. In one embodiment, the rupture pin of the apparatus comprises an upper portion, and a lower portion, the lower portion being configured to separate from the upper portion and eject from the jet when the fluid pressure exceeds the first threshold pressure.
[0014] In one embodiment, there is provided a first rupture pin that further comprises an undercut portion between the upper portion and the lower portion, the undercut portion configured to break when the fluid pressure exceeds the first threshold pressure. The first jet may comprise a threaded jet, but in another embodiment, abrasive jets are mounted in smooth holes drilled into the side of the jet perforating too, and protective plates are mounted thereafter surrounding the abrasive jets to hold them in place. In one embodiment, the first rupture pin comprises material selected from brass, tin, silver, zinc, copper, aluminum, magnesium, gallium, thorium, and gold.
[0015] Also disclosed herein is a rupture pin comprising an upper portion, and a lower portion, wherein the upper portion and the lower portion are coupled together by an undercut region, the undercut region having a smaller diameter than the upper portion and the lower portion. In one embodiment, the undercut region is configured to break when a fluid pressure is applied to the rupture pin that exceeds a first threshold pressure. In one embodiment, the upper portion comprises an opening to allow fluid flow through the upper portion. In another, the lower portion comprises an opening configured to receive a mating piece for securing the apparatus into a jet of a jet perforating tool. In still another embodiment, the lower portion comprises threads configured to receive a pin fastener for securing the apparatus into a jet of a jet perforating tool.
[0016] Also disclosed herein is a method comprising inserting a jet perforating tool into a well, the jet perforating tool comprising one or more jets, wherein at least one of the one or more jets comprises a first rupture pin, flowing a first fluid to the jet perforating tool at a first pressure, and increasing the pressure of the first fluid to a second pressure, wherein the second pressure is greater than a rupture threshold of the first rupture pin. The first fluid can be a non-abrasive fluid. In one embodiment, the method further comprises flowing a second fluid to the jet perforating tool after the first rupture pin is ruptured, wherein the second fluid comprises abrasive fluid. In another embodiment, the at least one of the one or more jets comprise a second rupture pin, the method further comprising increasing the pressure of the first fluid to a third pressure, wherein the third pressure is greater than a rupture threshold of the second rupture pin.
[0017] Also disclosed is an apparatus comprising a jet perforating tool comprising a plurality of jets, a first rupture pin inserted in a first jet of the plurality of jets, wherein the first rupture pin is configured to seal the first jet until a fluid pressure greater than a first threshold pressure is applied to the jet perforating tool, and means for securing the first rupture pin in the first jet of the plurality of jets. In one embodiment, the securing means comprises a chemical compound. In another, the securing means comprises a pin fastener, and in another, it comprises a mating piece.
[0018] The foregoing has outlined rather broadly the features and technical advantages of the present disclosure in order that the detailed description that follows may be better understood. Additional features and advantages will be described hereinafter which form the subject of the claims herein. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present designs. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope as set forth in the appended claims. The novel features which are believed to be characteristic of the designs disclosed herein, both as to the organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing(s), in which:
[0020] FIGS. 1A-B depict an abrasive jetting insert and rupture pin, with a cutaway view, according to one embodiment of the disclosure.
[0021] FIGS. 2A-B depict an abrasive jetting insert and rupture pin, with a cutaway view, according to one embodiment of the disclosure.
[0022] FIG. 3 shows a post-rupture cutaway view of one embodiment of the present disclosure.
[0023] FIG. 4 shows a post-rupture cutaway view of another embodiment of the present disclosure.
[0024] FIGS. 5A-B show abrasive jet perforating tools according to embodiments of the present disclosure.
[0025] FIGS. 6A-B show cutaway views of a rupture pin of the present disclosure with a pin fastener.
[0026] FIG. 7 represents a post-rupture cutaway view of a rupture pin of the present disclosure.
[0027] FIGS. 8A-B show cutaway views of a rupture pin of the present disclosure with a mating piece.
[0028] FIG. 9 represents a post-rupture cutaway view of a rupture pin of the present disclosure.
DETAILED DESCRIPTION
[0029] Abrasive jet perforating tools introduce abrasive slurry at high pressures through one or more jets located in the tool. According to one design, multiple jets can be contained within one tool. FIGS. 5A and 5B show two representations of conventional abrasive jet perforating tools with multiple jets. For example, the tool in FIG. 5B contains three jets per tool face, with two or more faces on the tool. In certain situations, it may be advantageous to open different jets at different times in a perforating job. Disclosed herein are systems and methods for using different fluid flows or pressures to operate an abrasive jet perforating tool. Opening jet locations at different pressures may aid in the operation of a perforating job.
[0030] In one embodiment, a rupture pin is inserted in jets of an abrasive jet perforating tool before lowering the jet perforating tool into the well. Each rupture pin, while intact, seals a corresponding jet, or restricts the flow thereto. The rupture pins are configured to break when a threshold fluid pressure is applied to the jet perforating tool. The threshold pressure may cause the rupture pin to split into an upper portion and a lower portion. The lower portion may flow out of the jets, clearing the jets to allow the fluid to flow through the jets. The upper portion, according to one embodiment, is configured to disintegrate in the abrasive fluid, such that little to none of the rupture pin remains after the pressure threshold is reached.
[0031] In tools that contain multiple jets, multiple corresponding rupture pins are contemplated. Each rupture pin can have a different threshold pressure for rupture, or banks of pins can be configured to rupture at certain pressure ranges.
[0032] The rupture pin may be a generally cylindrically-shaped tube having an upper portion and a lower portion, in which the upper portion has a larger outer diameter than the lower portion. The inner diameter of the tube may or may not be a complete through hole. The rupture pin may be manufactured from a material with desired tensile strength properties and with a wall thickness selected to shear at a desired pressure differential. The rupture pin may be used in any device with openings, including downhole tools with abrasive jetting orifices, such as an abrasive jet perforating tool.
[0033] FIGS. 1A-B and 2 A-B are illustrations of a rupture pin according to various embodiments of the disclosure. In this embodiment, a rupture pin 104 , 204 includes a lower portion 106 , 206 and an upper portion 108 , 208 . The lower portion 106 , 206 may be coupled to the upper portion 108 , 208 through an undercut portion 110 , 210 . The undercut portion 110 , 210 has a smaller diameter than either the lower portion 106 , 206 or the upper portion 108 , 208 . The rupture pin 104 , 204 may be manufactured from materials such as brass, tin, silver, zinc, copper, aluminum, magnesium, gallium, thorium, gold, and/or other low shear strength materials with good machinability Likewise, combinations of said materials are contemplated, as well as alloys. According to one embodiment, rupture pin 104 , 204 is fashioned from a material having a consistent tensile strength, resistance to chemicals potentially found in the well, and/or a high temperature tolerance. Rupture pins 104 , 204 are designed to fit inside the jet orifices themselves. Therefore, the lower portion 106 , 206 may have a diameter, in one embodiment, between approximately 0.100 inches and 0.250 inches. Upper portion 108 , 208 according to one embodiment, has a larger diameter and is designed to rest on the inside of the jet, as seen in FIG. 1B .
[0034] Rupture pin 104 , 204 , according to the embodiment shown in FIGS. 1A-B and 2 A-B, comprises a hollow portion running through upper portion 110 , 210 , undercut portion 110 , 210 , and into lower portion 106 , 206 . When fluid pressure is applied to abrasive jet perforating tool 500 , fluid fills the hollow portion of rupture pin 104 , 204 , enacting pressure on lower portion 106 , 206 , which in turn stresses undercut portion 110 , 210 . With enough pressure, undercut portion 110 , 210 breaks, rupturing the pin.
[0035] FIGS. 2A-B represent an alternative jet design. The interior portion of abrasive jet 200 is recessed so that upper portion 208 of rupture pin 204 becomes inset. This protects upper portion 208 from abrasive slurry that may be directed to other abrasive jets 200 .
[0036] According to one embodiment, the thickness and/or wall thickness of the undercut portion 110 , 210 of rupture pin 104 , 204 is selected such that the undercut portion 110 , 210 breaks or shears under stress from an applied fluid pressure. The lower portion 106 , 206 , the upper portion 108 , 208 , and the undercut portion 110 , 210 may be molded as a single piece, with the undercut portion 110 , 210 later machined to the desired diameter. The material composition of the rupture pin 104 , 204 , including the undercut portion 110 , 210 , may additionally or alternatively be adjusted to achieve rupture of the rupture pin 104 , 204 at a desired pressure. For example, rupture pin 104 , 204 may be fabricated with a rupture section having a different porosity than upper portion 108 , 208 and lower portion 106 , 206 , wherein the change in porosity facilitates the rupture at a desired threshold pressure. In an alternate embodiment, the rupture portion is mechanically scarred to facilitate rupture. In yet another embodiment, rupture pin 104 , 204 has a graduated change in material make-up configured to create a region of lower shear strength at a desired point. Rupture pins 104 , 204 of this nature can be fabricated through several means, such as casting and injection molding. One of ordinary skill in the art of material science would have knowledge in fabrication methods.
[0037] When a sufficient fluid pressure is applied to the rupture pin 104 , 204 , the rupture pin 104 , 204 breaks, such as by shearing, to allow the lower portion 106 , 206 to flow through the abrasive jetting insert 202 and allow fluid to flow through the abrasive jetting insert 202 . Fluid pressure exerted on the upper portion 108 , 208 and/or the undercut region 110 , 210 may cause the lower portion 106 , 206 to separate from the upper portion 108 , 208 . For example, the pressure may shear the undercut region 110 , 210 . The fluid pressure may then push the lower portion 106 , 206 through the abrasive jetting insert 102 , 202 and/or the abrasive jet 200 . With the lower portion 106 , 206 cleared from the abrasive jetting insert 102 , 202 and/or the abrasive jet 200 , fluid is free to flow through the insert 102 , 202 and/or the jet 200 . The upper portion 108 , 208 may remain on an inside of the insert 102 , 202 , but an opening in the upper portion 108 , 208 may allow fluid to flow through the insert 102 , 202 . When the fluid flow through the opening is an abrasive fluid, the upper portion 108 , 208 may disintegrate in an abrasive fluid.
[0038] FIG. 3 shows a cut-away view of one embodiment of rupture pin 104 just after rupture. High pressure fluid is applied to abrasive jet perforating tool, and in turn presses on abrasive jets 200 . As pressure builds, strains rupture pin 104 , pushing lower portion 106 away from the abrasive jet perforating tool center. Eventually, the strain on rupture pin 104 breaks the rupture pin in the undercut portion 110 region. Lower portion 106 is ejected from jet insert 102 and falls down in the casing or wellbore. Fluid then begins to flow through the hollow portion of upper portion 108 and what is left of undercut portion 110 . As the abrasive slurry makes it way down to jet insert 102 and rupture pin 104 , it begins to eat away the material of rupture pin 104 , opening the center hole region of upper portion 108 . According to one test, abrasive slurry contact can disintegrate the remaining part of rupture pin 104 in as little as 30 seconds, such that abrasive jet 200 is operating at full capacity.
[0039] FIG. 4 shows a cut-away view of another embodiment of the disclosure.
[0040] Rupture pin 204 is inset into the recessed portion of abrasive jet 200 . Fluid pressure applied to rupture pin 204 translates to lower portion 206 until the strain breaks undercut portion 210 . Lower portion 206 is then ejected from abrasive jet 200 and the jet begins to function. Upper portion 208 and remaining undercut portion 210 are eroded by the abrasive slurry so that jet 200 begins to function at full capacity.
[0041] The rupture pin described herein may be used in various tools, including tools for well completion, such as various abrasive jet perforating tools displayed in FIGS. 5A-B . FIGS. 5A-B are profile views of jet perforating tools with jets according to various embodiments of the disclosure. A perforating tool 502 may be, for example, a slim hole tool having jets with outer diameters of between approximately 2.25 inches and 2.5 inches. In one embodiment, threaded jets are screwed into tool 502 , for example, with threaded jets having an outer diameter of approximately 3.5 inches to 5.5 inches. In another embodiment, such as shown in FIG. 5A , abrasive jets are mounted in smooth holes drilled into the side of tool 502 , and protective plates are mounted thereafter surrounding the abrasive jets to hold them in place. Rupture pins as described herein may be used in either of the tools 502 or 504 or other tools not illustrated here. The rupture pins may be adapted for various openings sizes across any type of tool and operating pressures of the tools. Additional details regarding perforating tools may be found in U.S. Pat. No. 7,963,332, which describes, in one embodiment, a threaded jet with carbide insert, and may be found in U.S. Patent Publication No. 2014/0102705, which describes in one embodiment, a carbide jet, both of which are incorporated by reference in their entirety.
[0042] Once inserted, rupture pins remain in the tool under positive pressure exerted from the inside of the tool outward. They may also be glued or cemented in place, such as, for example, by use of a chemical compound adhesive. The chemical compound may have a high temperature rating, be resistant to other chemicals found in the well, and/or have a consistent strength without affecting the shearing capabilities of the pin. Where it is desireable for different jets to open at different times, however, pressure built up in the casing or wellbore from an open jet may impart pressure on the intact rupture pins of other jets, forcing them backward into the tool. To avoid this, there are presented methods and systems for fixing the rupture pins in a jet.
[0043] The rupture pin may also or alternatively be held in the abrasive jetting insert by mechanical means, such as a pin fastener and/or a mating piece as shown in FIGS. 6-9 . FIGS. 6A-B represent a cut-away view of a jet showing assembly of a rupture pin with a pin fastener according to one embodiment of the disclosure. An abrasive jetting insert 602 may have a jet into which a rupture pin 604 is inserted. In this embodiment, the rupture pin 604 includes a lower portion 606 and an upper portion 608 . A pin fastener 612 may be attached to an end of the rupture pin 604 to hold the rupture pin 604 in the jet. In the embodiment shown in FIG. 6A , the pin fastener 612 is a nut that attaches to the base of lower portion 606 . According to one embodiment, the rupture pin 604 may be threaded on a lower portion 606 to allow the pin fastener 612 to screw onto the rupture pin 604 .
[0044] The pin fastener 612 may provide an opposing force that prevents the rupture pin 604 from falling out the back of the jet of the abrasive jetting insert 602 and into fluid flow. The pin fastener 612 , for example, holds the rupture pin 604 in place during transport of the jet perforating tool containing the abrasive jetting insert 602 or during times of low fluid pressure in the jet perforating tool containing the abrasive jetting insert 602 . FIG. 7 is a cut-away view of a jet showing rupture of a rupture pin previously attached with a pin fastener according to one embodiment of the disclosure. When high pressure builds causing rupture pin 604 to shear, lower portion 606 along with pin fastener 612 are ejected from abrasive jet 602 .
[0045] Other mechanical means may be used to secure the rupture pin in the abrasive jetting inserts. For example, a mating piece may be used as an alternative to, or in addition to, the pin fastener described with reference to FIGS. 6-7 . FIGS. 8A-B represent a cut-away view of a jet showing assembly of a rupture pin with a mating piece according to one embodiment of the disclosure. FIG. 9 is a cut-away view of a jet showing rupture of a rupture pin previously attached with a mating piece according to one embodiment of the disclosure. In this embodiment, an abrasive jetting insert 802 has a jet into which a rupture pin 804 is inserted. The rupture pin 804 includes a lower portion 806 and an upper portion 808 . A mating piece 812 is attached to an end of the rupture pin 804 to hold the rupture pin 804 in the jet. According to one embodiment, the rupture pin 804 may include an opening (not shown) at an end of the lower portion 806 opposite the upper portion 808 . The opening allows insertion of the mating piece 812 to secure the rupture pin 804 in the abrasive jet 802 . In one embodiment, the opening of the lower portion 806 is threaded to allow the mating piece 812 to screw into the rupture pin 804 . The mating piece comprises threads of its own that match the threads of the opening of rupture pin 804 . In an alternative embodiment (not shown), an exterior section of lower portion 806 of rupture pin 804 contains threads that match the interior portion of mating piece 812 . The surfaces are reversed so that rupture pin inserts into mating piece 812 .
[0046] The mating piece 812 may provide an opposing force that prevents the rupture pin 804 from falling out the back of the jet of the abrasive jetting insert 802 and into fluid flow. The pin fastener 812 , for example, holds the rupture pin 804 in place during transport of the jet perforating tool containing the abrasive jetting insert 802 or during times of low fluid pressure in the jet perforating tool containing the abrasive jetting insert 802 . When high pressure builds causing rupture pin 804 to shear, lower portion 806 along with pin fastener 812 are ejected from abrasive jet 802 .
[0047] A tool with jets and rupture pins as described above may be used in well completion, including initial completion and re-completion. A tool with jets and rupture pins may also be used in other construction phases of a well after a well is drilled, cased, and/or cemented. When the tool is a jet perforating tool as described above, the tool may be used in perforating a well and/or stimulating a well, such as by fracking A tool with rupture pins may also be used in severe tubing and/or well intervention tasks.
[0048] According to one embodiment, a jet perforating tool with rupture pins may be used to perforate a well casing. For example, the jet perforating tool may be placed down a well with rupture pins in place. Then, a fluid pressure down the well may be increased to a breaking point of some or all of the rupture pins. When the rupture threshold pressure is reached, the corresponding rupture pins break and fluid flow through the jets begins. The jets may then be used to perforate the well casing, such as by rotating the jet perforating tool to make a partial or complete cut of the well casing.
[0049] Placement of the rupture pins in the jet perforating tool allows the jet perforating tool to be placed down the well with other tools to reduce the number of times tools are raised and lowered down the well. For example, the jet perforating tool may be one tool in a line of tools lowered down the well, wherein several of the tools are operated with fluid pressure from the surface. The jet perforating tool has no effect on the other tools in the well and allows fluid to flow through to reach the other tools until the fluid pressure exceeds a rupture pressure threshold. Fluid may flow through the jet perforating tool without activating the perforating jets and flow to other tools in the well. Tasks can be performed with other tools in the well. Then, when desired, fluid pressure is increased to the rupture threshold pressure to break the rupture pins and begin perforation with the jet perforating tool. Other tools may be used before and/or after the jet perforating tool without raising and lowering the tools to remove the jet perforating tool from the well.
[0050] In one embodiment, non-abrasive fluid, such as water, is sent down the well to operate the tools in the well. After other functions have been performed with the tools and non-abrasive fluid, the fluid pressure is increased to break the rupture pins after which the non-abrasive fluid is replaced with abrasive fluid for the perforating task. Before switching to abrasive fluid, a status of the jets may be verified as open (e.g., that the rupture pins have broken) to ensure that abrasive fluid does not pass through the perforating tool and damage other tools in the well.
[0051] A tool may also include one or more rupture pins configured to break at different fluid pressures. For example, a jet perforating tool may include a first plurality of jets with inserted rupture pins configured to break at a first pressure threshold and may also include a second plurality of jets with inserted rupture pins configured to break at a second pressure threshold different from the first pressure threshold. The perforating tool may be activated by increasing the fluid pressure beyond the first pressure threshold. At a later time, the fluid pressure may be increased beyond the second pressure threshold to active the second plurality of jets on the jet perforating tool.
[0052] In one embodiment, the first set of jets may be activated to begin the perforating task. Then, when the first plurality of jets have been worn out, the fluid pressure may be increased to activate the second plurality of jets.
[0053] Rupture pins need not only be used with jets configured to perforate. In some cases, it is desirable to circulate fluid through a perforating tool, for example, to remove abrasive slurry from the tool. According to one embodiment disclosed herein, a first plurality of jets may be activated to begin the perforating task. After the perforating task is complete, a second plurality of jets having a larger diameter is then activated to circulate fluid out of the well.
[0054] In one embodiment of a method for operating the jet perforating tool in the various embodiments described herein: the initial tool setup may allow fluid to flow through the tool and through any open ports (jets); once the initial task below the sand jet perforating (SJP) tool is complete, additional fluid may be pumped to increase the fluid pressure in the bottom hole assembly (BHA) to the desired pressure; once the fluid pressure is at or above the threshold pressure, the wall of the pin ruptures and the lower portion of the pin is pushed out of the jet, leaving only the upper portion of the pin remaining; fluid may then pass through the upper portion of the inner diameter of the hole in the pin and circulate through the jet decreasing the pressure in the BHA; once the decrease in pressure is noted at the surface, fluid flow may be increased to bring the fluid pressure in the BHA back to the desired pressure; and/or once the fluid is again at the desired pressure, another pin may rupture and as fluid flows through the newly opened jet, the internal fluid pressure may decrease in the BHA. This process may be repeated until all of the jets have been opened. After opening all of the jets, abrasive slurry may be pumped to the tool under pressure for the perforating job. When the abrasive reaches the sand jet perforating tool, the pressurized abrasive may quickly dissolve the upper portion of the pin, leaving no traces of the parts. Depending on the rupture pin material used, this can occur in as little as 30 seconds. Subsequently, the BHA may be pulled from the hole. If preferred, the BHA may be first flushed with non-abrasive fluid.
[0055] In various other methods, sets of jets may be opened at lower pressures, then perforating is performed. After perforating, other jets may be opened to increase the flow rate from the tool, such as for a fracturing operation or other high flow application. In yet another method, jets may be placed in multiple tool bodies separated by ball seats. After opening the first set of jets, a ball may be dropped to isolate the active tool from the other tools above. The pressure may then be increased to open a new set of jets and perforating may continue. This may be performed multiple times. One of ordinary skill in the art of abrasive jet perforating or fluid fracking would understand how to use ball seats to seal off one or more levels of abrasive jets. For example, this can be done by varying the inner diameter(s) of the tool such that the ball seats in the inner diameter section of the tool to seal it off.
[0056] Other embodiments are disclosed herein. By the nature of their operation, the rupture pins act as a pressure balancing mechanisms inside the jet perforating tool and tubing string. Therefore, in one embodiment, rupture pins are included in a sand jet perforating tool to prevent against pressure spikes that might be caused by a jet blockage, such as where a piece of debris becomes disposed inside the jet perforating tool. For example, a tool could have 4 open jets pumping at a rate of 2 barrels per minute at 2,500 psi. If a piece of debris (metal scale, a piece of rock or gravel) flows through the tubing and is too large to pass through the orifice, it could block the jet. This blockage would cause a spike in pressure that could damage the tool and/or hinder the perforating process. The blocking of the jet, in this example, would decrease the number of perforation holes being cut at one time by 25%, which would in turn raise the pressure within the tool. According to this embodiment, the increase in pressure ruptures another rupture pin set to rupture at a higher pressure, thus opening another jet. The tool could then still function as it was originally intended.
[0057] Some of the advantages of the rupture pin described herein and method of operating tool with the rupture pin described herein include: the inner diameter of the sand jet perforating tool contains no moving parts or assemblies, allowing a larger fluid flow path which reduces frictional pressures and erosive wear on the inside of the tool and which reduces mechanical-related failures; no actuator part (e.g., drop ball, conical plug, etc.) is used to open the flow to the jets, which would conventionally involve disconnecting the tubing string at the surface and time to get the actuator part to the tool, and avoids difficulties in circulating in horizontal tubing strings; the rupture pins may be used in any type of tool or setup with little or no modification; rupture pins that rupture at different pressures may also be present in one BHA in order to open for different phases of the operation allowing for greater flexibility in one trip; opening the jets results in fewer trips downhole; overall time to complete the required work is reduced; and/or changes to jet configuration and setup may be made at the well location.
[0058] The rupture pins disclosed herein can also be useful in the high pressure cleaning industry. When using high pressure cleaning for tanks, tubes, heat exchangers, and other industry components to be cleaned, jets with rupture pins allow the user to change the flow through said tool by simply increasing the pressure above the threshold of the pin. The increased flow can be used to wash out the debris created in the cleaning process. It would also guard against pressure spikes as described above.
[0059] Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the present invention, disclosure, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | There is disclosed herein a method and apparatus for using rupture pins to selectively open jets on a jet perforating tool. Rupture pins inserted in jets within a jet perforating tool are configured to rupture at pre-designed thresholds, thereby opening the jet to begin a perforating job, or to circulate fluid through the tool. Also disclosed are systems and methods for holding the rupture pins within the tool prior to rupture. | 4 |
RELATED APPLICATIONS
This application is a divisional application of U.S. Pat. Ser. No. 09/652,228, filed Aug. 29, 2000, now U.S. Pat. No. 6,447,675 entitled “Fish Pond Filter System.”
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of ornamental landscaping and, in particular, to a filter system designed to efficiently remove solid wastes and biologically decompose suspended wastes in fish ponds.
2. Description of the Related Art
Fish ponds accumulate and generate a variety of contaminants and waste products that must be removed and treated to maintain the attractive appearance of the fish pond and the health of the fish living therein. The exposed water surface tends to retain air blown dust, dirt, and leaves and other plant matter that falls in. The fish themselves produce excrement that is a solid waste material and a source of unwanted biological activity. The temperate closed water ecosystem that is essential for the fish is also an excellent environment for the growth of algae and other undesirable living organisms. Fish food that remains uneaten by the fish can contaminate the pond and nourish undesirable living organisms. The closed system of a fish pond also favors chemical processes such as ammonia production that, if left unchecked, can rapidly degrade the appearance of the fish pond and its ability to support healthy fish.
The accepted method of maintaining the health and appearance of a fish pond is to separate the solid waste from the water, react the chemicals to either remove them or make them non-damaging, and treat the water to kill undesirable organisms. Two methods have typically been used to do this. One is to filter out the solid wastes and dispose of them, treat the water with a variety of chemicals and/or high intensity UV light to kill biological undesirables, and react the undesirable chemicals. The other is to employ a filter medium that retains the solid waste and decomposes the waste with biologically active bacteria that live on the filter medium. This method would also typically require treatment with high intensity UV light or chemicals to eliminate the undesirable biological and chemical constituents, although the chemical and/or UV light treatment regimen may not be as rigorous as with simple filtering.
A variety of methods and apparatuses are known to remove solid material from a liquid, however a major concern with removal of solid waste is what to do with the waste once it is separated from the water. Separation devices that depend on density differences, such as a centrifuge, are not effective in fish pond applications because many of the waste solids are approximately the same density as the water they are in, therefore the effective devices typically employ some type of filtering to trap the solids. The two major ways to handle the separated waste are to discard the waste trapped in a filter along with the filter or to backwash the filter and direct the waste stream elsewhere. A disadvantage of removing the waste trapped in a filter along with the filter is that generally these types of filters are a single use filter and thus must be replaced with a new one when the old one is full. It can be appreciated that the labor and cost to perform this replacement would be a drawback to a user for which the fish pond is a decorative and recreational item.
In order to avoid the cost and inconvenience of changing filter elements, the preferred method of removing trapped waste is to utilize some form of backwashing. Backwashing essentially consists of reversing the direction of water flow in the filter and thereby forcing the waste products out a waste outlet. The filter media does not typically need to be removed and after the backwashing is complete, the filter media is ready to retain more waste. Advantageously, fish ponds are often located adjacent garden areas and the backwashed water contains partially decomposed fish and vegetable waste that makes a beneficial fertilizer in the garden. However, the water discharged in the backwashing procedure is typically a cost to the user and minimizing water discharge is a concern particularly in areas where water is in limited supply.
The biological reaction process is an advantageous adjunct because the heterotrophic bacteria that perform the reaction are naturally occurring in the pond water. No user action is needed to establish and maintain a colony of beneficial bacteria other than to provide a place for them to live. Also, biological reaction converts many of the undesirable chemicals to non-harmful forms and thus reduces the need for chemical treatment. The chemicals used for chemical treatment are relatively expensive and many users would understandably like to minimize their handling of chemicals. The heterotrophic bacteria are not suited to live freely suspended in water and require a surface on which to grow. This has typically been done on the filter medium which generally consists of a gravel bed or filter mat.
A disadvantage to biological reaction is the relatively large amount of reactor volume and time typically required for the process to occur. With traditional gravel or filter mats, a biological filter/reactor can require a filter/reactor volume of up to 40% of the volume of the pond itself. It can be appreciated that such a large filter/reactor assembly is expensive to purchase and install and can negatively affect the aesthetics of the fish pond system. In addition a traditional biological reaction filter design can require several weeks to several months for the bacteria to substantially decompose the deposited wastes. The time required for waste decomposition must be such that the waste is decomposed at at least the rate it is deposited. Otherwise the filter becomes overloaded and can no longer protect the health and appearance of the pond.
As the bacteria live on a solid surface, there is an upper limit to how many can live on a given area, i.e. their population density. The time and volume required for a biological reaction filter can be dramatically reduced by providing increased area for the bacteria to live on and thereby increasing the number of bacteria resident in the filter reactor. The optimal filter media provides the highest surface area-to-volume ratio possible. With gravel or fibrous mats, the bacteria live on the surface and from a consideration of the shape of a piece of gravel or fiber it can be seen that other configurations of filter media would provide greater surface area for a given volume of media.
One type of filter media on the market with a higher surface area to volume ratio than gravel or fibers is the ACE-1400 media. The ACE-1400 media is made of plastic tubing with a specific gravity slightly less than one, which is cut to be slightly longer than the diameter of the tubing. The ACE-1400 is approximately 3.5 mm in diameter and 5 mm long. It can be appreciated that a hollow tube can support bacteria on both the outer and the inner surface. The size and shape of the hollow tube media is such that it has 15 to 20 times the surface area of an equivalent volume of gravel or fiber matting.
The ACE-1400 type media is typically placed in a container and pond water is pumped through the container so as to flow generally upwards. Since the ACE-1400 media has a specific gravity slightly less than one, the media floats towards the top of the container. Since the pond water is generally flowing upwards in the container, waterborne waste material is trapped throughout the media, but predominantly towards the bottom. The naturally occurring bacteria reside on and within the ACE-1400 media and digest the waste that lodges within the media.
The container is also provided with valves and piping to backwash the container periodically by reversing the water flow direction downwards and then out of the container. The backwashing causes the media to swirl and tumble, thereby releasing trapped solids. A properly sized container filled with the appropriate amount of media would generally require backwashing once a week. The container is provided with screens so that the media does not escape the container during either backwashing or normal operation. The filter system is also provided with screens to restrict larger solids such as leaves, twigs, and fish from being pumped into the filter container.
It can be appreciated that the more media that is in a filter system, the more surface area is provided for heterotrophic bacteria growth. However, because the ACE-1400 filter media is of a uniform size and shape, movement of the water tends to cause the filter elements to stack in a uniform manner, particularly when the container is filled to a relatively high percentage of capacity. The stacking process tends to create channels or voids in the filter media. These channels provide paths for the water to flow along without requiring that the water pass through the filter media. It can be appreciated that the filter is not effective in trapping and decomposing wastes if the water is not passing through the media. The stirring motion of backwashing randomizes the orientation of the filter elements, however they tend to re-stack and create channels in a relatively short time after the system returns to normal filtering flow.
While the ACE-1400 filter media and system offer advantages over traditional disposable filters and chemical treatment or gravel or fiber matting filter systems employing biological waste decomposition, it can be appreciated that improvements upon this system would be an advantage to the users of fish ponds. It can be appreciated that there is an ongoing need for a filter system for fish ponds that employs naturally occurring bacterial metabolization of wastes to remove these wastes from fish ponds. The system should be economical to purchase and install. The filter media should be reusable and provide the maximum surface area to volume ratio possible to support a maximum number of beneficial bacteria and to enable the system to be sized as small as possible and decompose the solid wastes as rapidly as possible. The system should require minimal use of chemicals to treat the water. The backwashing method should be as efficient as possible to remove the maximum amount of waste and extend the periods between backwashes, while avoiding channeling effects and corresponding failure to filter.
SUMMARY OF THE INVENTION
The aforementioned needs are satisfied by the fish pond filter system of the present invention, which in one aspect is a novel filter media with an increased surface area-to-volume ratio. In another aspect, the invention is a filter reactor with a more efficient backwashing system.
The extruded bio-tube filter media of the present invention is formed from extruded ABS plastic with a specific gravity slightly greater than one. The extruded bio-tube is generally tubular with internal and external ribbing. The addition of the internal and external ribbing provides approximately twice the surface area for the bio-tube of the present invention compared to a similar sized simple tube media, such as the ACE-1400. In addition, the internal ribbing provides smaller interior passages and allows the media to trap proportionally smaller waste material.
An additional advantageous feature of the present invention is that the media is provided in several different sizes. Also, the present invention is sized so as to be generally 1.3 times as long as it is in diameter. The differing sizes and the shape of the media of the present invention inhibit uniform stacking of the media material. Since the media cannot readily stack together in a uniform fashion, channeling of the material is also inhibited.
In another aspect of the invention, an efficient backwashing system is provided. The system includes jets adapted to create a vortex within the filter media container during the backwashing operation. The vortex created more efficiently dislodges accumulated waste material and directs the dislodged waste and carrier water out a waste pipe. The vortex created within the fish pond filter system of the present invention more completely cleans the filter media in a shorter time and requires less water to do so. Thus, the fish pond filter system saves time and money. These and other objects and advantages of the present invention will become more fully apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end view of a typical bio-tube of the present invention;
FIG. 2 is a side view of a typical bio-tube of the present invention;
FIG. 3 shows end and side views of three different sizes of bio-tubes of the present invention and their relative sizes;
FIG. 4 is an assembled, perspective view of the internal plumbing of a fish pond filter container assembly;
FIG. 5 is a close-up perspective view of the backwash jets and intake pipe assemblies of a fish pond filter system;
FIG. 6 is an exploded, cutaway, perspective view of the filter mode of the fish pond filter system;
FIG. 7 is an exploded, cutaway, perspective view of the backwash mode of the fish pond filter system;
FIG. 8 is a top view of a valve body and valve handle of the present invention showing the positions of the different operational modes of the valve body and filter system;
FIG. 9 is a side view of the assembled fish pond filter system; and
FIG. 10 shows a typical installation of the fish pond filter system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made to the drawings, wherein like numerals refer to like parts throughout. A fish pond filter system 100 draws water from a fish pond 300 , filters and treats the water to remove waste 304 , and returns the water to the fish pond 300 as shown in FIG. 10 . The fish pond 300 of this embodiment is an open air, closed-system container of water. The fish pond 300 can be outside or placed within a building or other enclosed structure. The fish pond 300 includes a plurality of fish 302 . Fish 302 shall herein be understood to include fish, crawdads, mud puppies, frogs, turtles, shrimps, or any other vertebrate or invertebrate animals suited to live at least partially in an aquatic environment. The fish 302 generate waste 304 , which is at least in part at least semi-solid biological waste material. Waste 304 shall be herein understood to also include other material that finds its way into the fish pond 300 such as leaves, other vegetable matter, dirt, or insects. The fish pond filter system 100 also includes naturally occurring heterotrophic bacteria 310 . The heterotrophic bacteria 310 feed on the waste 304 typically found in a fish pond 300 and remove the waste 304 from the fish pond 300 in a manner that will be described in greater detail below. The fish pond filter system 100 comprises a pre-filter 306 as shown in FIG. 10 which is positioned and adapted to screen out larger waste 304 particles which are approximately larger than ⅛″ in a well known manner.
The fish pond filter system 100 comprises bio-tube 102 filter media as shown in FIGS. 1 and 2. The bio-tubes 102 provide a surface to support the growth of heterotrophic bacteria 310 in a manner which is well known in the art and will be better appreciated following a more detailed description of the structure of the bio-tubes 102 and the fish pond filter system 100 . The bio-tubes 102 also retain and subsequently release water-borne solid waste 304 materials which the fish pond filter system 100 passes over the bio-tubes 102 in a manner that will be described in greater detail below. The bio-tubes 102 , of this embodiment, are extruded from ABS plastic in a well known manner. The bio-tubes 102 are provided with a plurality of integral structures formed at the same time and which will be described in greater detail below. The bio-tubes 102 of this embodiment have a finished specific gravity slightly greater than one so as to be slightly non-buoyant in water.
The bio-tubes 102 structure comprises a ring wall 104 . The ring wall 104 , of this embodiment, is made of ABS plastic and is generally an elongate, hollow, open-ended cylinder approximately 0.300″ outside diameter, 0.250″ inner diameter, and 0.390″ in length. The ring wall 104 has a wall thickness of approximately 0.025″ and provides a growth surface for bacteria in a manner that will be described in greater detail below. The ring wall 104 has an inner surface 106 and an outer surface 110 coaxial with and opposite the inner surface 106 .
The structure of the bio-tubes 102 further comprises external ribs 112 . The external ribs 112 are made of the same ABS plastic material as the bio-tubes 102 and are generally elongate rectangles of approximately 0.018″×0.035″×0.390″. The external ribs 112 are extruded with the bio-tubes 102 such that a first side of the external ribs 112 is adjacent and materially continuous with the outer surface 110 of the ring wall 104 . The external ribs 112 are positioned such that the long axis of the external ribs 112 (0.390″) is coaxial with the long axis of the bio-tube 102 . In this embodiment, 18 external ribs 112 extend radially outward from the outer surface 110 of the ring wall 104 and are approximately equally spaced about the circumference of the ring wall 104 which in this embodiment is approximately every 20° of angle. The external ribs 112 provide additional surface area to support the growth of heterotrophic bacteria 310 .
The structure of the bio-tubes 102 also comprises divider walls 114 . In this embodiment, the divider walls 114 are three elongate rectangles approximately 0.018″×0.125″×0.390″ and are made from the same ABS plastic as the bio-tubes 104 . The divider walls 114 have a first edge 116 along a long edge (0.390″) and a second edge 120 opposite the first edge 116 . The divider walls 114 are positioned such that the first edges 116 of the divider walls 114 are adjacent and materially continuous with the inner surface 106 of the ring wall 104 and the second edge 120 of each divider wall 114 is adjacent and materially continuous with the second edge 120 of each of the other divider walls 114 . The divider walls 114 are further positioned so as to be approximately equally spaced radially outwards from the common second edges 120 , which in this embodiment is 120° of angle. The divider 114 walls also support growth of heterotrophic bacteria 310 .
It should be appreciated that the ring wall 104 , externals ribs 112 , and divider walls 114 are all structures of the bio-tube 102 and, in the preferred embodiment, are extruded at the same time and from the same ABS material. The bio-tube 102 with the structures described has a surface area available for bacterial 310 growth that is approximately twice the surface area of a simple hollow, open-ended cylinder of similar dimensions, but without the external ribs 112 and the divider walls 114 . It should be appreciated that the overall shape of the bio-tube 102 and the number, shape, and placement of the external ribs 112 and divider walls 114 can be varied by one skilled in the art from the configurations described in this preferred embodiment without detracting from the spirit of the disclosed invention.
The bio-tubes 102 also comprise a plurality of internal passages 122 . The internal passages 122 are the openings within the bio-tubes 102 defined by two adjacent divider walls 114 and the included arc of the inner surface 106 of the ring wall 104 . The inner passages 122 provide a restricted opening for the passage of water and block and hold solid waste 304 material that is larger than the dimensions of the inner passage 122 . In this embodiment, the inner passages 122 will block solid objects that are generally larger than 0.100″ in at least two orthogonal dimensions. The bio-tubes 102 with internal passages 122 block solid objects that are approximately one-third as large as simple hollow cylinders of comparable size.
FIG. 3 shows one embodiment of the present invention with three different sizes of bio-tubes 102 . The bio-tubes 102 as shown are generally cylinders and in this embodiment are approximately 0.180″ diameter by 0.234″ long, 0.240″ in diameter by 0.312″ long, and 0.300″ in diameter by 0.390″ long. The different sizes of bio-tubes 102 inhibits uniform stacking of the bio-tubes 102 during use in a manner which will be described in greater detail below. It should be appreciated that alternative shapes, sizes, and number of different sizes and/or shapes of bio-tubes 102 could be employed without detracting from the spirit of the present invention.
The fish pond filter system 100 also comprises a water flow controller 124 as shown in FIG. 4 . The water flow controller 124 comprises a valve body 130 . The valve body 130 is provided with internal structures to control water flow in a manner well understood by those skilled in the art. The water flow controller 124 also comprises a valve handle 126 , which is an elongate member, approximately 8″ in major dimension and made of a plastic material. A first end 128 of the valve handle 126 is rotatably affixed to a top end 154 of the valve body 130 such that rotation of the valve handle 126 induces the valve body 130 to freely permit or restrict water flow through an inlet pipe 132 , an outlet pipe 134 , a waste pipe 136 , and/or a stand pipe 146 all exiting from the valve body 130 in response to the positioning of the valve handle 126 .
The inlet pipe 132 , outlet pipe 134 , waste pipe 136 , and stand pipe 146 of this embodiment are elongate members, generally open cylinders in profile, and made of a PVC plastic material. The inlet pipe 132 receives untreated water from the fish pond 300 . The outlet pipe 134 directs water which has been treated and filtered by the fish pond filter system 100 in a manner which will be described in greater detail below back to the fish pond 300 . The waste pipe 136 directs water, which may contain waste material 304 , out of the fish pond filter system 100 . The stand pipe 146 directs water flow to and from a backwash jet assembly 170 and intake tube assembly 172 in a manner which will be described in greater detail below.
The water flow controller 124 also comprises a pressure gauge/sight glass 140 . A first end 141 of the pressure gauge/sight glass 140 is provided with standard ¼″ NPT and is therewith threaded into the valve body 130 in a well known manner. The pressure gauge/sight glass 140 is adapted to provide a visual indication of the water pressure within the valve body 130 in a well known manner. The pressure gauge/sight glass 140 is also adapted to provide a visual indication of the presence of water within the valve body 130 . The water pressure indicated by and the visual condition of the water seen in the pressure gauge/sight glass 140 serve as indicia for an operator to control the operation of the fish pond filter system 100 in a manner which will be described in greater detail below.
The water flow controller 124 also comprises an attachment flange 142 . The attachment flange 142 is generally circular and approximately 7″ in diameter. The attachment flange 142 is made of a plastic material and is adapted to attach the water flow controller 124 to a container 202 , as shown in FIG. 9, in a manner that will be described in greater detail below.
The water flow controller 124 also comprises a media screen 144 . The media screen 144 is generally a cylinder, open on a first end 150 , closed on a second end 152 and approximately 6″ in diameter and 4″ high. The media screen 144 is made of a plastic material and is provided with a plurality of openings 148 . The openings 148 are generally rectangular, through-going holes in the media screen 144 sized so as to block passage of the bio-tubes 102 through the media screen 144 yet to readily allow the passage of liquid water. The media screen 144 has a second end 152 opposite the first end 150 . A circular opening 160 is provided in the center of the second end 152 of the filter screen 144 . The opening 160 is sized to fit closely around the outer diameter of the stand pipe 146 , which, in this embodiment, is approximately 1 ½″ in diameter.
The first end 150 of the media screen 144 is placed adjacent a bottom end 156 of the valve body 130 opposite the top end 154 . The media screen 144 is positioned such that the opening 160 is aligned with the center of the bottom end 156 of the valve body 130 . The media screen 144 is attached to the bottom end 156 of the valve body 130 with a plurality of screws in a well known manner. A first end 164 of the stand pipe 146 is positioned through the opening 160 in the media screen 144 and further into contact with the valve body 130 so as to securely attach to the valve body 130 and the media screen 144 in a friction fit in a well known manner.
A second end 166 of the stand pipe 146 is connected to the backwash jet assembly 170 and the intake tube assembly 172 as shown in FIG. 4 and in a close-up view in FIG. 5 . The backwash jet assembly 170 of this embodiment comprises a manifold 174 . The manifold 174 is made of a PVC plastic material and is adapted to contain and direct water flow in a manner which will be described in greater detail below. The manifold 174 includes 12 ports 176 . The ports 176 are adapted to direct water flow and are part of and made of the same material as the manifold 174 . The ports 176 are generally circular structures of the manifold 174 which extend radially outward and are arranged in three levels 184 a-c . Each level 184 a-c comprises four ports 176 positioned so as to be at the same distance along the major axis of the manifold 174 and to be approximately equally spaced about the circumference of the manifold 174 which is approximately a spacing of 90° of angle apart.
A top end 180 of the manifold 174 is provided with female threads in a well known manner. The second end 166 of the stand pipe 146 is provided with male threads in a well known manner such that the male threads of the stand pipe 146 mate with the female threads of the manifold 174 . The top end 180 of the manifold 174 and the second end 166 of the stand pipe 146 are threaded together to achieve the connection between the stand pipe 146 and the backwash jet assembly 170 and the intake pipe assembly 172 . In an alternative embodiment, the threading referred to above need not be present and the manifold 174 and the second end 166 of the stand pipe 146 are joined with a cementing process well known to those skilled in the art.
A first level 184 a comprising four ports 176 is located approximately 1″ from the top end 180 of the manifold. A t-fitting 186 is connected to each port 176 by a cementing process well known in the art. The t-fittings 186 are plastic pipe structures adapted to direct the flow of water in two substantially orthogonal directions. The t-fittings 186 have three openings 188 for the passage of water. A first opening 188 of each t-fitting 186 is attached to a port 176 of the first level 184 of the manifold 174 with a known cementing process. A second opening 188 of each t-fitting 186 opposite the first opening 188 is connected to a first opening 188 of an elbow 190 with a known cementing process.
The elbows 190 are plastic pipe structures which are bent at approximately a 90° angle such that water that enters one opening 188 of the elbow exits a second opening 188 in a direction generally 90° from the direction it entered. Jet caps 192 are connected to the second opening 188 of each elbow 190 and to the third opening 188 of each t-fitting 186 using a known cementing process. The jet caps 192 are generally cylindrical, open on one end, and closed on the other end. The jet caps 192 are made of a PVC plastic material and are sized to conform closely to the openings 188 of the t-fittings 186 and the elbows 190 . The jet caps 192 are provided with a jet opening 194 in the closed end. The jet opening 194 is a through-going hole in the jet cap 192 . The jet opening 194 is sized to permit restricted flow of water such that water delivered under pressure to the inside of the jet caps 194 exits at a high velocity through the jet opening 194 .
The t-fittings 186 and elbows 190 are connected to each other and the manifold 174 such that the jet caps 192 fitted to the t-fittings 186 and the elbows 190 point generally tangentially in a clockwise or counterclockwise direction in the plane of the first level 184 . The t-fittings 186 and elbows 190 are further positioned such that the t-fittings 186 and elbows 190 point at an elevation or declination from the plane of the level 184 a so as to have an elevation or declination of generally between 0° and ±45° from the plane of the level 184 a and thereby the plane of the tangential clockwise or counterclockwise direction. Thus water that is supplied to the t-fittings 186 and elbows 190 is directed out of the jet openings 194 so as to spray out in a generally tangential manner but also in a slightly elevated or declined direction. This serves to create a vortical flow pattern for the backwashing in a manner that will be described in greater detail below.
The intake tube assembly 172 comprises a second 184 b and third level 184 c located approximately 3″ and 5″ from the top end 180 of the manifold 174 respectively. Each of the second and third levels 184 comprises four ports 176 as previously described with respect to the backwash jet assembly 170 . A first end of an intake tube 196 is attached to each of the ports 176 of the second and third levels 184 of the manifold 174 such that the intake tube assembly 172 comprises eight intake tubes 196 . The intake tubes 196 are generally hollow, cylindrical, elongate members, open on the first end, closed on a second end, and made of a plastic material. The intake tubes 196 are provided with a plurality of intake openings 198 positioned between the first and second ends. The intake openings 198 of this embodiment are through-going slits in the wall of the intake tubes 196 and are sized and positioned to inhibit the passage of the bio-tubes 102 yet to allow minimally impeded passage of liquid water.
The ports 176 of the second and third levels 184 b and 184 c are positioned such that the intake tubes 196 extend radially outward from the manifold 174 . The ports 176 are further positioned such that the intake tubes 196 of each of the second and third levels 184 are positioned approximately 90° apart about the circumference of the manifold 174 and such that the ports 176 of the second and third levels 184 are positioned approximately 45° from being in alignment with each other. Thus, the intake tubes 196 extend radially outward approximately every 45° about the circumference of the manifold 174 in two levels 184 .
The fish pond filter system 100 comprises a filter mode 200 as shown in FIG. 6 . It should understood that FIG. 6 is an exploded, cutaway perspective view of the fish pond filter system 100 with several components of the fish pond filter system 100 not shown for clarity. FIG. 6 shows an alternative embodiment of the intake tube assembly 172 wherein the intake tubes 196 are positioned so as to extend radially outward from the manifold 174 and so as to be positioned approximately every 45° about the circumference of the manifold 174 in a single level 184 . It should be appreciated by one skilled in the art that the operation of the intake tube assembly 172 as described as follows is substantially similar to the operation of the embodiment of the intake tube assembly 172 previously described.
The fish pond filter system 100 comprises a container 202 . The container 202 is a hollow, closed structure made of a plastic material. The container 202 is sized and adapted to hold approximately 15 to 150 liters of water. The container 202 is preferably sized to adequately filter the volume of the fish pond 300 in a manner well known to those skilled in the art. The container 202 comprises an opening 204 in a top end 206 . The opening 204 is a generally circular through-going hole in the top end 206 of the container 202 and is approximately 6″ in diameter.
The water flow controller 124 is partially inserted into the container 202 through the opening 204 such that the stand pipe 146 , the backwash assembly 170 , and the intake tube assembly 172 pass into the interior of the container 202 . An O-ring 210 is placed between the top end 206 of the container 202 and the valve body 130 . The O-ring 210 is generally a toroid approximately 6″ in overall diameter and ¼″ in cross-section and is made of a rubber material. The O-ring 210 inhibits water flow out of the container 202 . The attachment flange 142 is removably attached to the container 202 so as to secure the water flow controller 124 to the container 202 and also so as to hold the O-ring 210 between the container 202 and the water flow controller 124 in compression. The attachment of the attachment flange 142 in this embodiment comprises a clamping procedure well known in the art. In an alternative embodiment, the attachment of the attachment flange 142 comprises a threading procedure or other known methods of removably attaching two assemblies.
The container 202 also comprises a bottom end 220 opposite the top end 206 . The container 202 also comprises a drain hole 216 adjacent the bottom end 220 . The drain hole 216 is a through-going hole in the container 202 and is provided with internal, female threads. The container also comprises a drain plug 212 and gasket 214 . The drain plug 212 is a brass assembly provided with external, male threads and is sized and threaded so as to be removably threaded into the drain hole 216 so as to hold the gasket 214 between the container 202 and the drain plug 212 in a known manner. The drain plug 212 and gasket 214 inhibit water flow out of the container 202 when they are inserted into the container 202 . Removal of the drain plug 212 and gasket 214 allow water contained within the container 202 to freely flow out of the container 202 .
A plurality of bio-tubes 102 as previously described are inserted into the container 202 prior to the attachment of the water flow controller 124 previously described so as to fill the container 202 to approximately 50% of capacity. The filtering mode 200 comprises positioning the valve handle 126 to the filter mode 200 position such that water flows freely into the inlet pipe 132 and exits the bottom end 156 of the valve body 130 through the media screen 144 . The water fills the container 202 and exits the container 202 by passing into the intake tube assembly 172 , through the stand pipe 146 , through the valve body 130 , and out the outlet pipe 134 .
The water entering the fish pond filter system 100 typically is drawn from the fish pond 300 and includes waste 304 . The water enters at the top end 206 of the container 202 and exits adjacent the bottom end 220 . Thus, the water flow is generally downwards. The bio-tubes 102 have a specific gravity slightly greater than unity and thus will tend to sink and rest adjacent the bottom end 220 of the container 202 in the general manner shown in FIG. 6 thereby defining the filtering media for the system 100 . Thus waste 304 contained within the water will pass generally downwards and because of the configuration of the bio-tubes 102 as previously described, the waste 304 will be substantially trapped within and on the upper extent of the bio-tubes 102 . The differing shapes and sizes of the bio-tubes 102 are such that the flow of water within the container 202 and through the bio-tubes 102 induces the bio-tubes 102 to stack in a random manner and to not create channels or voids with the bio-tubes 102 .
The waste 304 trapped within and on the bio-tubes 102 serves as food material for heterotrophic bacteria 310 . The heterotrophic bacteria 310 are naturally occurring in the fish pond 300 and are carried into the fish pond filter system 100 during use. Over time, the heterotrophic bacteria 310 establish colonies on the surface of and within the bio-tubes 102 . The heterotrophic bacteria 310 metabolize the waste 304 that becomes trapped on and within the bio-tubes 102 and substantially transform the waste 304 into forms which are more aesthetically pleasing in the fish pond 300 and which are not harmful to the health of the fish 302 in a well known manner. For example, the heterotrophic bacteria 310 metabolize nitrogenous compounds such as ammonia. The structures of the bio-tubes 102 as previously described provide a greater surface area for the culturing of the heterotrophic bacteria 310 than other known filtering systems and can support a greater density of heterotrophic bacteria 310 . Thus, the fish pond filter system 100 can process a greater waste 304 load and/or at a faster rate than other comparably sized filtering systems.
The heterotrophic bacteria 310 are not capable of completely metabolizing all of the waste 304 that typically enters a fish pond 300 and this unreacted waste 304 will accumulate over time. Eventually the amount of unreacted waste 304 will accumulate to the point of restricting flow through the fish pond filter system 100 . This situation is indicated by the water pressure indicated by the pressure gauge/sight glass 140 .
The fish pond filter system 100 comprises a backwash mode 230 as shown in FIG. 7 . The backwash 230 mode is initiated by positioning the valve handle 126 to the backwash 230 mode position. This induces the valve body 130 to direct water flow from the inlet pipe 132 , through the valve body 130 , through the stand pipe 146 , and out through the intake tube assembly 172 and the backwash jet assembly 170 and into the container 202 . The water fills the container 202 if it is not already full and then flows past the media screen 144 , into the valve body 130 , and out the waste pipe 136 .
The water flow out of the intake tube assembly 172 dislodges waste 304 material that has accumulated on the intake tubes 196 . The water flow out of and the orientation of the backwash jet openings 194 induces a vortical or cyclonic flow 232 pattern within the container 202 . This vortical flow 232 causes the bio-tubes 102 to tumble and swirl, efficiently dislodging waste 304 trapped within or on the bio-tubes 102 . The vortical flow 232 further advantageously sweeps the dislodged waste 304 upwards and tends to cause the waste and its carrier water to segregate from the bio-tubes 102 .
The backwash 230 mode is conducted for a variable period depending on accumulated waste 304 load that, in this embodiment, is approximately 10 minutes. A user can consult the pressure within the valve body 130 and the visible condition of the water flowing therethrough as indicated by the pressure gauge/sight glass 140 as indicia for terminating the backwash 230 mode.
Advantageously, the vortical action results in the bio-tubes 102 and the accumulated waste 304 being entrained in the circling water so as to be urged upwards to the level of the waste pipe 136 . The configuration of the backwash ports 176 is such that the water is circulated at a higher velocity in the vortical or cyclonic fashion. The higher velocity of the water results in more of the waste matter 304 being entrained in an upward motion to the level of the waste pipe 136 (FIG. 4) thereby allowing for removal of the waste material 304 . Hence, the cyclonic motion of the water as a result of the placement and configuration of the backwash assembly 170 is better able to urge the waste material 304 into the waste pipe 136 for removal from the system 300 .
Moreover, the bio-tubes 102 are preferably selected so as to be heavier than the waste material 304 and preferably have a specific gravity selected so that the bio-tubes reside on the bottom 220 of the container 202 in the general manner illustrated in FIG. 6 . The waste material 304 generally collects near the upper surface of the layer of bio-tubes 102 comprising the filtration media and is thus located more proximal to the waste pipe 136 . Further, since the bio-tubes 102 are generally heavier than the waste material 304 , when the system 300 is being backwashed, the waste material 304 is generally entrained in the water above the bio-tubes 102 . This allows for flushing of the waste material 304 while reducing the loss of the bio-tubes 102 during the backwashing 230 process.
Following conclusion of the backwash 230 mode, the valve handle 126 is positioned to select a rinse 240 mode. In the rinse 240 mode, water enters the inlet pipe 132 , passes through the valve body 130 and enters the container 202 through the media screen 144 . The water then exits through the intake tube assembly 172 , the stand pipe 146 and out the waste pipe 136 . The rinse 240 mode settles the bio-tubes 102 in preparation for return to the filtering mode 200 previously described.
The fish pond filter system 100 further comprises a waste 250 , re-circulate 260 , and closed 270 modes selectable by positioning the valve handle 126 as shown in FIG. 8 . The waste 250 mode directs water flow into the inlet pipe 132 , through the valve body 130 and out the waste pipe 136 , bypassing the container 202 and filtering 200 process previously described. The waste 250 mode is used to lower the level of the fish pond 300 without filtering 200 the water. The re-circulate 260 mode directs water into the inlet pipe 132 , through the valve body 130 , and back out the outlet pipe 134 , bypassing the filtering 200 process previously described. The re-circulate 260 mode is used to circulate water in the fish pond 300 without running it through the filtering 200 process previously described. The closed 270 mode blocks water flow into the inlet pipe 132 . The closed 270 mode is used to shut off the fish pond filter system 100 from the rest of the fish pond 300 .
A side view of a typical installation of the fish pond filter system is shown in FIGS. 9 and 10. The fish pond filter system 100 comprises a pump 320 as shown in FIG. 9 . The pump 320 is connected between the fish pond 300 and the inlet pipe 132 and is adapted to pump water from the fish pond 300 to the inlet pipe 132 when supplied with electrical or mechanical power in a well known manner. The pre-filter 306 screens out larger waste 304 particles such as leaves, sticks, or dead fish 302 which are approximately greater than ⅛″ in two dimensions that could damage the pump 320 or plug up the fish pond filter system 100 . In the embodiment shown in FIG. 10, the waste pipe 136 extends to discharge unreacted waste 304 and water in the backwash mode 230 as previously described.
The fishpond filter system 100 employs naturally occurring heterotrophic bacteria 310 as part of the filter mode 200 . The heterotrophic bacteria 310 metabolizes at least some of the biological waste 304 that is generated and accumulated in the fish pond 300 and thus reduces the chemical treatment that a user of the fish pond filter system 100 needs to employ to maintain the health and appearance of the fish pond 300 . Thus a user of the fish pond filter system 100 reduces the inconvenience and health risks associated with handling chemicals.
The bio-tubes 102 of the present invention provide a high surface area-to-volume ratio and thus can support an adequately large population of heterotrophic bacteria 310 in a relatively small container 202 . The shape and differing sizes of the bio-tubes 102 of the fish pond filter system 100 are configured to inhibit uniform stacking and channeling during the filter mode 200 . Other known filter media have a relatively low surface area-to-volume ratio and thus require larger, more obtrusive systems or are configured such that they tend to uniformly stack during filtering, which leads to the creation of channels within the filter media, which reduces the effectiveness of a filter system so equipped. By minimizing the size of the container 202 needed to adequately filter a given size of fish pond 300 , the fish pond filter system 100 minimizes the purchase cost, installation time and cost, and aesthetic impact of the fish pond filter system 100 while still efficiently and reliably filtering the fish pond water.
The fish pond filter system 100 also includes a backwash mode 230 , which creates a vortical flow pattern within the filter media container 202 . The vortical flow efficiently dislodges accumulated waste 304 trapped within the bio-tubes 102 and entrains the waste 304 out of the fish pond filter system 100 . The efficient backwash mode 230 , employing the vortical flow, takes less time to clean the filter media and directs less wastewater out of the system 100 . Thus, the fish pond filter system 100 furthers saves time and money for a user.
Although the preferred embodiments of the present invention have shown, described and pointed out the fundamental novel features of the invention as applied to those embodiments, it will be understood that various omissions, substitutions and changes in the form of the detail of the device illustrated may be made by those skilled in the art without departing from the spirit of the present invention. Consequently, the scope of the invention should not be limited to the foregoing description but is to be defined by the appended claims. | A system for filtering and treating waste generated or collected in the water of a fish pond. The system includes a pump, pre-filter, piping, a valve assembly, and a filter media container enclosing a plurality of discrete filter media. The filter media are generally hollow, plastic structures with a plurality of external ribs and internal dividing walls. The filter media has a high surface area-to-volume ratio and can support a high volumetric density of naturally occurring heterotrophic bacteria. The heterotrophic bacteria establish colonies on the internal and external surfaces of the filter media and biologically metabolize waste that is trapped on the media. The bacterial metabolization transforms much of the waste to an aesthetically and biologically neutral form thereby reducing the need for chemical treatment of the pond water. The system includes a backwashing mode to agitate and remove unreacted waste from the system and direct the waste stream out of the system, preferably to be used as fertilizer. | 8 |
FIELD OF THE INVENTION
The present invention relates to foam core panels in general, and more particularly to a method and devices used to connect the edges of two or more panels. The method and devices of the present invention are particularly useful in constructing point of purchase displays.
BACKGROUND
The use of foam core panels in the construction of point of purchase displays or the like has become increasingly popular because such panels are light, rigid, relatively inexpensive, and easy to use. Such panels typically consist of an extruded polystyrene, polyethylene or polyurethane foam core laminated on both sides with bleached white clay coated Kraft paper liners.
Foam core panels are popular in part because they are great for printing, easily accept most glues and are easy to cut. However, one long felt but unmet need relates the connection together of foam core panels and their use to construct three-dimensional displays. It is often desirable to join two or more panels edge-to-edge to form a smooth continuous surface. However, conventional methods for joining foam core panels are not sufficiently sturdy or easy to use.
One conventional method for connecting foam core panels is through the use of glue. However, the use of glue is not desirable in many applications. Moreover, the use of glue may not be practical depending on the size and weight of the panels being connected. Moreover, the use of glue requires time for the glue to set.
Another conventional method for connecting foam core panels uses screws and grommets. The use of grommets and screws is particularly suited to connecting high density boards but is not suitable in applications in which the panels must be rigidly connected to form a continuous surface. Further, conventional panel connection hardware remains visible in the end of the product. One Objective in creating multi-panel point of purchase displays is to present “clean” surfaces which are free of straps, tape, rivets and like visually distracting artifacts of connection.
Accordingly, what is needed is an inexpensive and easy to use connector for rigidly connecting foam core panels, without the use of adhesives, screws, or other visible hardware.
SUMMARY OF THE INVENTION
The present invention provides a connector used to join two or more panels, each having a foam core and having a cavity, bounded by internal sidewalls, defined in an edge thereof. The connector includes a body having at least two attachment heads dimensioned to fit snugly within corresponding cavities defined in edges of the foam core panel. Plural barbs provided on each attachment head are configured to enter respective cavities, pierce the internal sidewalls and inhibit withdrawal of the attachment head from the cavity.
According to one aspect of the invention, the foam core has a density D foam and the internal sidewalls bounding the cavity have a density D skin wherein D foam <D skin .
According to one embodiment of the present invention the barbs are configured to facilitate easy insertion into the cavity and subsequently resist withdrawal of the barbs from the foam core.
According to another embodiment, the body of the connector includes a spacer portion which inhibits insertion of the body into the cavity beyond a predetermined depth such that the spacer portion provides predetermined spacing between adjacent panels.
The connector of the present invention may be used to construct a point of purchase display including a support member having at least one hole defined therethrough and at least two foam core panels. Each panel has a foam core having a cavity, bounded by internal sidewalls, formed to extend inwardly from an edge of the panel. A connector having a body portion is provided having at least two attachment heads dimensioned to fit snugly within corresponding cavities defined in the foam core panels. Plural barbs provided on each attachment head are configured to pierce the internal sidewalls and inhibit withdrawal of the attachment head from the cavity. In operation, the connector is inserted into the hole defined in the support member and connects foam core panels on opposite sides of the support member.
The support member may optionally be formed of a flexible transparent or translucent material such as plastic, and may optionally be curved with the curved member being contoured to conform to the edges of the foam core panels and provide additional rigidity to the member.
The connector of the present invention may further be used to construct a point of purchase display including a plurality of panels, each having a foam core having a first cavity defined in a vertical edge portion thereof and a second cavity defined in a horizontal side edge portion thereof. Each cavity being bounded by internal sidewalls. A plurality of connectors are provided, each having a body portion and at least two attachment heads dimensioned to fit snugly within corresponding ones of the cavities. Barbs provided on each attachment head are configured to pierce the internal sidewalls and inhibit withdrawal of the attachment head from the cavity. The plurality of panels are connected in a series of rows and columns with connectors connecting adjacent ones of the plurality of panels.
These and other aspects of the invention will be better explained in the detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1L show several different configurations of a connector according to the present invention;
FIG. 2A shows an exploded view of a conventional foam core panel;
FIG. 2B shows an enlarged sectional detail view of the foam core panel of FIG. 2A;
FIG. 3 shows a cavity-forming tool according to the present invention;
FIGS. 4A and 4B show how the cavity-forming tool of FIGS. 3A and 3B is used to form a cavity in the foam core;
FIGS. 5A and 5B shows an enlarged view of a connector attachment head piercing the foam core of a panel according to the present invention;
FIG. 5C is a sectional view showing the connector of the present invention connecting two foam core panels;.
FIGS. 6A and 6B show an enlarged view of an attachment head according to the present invention;
FIGS. 7A and 7B show a first configuration of a display constructed using a connector having a spacer portion according to the present invention;
FIGS. 8A and 8B show a second configuration of a display constructed using a connector according to the present invention;
FIGS. 9A and 9B show a third configuration of a display constructed using a connector according to the present invention; and
FIG. 10 shows a fourth configuration of a display constructed using a connector according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1A-1L illustrate several alternative configurations of a connector 10 according to the present invention. In its simplest form the connector 10 has a body 12 with at least one attachment head 14 and plural barbs projecting away from the attachment head 14 . However, the connector 10 may have any number of attachment heads 14 at varying angles relative to the connector body 12 .
In the configuration shown in FIG. 1A the connector 10 has two attachment heads 14 , each head 14 having plural barbs 16 . Indentations 13 may be used to form a hinge line H where the connected panels are not to be coplanar.
In the configuration shown in FIG. 1B the connector 10 has two attachment heads on a first side of the connector body 12 , and two additional attachment heads on a second side of the connector body 12 .
In the configuration shown in FIG. 1C the connector body 12 is generally circular and includes plural attachment heads 14 radially projecting from a central disk.
In the configuration shown in FIG. 1D the connector body 12 includes a spacer portion 18 which will be described herein below.
In the configuration shown in FIG. 1E the connector body 12 is stepped such that two attachment heads 14 A are on a different plane than another opposed attachment head 14 B.
In the configurations shown in FIGS. 1F and 1G the connector 10 includes three attachment heads 14 , two on one side of the connector body 12 and one on the other side. In FIG. 1F, the attachment heads on one side are parallel to each other, while in FIG. 1G the attachment heads 14 on one side of the spacer 18 project at an angle to each other.
In the configuration shown in FIG. 1H the connector 10 includes four attachment heads 14 , two on each side of the connector body 12 .
In the configuration shown in FIG. 11 the connector 10 includes six attachment heads 14 , three on each side of the connector body 12 and projecting outwardly at different angles.
In the configuration shown in FIGS. 1J-L the connector 10 has a single attachment head 14 . More particularly, the connector 10 in FIGS. 1J and 1K includes an attachment head 14 at one end and a mounting hole 15 at another end. The mounting hole 15 may be connected, for example, to a support (not shown) such as a hook, or a string or wire suspended from a ceiling. The body 12 in FIG. 1J is generally in the same plane with the attachment head 14 , whereas in FIG. 1K the connector body 12 is in a different plane than the attachment head 14 .
The connector 10 shown in FIG. 1L includes an attachment head 14 at one end and a support portion 17 at another end. The support portion 17 may be used, for example, to support a display item (shown in dashed lines in FIG. 10) such as a shoe, a shelf or the like.
Referring to FIG. 1A, the attachment heads 14 generally have a width W head and a thickness T head which is varied depending on the density and thickness of the foam core and the required fastening force and the resiliency of the material from which the barbs are made. The barbs 16 generally have length L barb which is also varied depending on the density and thickness of the foam core and the required fastening force. The width W head is generally much greater than the thickness T head (W head >>T head ), such that the connector 10 may be used with relatively thin panels 20 , be made of a material such as plastic yet possess the strength required to perform its fastening function.
The width W may be dictated by the strength of the material used to form the connector. Moreover, a wide connector 10 acts against torsion of the panels around the connector axis, and thus is useful in constructing a more rigid connection.
The barbs 16 are preferably resilient or springy, and should be elongated so that they will yield to a cantilever force placed on them more easily than to a column force applied in alignment with their lengths.
According to a preferred embodiment, the head 14 has a thickness T head is selected in relation to the thickness of the foam core T foam into which of the head is being inserted. According to a preferred embodiment, the ratio of T head to T foam is generally 1:3. In other words, the thickness of the head 14 is generally ⅓ of the thickness of the foam core 22 .
The connector 10 is suitable for use in conjunction with a wide variety of low-density foam products, and provides between 5.5 and 12 pounds of fastening force depending on the density of the foam core, the size and number of attachments heads, and the size and number of barbs 16 .
The connector 10 may be formed from any of a number of different materials such as plastic, metal, or the like. According to a presently preferred embodiment, the connector 10 is integrally formed from injection molded plastic.
Preferably, the attachment heads 14 , connector body 12 , and barbs 16 are integrally formed as a single piece. However, the attachment heads 14 and barbs may be formed separately from the connector body 12 , such that the attachment head is later joined with the connector body by thermo-bonding or the like.
The dimensions of the connector 10 may be adjusted depending on the size and thickness of panels to be connected, and the amount of fastening force required. According to a presently preferred embodiment, the head 14 has a thickness generally falling in the range {fraction (1/16)} inch≦T head ≦{fraction (3/16)} which generally corresponds to a foam core thickness in the range {fraction (3/16)} inch≦T foam ≦½ inch. However, it should be appreciated that the invention is not limited to any particular dimensions.
FIG. 2A shows an exploded view of a conventional foam core panel 20 which includes a foam core 22 formed of a thermoplastic, foamed polymer such as polystyrene, polyethylene or polyurethane laminated on both sides with bleached white clay coated Kraft paper liners 24 . FIG. 2B shows an enlarged sectional view showing that the foam core 22 is composed of plural foam cells 26 .
Use of the connector 10 of the present invention is not limited to any particular composition of foam core panel, and will work with commercially available foam core boards. However, the density of the foam core must be sufficiently low to allow the barbs to pierce a heat-collapsed skin made from the foam core. Preferably, the density of the foam core is between 0.02 and 0.15 grams per cubic centimeter.
FIG. 3 shows a cavity-forming tool 40 according to the present invention, and FIGS. 4A and 4B show how the tool 40 is used to form a cavity 28 in the foam core 22 . As best r seen in FIG. 4B heat generated by the heating element 42 of the tool 40 causes the foam cells 26 to collapse upon insertion of the element 42 into the foam core layer 22 , creating a cavity 28 . More particularly, the foam has a melting point of approximately 375 to 425 degrees Fahrenheit. As the cells collapse due to the heat they form a skin 30 of collapsed material which is denser than the foamed material. Notably, the foamed material has a density between 0.02 and 0.15 grams per cubic centimeter, whereas the collapsed or unfoamed material has a density between 0.9 and 1.25 grams per cubic centimeter. Specifically, unfoamed polystyrene has a density of approximately 1.04 to 1.09 grams per cubic centimeter, unfoamed polyethylene has a density of approximately 0.91 to 0.965 grams per cubic centimeter, and unfoamed polyurethane has a density of approximately 1.05 to 1.25 grams per cubic centimeter.
The cavity 28 is dimensioned to snugly accommodate one of the attachment heads 14 . Care must be exercised to ensure that the cavity 28 is slightly narrower than the combined width W combined of the attachment head 14 and barb 16 connector, and is of generally the same thickness as the thickness T of the attachment head 14 of the connector 10 . See FIG. 5 B.
The attachment head 14 is forcedly inserted into the cavity 28 such that the barbs 16 pierce the denser skin 30 and are retained therein. See FIGS. 5A and 5B.
FIG. 5C is a sectional view showing the connector 10 inserted into corresponding cavities 28 of the foam core panels 20 , and providing a substantially smooth planar connection therebetween.
According to an alternative embodiment, the cavity 28 may be formed by mechanically removing the foam using, for example, a knife or the like rather than by the heating tool 40 . However, the use of heating tool 40 is preferred because it creates the denser skin 30 which is believed to more effectively retain the barbs 16 of the connector 10 .
As shown in FIGS. 1D and 1E, the connector body 12 may be provided with a spacer portion 18 which provides spacing between adjacent panels 20 . The spacer portion 18 is configured to prevent more than a predetermined length of the connector 10 from being inserted into the cavity 28 . When the connector 10 is formed of a clear plastic, an effect may be achieved whereby a panel looks as if it is suspended in mid-air without any support.
In the embodiment depicted in FIG. 1D, the spacer portion 18 has a width W spacer which is larger than the combined width W combined of the attachment head 14 and the barb 16 . In the embodiment depicted in FIG. 1E, the spacer portion 18 is stepped such that attachment head 14 A is in a different plane from attachment head 14 B. Moreover, the spacer portion 18 may be mutually perpendicular to both attachment heads 14 A and 14 B.
According to one aspect of the present invention, the connector 10 is configured such that when a cantilever loading is imposed on the barbs 16 they are generally more resilient and yielding in an insertion direction (FIG. 6) than they are in a withdrawal direction.
More particularly, and referring to FIG. 5B, when an insertion force is applied to urge the connector 10 into the cavity 28 , the peripheral wall of the foam core 22 contacts the barbs 16 and imposes a compressive force F cantilever at a significant angle to axis A of the barbs 16 , urging the barbs inwardly toward the body 12 . Correspondingly, when a withdrawal force is applied to withdraw the connector 10 from the cavity 28 , the peripheral wall of the foam core 22 interferes with the barbs 16 and imposes a column loading force F column that is at an acute angle to axis A of the barbs, pulling the barbs 16 away from the body 12 . Importantly, F column is significantly greater than F cantilever such that a greater force is required to withdraw the connector from the cavity 28 than the force required to insert the connector into the cavity 28 . Stated in another way, the elongate, resilient barbs 16 are more yielding to forces at a substantial angle to the direction of the length of the connector body than they are to an extraction force in substantial alignment with that direction. The barbs 16 elastically deform toward the center of the attachment head 14 when the attachment head is inserted into the cavity 28 , but resist deformation when an attempt is made to withdraw the attachment head 14 from cavity 28 .
The simplest use of the connector 10 is the edge-to-edge assembly of two or more panels 20 into a single contiguous display. The form of connector 10 shown in FIG. 2A is used for this kind of construction. Such a multipanel display may be chosen to reside substantially in the same plane, or may be hinged such that the panels are at angles to each other. One important technical advantage of the present invention is that in use, the form of connector 10 shown in FIG. 2A is invisible to an observer of the display, providing a neater and less cluttered appearance.
The connector 10 of the present invention facilitates the construction of several other novel displays, which for example may be point of purchase displays. By way of illustration, FIGS. 7A and 7B show a display 70 constructed using the connector 10 having a spacer portion 18 (FIGS. 1 D and 1 E). The display 70 is composed of plural foam core panels 20 which are connected in vertically in columns, which vertical columns are connected horizontally to adjacent columns. For example, panels 20 A- 20 C, panels 20 D- 20 F and panels 20 H- 20 J, respectively, are connected in a vertically spaced relationship using a connector 10 having a spacer portion 18 such depicted in FIG. 1 D. The spacer portion 18 ensures that the panels 20 A- 20 C and 20 D- 20 F are uniformly spaced a predetermined distance from one another.
More particularly, the panels 20 are connected using the above described method in which a cavity 28 is formed in the foam core 22 using a cavity-forming heating tool, resulting in the formation of a cavity skin 30 which aids in retaining the barbs 16 .
The column of panels 20 A- 20 C is horizontally connected to the column of panels 20 D-F and 20 H-J using a connector 10 having a spacer portion 18 such as depicted in FIG. 1 E. Importantly, the spacer portion 18 (FIG. 1E) is stepped such that attachment head 14 A is in a different plane from attachment head 14 B. Consequently, the connector 10 shown in FIG. 1E will position the column of panels 20 A- 20 C in a fixed, spaced relationship in a different plane from the columns of panels 20 D-F and 20 H-J.
FIGS. 8A and 8B illustrate a second point of purchase display 80 which may be constructed using the connector 10 of the present invention. The display 80 includes a panel 82 and two foam core panels (leg members) 20 . For visual design reasons, the panel 82 may be formed of transparent plastic; however, the panel 82 may be formed of practically any material, and need not be formed of foam core, and may as easily be translucent or opaque. While the constructions illustrated herein are built around thin intervening panels, the present invention can also be used with central or intermediate through-connected members having greater thicknesses.
As best see in FIG. 8B, one or more holes 86 are defined in panel 82 to facilitate connector 10 to interconnect panels 20 . The attachment head 14 A of connector 10 A is inserted through the hole 86 into the cavity 28 A formed in a side edge portion of the foam core 22 A, and attachment head 14 B is inserted through the hole 86 into the cavity 28 B formed in a side edge portion of the foam core 22 B. It should be noted that the panels 20 provide additional support or rigidity for the panel 82 .
The panels 20 are connected using the above described method in which a cavity 28 is formed in the foam core 22 using a cavity-forming heating tool, resulting in the formation of a cavity skin 30 which aids in retaining the barbs 16 .
FIGS. 9A and 9B illustrate yet another point of purchase display 90 which may be constructed using the connector 10 of the present invention. The display 90 includes a support member 92 and two or more foam core panels 20 . For aesthetic reasons, the support member 92 is preferably formed of transparent plastic; however, the support member 92 may be formed of practically any material and need not be formed of foam core. As shown in FIG. 9A the support member 92 does not have to be planar (flat). In particular, the support member 92 may be curved in any number of shapes. The foam core panels 20 are contoured to match the surface profile of the support member 92 , and provide additional support or rigidity to the support member 92 . The panels 20 may be used as shelves to support samples of goods for sale.
As best seen in FIG. 9B, one or more holes 96 are defined in the support member 92 to facilitate connector 10 to interconnect corresponding panels 20 . The attachment head 14 A of connector 10 A is inserted through the hole 96 into the cavity 28 A formed in a side edge portion of the foam core 22 A, and attachment head 14 B is inserted through the hole 96 into the cavity 28 B formed in a side edge portion of the foam core 22 B.
The panels 20 are connected using the above described method in which a cavity 28 is formed in the foam core 22 using a cavity-forming heating tool, resulting in the formation of a skin 30 which aids in retaining the barbs 16 .
FIG. 10 illustrates yet another point of purchase display 1000 which may be constructed using the connector 10 of the present invention. The display 1000 includes a foam core panel 20 and at least one connector 10 A. The connector 10 of the type shown in FIG. 1J or FIG. 1K is inserted in an edge portion, with the mounting hole 15 exposed. The mounting hole 15 enables the display 1000 to be removably attached to a hook, or a vertical support such as a wire or the like.
More particularly, the display 1000 may be constructed as any of the displays 70 , 80 , or 90 shown in FIGS. 7A-9B, and further including the connector 10 of the type shown in FIG. 1J or FIG. 1 K.
Still further any of the displays 70 , 80 , 90 or 1000 may further be provided with a connector 10 of the type shown in FIG. 1L having a support portion 17 . In this manner, a display capable of supporting display items may be constructed.
While the preferred embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the spirit of the invention, the scope of which is defined by the appended claims. | The present invention discloses a connector used to join two or more panels having a foam core and having a cavity defined in a edge thereof. The connector includes a connector body having at least two attachment heads which are dimensioned to fit snugly within the corresponding cavities bounded by internal sidewalls defined in the foam core. Barbs provided on each attachment head are configured to pierce the internal sidewalls of the panels and inhibit withdrawal of the attachment head from the cavity defined in the foam core. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a U.S. nonprovisional patent application of, and claims priority under 35 U.S.C. §119(e) to, U.S. provisional patent application Ser. No. 62/044,217, filed Aug. 30, 2014, which provisional patent application is incorporated by reference herein.
COPYRIGHT STATEMENT
All of the material in this patent document is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved.
BACKGROUND OF THE PRESENT INVENTION
Field of the Present Invention
The present invention relates generally to pet toys, and, in particular, to throw and fetch equipment and systems using a variety of balls and/or other projectiles.
BACKGROUND
Many dogs are natural retrievers that enjoy retrieving objects such as sticks or balls, especially when the objects are thrown very far or with great force. Manually throwing such objects great distances for long periods of time, makes a person's back and arm tired before the animal is ready to rest.
To reconcile this problem, some individuals have resorted to using a bat, sling shot, tennis racket or ball wand launcher to throw a ball great distances. Unfortunately, such devices are only usable with a single type of projectile. This is primarily due to the shape of the launcher “socket” or “holder,” which is typically shaped to match the shape of the projectile being launched. For example, launchers for spherical balls utilize sockets or holders that are in the form of a portion of a sphere. It is thus difficult for such launchers to be used with non-spherical projectiles.
In addition to one's back and arm becoming tired, another drawback of playing the game of fetch with a dog is having to physically pick up the ball with your hands. Typically, after a few throws, the ball is covered with dog saliva, which can be distasteful and unhealthy to touch. A further drawback is the possibility of getting bitten by the dog when initially picking the ball up off the ground after the dog has dropped it. Thus, some ball launchers have been developed which can be used to pick a ball or other projectile up without touching it.
Currently, there are several ball throwing devices available for pet owners whose dogs enjoy playing fetch for exercise and/or fun. Such devices range and have many various and different features, such as automatic or remote controlled operation, various ball gripping, grabbing or picking-up methods, man-powered to automatic and/or remote controlled, folding or telescopic wands, retracting, and such. Such prior art devices are disclosed, for example, in U.S. Pat. No. 1,535,029 to Murch, U.S. Pat. No. 3,428,036 to Parker, U.S. Pat. No. 3,589,349 to Parker, U.S. Pat. No. 3,841,292 to Hoffman, U.S. Pat. No. 4,974,574 to Cutlip, U.S. Pat. No. 5,390,652 to Minneman et al, U.S. Pat. No. 6,076,829 to Oblack, U.S. Pat. No. 7,686,001 to Fitt, U.S. Pat. No. 7,677,994 to Matsumoto et al, and U.S. Pat. No. 8,418,681 to Levin et al, as well as U.S. Patent Application Publication Nos. 2012/0227721 to Geller and 2013/0284158 to Hansen.
Of these prior art devices, the ball throwing apparatus shown in U.S. Pat. No. 6,076,829 is typical. The ball throwing apparatus includes an elongated shaft, having a longitudinal axis and opposite distal and proximal ends, and a ball holder in the form of a half-spherical structure integrally formed on the distal end of the elongated shaft. Such a ball holder is useful with spherical balls of a particular size, but not with other projectiles of other shapes or even with spherical balls of other sizes.
In view of the above, a need is believed to exist for a ball throwing or launching device and system that is adaptable for use with projectiles of different sizes and/or shapes to enable a user to “play fetch” with a dog or other pet in various environments.
SUMMARY OF THE PRESENT INVENTION
Some exemplary embodiments of the present invention may overcome one or more of the above disadvantages and other disadvantages not described above, but the present invention is not required to overcome any particular disadvantage described above, and some exemplary embodiments of the present invention may not overcome any of the disadvantages described above.
Broadly defined, the present invention according to one aspect is a throw and fetch apparatus, including: a universal handle; a projectile; and an interchangeable projectile holder element, having an interior that is sized and shaped to correspond to the size and shape of the projectile, wherein in a first state the projectile holder element is attached to a distal end of the universal handle, and wherein in a second state the interchangeable projectile holder element is detached from the distal end of the universal handle such that an alternative interchangeable projectile holder element, having an interior sized and shaped to correspond to an alternative projectile, may be attached thereto.
In a feature of this aspect, the universal handle includes a handgrip at a proximal end thereof, a projectile holder base for attachment to the interchangeable projectile holder element, and a shaft extending between the handgrip and the projectile holder base.
In further features, a projectile holder, adapted to receive the projectile and to release the projectile when the universal handle is whipped forward, is defined by one or more elements of the throw and fetch apparatus; the projectile holder is defined by a portion of the projectile holder base and a portion of the interchangeable projectile holder element; and/or the projectile holder is defined solely by the interchangeable projectile holder element.
In other further features, the projectile holder base includes a first fitting and the interchangeable projectile holder element includes a second fitting, the first and second fitting being couplable such that the interchangeable projectile holder element may be attached and detached from the projectile holder base; the first and second fittings are pieces of a buckle; the buckle is a snap-fit “parachute” buckle; and/or the first and second fittings are threaded fittings that may be screwed together.
Broadly defined, the present invention according to another aspect is a throw and fetch system, including: a universal handle; a first projectile, having a first size and/or shape; a first interchangeable projectile holder element, having an interior that is sized and shaped to correspond to the size and shape of the first projectile; a second projectile, having a second size and/or shape, the second size and/or shape being different from the first size and/or shape; and a second interchangeable projectile holder element, having an interior that is sized and shaped to correspond to the size and shape of the second projectile; wherein in a first state the first projectile holder element is attached to a distal end of the universal handle such that the first projectile may be held then thrown therefrom by a user; and wherein in a second state the second projectile holder element is attached to the distal end of the universal handle such that the second projectile may be held then thrown therefrom by the user.
In a feature of this aspect, the universal handle includes a handgrip at a proximal end thereof, a projectile holder base for attachment to the interchangeable projectile holder element, and a shaft extending between the handgrip and the projectile holder base.
In further features, a projectile holder, adapted to receive the projectile and to release the projectile when the universal handle is whipped forward, is defined by one or more elements of the throw and fetch apparatus; the projectile holder is defined by a portion of the projectile holder base and a portion of the first or second interchangeable projectile holder element; and/or the projectile holder is defined solely by the first or second interchangeable projectile holder element.
In other further features, the projectile holder base includes a first fitting and each interchangeable projectile holder element includes a second fitting, the first and either of the second fittings being couplable such that the respective interchangeable projectile holder element may be attached and detached from the projectile holder base; the first and second fittings are pieces of a buckle; the buckle is a snap-fit “parachute” buckle; and/or the first and second fittings are threaded fittings that may be screwed together.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features, embodiments, and advantages of the present invention will become apparent from the following detailed description with reference to the drawings, wherein:
FIG. 1 is a perspective view of elements of a throw and fetch system utilizing interchangeable projectile holders in accordance with one or more preferred embodiments of the present invention;
FIG. 2 is a perspective view of portions of the throw and fetch system of FIG. 1 , wherein one of the interchangeable projectile holder elements has been attached to the universal handle;
FIG. 3 is an environmental view of a user picking up or retrieving the spherical ball as part of a method of using the system of FIG. 1 in accordance with one or more preferred embodiments of the present invention;
FIG. 4 is an environmental view of a user throwing the spherical ball as part of a method of using the system of FIG. 1 in accordance with one or more preferred embodiments of the present invention;
FIG. 5 is a fragmentary side view of portions of the projectile thrower of FIG. 2 ;
FIG. 6 is a side view of the of the projectile thrower portions of FIG. 5 , shown in a disassembled state;
FIG. 7 is a front/side perspective view of the projectile thrower portions of FIG. 6 ;
FIG. 8 is a front view of the projectile thrower portions of FIG. 6 ;
FIG. 9 is a rear view of the projectile thrower portions of FIG. 6 ;
FIG. 10 is a perspective view of portions of the throw and fetch system of FIG. 1 , wherein another interchangeable projectile holder element has been attached to the universal handle to form an alternative projectile thrower; and
FIG. 11 is a fragmentary front/side view of portions of the projectile thrower of FIG. 10 , shown in a disassembled state.
DETAILED DESCRIPTION
As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art (“Ordinary Artisan”) that the present invention has broad utility and application. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the present invention. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure of the present invention. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the invention and may further incorporate only one or a plurality of the above-disclosed features. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present invention.
Accordingly, while the present invention is described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present invention, and is made merely for the purposes of providing a full and enabling disclosure of the present invention. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded the present invention, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection afforded the present invention be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.
Thus, for example, any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the present invention. Accordingly, it is intended that the scope of patent protection afforded the present invention is to be defined by the appended claims rather than the description set forth herein.
Additionally, it is important to note that each term used herein refers to that which the Ordinary Artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein—as understood by the Ordinary Artisan based on the contextual use of such term—differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the Ordinary Artisan should prevail.
Regarding applicability of 35 U.S.C. §112, ¶6, no claim element is intended to be read in accordance with this statutory provision unless the explicit phrase “means for” or “step for” is actually used in such claim element, whereupon this statutory provision is intended to apply in the interpretation of such claim element.
Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. Thus, reference to “a picnic basket having an apple” describes “a picnic basket having at least one apple” as well as “a picnic basket having apples.” In contrast, reference to “a picnic basket having a single apple” describes “a picnic basket having only one apple.”
When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Thus, reference to “a picnic basket having cheese or crackers” describes “a picnic basket having cheese without crackers,” “a picnic basket having crackers without cheese,” and “a picnic basket having both cheese and crackers.” Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.” Thus, reference to “a picnic basket having cheese and crackers” describes “a picnic basket having cheese, wherein the picnic basket further has crackers,” as well as describes “a picnic basket having crackers, wherein the picnic basket further has cheese.”
Referring now to the drawings, in which like numerals represent like components throughout the several views, one or more preferred embodiments of the present invention are next described. The following description of one or more preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its implementations, or uses.
FIG. 1 is a perspective view of elements of a throw and fetch system 10 utilizing interchangeable projectile holders in accordance with one or more preferred embodiments of the present invention. As shown therein, the system includes a universal handle 40 , one or more projectiles 12 , 112 , and one or more interchangeable projectile holder elements 62 , 162 . The system 10 , and particularly the interchangeable projectile holder elements 62 , 162 , enables a user 101 , 102 to throw or otherwise launch projectiles of different shapes and sizes for retrieval by a pet 104 . It will be appreciated that such a system 10 may be utilized with any pet that can be taught or trained to retrieve a ball or other object, but that the system 10 may find particular utility with dogs, and thus the system 10 will be described herein with particular regard to dogs.
The illustrated handle 40 , which may sometimes be referred to as a “wand,” includes a projectile holder base 42 , a shaft 44 , and a handgrip 46 . It will be appreciated that the particular handle 40 shown in FIG. 1 , and particularly the shaft 44 and handgrip 46 thereof, is exemplary only, and that the shape, dimensions, elements, and general form factor of the ball thrower may be varied considerably without departing from the scope of the present invention. For example, the handle 40 may take the form of a bat, paddle, tennis racket, lacrosse stick, cesta, scoop, slingshot, or the like, or alternatively may be in some cases be an automatic launching device, such as a tennis ball thrower or other specialized projectile launching device.
Use of the system 10 involves a user 101 , 102 selecting a desired projectile 12 , 112 and attaching a corresponding projectile holder element 62 , 162 to the universal handle 40 . In this regard, FIG. 2 is a perspective view of portions of the throw and fetch system 10 of FIG. 1 , wherein one of the interchangeable projectile holder elements 62 has been attached to the universal handle 40 . In particular, a projectile holder element 62 that is in the approximate form of a quarter of a sphere has been selected from the available projectile holder elements 62 , 162 and attached to the projectile holder base 42 . The selected projectile holder element 62 and the projectile holder base 42 together form a projectile holder 60 that is particularly suitable for use with the spherical ball 12 of the size shown in FIGS. 1 and 2 .
Once a ball or other projectile 12 is selected and the corresponding projectile holder element 62 attached, the ball thrower 50 is ready for use. In at least some embodiments, the ball thrower 50 is used to throw or launch the ball 12 , and in at least some of these embodiments, the assembled ball thrower may also be utilized to lift the ball 12 from the ground so that it need not be touched by the user's hand. By way of example, FIG. 3 is an environmental view of a user 101 picking up or retrieving the spherical ball 12 as part of a method of using the system 10 of FIG. 1 in accordance with one or more preferred embodiments of the present invention. In particular, the user 101 is holding the ball thrower 50 by the handgrip 46 and using the ball holder 60 to scoop the ball 12 up so that it can be cradled therein. FIG. 4 is an environmental view of a user 102 throwing the spherical ball 12 as part of a method of using the system 10 of FIG. 1 in accordance with one or more preferred embodiments of the present invention. In particular, the user 102 is holding the ball thrower 50 by the handgrip 46 , with the ball 12 still cradled in the ball holder 60 , and whipping the thrower 50 forward such that the ball 12 is thrown or launched from the ball holder 60 to achieve a desired trajectory and travel distance. Assuming the dog 104 is trained to do so, the intent is for the dog 104 to follow the ball 12 (or in some cases to intercept that ball 12 along its trajectory) and return or fetch the ball 12 to the user 101 , 102 .
The interchangeable projectile holder elements 62 , 162 may be attached to the projectile holder base 42 in any of a variety of ways. In the illustrated embodiments, the projectile holder base 42 includes one piece (half) 48 of a conventional snap-fit buckle of nylon, other thermoplastic polymers, or the like, while each projectile holder elements 62 , 162 includes a corresponding piece (half) 68 of such a buckle. In this regard, FIG. 5 is a fragmentary side view of portions of the projectile thrower 50 of FIG. 2 , and FIGS. 6-9 are a side view, a front/side perspective view, a front view, and a rear view, respectively, of the projectile thrower portions of FIG. 5 , shown in a disassembled state. As shown therein, the half-spherical ball holder 60 of FIG. 5 is formed from two quarter-spherical sections, wherein one of the quarter-spherical sections is part of the projectile holder base 42 and the other quarter-spherical section is part of the projectile holder element 62 . Notably, it will be appreciated that other connection/attachment mechanisms may be substituted for the “parachute”-type buckle illustrated in the various drawings without departing from the present invention. For example, threaded fittings (not shown) may be utilized to allow the interchangeable projectile holder elements 62 , 162 to be screwed onto the projectile holder base 42 .
Regardless of the connection mechanism utilized, however, it is preferred that the mechanism be easily releasable so that an alternative projectile holder element, such as the alternative projectile holder element 162 illustrated in FIG. 1 , may be used instead. In this regard, FIG. 10 is a perspective view of portions of the throw and fetch system 10 of FIG. 1 , wherein another interchangeable projectile holder element 162 has been attached to the universal handle 40 to form an alternative projectile thrower 150 , and FIG. 11 is a fragmentary front/side view of portions of the projectile thrower 150 of FIG. 10 , shown in a disassembled state. As shown therein, the quarter-spherical projectile holder element 62 of FIGS. 2-9 has thus been replaced with an elongated projectile holder element 162 that is more suitable for a prolate or elongated spheroid projectile, American football-shaped projectile, or the like. Like the first projectile holder element 62 , this alternative projectile holder element 162 has a buckle piece (half) 68 that mates with the buckle piece (half) 48 on the projectile holder base 42 . As illustrated thereby, the interchangeable projectile holder elements 62 , 162 may be detached from the projectile holder base 42 and replaced with any number of alternative projectile holder elements to accommodate balls, discs, and other projectiles of different sizes and/or shapes.
It will be appreciated that in some embodiments, the projectile holder base 42 may be primarily comprised only of a fitting, such as the illustrated buckle piece 48 , and that the interchangeable projectile holder elements may each comprise an entire projectile holder with a corresponding fitting, such as the other illustrated buckle piece 68 , wherein the two buckle pieces 48 , 68 may be coupled together to attach the interchangeable projectile holder to the projectile holder base. Such an arrangement would enable the entire projectile holder to be customized for a particular projectile size or shape, rather than limiting the customization to the types of interchangeable elements 62 , 162 shown in FIGS. 1-11 . However, such an arrangement may increase the manufacturing cost of the interchangeable portions due to increased material requirements and/or create other difficulties in manufacturing or otherwise.
Notably, the various projectile throwers and systems described and/or illustrated herein may also be adapted for use with other projectile thrower technologies. In one example, lighting effects may be added as described, for example, in commonly-assigned U.S. patent application Ser. No. 14/751,398, filed Jun. 26, 2015 and entitled “LIGHTED THROW AND FETCH EQUIPMENT AND SYSTEMS,” the entirety of which is attached as APPENDIX A and incorporated herein by reference. In another example, technology for use with mobile devices may be added as described, for example, in commonly-assigned U.S. patent application Ser. No. 14/673,361, filed Mar. 30, 2015 and entitled “PET TOY LAUNCHING SYSTEM AND METHOD FOR USE WITH MOBILE DEVICES,” the entirety of which is attached as APPENDIX B and incorporated herein by reference. Notably, the use of a universal handle enables such technologies to be implemented in the shaft or handgrip of the handle without need for replacement when use with a different projectile is desired, thereby providing significant cost savings to the user 101 , 102 .
It will be appreciated, however, that the particular projectiles 12 , 112 shown in FIG. 1 are exemplary only, that other projectile types may be utilized. Notably, the shape, dimensions, elements, and general form factor of the balls 12 , 112 or other projectiles, as well as any decorative features, may be varied considerably without departing from the scope of the present invention. For example, the ball may be round (spherical) (with or without perforations), or it may be a flying disc (with or without perforations), or it may be a spheroid (sphere-like but not spherical), including prolate spheroids, or it may take various abstract shapes. The ball or other projectile may be of proprietary design, or third party products may in some cases be utilized as the ball or other projectile 12 , 112 .
In some embodiments, a universal handle, a plurality of balls or other projectiles, and a plurality of interchangeable projectile holder elements are marketed and sold as a single kit. The kit may be contained together in a single box or other package. In other embodiments, the balls or other projectiles and/or corresponding interchangeable projectile holder elements may be marketed and/or sold separately or omitted entirely. Furthermore, ball throwers of different lengths, ball holder sizes, projectile types, and interchangeable projectile holder elements may be offered as part of a commonly-branded and/or marketed product line.
In summary, the ball throwers described herein are used to launch balls and other projectiles. The universal handle may be utilized with projectiles of different shapes and sizes by utilizing different projectile holders, each being created by attaching an interchangeable projectile holder element to a projectile holder base.
Based on the foregoing information, it will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those specifically described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing descriptions thereof, without departing from the substance or scope of the present invention.
Accordingly, while the present invention has been described herein in detail in relation to one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements; the present invention being limited only by the claims appended hereto and the equivalents thereof. | A throw and fetch system includes a universal handle, at least two projectiles, and at least two interchangeable projectile holder elements. A first projectile has a first size and/or shape, and a second projectile has a second size and/or shape. A first interchangeable projectile holder element has an interior that is sized and shaped to correspond to the size and shape of the first projectile, and a second interchangeable projectile holder element has an interior that is sized and shaped to correspond to the size and shape of the second projectile. In a first state the first projectile holder element is attached to a distal end of the universal handle such that the first projectile may be held then thrown therefrom by a user, and in a second state the second projectile holder element is attached such that the second projectile may be held then thrown therefrom by the user. | 5 |
BACKGROUND OF THE INVENTION
THE PRESENT INVENTION relates to a child seat and more particularly relates to a child seat integrated into an ordinary or "adult" seat in a motor vehicle.
SUMMARY OF THE INVENTION
According to this invention there is provided a seat for a vehicle comprising a main or "adult" seat incorporating an integrated child seat, the main or "adult" seat comprising a back and a squab, and the child seat having a squab which, in an initial condition, is present in a recess formed in the back of the adult seat in a substantially upright position, the squab of the child seat being movable to a second position in which the squab of the child seat is substantially horizontal, the position of the squab of the child seat, when in the said substantially horizontal position, being adjustable relative to the squab of the "adult" seat, the "adult" seat being provided with a safety belt which includes at least a shoulder strap to be used both for an occupant of the adult seat and for an occupant of the child seat.
Preferably the child seat is provided with a foot rest.
Advantageously the foot rest comprises elements which can be moved between a retracted position and an operative position.
Conveniently when the foot rest is in the retracted position the foot rest lies adjacent the upper-surface of the squab of the child seat.
Conveniently the foot rest is telescopic and thus of adjustable length.
Conveniently the foot rest is provided with two side arms which support between them a pivotally mounted foot support member.
Preferably the foot rest comprises two side arms, an element extending between the side arms to protect the squab of the adult seat when the child seat is in the operative position.
Preferably the squab of a child seat is supported by two support arms, the support arms being mounted for movement between a position in which they support the squab of a child seat in a substantially vertical position retracted within the back of the adult seat, and a substantially horizontal operative position.
Advantageously the under-surface of the squab of the child seat is padded or cushioned, the under-surface of the squab of the child seat defining part of the back of the adult seat when the child seat is in the retracted position.
Preferably the support arms are pivotally connected to the back of the adult seat.
Conveniently the position of the squab of the child seat is adjustable relative to the said support arms.
Advantageously means are provided to retain the child seat in a selected one of a plurality of possible positions relative to the support arms.
Conveniently the retaining means comprise a locking pin mounted in the squab of the child seat adapted to engage a selected locking aperture provided in the support arm.
Preferably the locking pin is biassed into engagement with the aperture and means are provided for withdrawing the locking pin from the aperture against the bias.
Advantageously guide pins are provided projecting from the squab of the child seat, the guide pins being received in elongate apertures provided in the support arms in order to guide movement of the squab of the child seat relative to the support arms.
Conveniently the squab of the child seat is pivotally connected to the support arm and can move pivotally relative to the support arm against a spring bias.
Preferably the child seat is provided with a back, the back being formed by an element which is pivotally connected to the support arms.
Alternatively the child seat may be provided with a back, the back being formed by an element which is pivotally connected to the back of the adult seat.
In this case the element forming the back of the child seat may be pivotally connected to the back of the adult seat adjacent an upper end of the back of the child seat. The squab of the child seat may be adjustable relative to the squab of the adult seat by pivoting the complete child seat about the pivot connection between the back of the child seat and the back of the adult seat, this pivotal movement of the child seat enabling the child seat to be set to a reclined position.
Preferably means are provided to retain the child seat in a selected one of a plurality of possible positions relative to the adult seat.
Conveniently the retaining means comprise a two-bar linkage inter-connecting the back and the squab of the child seat, part of the linkage engaging the back of the adult seat in order to "prop" the child seat in the reclined position.
Alternatively the retaining means further comprise a locking pin mounted on one bar of the linkage, the pin being adapted to engage one of a plurality of apertures provided at different settings in the back of the child seat.
The back of the child seat may, in another alternative be formed by the back of a recess which accommodates the squab of a child seat when the squab of a child seat is in the retracted position.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more readily understood, and so that further features thereof may be appreciated, the invention will now be described, by way of example, with reference to the accompanying drawings in which
FIG. 1 is a side view of an adult seat in a motor vehicle with parts thereof cut away for the sake of clarity of illustration, the figure illustrating the squab and back-rest of an adult seat and the components of a child seat in a retracted position,
FIG. 2 is a view corresponding to FIG. 1 showing the child seat in a partly erected condition,
FIG. 3 illustrates a child seat in a fully erected condition,
FIG. 4 corresponds to FIG. 3 but shows the seat in an adjusted position,
FIG. 5 is a top plan view of the seat in the condition of FIG. 4,
FIG. 6 is a side view of an alternative embodiment of the seat, illustrating the child seat in a retracted position,
FIG. 7 illustrates the child seat of FIG. 6 in an erected condition,
FIG. 8 illustrates the child seat of FIGS. 6 and 7 in an adjusted position,
FIG. 9 is a top plan view of the child seat of FIG. 8,
FIG. 10 is a side view of a further alternative embodiment of a child seat showing the seat in a retracted position within an adult seat in a motor vehicle,
FIG. 11 shows the seat of FIG. 10 when in an erected or operative position, and
FIG. 12 shows the seat of FIGS. 10 and 11 when in the operative position, but in an adjusted setting.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1 to 5 a child seat 1 is so formed that the components of the child seat may move from an initial retracted condition, illustrated in FIG. 1, in which the components of the child seat 1 are effectively contained within the back 2 of an adult seat in a motor vehicle having a squab 3 to a fully extended position, as illustrated in FIGS. 3 and 4. Thus as will be described the child seat 1 is such that it is provided with a squab 4 which is adjustable in height, relative to the squab 3 of the adult seat, so that the child seat can be positioned so that the safety belt provided primarily for use by an adult in the adult seat will be correctly positioned to retain a child in the child seat. The child seat 1 is also provided with a foot rest 5 which provides a degree of comfort for a child in the child seat and also provides a degree of protection for the squab 3 of the adult seat.
Referring to the drawings in greater detail, the child seat comprises a squab 4 to which is connected the foot rest 5. The squab is supported by two support arms 6 located on each side of the squab, only one of which is shown. The support arms also support a back 7 for the child seat.
The squab 4 is provided with a padded or upholstered under-surface 8 and a padded or upholstered over-surface 9. The two opposed side edges of the squab 4 are each associated with a respective support arm 6. Each support arm 6 is provided with two elongate apertures 10,11 inclined at an acute angle to the plane substantially defined by the padded under and over-surfaces 8,9 of the squab. The squab is provided with projecting pins 12,13 which are respectively received within the elongate apertures 10,11. The support arm 6 is also provided with a plurality of apertures 14,15,16. One of the apertures 14, is shown receiving a locking pin 17. The locking pin 17 is adapted to be retracted from the aperture 14, thus permitting the squab 4 of the child seat to slide relative to the support arm 6 with a movement of the pins 12 and 13 along the elongate slots 10 and 11. The pin 17 is spring biassed by means of a spring 18 into the locking position, and a mechanism may be provided for withdrawing the pin, against the spring bias, out of the locking condition. This mechanism may be controlled by an appropriately located knob connected to the locking pin 17 by a Bowden cable or some other appropriate mechanism.
The support arm 6 is itself mounted for pivoting movement about a pivot axis 19.
The support arm 6 is provided with a projecting lug 20 which pivotally supports the back rest 7 by means of a pivot connection 21. The back rest comprises a rear support 22 and a padded front 23. The rear support and the padded front are connected to the pivotal connection 21 by two downwardly projecting arms which extend down beyond the lower edge of the rear support 22 and the associated padded front 23.
The foot rest 5 is pivotally connected to the squab by a pivot connection 24, and comprises two side arms 25, each of which is hollow and is provided with apertures aligned axially of the arm 26,27,28. The arm 25 receives telescopically a foot rest support element 29, the foot rest support element 29 carrying a spring-biassed pin adapted selectively to engage with one of the apertures 26,27,28. The support element 29 supports a pivotally mounted foot engaging plate 30 using of a pivotal connection 31.
The embodiment has been described with reference to side views taken from one side. It is to be noted that the other side of the child seat will correspond, with the illustrated components being duplicated, as appropriate.
FIG. 5 illustrates the seat from above when in the condition illustrated in FIG. 4. It can be seen that an appropriate protecting element 32 formed of plastic, metal or fabric, extends between the arms 28 and the support element 29.
It is to be appreciated that in an initial, retracted condition all the components of the child seat 1 are effectively received within a recess 23 provided for that purpose in the back 2 of the adult seat. The padded under-surface 8 of the squab 4 of the child seat effectively forms a closure for the recess 33 and forms part of the operative back 2 of the adult seat 3. The adult seat 3 will be provided with a conventional seat belt.
It is to be observed that in the condition of FIG. 1 the plane defined by the opposed under and over-surfaces of the squab 4 of the child seat is substantially vertical, and the foot rest lies adjacent the upper surface 9 of the squab 4 of the child seat, whilst the back 7 of the child seat lies adjacent the foot rest.
In order to render the child seat operative, initially the entire assembly is pivoted about the pivot axis 19, so that the squab 4 of the child seat is then substantially horizontal. The back 7 of the child seat is then pivoted about the pivot axis 21 to a substantially upright condition. An appropriate catch may be provided adjacent the top of the recess 33 to engage co-operating means provided on the back 7 of the child seat.
The foot rest 5 of the child seat is then moved about the pivot axis 24 until the support arms 25 are in the position illustrated in FIG. 3. The foot engaging member 30 is pivoted about the pivot axis 31 to the operative condition illustrated in FIG. 3.
Depending upon the size of the child to use the child seat, various adjustments may then be made to the child seat. Initially, the height of the squab 4 of the child seat above the squab 3 of the adult seat may be adjusted. This is accomplished by retracting the locking pin 17 from the aperture (one of the apertures 14,15,16 in the support arm 6) initially engaged by the pin, and then moving the squab of the seat so that the pins 12 and 13 move along the inclined elongate slots 10 and 11. Thus the height of the squab 4 of the child seat above the squab 3 of the adult seat may be adjusted. When the squab of the child seat is in an appropriate position the pin 17 is released to re-engage an appropriate aperture 14,15 or 16. FIGS. 3 and 4 illustrate the squab 4 of the child seat into extreme positions of adjustment. It is to be noted that in FIG. 4 part of the squab of the child seat extends between the two arms extending from the main portion of the back rest 7 and the pivotal connection 21 to the extensions 20 of the support arm 6. When the height of the squab 4 is adjusted, the effective length of the squab (as measured front-to-back) will also be adjusted at the same time due to the inclination of the elongate apertures 10,11.
A further adjustment that may be made relates to the effective length of the foot rest.
It is to be appreciated that the adjustment of the height of the squab 4 of the child seat will be made primarily to ensure that when a child is sitting on the squab 4 of the child seat the belt provided with the adult seat will pass across that child in a correct position. The adjustment of the length of the foot rest 5 depends, of course, upon the length of the legs of the child.
It is to be appreciated that the provision of the foot rest 5 prevents the legs of the child resting on the edge of the squab 3 of the adult seat. This means that the child will be more comfortable than if the foot rest were omitted. Also, the protecting element 32 of the foot rest provides some degree of protection for the squab 3 of the adult seat, since if the foot rest and the protecting element were not present the squab 3 of the adult seat might be scuffed or otherwise damaged by the shoes of a child sitting on the child seat and, if those shoes were dirty or soiled, then the squab 3 of the adult seat would become dirty or soiled.
It is to be appreciated that, when the child seat of FIGS. 1 to 5 is no longer to be used, the child seat may be returned to the initial position simply by reversing the procedure used to erect the child seat.
FIGS. 6 to 9 illustrate an alternative embodiment of the invention. In this embodiment a child seat 40 is provided which has an initial retracted position within the back 41 of an adult seat which has a squab 42. The child seat comprises a squab 43 of generally rectangular form mounted on two support arms located on either side of the squab, only one of which, 44 is shown.
The squab 43 of the child seat has a padded or upholstered under-surface 45 and a padded or upholstered upper-surface 46. The squab 43 is pivotally connected to the support arm 44 by means of a pivot axis 47 located towards the upper edge of the seat squab when it is in the initial retracted position or the forward edge of the seat squab when it is in the operative condition. At the other end of the support arm a plurality of apertures 48,49,50 are provided adapted to receive a spring-biassed locking element 17a which may be similar to the spring-biassed locking pin 17 of FIG. 5. An elongate aperture 51 is also provided which receives a pin 52 projecting from the squab 43 of the child seat, the pin 52 being associated with a spring, such as spring 53 which provides a predetermined bias to the pin 52. Each support arm 44 is pivotally mounted to the back of the adult seat about a pivot axis 54.
The back of the child seat is formed by a substantially rigid element 55 provided with padding and/or upholstering which effectively forms the rear part of a recess adapted to receive the child seat when it is in the retracted position as illustrated in FIG. 6.
Pivotally mounted, by means of a pivot 56, to the top of the element 55, is a padded element 57 which can be moved between two positions as illustrated in FIGS. 6 and 7. In the position illustrated in FIG. 6, in which the squab of the child seat is substantially vertical, a forward face 58 of the element 47 is aligned with the padded under-surface 45 of the squab 43 of the child seat, the under-surface of the squab of the child seat and the element 57 combining to form the back of the "adult" seat. The element 57 may also be moved to the position illustrated in FIG. 7 in which an under-surface 59 is substantially aligned with the padded part 55 of the element 54 forming the back rest of the child seat, so that the element 57 forms an extension of that back rest for the child seat.
The seat initially occupies the retracted position illustrated in FIG. 6, in which the child seat is not operational, and an adult may use the seat. When the child seat is to be operational initially the element 57 is moved about the pivot axis 56 to the elevated position shown in FIG. 7. Subsequently the support arms 44 are moved about the pivot axis 54 so that the squab of the child seat is substantially horizontal at a position above the squab 42 of the adult seat. A child may then be placed upon the child seat. If the locking pin 17a is then retracted from the apertures 48, 49 and 50 the weight of the child sitting on the squab 43 of the child seat will tend to pivot the squab of the child seat in a clockwise direction (as shown in FIGS. 6 to 8) about the pivot axis 47 against the bias of the spring 53. The distance of pivotal movement of the squab of a child seat would depend upon the weight of the child. The locking pin 17a may then be released when it will re-engage an appropriate aperture 48, 49 or 50. FIG. 8 illustrates the seat squab in a condition that it will occupy if a heavy child is sitting on the squab.
It is to be appreciated that the arrangement illustrated in FIGS. 6 to 9 is such that when a child is placed on the child seat, the height of the squab is adjusted automatically, thus ensuring that the seat belt provided for the adult seat will engage the child in a correct manner.
It is to be appreciated that whilst in the embodiment illustrated in FIGS. 6 to 9 a locking pin adapted to cooperate with apertures 48 to 50 is provided to lock the squab of the child seat in the desired position once automatic adjustment has been effected, many other arrangements may be utilised to lock and retain the squab of the child seat in an appropriate position. However, it is preferred that some mechanism is provided which can be used to release the locking mechanism when a child is initially placed on the squab of the child seat, thus permitting the position of the squab of the child seat to be adjusted automatically, the locking mechanism then again becoming operative.
It is to be appreciated that the seat illustrated in FIGS. 6 to 9 may be provided with a foot rest directly equivalent to the foot rest of the embodiment of FIGS. 1 to 5.
Referring now to FIGS. 10, 11 and 12 a further alternative arrangement of a child seat 60 is shown, the child seat again being mounted upon an adult seat having a squab 61 and a back 62 so as to form part of the back 62 of the adult seat when not in use. The child seat is therefore mounted in the back of the adult seat and is movable between a retracted position, shown in FIG. 10, and an extended or operative position as shown in FIG. 11.
The child seat 60 comprises a squab 63 and a back 64. Both the upper surface and the under-side of the squab 63 are padded. The outwardly directed front surface of the back 64 of the child seat is, of course, also padded.
The upper-most end of the back 64 of the child seat is pivotally connected to the back 62 of the adult seat by means of a pivot pin 65 or the like. It will of course be appreciated that in the accompanying drawings the child seat is illustrated from one side only and there would, of course, be pivot pins 65 on either side of the back 64 of the child seat or a single pivot pin 65 which extends over the full width of the back 64 of the child seat to project from both sides thereof. The squab 63 of the child seat is connected to the lower end of an extension 66 at the lower end of the back 64 of the child seat by way of a pivotal connection 67. Thus, the squab 63 of the child seat may be raised and lowered relative to the back 64 by pivoting the squab 63 about the axis of the pivotal connections 67.
Two support arms 68 (only one of which is visible in the drawings) extend between approximately mid points on the back and squab of the child seat on opposite sides thereof. The support arms 68 each comprise two pivotally inter-connected links 69,70 which serve to limit downwards movement of the squab 63 when it is lowered relative to the back 64 by pivoting it about the axis of the pivot connection 67. When the support arms 68 are fully extended so as to extend in a straight line between the mounting points for the links 69,70 on the back and squab of the child seat respectively, the squab 63 is approximately at right angles to the back 64, with this position defining the operative setting of the child seat.
A padded element 71 is mounted on the back of the adult seat by means of a pivotal connection 72 at a position just above the level of the child seat 60. The element 71 is padded on its front and rear surfaces. The element 71 is movable between a lowered position, as shown in FIG. 10, in which it forms part of the back 62 of the adult seat just above the squab 63 of the child seat when the squab is in the retracted position and a raised position, as shown in FIG. 11, in which the element 71 forms an extension to the height of the back of the child seat.
It will of course be appreciated that the child seat is, when not in use, accommodated within a recess 73 formed in the back of the adult seat in a motor vehicle. When the child seat is to be used the padded element 71 may be pivoted upwardly about the pivot connection 72 and then the squab 63 of the child seat may be pivoted downwardly about the pivot connection 67 until the support arms 68 are fully extended and the child seat is in the position shown in FIG. 11 when it is ready for use by a child.
In order to provide for adjustment of the setting of the squab 63 of the child seat to allow a child using the seat safely to wear an adult seat belt or to make the child seat more comfortable for a child who may wish to go to sleep, the seat is additionally provided with a linkage 74 comprising two bars 75,76, the linkage inter-connecting an upper region of the back 64 of the child seat and a rear-most region of the squab 63 of the child seat. Thus, the bar 75 is pivotally connected to an upper region of the back of the child seat whilst the bar 76 is pivotally connected to the pivot connection 67 adjacent the rear of the squab of the child seat. The bars 75,76 are, of course, pivotally interconnected with each other. The connection of the bar 75 to the upper region of the back of the child seat is an adjustable connection, with the back of the child seat defining a plurality of settings 77,78,79,80 to which the upper end of the bar 75 may be releasably connected. The settings 77,78,79,80 are spaced apart over the height of the back of the child seat in an upper region thereof, that is to say above the point at which the upper link of the support arm 68 connects with the back 64 of the child seat.
The two bar linkage 76 permits the child seat 60 to be adjusted so that the squab of the child seat is raised from the position shown in FIG. 11 and also so that the entire child seat may be angled rearwardly or reclined in order to make the seat more comfortable for a child wishing to go to sleep.
FIG. 11 illustrates the child safety seat in the operative position when the upper bar 75 of the linkage 76 is connected to the upper-most setting 77 in the back of the child seat. In this position the child seat 60 is in its lower-most operative condition. FIG. 12 illustrates the child seat when the upper bar 75 of the linkage 76 is connected to the lower-most setting 80 in the back 64 of the child seat and, as can clearly be seen from the accompanying drawing, the child seat has been pivoted about the pivot connection 65 so that it is now in a raised and reclined position. The child seat may, of course, be set to one of the other settings between the two settings illustrated in FIGS. 11 and 12. The releasable connection between the upper end of the bar 75 and the various settings in the upper region of the back of the child seat may comprise a very simple arrangement such as a spring biassed pin mounted on the upper-most end of the bar 75 and a plurality of holes in an element mounted on the side of the back of the child seat with the spring biassed pin being manually retractable from one hole to permit raising or lowering of the complete child seat about the pivot connection 65 before the pin is released so as to engage within another hole at a different setting. The pivotal connection between the bars 75,76 engages the outwardly directed surface of the recess 73 in the adult seat and acts to "prop" the child seat in the desired setting.
It is again to be appreciated that the seat illustrated in FIGS. 10, 11 and 12 may be provided with a foot-rest equivalent to that shown in the embodiment of FIGS. 1 to 5. | A seat for a vehicle comprising a main or "adult" seat incorporating an integrated child seat, the main or "adult" seat comprising a back and a squab, and the child seat having a squab which, in an initial condition, is present in a recess formed in the back of the adult seat in a substantially upright position, the squab of the child seat being movable to a second position in which the squab of the child seat is substantially horizontal, the position of the squab of the child seat, when in the said substantially horizontal position, being adjustable relative to the squab of the "adult" seat, the "adult" seat being provided with a safety belt which includes at least a shoulder strap to be used both for an occupant of the adult seat and for an occupant of the child seat. | 1 |
FIELD OF THE INVENTION
[0001] The present invention is generally related to a device and a method for input detection and, more particularly, to an optical touch device and an optical touch method.
BACKGROUND OF THE INVENTION
[0002] Touch input has been extensively applied and further developed into gesture input applications. For example, U.S. Pat. No. 7,966,578 provides a method for multi-touch gesture detection, which not only simplifies an input device but also allows intuitional input operation. Conventionally, however, gesture detection is carried out by using a resistive or capacitive touch pad or touch panel, and thus has some unconquerable problems. The resistive touch panel uses a flexible film to receive pressing of a stylus for generating deformation to identify a touch point, and thus is less durable, has poor location resolution, and is hard to implement multi-touch applications. The capacitive touch pad and touch panel are stronger, but their location resolution depends on trace density. Thus, the location resolution is inherently limited by the width of each trace itself and the pitch between adjacent traces, and can only be improved by an algorithm of a post-end circuit. Moreover, the large number of interconnections between the traces and the microcontroller chip adds difficulty in performing wire layout on a printed circuit board. Further, since the microcontroller chip has so many pins to be bonded to the traces, it is hard to be downsized, and the numerous bonding points thereof can also reduce the reliability. Additionally, the capacitance detection of one trace requires charging and discharge one or more traces, and thus consumes considerable power and takes a long time. For either a resistive touch panel or a capacitive touch pad or touch panel, input detection includes scanning all its sensors for completing a frame of raw data and thus requires high-speed scanning and high-speed calculation, and even with a high-speed hardware, the time for obtaining one frame of data is still relatively long, which makes the frame rate hard to be increased and the response to input operation slower.
SUMMARY OF THE INVENTION
[0003] An objective of the present invention is to provide an optical touch device and a method for input detection of an optical touch device.
[0004] Another objective of the present invention is to provide a device and a method for optical touch input by gesture detection.
[0005] A further objective of the present invention is to provide an input device and an input method that integrate gesture detection with a mouse function.
[0006] According to the present invention, an optical touch device includes a touch surface, a light source and an image sensor unit configured such that the light source provides light to project to the touch surface and the image sensor unit captures images by receiving light from the touch surface. The captured images are sent to a processing unit to identify if any gesture operates on the touch surface and to generate a corresponding gesture signal if a gesture is identified.
[0007] According to the present invention, a method for input detection includes providing light to project to a touch surface, capturing images by receiving light from the touch surface, identifying the captured images to detect if any gesture operates on the touch surface, and generating a corresponding gesture signal if a gesture is detected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] These and other objectives, features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings, in which:
[0009] FIG. 1 is a system block diagram of a first embodiment according to the present invention;
[0010] FIG. 2 is a hardware arrangement of the optical touch device shown in FIG. 1 when it is applied to a mouse;
[0011] FIG. 3 is a system block diagram of a second embodiment according to the present invention;
[0012] FIG. 4 is a hardware arrangement of the optical touch device shown in FIG. 3 when it is applied to a mouse; and
[0013] FIG. 5 shows images of various gestures detected by an optical touch device according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 1 is a system block diagram of a first embodiment according to the present invention, in which an optical touch device 10 includes a touch surface 14 to receive gesture operation thereon, a light source 26 arranged to be optically coupled to the touch surface 14 such that it can provide light to project to the touch surface 14 , an image sensor unit 16 arranged to be optically coupled to the touch surface 14 such that it can capture images by receiving light from the touch surface 14 and generates an input signal Si to carry the captured images, and a processing unit 18 electrically coupled to the image sensor unit 16 to receive the input signal Si, to identify the images carried by the input signal Si to detect if any gesture operates on the touch surface 14 , and to generate a corresponding gesture signal Sg if a gesture is detected. When a finger touches the touch surface 14 , it will reflect light at the touch point, so that a light spot will appear in the image captured by the image sensor unit 16 . According to the number and the locations of light spots in an image, the processing unit 18 can identify the number and the locations of fingers on the touch surface 14 . From the varying images, the processing unit 18 can further identify change of the finger number and the moving direction of each finger to detect if any gesture operates on the touch surface 14 . As is well known, the image sensor unit 16 includes an optical sensor, such as a CMOS image sensor (CIS) and a charge coupled device (CCD), to convert the received light into electronic signals, and may further include a lens or a pinhole for imaging on the optical sensor. Preferably, the image sensor unit 16 operates with one or more frame rates to generate images in a unit of frame, thus the input signal Si will contain image contents in a manner of frame by frame in a time sequence, and then the processing unit 18 can compare the image contents in two or more successive frames to identify variation of the images. The processing unit 18 can further calculate the moving speed of a finger with the frame rate of the image sensor unit 16 and the detected displacement of the finger. Since the processing unit 18 can identify different gestures from the input signal Si, it can generate various gesture signals Sg corresponding to the detected gestures.
[0015] The optical touch device 10 may further integrate a mouse function. For example, as shown in FIG. 1 , a movement detection module 20 includes a core established by a rolling-ball mechanism, an optical sensor, a motion sensor or a gyroscope, to detect the movement of the optical touch device 10 for generating a movement signal Sm, and a transmission interface 22 receives and then convert the gesture signal Sg and the movement signal Sm into an output signal So, for example by encoding under a communication protocol, to send to a host 24 . Thus, the host 24 can control a cursor according to the movement signal Sm, and execute a command corresponding to the gesture signal Sg. A such integrated device may have a hardware arrangement as shown in FIG. 2 . In a mouse housing 100 , the movement detection module 20 is mounted at the bottom of the mouse housing 100 such that when the mouse housing 100 is placed on an operational plane 30 , the movement detection module 20 is close to the operational plane 30 , and similarly to a typical optical mouse, the movement detection module 20 includes a light source 32 to provide light to project to the operational plane 30 through a lens and then reflected by the operational plane 30 to impart on an image sensor 34 through another lens, the image sensor 34 keeps its image capturing, and a processing unit (not shown in the figure) generates a movement signal Sm according to the varying images. In this embodiment, the touch surface 14 is on the upper surface of a light guide plate 12 mounted in a front part of the top of the mouse housing 100 , taking the place traditionally occupied by buttons and wheels of a conventional mouse, the light source 26 is fixed to a lateral of the light guide plate 12 and provides light of a specific wavelength, for example infrared ray, to project to the light guide plate 12 , and the provided light penetrating into the light guide plate 12 propagates within the light guide plate 12 by internal total reflection and has a portion scattered by the light guide plate 12 to penetrate through the touch surface 14 outward. If a finger touches the touch surface 14 , the finger will establish a reflective surface at the touch point to reflect light back into the mouse housing 100 and thus imparting on the image sensor unit 16 . In another embodiment, the light guide plate 12 only allows invisible light, such as infrared ray, to pass therethrough, thereby preventing interference caused by ambient visible light. In the embodiment shown in FIG. 2 , by detecting the gesture operating on the touch surface 14 , the optical touch device can generate not only button signals and wheel signals as a normal mouse, but also many control signals that can not be generated by a normal mouse.
[0016] Preferably, referring back to FIG. 1 , in addition to the light source 26 , the optical touch device 10 further includes a light control unit 28 to control the light source 26 . For example, the light control unit 28 may turn off the light source 26 in shutdown or standby, or may maintain the light source 26 at a small mute current in standby, or may only turn on the light source 26 when the image sensor unit 16 is going to capture images. Additionally, the processing unit 18 may identify brightness of one or more images from the input signal Si and generate a control signal Sc accordingly, for the light control unit 28 to adjust light intensity of the light source 26 to optimize the clarity of the captured images by the image sensor unit 16 . Preferably, the processing unit 18 controls the light source 26 to be blinking fast during image capturing, so that the image sensor unit 16 will capture images when the light source 26 emits light and when the light source 26 does not emit light, respectively. Then, the difference between the images captured when the light source 26 emits light and when the light source 26 does not emit light can be used to eliminate the background value caused by ambient light. Since the image taken by the image sensor unit 16 when the light source 26 is off is the background value caused by ambient light, the interference from ambient light can be reduced by eliminating this background value. In other embodiments, it may switch the light projecting to the touch surface 14 by other means, for example using a shutter, such that the image sensor unit 16 can capture images when the light is on and off.
[0017] FIG. 3 is a system block diagram of a second embodiment according to the present invention, in which an optical touch device 36 also integrates gesture detection with a mouse function, while the difference from the embodiment shown in FIG. 1 is that this embodiment uses some common components to carry out the gesture detection and the mouse function. In the optical touch device 36 , a light source 26 , a light control unit 28 , a touch surface 14 , an image sensor unit 42 and a processing unit 44 establish a gesture detection module which operates as the embodiment shown in FIG. 1 , and a light source 32 , the image sensor unit 42 and the processing unit 44 establish a movement detection module which executes the mouse function as the embodiment shown in FIG. 2 . As shown in FIG. 4 , the optical components are properly arranged, including lens and a reflector to establish the optical paths, such that the light reflected by the touch surface 14 and the light reflected by the operational plane 30 both incident upon the image sensor unit 42 . Since the optical touch device 36 uses a single image sensor unit 42 and a single processing unit 44 to accomplish the gesture detection and the movement detection, the costs can be reduced. Referring to FIG. 3 and FIG. 4 , the processing unit 44 provides control signals Sc 1 and Sc 2 for the light control units 28 and 40 to control the light sources 26 and 32 , respectively, for example, turning on and off the light sources 26 and 32 or adjusting light intensity of the light sources 26 and 32 . Preferably, the light sources 26 and 32 are controlled to provide light alternately in a time sequence, such that when the light source 26 emits light, the image sensor unit 42 captures images by receiving light from the touch surface 14 for generating an input signal Si 1 , and when the light source 32 emits light, the image sensor unit 42 captures images by receiving light from the operational plane 30 for generating an input signal Si 2 . The processing unit 44 processes the input signals Si 1 and Si 2 separately, thereby generating a gesture signal Sg and a movement signal Sm for a transmission interface 22 to convert into an output signal So to sent to a host 24 that executes a command corresponding to the gesture signal Sg and controls a cursor according to the movement signal Sm. Preferably, the processing unit 44 may identify brightness of one or more images from the input signals Sit and Si 2 to adjust light intensity of the light sources 26 and 32 for optimizing the clarity of the captured images, respectively.
[0018] There have been many arts developed for gesture detection and relevant command execution. In addition to those commands for typical mouse operation, such as single click, double click, drag and scroll, there are popular commands such as zoom-in, zoom-out, rotate clockwise, rotate Anticlockwise, flip-up and flip-down, and more gesture-triggered commands may be found from related arts. In an embodiment, referring to the images shown in FIG. 5 , various gestures can be predefined and then identified by detecting the number and the absolute movement or relative movement of fingers (i.e. light spots in the images), with corresponding commands listed in Table 1 in the following:
[0000] TABLE 1 Item No. Finger No. Gesture Type Command 1 1 Move to Right Move to Right 2 1 Move to Left Move to Left 3 1 Move Up Move Up 4 1 Move Down Move Down 5 1 Rotate Clockwise Rotate Clockwise 6 1 Rotate Anticlockwise Rotate Anticlockwise 7 1→2 Press & Tape Right Click 8 1→2 Press & Tape Left Click 9 2 Move to Right Flip to Right 10 2 Move to Left Flip to Left 11 2 Move Up Flip Up 12 2 Move Down Flip Down 13 2 Rotate Clockwise Rotate Clockwise 14 2 Rotate Anticlockwise Rotate Anticlockwise 15 2 Out to In Zoom In 16 2 In to Out Zoom Out 17 3 Move Up Scroll Up 18 3 Move Down Scroll Down
In different embodiments, the displacement and/or the moving speed of one or more fingers may be taken into consideration for gesture definition and identification. In other embodiments, gesture definition and corresponding commands may be user defined through the operating system or relevant software running on the host 24 , to optimize the operation.
[0019] In the optical touch devices 10 and 36 , the touch surface 14 is on a stiff plate such as a glass plate so is highly durable. The touch point on the touch surface 14 is imaged through optical sensing and thus, not only the image can be obtained instantly, but also the location resolution depends on the resolution of the image sensor unit 16 or 42 , which is much higher than the existing resistive touch panels and capacitive touch pads and touch panels. Moreover, the light sources 26 and 32 may be realized by LEDs to reduce power consumption.
[0020] While the present invention has been described in conjunction with preferred 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 scope thereof as set forth in the appended claims. | Optical imaging is used for touch input to implement device and method for gesture detection for better durableness, high resolution, simplifier structure, higher reliability, less power consumption, and faster response. A touch surface is provided for gesture operation thereon, and under light projecting to the touch surface, images are captured by receiving light from the touch surface. The varying images are monitored to detect if any gesture operates on the touch surface, and if a predefined gesture is detected, a gesture signal is generated. | 6 |
FIELD OF THE INVENTION
The invention relates to a filtering device comprising a plurality of filtering elements with bodies defining longitudinal axes and arranged adjacent to one another in a housing such that the longitudinal axes of the filtering elements extend parallel to one another. The bodies of at least some of the filtering elements have a shape that deviates from a circular cylinder in at least one part of the body length. The invention further relates to a filtering element that is provided for use in such filtering device.
BACKGROUND OF THE INVENTION
Filtering devices of this kind are often used in technical facilities for filtering process liquids and pressure liquids such as hydraulic oils, coolant lubricants, and for treating liquid media and the like. Facilities that use such filtering devices can often only provide a limited amount of usable space for incorporating or attaching the filtering device. However, to be able to filter correspondingly large volume flows, the filtering surface that is provided by the filtering device must be sufficiently large. Wth regard to this requirement, a known filtering device of this kind is disclosed, for example, in DE 10 2004 026 862 A1. That device provides for filtering elements having bodies that deviate from the cross-section of a circular cylinder form, having the form of a Reuleaux triangle instead. In comparison to devices having circular cylindrical or block-shaped filtering elements, the shape of the Reuleaux triangle accommodates a larger filtering area inside a given installation space.
SUMMARY OF THE INVENTION
An object of the present invention to provide a filtering device that allows for a further improvement of the ratio between the installation space and the achievable filtering area.
According to the invention, this object is basically achieved with a filtering device including the filtering elements with cross-sections deviating from the cross-section of the circular cylinder shape and with cross-sections having sizes that change, at least in part, from one end to the other end. The filtering elements are oriented inside the housing such that the filtering elements adjacently disposed relative to each other have areas with larger cross-sections paired with areas having smaller cross-sections. Correspondingly, in a group of filtering elements containing filtering elements that are disposed next to each other and paired with each other and thereby forming a single group, more slender areas are disposed across from the thicker areas of the adjacently disposed partner element. Any free spaces or unused “dead space” within the group can then be minimized, achieving a correspondingly high packing density with an optimally large filtering area.
Especially advantageously, filtering elements in form of tapered candle filters are used, which are disposed adjacent to each other. The tapering of those candle filters are oriented in opposite directions, respectively. In this case, the filtering elements that are arranged into a group of adjacently disposed filtering elements delimit funnel-type fluid spaces inside the filter housing. Obvious combinations of convex external geometries with concave structures are also possible. This way, for example, layer-cake-shaped filtering elements can be combined with each other by providing that one convex layer-cake-shaped ring, in each case, engages in a concave recess between two adjacently disposed convex layer-cake-shaped rings of the other filtering element, preferably while maintaining a radial spacing. Aside from such stepwise ring arrangement, continually changing structures are conceivable as well, which provide for a barrel-like filtering element having a central, convexly protruding barrel part that engages, leaving a spacing, in a concave recess of an adjacent filtering element having a hose-shaped configuration, such that a rotational hyperboloid is formed. The abovementioned spacings between individual filtering elements are necessary for any sensible routing of the fluids inside the filter housing. All of the filtering elements constituted in this manner are preferably configured as rotationally symmetrical.
In especially advantageous embodiments, the filtering elements are tapered candle filters disposed inside the filter housing between a planar base plate and a cover plate that is disposed in a parallel plane in relation to the base plate. The corresponding result is a pot-shaped filter housing that receives the filtering elements by mounts on the base plate. An axial spacing exists between the ends of the filtering elements and the top cover plate.
Especially advantageously, the base plate can be configured as a connection plate and provided with fluid openings that can be used to bring fluid passages in fluid communication with the inner filtering cavities of the filtering elements. The elements are held by their ends on the base plate.
With candle filters having a tube-like support structure and a filtering medium surrounding the inside filtering cavity, especially advantageously, the ends of the tube-like support structure, allocated to the base plate, can constitute the fluid passages and engage with the fluid openings of the base plate, when each filtering element is in the functional position thereof.
On a base plate that serves as a connection plate, a closure piece can be located at the ends of the tube-shaped support structure on the filter candles, where the inner filtering cavities are allocated to the cover plate. The closure piece seals each filtering cavity in a fluid-proof manner.
Regarding the connection of the candle filters that are directed toward the base plate by the slender ends thereof, advantageously the tube-shaped support structure is extended by a connection tube, which engages in the related fluid opening and is axially secured on the base plate.
If candle filters are provided that include an external tube-shaped support structure, the support structure can form a radially protruding annular edge on the thicker end thereof. For candle filters having the thick end thereof oriented toward the base plate, this edge can be a contact area on the base plate.
On the more slender end, the internal support structure can form a cylinder part, which passes through a hollow cylindrical collar on the slender end of the external support structure. The collar is axially secured on the cylinder part. After disengaging this secured connection, the external support structure of the candle filter can be pulled off, for example, to replace the filter medium.
Especially advantageously, the collar can include a step constituting a shoulder, which is disposed in the radial plane. The annular edge of the external support structure of the respectively adjacent candle filter grips there-across. The annular edge of the external support structure thus constitutes a stop element for axially securing the candle filters inside the group.
To support the candle filters on the cover plate, spacers can be provided, respectively, on the collar of the external support structure and on the closed thicker end of the internal support structure. Preferably, they are formed thereto in one piece.
Another subject-matter of the present invention is a filtering element that is provided for use in the context of a filtering device according to the invention.
However, groups of filtering elements having varying cross-sections that are combined with such filtering elements having identical cross-sections inside the same filter housing, for example in the customary cylindrical design, also fall within the scope of the present invention.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings that form a part of this disclosure:
FIG. 1 is a schematically simplified, functional perspective view of a part of the base plate of the filter housing and a partial group of the filtering elements disposed on the base plate of a filtering device according to an exemplary embodiment of the invention;
FIG. 2 is a schematically simplified, side view in section of only a partial group of tapered candle filters on a partial section of the base plate of FIG. 1 ;
FIG. 3 is a perspective view of only the external support structure of a candle filter for use in the filtering device of FIG. 1 ;
FIG. 4 is an enlarged, partial perspective view of only the more slender end of the external support structure of FIG. 3 ;
FIG. 5 is an enlarged, partial side view in section of only part of the filter candles on the base plate of FIG. 2 ;
FIG. 6 is an enlarged, partial side view in section of only the partial area of FIG. 2 that borders on the cover plate, which is not shown; and
FIG. 7 is an enlarged, partial perspective view of only the partial area of the group of candle filters from the group shown in FIG. 1 that borders on the cover plate.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 only depicts a partial section of the base plate 1 , which is part of the embodiment of the filtering device according to the invention that shall be presently described and that is part of a filter housing, which is not shown in further detail. Base plate 1 accommodates a plurality of filtering elements formed as tapered candle filters 3 (in FIG. 1 , not all of the candle filters are identified by reference numerals). As shown in FIG. 1 , the candle filters 3 are grouped as densely packed, wherein the order thereof as provided is as follows.
In one given row, the candle filters 3 are oriented with the more slender or small ends thereof towards the base plate 1 and, in the respectively given adjacent row, the candle filters 3 are oriented with the thicker or large ends thereof toward the base plate 1 . The sequential rows of candle filters 3 are offset in relation to one another, respectively following such an arrangement in that the candle filters 3 that are in consecutive rows are disposed inside the gaps left by the respectively previous row.
Only a partial group of the total number of candle filters 3 is depicted in FIG. 1 . The side wall, constituting a hollow cylinder, and the cover plate disposed in a parallel plane opposite in relation to the base plate 1 have also been omitted. During the filtration process, the internal space of the filter housing that surrounds the candle filters 3 constitutes the untreated side 51 ( FIGS. 5 and 6 ). The untreated fluid that must be cleaned can be supplied to untreated side 51 via a fluid inlet. The base plate 1 is configured as a connection plate and includes a fluid opening 5 for each candle filter 3 (in FIG. 1 , not all of the candle filters are identified by reference numerals). The candle filters 3 are held or clamped between the cover plate and the base plate 1 such that the fluid passages 7 and 9 , see FIGS. 2 and 5 , which are disposed at the thicker or large end or the more slender end of the candle filters 3 , respectively, are in fluid communication with the openings 5 of the base plate 1 . These fluid passages 7 , 9 constitute the outlet from of the respective internal filter cavity 11 of the candle filters 3 . The internal fluid cavity constitutes the clean side during the filtration process, such that the cleaned fluid flows out of the filter housing via the openings 5 of the base plate 1 .
In FIGS. 2, 3 and 6 , the candle filters 3 each feature an identical tapering. The ends of the filter cavities 11 , however, are configured differently, depending on whether the candle filters 3 are disposed in fluid communication with the openings 5 by the more slender ends thereof or by the thicker ends thereof. More precisely, the filter cavity 11 , which is open at the bottom end due to the passages 7 and 9 , and connected by the openings 5 of the base plate 1 , is closed at the opposite end that is depicted as the top end in the drawing. Regarding tapered candle filters, it is known in the art that a tube-like internal support structure 13 defines the internal filter cavity 11 . As most clearly visible in FIG. 6 , on the candle filters 3 that are closed at the more slender or small top ends thereof, a cylinder part 15 , which is formed in one piece to the end of the support structure 13 , constitutes the closure of the filter cavity 11 . However, on each thicker, closed top end, an end part 19 of the internal support structure 13 , with screwed-in closure plug 17 configured as having a closed wall part, constitutes the closure piece of the internal filter cavity 11 .
A filter mat 21 , disposed on the outside of the internal support structure 13 can be provided, for example, as a non-woven filtration material, such as a non-woven polyester or the like, which is placed around the support structure 13 . Alternatively, a fiber application can be directly applied to the support structure 13 by a melt-blown process. The type and specification of the respective filter medium 21 will depend on the purpose of use and the operating conditions of the filtering device.
At the end that is oriented toward the base plate 1 , the internal support structure 13 forms, together with the closed end part 19 , a connection piece 23 for the engagement in the corresponding opening 5 of the base plate 1 . The candle filters 3 that are oriented with the more slender ends thereof toward the base plate 1 include, instead of the cylinder part 15 serving as closure piece, a connection tube 25 formed in one piece with the internal support structure 13 and passing through the related opening 5 . The tube 25 , and thereby the candle filter 3 , is axially secured inside the opening 5 . In the present example, a bayonet catch 27 is provided for this purpose. Alternately, providing a clip for securing the screwed connection is also possible.
In the present example, the candle filters 3 include an external, tube-like support structure 29 that surrounds the outer side of the filter medium 21 , which is shown separately in FIG. 3 . The outer support structure 29 is a grate-shaped structure, like the internal support structure 13 , preferably press-formed in one piece of a plastic material. Structure 29 can accommodate a through-flow of fluid through the openings that are provided by the grate structure. At the thicker end, the support structure 29 forms a radially protruding annular edge 31 , which rests against the base plate 1 in the installed state. Formed in one piece with the opposite, closed end of the support structure 29 is a removal part 33 , showing a removal ring 35 for manually extracting the filtering element from the filter housing. The outer support structure 29 is connected to the cylinder part 15 by a bayonet attachment 37 , which is hinted at only in FIG. 4 . After releasing the bayonet 37 , the external support structure 29 can be drawn off and removed. Corresponding to the removal part 33 of the respectively closed ends of the candle filters 3 , the removal parts 39 , which are disposed on the thicker, closed ends, are provided with the removal rings 41 , corresponding to the removal rings 35 on the more slender ends.
The annular edges 31 on the external support structure 29 form a kind of toothing with the more slender ends of the external support structure 29 of adjacent candle filters to provide mutual, axial cohesion of the group of the candle filters 3 . More precisely, as shown particularly in FIG. 6 , the external support structures 29 include on the ends thereof a collar 43 that forms a type of a hollow cylinder. The cylinder part 15 of the internal support structure 13 passes there-through. The collar 43 constitutes a circumferential step 45 that forms a shoulder area 47 , which is disposed in the radial plane, and that reaches over the annular edge 31 of the thicker end of the external support structure 29 of the respectively adjacent candle filter 3 , as demonstrated particularly in FIGS. 5 and 6 .
With the group of candle filters 3 cohesively held together in this manner by the base plate 1 , the untreated side 51 is sealed off from the clean side that is located inside the filter cavity 11 , by sealing edges 53 that are formed, as hinted at in FIG. 5 , on the collar 43 of the internal support structure 13 . Furthermore, there exists the option of backwashing the candle filters 3 by reversing the fluid flow from the clean side 11 in the direction of the untreated side 51 .
In the preceding, the tapered candle filters 3 were described as comprising multiple structural parts with support structures 13 , 29 and filter medium 21 disposed there-between. However, the candle filters can be envisioned as tapered slotted screen tube elements that would be disposed in corresponding groups having a reversed tapering in relation to each other.
While one embodiment has been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the claims. | A filtering device includes multiple filtering elements ( 3 ) with bodies defining longitudinal axes. The filtering elements ( 3 ) are arranged adjacent to one another in a housing such that the longitudinal axes extend parallel to one another. The bodies of at least some of the filtering elements ( 3 ) have a shape that deviates from a circular cylinder at at least one part of the body length. The filtering elements ( 3 ) with bodies having a shape deviating from a circular cylinder have a cross-sectional size at least partially changing from one end to the other end. The filtering elements are oriented in the housing such that the regions of a larger cross-section are associated with the regions of a smaller cross-section in adjacent filtering elements. | 1 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims foreign priority benefits under 35 U.S.C. 119(a)-(d) or (f) of application number 1626/DEL/2007 filed in India on Aug. 1, 2007 which is herein incorporated by reference.
STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT
[0002] (Not Applicable)
REFERENCE TO AN APPENDIX
[0003] (Not Applicable)
FIELD OF THE INVENTION
[0004] The present invention relates to novel pyrrolo[2,1-c][1,4]benzodiazepine prodrug useful as a selective anti tumor agent for cancer therapy. Particularly, the present invention relates to (11S)-10-(4- -D-galactopyranosyloxy-3-nitrophenyl)methoxy carbonyl-11-hydroxy-7-methoxy-1,2,3,-10,11,11a-hexahydro-5H-pyrrolo[2,1-c][1,4]-benzodiazepin-5-one] and 1,1′-[[(propane-1,3-diyl)dioxy]-bis(11S,11aS)-10-(4-□-D-galactopyranosyloxy-3-nitrophenyl)methoxycarbonyl-11-hydroxy-7-methoxy-1,2,3,-10,11,11a-hexahydro-5H-pyrrolo[2,1-c][1,4]-benzodiazepin-5-one]. The present invention also relates to a process for the preparation of novel pyrrolo[2,1-c][1,4]benzodiazepine (PBD-glycoside) prodrug useful as a selective anti tumor agent for cancer therapy. The present invention also relates to a process of activation of the PBD-glycoside prodrugs to drugs by the enzyme □-galactosidase.
[0005] The structural formula of novel PBD-glycoside prodrugs is as follows,
[0000]
BACKGROUND OF THE INVENTION
[0006] Prodrugs are modified form of drugs, which on activation form drugs. Recently some prodrugs of PBDs have been reported which do not get activated by the enzyme β-galactosidase (Marina J. Sagnou, Philip W. Howard, Stephen J. Gregson, Ebun Eno-Amooquaye, Philip J. Burke, David E. Thurston, Bioorg Med. Chem. Lett. 2000, 10, 2083-2086; Jane M. Berry, Philip W. Howard, Lloyd R. Kelland, David E. Thurston, Bioorg Med. Chem. Lett. 2002, 12, 1413-1416; Luke A. Masterson, Victoria J. Spanswick, John A. Hartley, Richard H. Begent, Philip W. Howard, David E. Thurston, Bioorg. Med. Chem. Lett. 2006, 16, 252-256).
[0007] Pyrrolo[2,1-c][1,4]benzodiazepine antitumour antibiotics are commonly known as anthramycin class of compounds. In the last few years, a growing interest has been shown in the development of new pyrrolo[2,1-c][1,4]benzodiazepines (PBDs). These PBDs are a family of sequence selective DNA-binding antitumour antibiotics that bind exclusively to the exocyclic N2-guanine in the minor groove of DNA via an acid-labile animal bond to the electrophilic imine at the N10-C11 position. (Kunimoto, S.; Masuda, T.; Kanbayashi, N.; Hamada, M.; Naganawa, H.; Miyamoto, M.; Takeuchi, T.; Unezawa, H. J. Antibiot., 1980, 33, 665.; Kohn, K. W.; Speous, C. L. J. Mol. Biol., 1970, 51, 551.; Hurley, L. H. Gairpla, C.; Zmijewski, M. Biochem. Biophys. Acta., 1977, 475, 521.; Kaplan, D. J.; Hurley, L. H. Biochemistry, 1981, 20, 7572.; Ahmed Kamal, G. Ramesh, N. Laxman, P. Ramulu, O. Srinivas, K. Neelima, Anand K. Kondapi, V. B. Sreenu, H. A. Nagarajaram. J. Med. Chem. 2002, 45, 4679-4688).
[0008] All biologically active PBDs possess the (S) configuration at the chiral C11a position, which provides the molecule with a right-handed twist, which allows them to follow the curvature of the minor groove of B-form double-stranded DNA spanning three base pairs. The PBDs are of considerable current interest due to their ability to recognize and subsequently form covalent bonds to specific base sequences of double-stranded DNA. Naturally occurring pyrrolo[2,1-c][1,4]benzodiazepines belong to a group of antitumour antibiotics derived from Streptomyces species with family members including anthramycin, tomaymycin, sibiromycin, chicamycin, neothramycins A and B, and DC-81.
[0000]
[0009] However, the clinical efficacy for these antibiotics is hindered by several limitations, such as poor water solubility and cardiotoxicity and development of drug resistance, lack of tumour selectivity, metabolic inactivation. Therefore it is of considerable interest to design and prepare glycoside prodrugs of PBDs that could be activated by the enzyme □-galactosidase. This enzyme is found in some tissues like liver specifically or it can be delivered as an enzyme-antibody conjugate to the malignant cells. It is expected that these prodrugs get activated by the enzyme to the active moiety, and then interact with DNA.
OBJECTIVES OF THE INVENTION
[0010] The main objective of the present invention is to provide novel pyrrolo[2,1-c][1,4]benzodiazepine prodrug with increased water solubility useful as selective antitumour agent.
[0011] Another objective of the present invention is to provide novel pyrrolo[2,1-c][1,4]benzodiazepine prodrug, which could be activated to drugs in the presence of the enzyme □-galactosidase.
[0012] Yet another object of the present invention is to provide a process for the preparation of novel pyrrolo[2,1-c][1,4]benzodiazepine-glycoside prodrug useful as antitumour agent for selective therapy of cancer.
SUMMARY OF THE INVENTION
[0013] Accordingly the present invention provides novel pyrrolo[2,1-c][1,4]benzodiazepine-glycoside prodrug of formula 1 useful as a selective anti tumour agent.
[0000]
wherein R=Phenyl or CH 2 and n=1 or 2.
[0015] In an embodiment of the present invention the representative compounds of formula 1 are as follows:
(11S)-10-(4- -D-galactopyranosyloxy-3-nitrophenyl)methoxy carbonyl-11-hydroxy-7-methoxy-1,2,3,-10,11,11a-hexahydro-5H-pyrrolo[2,1-c][1,4]-benzodiazepin-5-one] (1a) and 1,1′-[[(propane-1,3-diyl)dioxy]-bis(11S,11aS)-10-(4-□-D-galactopyranosyloxy-3-nitrophenyl)methoxycarbonyl-11-hydroxy-7-methoxy-1,2,3,-10,11,11a-hexahydro-5H-pyrrolo[2,1-c][1,4]-benzodiazepin-5-one] (1b).
[0018] In yet another embodiment the compound of formula 1 is useful as anti tumour agent for selective therapy of cancer.
[0019] In yet another embodiment compound of formula 1 is activated to drug by the enzyme E. coli β-galactosidase.
[0020] In yet another embodiment compound of formula 1 is toxic to human cancer cell line A375 in the presence of E. coli β-galactosidase.
[0021] In yet another embodiment compound of formula 1 is toxic to human cancer cell line HeG2 in the absence of E. coli β-galactosidase.
[0022] The present invention further provides a process for the preparation of pyrrolo[2,1-c][1,4]benzodiazepine-glycoside prodrug of formula 1 useful as a selective anti tumour agent,
[0000]
[0023] wherein R=phenyl or CH 2 and n=1 or 2, and the said process comprising the steps of:
a. reacting the compound of formula 2 a-b with triethylamine and triphosgene in dry dichloromethane, under stirring for a period of 20-30 minutes, evaporating the dichloromethane from the resultant mixture and redissolving it in tetrahydrofuran followed by filtration to remove the white solid mass, evaporation of the tetrahydrofuran from the resultant filtrate and redissolving the residue obtained in dichloromethane and reacting it with a compound of formula 5 in the presence of catalytic amount of dibutyl tin dilaurate, under stirring for a period of 6-7 hrs to obtain the desired compound of formula 3 a-b
[0000]
b. reacting the compound of formula 3 a,b obtained in step (a) with calcium carbonate and mercuric chloride in a solvent mixture of acetonitrile and water in a ratio of about 3:1, under stirring for a period of 10-14 hrs, followed by filtration and evaporation of acetonitrile from the filtrate and finally extraction with ethylacetate, drying and purification of the resultant extract by known method to obtain the desired compound of formula 4 a,b
[0000]
c. reacting the compound of formula 4 a,b obtained in step (b) with catalytic amount of NaOMe in methanol, at a temperature in the range of 0-5° C., for a period of 20-35 minutes to obtain the desired compound of formula 1 a .
[0027] In an embodiment of the present invention the compound of formula 2 used in step (a) is selected from [(2-Amino-4-benzyloxy-5-methoxy-1,4-phenylene)carbonyl] (2S)-pyrrolidine-2-carboxaldehyde diethylthioacetal (2a) and 1,1β-[(Propane-1,3-diyl)dioxy]-bis[(2-amino-5-methoxy-1,4-phenylene)carbonyl]]-bis[(2S)-pyrrolidine-2-carboxaldehyde diethylthioacetal (2b).
[0028] In yet another embodiment the compound of formula 5 used in step (a) is (4-β-D-2,3,4,6-tetra-O-acetylgalactopyranosyloxy-3-nitrophenyl)methanol.
[0029] In yet another embodiment the compound of formula 3 obtained in step (a) is selected from [2-amino-N-(4-β-D-2,3,4,6-tetra-O-acetylgalactopyranosyloxy-3-nitrophenyl)methoxycarbonyl-4-benzyloxy-5-methoxy-1,4-phenylene]carbonyl] (2S)-pyrrolidine-2-carboxaldehyde diethylthioacetal (3a) and 1,1β-[(Propane-1,3-diyl)ioxy]-bis[(2-amino-N-(4-β-D-2,3,4,6-tetra-O-acetylgalactopyranosyloxy-3-nitrophenyl)methoxycarbonyl-5-methoxy-1,4-phenylene)carbonyl]]-bis[(2S)-pyrrolidine-2-carboxaldehyde diethylthioacetal (3b).
[0030] In yet another embodiment the compound of formula 4 obtained in step (b) is selected from (11S)-10-(4-β-D-2,3,4,6-tetra-O-acetylgalactopyranosyloxy-3-nitrophenyl)methoxycarbonyl-[1-hydroxy-7-methoxy-1,2,3,-10,11,11a-hexahydro-5H-pyrrolo[2,1-c][1,4]-benzodiazepin-5-one] (4a) and 1,1β-[(Propane-1,3-diyl)dioxy]-bis(11S,11aS)-10-(4-β-D-2,3,4,6-tetra-O-acetyl galactopyranosyloxy-3-nitrophenyl)methoxycarbonyl-[1-hydroxy-7-methoxy-1,2,3,-10,11,11a-hexahydro-5H-pyrrolo[2,1-c][1,4]-benzodiazepin-5-one] (4b).
[0031] In yet another embodiment, the representative compounds of formula 1 obtained are (11S)-10-(4- -galactopyranosyloxy-3-nitrophenyl)methoxy carbonyl-11-hydroxy-7-methoxy-1,2,3,-10,11,11a-hexahydro-5H-pyrrolo[2,1-c][1,4]-benzodiazepin-5-one] (1a) and 1,1′-[[(propane-1,3-diyl)dioxy]-bis(1S,11aS)-10-(4-□-D-galactopyranosyloxy-3-nitrophenyl)methoxycarbonyl-11-hydroxy-7-methoxy-1,2,3,-10,11,11a-hexahydro-5H-pyrrolo[2,1-c][1,4]-benzodiazepin-5-one] (1b).
DETAILED DESCRIPTION OF THE INVENTION
[0032] The present invention provides a process for the preparation of new pyrrolo[2,1-c][1,4]benzodiazepine-glycoside prodrugs, of formula 1a and 1b, useful as agents for selective therapy of solid tumours.
[0000]
[0000] The detail reaction scheme involved in the present invention is shown below:
[0000]
[0033] The following examples are given by way of illustration and therefore should not be construed to limit the scope of present invention.
EXAMPLE
Synthetic Procedures for the Preparation of the Prodrugs 1a and 1b
[0034] Compound 2a and/or 2b (0.9 g, 1.95 m·mol 2a or 1.3 g, 1.66 mmol 2b) was taken in dry CH 2 Cl 2 , to which triethylamine (4.29 m·mol, 0.6 ml for 2a and 7.30 m·mol, 1.02 ml for 2b) and triphosgene (0.64 m·mol, 0.19 g for 2a and 1.09 mmol, 0.32 g for 2b) were added and stirred for 25 minutes, after which CH 2 Cl 2 was evaporated and the reaction mixture was dissolved in THF and was filtered leaving behind a white solid. The THF in the filtrate was evaporated and the residue was redissolved in CH 2 Cl 2 and comp. 6 (1.95 m·mol, 0.97 g for 2a and 3.32.m mol, 1.65 g for 2b) and catalytic amount of dibutyl tin dilaurate were added and stirred for 6 hours to get the desired compound. The reaction mixture was washed with brine dried with anhydrous sodium sulfate and purified by column chromatography (1.53 g, 1.56 m mol, of 3a 80% yield and 2.46 g, 1.16 m mol, of 3b, 70% yield).
[0035] Compound 3a Yield=1.53 g, (80%); 1 H NMR (CDCl 3 , 300 MHz) δ 7.95 (bs, 1H), 7.84 (d, 1H, J=2.26), 7.56 (dd, 1H, J 1 =2.07, J 2 =8.49), 7.49-7.45 (m, 2H), 7.41-7.31 (m, 4H), 6.92 (s, 1H), 5.55 (dd, 1H, J 1 =7.93, J 2 =10.57), 5.47 (dd, 1H, J 1 =0.94, J 2 =3.21), 5.18 (s, 2H), 5.15 (s, 2H), 5.10 (dd, 1H, J 1 =3.39, J 2 =10.57), 5.06 (d, 1H, J=7.93), 4.68 (m, 2H), 4.28-4.04 (m, 3H), 3.83 (s, 3H), 3.61-3.54 (m, 2H), 2.80-2.59 (m, 4H), 2.33-1.86 (m, 16H), 1.97-1.36 (m, 6H), ESI-MS: m/z=1008 (M+Na) +
[0036] Compound 3b Yield=2.46 g, (70%); 1 H NMR, (CDCl 3 , 400 MHz) δ 9.18 (bs, 1H, NH), 7.9-7.82 (m, 4H), 7.59-7.54 (m, 4H), 7.37 (s, 1H), 7.34 (s, 1H), 6.90 (s, 2H), 5.58-5.45 (m, 4H), 5.18-5.04 (m, 8H), 4.73-4.63 (m, 4H), 4.35-4.04 (m, 10H), 3.81 (s, 6H), 3.60-3.53 (m, 4H), 2.79-2.59 (m, 8H), 2.44-1.55 (m, 22H), 1.35-1.20 (m, 12H), ESI-MS: m/z=1853 (M+Na) +
[0037] Compound 3a and/or 3b (1.4 g, 1.42 mmol 3a or 2 g, 1.09 m·mol 3b) was taken in CH 3 CN/H 2 O 3:1 mixture, to it CaCO 3 (3.55 mmol, 0.35 g for 3a and 5.45 mmol, 0.54 g for 3b) and HgCl 2 (3.12 mmol, 0.84 g for 3a and 4.90 m·mol, 1.33 g for 3b) were added and stirred for 12 hrs. The reaction mixture was filtered through celite bed. Acetonitrile was evaporated from the filtrate and extracted with ethylacetate. The ethyl acetate extract was dried with anhydrous sodium sulfate. The solvent was evaporated and the compound was purified by column chromatography (yield 0.95 g, 1.09 mmol 76% of 4a and 1.31 g, 0.81 mmol, 75% of 4b).
[0038] Compound 4a Yield=1.09 g, (76%); 1 H NMR (CDCl 3 , 300 MHz) δ 7.57 (s, 1H), 7.42-7.23 (m, 8H), 6.63 (s, 1H), 5.59 (d, 1H, J=9.82), 5.52 (dd, 1H, J 1 =7.55, J 2 =10.57), 5.16-4.90 (m, 6H), 4.23-4.10 (m, 3H), 3.93 (s, 3H), 3.75-3.43 (m, 3H), 2.20-1.55 (m, 16H), ESI-MS: m/z=902 (M+Na) +
[0039] Compound 4b Yield=1.31 g, (75%); 1 H NMR (CDCl 3 , 500 MHz) δ 7.73-7.69 (m, 2H), 7.54-7.48 (m, 4H), 7.35-7.11 (m, 2H), 6.85 (s, 2H), 5.71 (d, 2H, J=9.82), 5.59 (dd, 2H, J 1 =8.54, J 2 =9.97), 5.46 (d, 2H, J=3.02), 5.30 (d, 2H, J 1 =12.84), 5.07 (dd, 2H, J 1 =3.02, J 2 =10.57), 5.01 (d, 2H, J=7.55), 4.83 (d, 2H, J=12.08), 4.27-3.95 (m, 10H), 3.87 (s, 6H), 3.35-1.95 (m, 34H); ESI-MS m/z: 1641 [M+Na] +
[0040] Compound 4a and/or 4b (0.9 g, 1.02 mmol 4a or 1 g, 0.61 mmol 4b) was dissolved in methanol and catalytic amount of NaOMe was added at 0° C. and stirred for 30 minutes to get the final compounds 1a and/or 1b. Compound 1a was purified by column chromatography to get 0.61 g, 0.86 mmol, 85% yield while the crude yield of 1b was 0.63 g, 0.49 mmol, 80%. Compound 1b was purified by preparative reverse phase HPLC.
[0041] Compound 1a Yield=0.61 g, (85%); 1 H NMR (CD 3 OD, 500 MHz) δ 7.60-7.53 (m, 1H), 7.45-7.24 (m, 7H), 7.21 (s, 2H), 6.91-6.81 (m, 1H), 5.66 (d, 1H; J=9.73), 5.13-4.92 (m, 5H), 3.89 (s, 3H), 3.84-3.39 (m, 9H), 2.17-1.97 (m, 4H); HRMS [M+Na] + calcd for C34H38N3O14 m/z=712.2353, found (FAB) m/z=712.2336
[0042] Compound 1b Yield=0.63 g, (80%); 1 H NMR (CD 3 OD, 500 MHz) δ 7.72-7.32 (m, 6H), 7.21 (s, 2H), 7.00-6.90 (m, 2H), 5.70 (d, 2H, J=8.97), 5.22 (d, 2H, J=11.73), 5.07-4.91 (m, 4H), 4.29-4.03 (m, 4H), 3.96-3.92 (m, 2H), 3.90-3.82 (m, 8H), 3.78-3.71 (s, 6H), 3.66-3.58 (m, 4H), 3.54-3.42 (m, 4H), 2.30-2.23 (m, 2H), 2.20-1.99 (m, 8H); ESI-MS: m/z=1305 (M+Na) + ; HRMS [M+Na] + calcd for C57H66N6O28Na m/z=1305.3822, found (FAB) m/z=1305.3802.
Activation of the Prodrugs by the Enzyme β-Galactosidase
[0043] The prodrugs of structural formula 1a and 1b were activated to their corresponding carbinolamines that are equivalent to their parent imines under the conditions mentioned below:
[0000] 1. In the presence of the enzyme β-galactosidase.
2. Time duration of 60-90 minutes.
3. Temperature 37° C.
[0044] 4. At a pH of 7.2 (phosphate buffer)
Mechanism of activation of the prodrug 1a to 6a
[0000]
[0000] Mechanism of activation of the prodrug 1b to 6b
[0000]
[0000] The prodrug 1a 1 {tilde over (μ)}mole was treated with 2 units of E. coli β galactosidase enzyme and the progress of the hydrolysis was monitored by reverse phase HPLC. The results are presented in the form of a graph.
HPLC conditions: C18 Reverse phase column. Mobile phase 40:60 CH 3 CN/H 2 O, flow rate of 1 ml/min. UV detection: wave length 254 nm.
Biological Studies of the Prodrugs
[0045] The cytotoxic effects of the newly synthesized compounds 1a and 1b and their respective PBD imines were examined by cell cycle progression experiments on human tumor cells, by using fluorescence-activated cell sorting (FACS) analysis, in the absence and in the presence of β-galactosidase enzyme. In the primary flow cytometric study, the DNA content of the cells was used as a major determinant for cell count. The subG1 population, a conspicuous indicator for cell death, presumably apoptosis, and G2/M population was also determined in HepG2 and A375 cell lines.
[0046] The cytometric assay of A375 cells treated with both the prodrugs 1a and 1b along with E. coli β-galactosidase, not only resulted in apoptosis identical to that of the parent drugs 6a and 6b respectively, but also the amount of cell death was insignificant in the absence of the enzyme, indicating the prodrugs to be nontoxic even at such a high concentration (1a 42 μM and 1b 23.4 μM).
[0047] Next we evaluated the prodrugs for their activation efficiency by intracellular β-galactosidase, in human liver cancer, HepG2 cells. The cytometric assay of HepG2 cells with the prodrug 1a in the presence and in the absence of E. coli β-galactosidase enzyme was found to show an apoptotic response comparable to that of the parent drug 6a. Prodrug 1b in HepG2 cell line in the presence of E. coli β-galactosidase showed a profile comparable to that of the parent drug 6b. The prodrug with out the enzyme produced a block in the G2/M phase of the cell cycle, a characteristic of cross-linking drugs.
[0048] Picture representing the histogram overlay of HepG2 cells treated with compounds 1a, 6a and 1a+ E. coli β-galactosidase enzyme. It can be observed that the effect of the prodrug without any added enzyme is similar to that of the active molecule, benzylated ether of DC-81. The profile of the prodrug with E. coli enzyme added is also comparable to that of the DC-81.
[0000] The PBD glycoside prodrugs 1a and 1b are found to be useful for selective therapy of cancer especially solid tumours, with minimal toxic effect on the normal tissues. | The present invention provides novel pyrrolo[2,1-c][1,4]benzodiazepine-glycoside prodrug of general formula 1a-b, useful as selective anticancer agents. The present invention also provides a process for the preparation of novel pyrrolo[2,1-c][1,4]benzodiazepine-glycoside prodrugs of general formula 1a-b. This invention also provides activation of these produgs by E. coli β galactosidase and envisaged that these molecules are toxic to human cancer cell lines in the presence of the enzyme E. coli β-galactosidase. The prodrugs 1a and 1b were also found to be toxic to human cancer HepG2 cells even in the absence of the E. coli □-galactosidase. The toxic effect of the molecules when activated was similar to that of the parent molecules 6a and 6b, respectively. | 2 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 09/971,367, filed on Oct. 4, 2001 now U.S. Pat. No. 6,788,011, which is a continuation of U.S. application Ser. No. 09/669,121, filed on Sep. 25, 2000 now U.S. Pat. No. 6,806,659, which is a continuation of U.S. application Ser. No. 09/425,770, filed Oct. 22, 1999, now U.S. Pat. No. 6,150,774, which is a continuation of U.S. application Ser. No. 08/920,156, filed Aug. 26, 1997, now U.S. Pat. No. 6,016,038.
BACKGROUND OF THE INVENTION
The present invention relates to providing light of a selectable color using LEDs. More particularly, the present invention is a method and apparatus for providing multicolored illumination. More particularly still, the present invention is an apparatus for providing a computer controlled multicolored illumination network capable of high performance and rapid color selection and change.
It is well known that combining the projected light of one color with the projected light of another color will result in the creation of a third color. It is also well known that the three most commonly used primary colors—red, blue and green—can be combined in different proportions to generate almost any color in the visible spectrum. The present invention takes advantage of these effects by combining the projected light from at least two light emitting diodes (LEDs) of different primary colors.
Computer lighting networks are not new. U.S. Pat. No. 5,420,482, issued to Phares, describes one such network that uses different colored LEDs to generate a selectable color. Phares is primarily for use as a display apparatus. However, the apparatus has several disadvantages and limitations. First, each of the three color LEDs in Phares is powered through a transistor biasing scheme in which the transistor base is coupled to a respective latch register through biasing resistors. The three latches are all simultaneously connected to the same data lines on the data bus. This means it is impossible in Phares to change all three LED transistor biases independently and simultaneously. Also, biasing of the transistors is inefficient because power delivered to the LEDs is smaller than that dissipated in the biasing network. This makes the device poorly suited for efficient illumination applications. The transistor biasing used by Phares also makes it difficult, if not impossible, to interchange groups of LEDs having different power ratings, and hence different intensity levels.
U.S. Pat. No. 4,845,481, issued to Havel, is directed to a multicolored display device. Havel addresses some, but not all of the switching problems associated with Phares. Havel uses a pulse width modulated signal to provide current to respective LEDs at a particular duty cycle. However, no provision is made for precise and rapid control over the colors emitted. As a stand alone unit, the apparatus in Havel suggests away from network lighting, and therefore lacks any teaching as to how to implement a pulse width modulated computer lighting network. Further, Havel does not appreciate the use of LEDs beyond mere displays, such as for illumination.
U.S. Pat. No. 5,184,114, issued to Brown, shows an LED display system. But Brown lacks any suggestion to use LEDs for illumination, or to use LEDs in a configurable computer network environment. U.S. Pat. No. 5,134,387, issued to Smith et al., directed to an LED matrix display, contains similar problems. Its rudimentary cur-rent control scheme severely limits the possible range of colors that can be displayed.
It is an object of the present invention to overcome the limitations of the prior art by providing a high performance computer controlled multicolored LED lighting network.
It is a further object of the present invention to provide a unique LED lighting network structure capable of both a linear chain of nodes and a binary tree configuration.
It is still another object of the present invention to provide a unique heat-dissipating housing to contain the lighting units of the lighting network.
It is yet another object of the present invention to provide a current regulated LED lighting apparatus, wherein the apparatus contains lighting modules each having its own maximum current rating and each conveniently interchangeable with one another.
It is a still further object of the present invention to provide a unique computer current-controlled LED lighting assembly for use as a general illumination device capable of emitting multiple colors in a continuously programmable 24-bit spectrum.
It is yet a still further object of the present invention to provide a unique flashlight, inclinometer, thermometer, general environmental indicator and lightbulb, all utilizing the general computer current-control principles of the present invention.
Other objects of the present invention will be apparent from the detailed description below.
SUMMARY OF THE INVENTION
In brief, the invention herein comprises a pulse width modulated current control for an LED lighting assembly, where each current-controlled unit is uniquely addressable and capable of receiving illumination color information on a computer lighting network. In a further embodiment, the invention includes a binary tree network configuration of lighting units (nodes). In another embodiment, the present invention comprises a heat dissipating housing, made out of a heat-conductive material, for housing the lighting assembly. The heat dissipating housing contains two stacked circuit boards holding respectively the power module and the light module. The light module is adapted to be conveniently interchanged with other light modules having programmable current, and hence maximum light intensity ratings. Other embodiments of the present invention involve novel applications for the general principles described herein.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a stylized electrical circuit schematic of the light module of the present invention.
FIG. 2 is a stylized electrical circuit schematic of the power module of the present invention.
FIG. 2A illustrates a network of addressable LED-based lighting units according to one embodiment of the invention.
FIG. 3 is an exploded view of the housing of one of the embodiments of the present invention.
FIG. 4 is a plan view of the LED-containing side of the light module of the present invention.
FIG. 5 is a plan view of the electrical connector side of the light module of the present invention.
FIG. 6 is a plan view of the power terminal side of the power module of the present invention.
FIG. 7 is a plan view of the electrical connector side of the power module of the present invention.
FIG. 8 is an exploded view of a flashlight assembly containing the LED lighting module of the present invention.
FIG. 9 is a control block diagram of the environmental indicator of the present invention.
DETAILED DESCRIPTION
The structure and operation of a preferred embodiment will now be described. It should be understood that many other ways of practicing the inventions herein are available, and the embodiments described herein are exemplary and not limiting. Turning to FIG. 1 , shown is an electrical schematic representation of a light module 100 of the present invention. FIGS. 4 and 5 show the LED-containing side and the electrical connector side of light module 100 . Light module 100 is self-contained, and is configured to be a standard item interchangeable with any similarly constructed light module. Light module 100 contains a ten-pin electrical connector 110 of the general type. In this embodiment, the connector 110 contains male pins adapted to fit into a complementary ten-pin connector female assembly, to be described below. Pin 180 is the power supply. A source of DC electrical potential enters module 100 on pin 180 . Pin 180 is electrically connected to the anode end of light emitting diode (LED) sets 120 , 140 and 160 to establish a uniform high potential on each anode end.
LED set 120 contains red LEDs, set 140 contains blue and set 160 contains green, each obtainable from the Nichia America Corporation. These LEDs are primary colors, in the sense that such colors when combined in preselected proportions can generate any color in the spectrum. While three primary colors is preferred, it will be understood that the present invention will function nearly as well with only two primary colors to generate any color in the spectrum. Likewise, while the different primary colors are arranged herein on sets of uniformly colored LEDs, it will be appreciated that the same effect may be achieved with single LEDs containing multiple color-emitting semiconductor dies. LED sets 120 , 140 and 160 each preferably contains a serial/parallel array of LEDs in the manner described by Okuno in U.S. Pat. No. 4,298,869, incorporated herein by reference. In the present embodiment, LED set 120 contains three parallel connected rows of nine red LEDs (not shown), and LED sets 140 and 160 each contain five parallel connected rows of five blue and green LEDs, respectively (not shown). It is understood by those in the art that, in general, each red LED drops the potential in the line by a lower amount than each blue or green LED, about 2.1 V, compared to 4.0 V, respectively, which accounts for the different row lengths. This is because the number of LEDs in each row is determined by the amount of voltage drop desired between the anode end at the power supply voltage and the cathode end of the last LED in the row. Also, the parallel arrangement of rows is a fail-safe measure that ensures that the light module 100 will still function even if a single LED in a row fails, thus opening the electrical circuit in that row. The cathode ends of the three parallel rows of nine red LEDs in LED set 120 are then connected in common, and go to pin 128 on connector 110 . Likewise, the cathode ends of the five parallel rows of five blue LEDs in LED set 140 are connected in common, and go to pin 148 on connector 110 . The cathode ends of the five parallel rows of five green LEDs in LED set 160 are connected in common, and go to pin 168 on connector 110 . Finally, on light module 100 , each LED set is associated with a programming resistor that combines with other components, described below, to program the maximum current through each set of LEDs. Between pin 124 and 126 is resistor 122 , 6 . 2 . Between pin 144 and 146 is resistor 142 , 4 . 7 . Between pin 164 and 166 is resistor 162 , 4 . 7 . Resistor 122 programs maximum current through red LED set 120 , resistor 142 programs maximum current through blue LED set 140 , and resistor 162 programs maximum current through green LED set 160 . The values these resistors should take are determined empirically, based on the desired maximum light intensity of each LED set. In the present embodiment, the resistances above program red, blue and green currents of 70, 50 and 50 A, respectively.
With the electrical structure of light module 100 described, attention will now be given to the electrical structure of power module 200 , shown in FIG. 2 . FIGS. 6 and 7 show the power terminal side and electrical connector side of an embodiment of power module 200 . Like light module 100 , power module 200 is self contained. Interconnection with male pin set 110 is achieved through complementary female pin set 210 . Pin 280 connects with pin 180 for supplying power, delivered to pin 280 from supply 300 . Supply 300 is shown as a functional block for simplicity. In actuality, supply 300 can take numerous forms for generating a DC voltage. In the present embodiment, supply 300 provides 24 Volts through a connection terminal (not shown), coupled to pin 280 through transient protection capacitors (not shown) of the general type. It will be appreciated that supply 300 may also supply a DC voltage after rectification and/or voltage transformation of an AC supply, as described more fully in U.S. Pat. No. 4,298,869.
Also connected to pin connector 210 are three current programming integrated circuits, ICR 220 , ICB 240 and ICG 260 . Each of these is a three terminal adjustable regulator, preferably part number LM317B, available from the National Semiconductor Corporation, Santa Clara, Calif. The teachings of the LM317 datasheet are incorporated herein by reference. Each regulator contains an input terminal, an output terminal and an adjustment terminal, labeled I, O and A, respectively. The regulators function to maintain a constant maximum current into the input terminal and out of the output terminal. This maximum current is pre-programmed by setting a resistance between the output and the adjustment terminals. This is because the regulator will cause the voltage at the input terminal to settle to whatever value is needed to cause 1.25 V to appear across the fixed current set resistor, thus causing constant current to flow. Since each functions identically, only ICR 220 will now be described. First, current enters the input terminal of ICR 220 from pin 228 . Of course, pin 228 in the power module is coupled to pin 128 in the light module, and receives current directly from the cathode end of the red LED set 120 . Since resistor 122 is ordinarily disposed between the output and adjustment terminals of ICR 220 through pins 224 / 124 and 226 / 126 , resistor 122 programs the amount of current regulated by ICR 220 . Eventually, the current output from the adjustment terminal of ICR 220 enters a Darlington driver. In this way, ICR 220 and associated resistor 122 program the maximum current through red LED set 120 . Similar results are achieved with ICB 240 and resistor 142 for blue LED set 140 , and with ICG 260 and resistor 162 for green LED set 160 .
The red, blue and green LED currents enter another integrated circuit, IC 1 380 , at respective nodes 324 , 344 and 364 . IC 1 380 is preferably a high current/voltage Darlington driver, part no. DS2003 available from the National Semiconductor Corporation, Santa Clara, Calif. IC 1 380 is used as a current sink, and functions to switch current between respective LED sets and ground 390 . As described in the DS2003 datasheet, incorporated herein by reference, IC 1 contains six sets of Darlington transistors with appropriate on-board biasing resistors. As shown, nodes 324 , 344 and 364 couple the current from the respective LED sets to three pairs of these Darlington transistors, in the well known manner to take advantage of the fact that the current rating of IC 1 380 may be doubled by using pairs of Darlington transistors to sink respective currents. Each of the three on-board Darlington pairs is used in the following manner as a switch. The base of each Darlington pair is coupled to signal inputs 424 , 444 and 464 , respectively. Hence, input 424 is the signal input for switching current through node 324 , and thus the red LED set 120 . Input 444 is the signal input for switching current through node 344 , and thus the blue LED set 140 . Input 464 is the signal input for switching current through node 364 , and thus the green LED set 160 . Signal inputs 424 , 444 and 464 are coupled to respective signal outputs 434 , 454 and 474 on microcontroller IC 2 400 , as described below. In essence, when a high frequency square wave is incident on a respective signal input, IC 1 380 switches current through a respective node with the identical frequency and duty cycle. Thus, in operation, the states of signal inputs 424 , 444 and 464 directly correlate with the opening and closing of the power circuit through respective LED sets 120 , 140 and 160 .
The structure and operation of microcontroller IC 2 400 will now be described. Microcontroller IC 2 400 is preferably a MICROCHIP brand PIC16C63, although almost any properly programmed microcontroller or microprocessor can perform the software functions described herein. The main function of microcontroller IC 2 400 is to convert numerical data received on serial Rx pin 520 into three independent high frequency square waves of uniform frequency but independent duty cycles on signal output pins 434 , 454 and 474 . The FIG. 2 representation of microcontroller IC 2 400 is partially stylized, in that persons of skill in the art will appreciate that certain of the twenty-eight standard pins have been omitted or combined for greatest clarity.
Microcontroller IC 2 400 is powered through pin 450 , which is coupled to a 5 Volt source of DC power 700 . Source 700 is preferably driven from supply 300 through a coupling (not shown) that includes a voltage regulator (not shown). An exemplary voltage regulator is the LM340 3-terminal positive regulator, available from the National Semiconductor Corporation, Santa Clara, Califa. The teachings of the LM340 datasheet are hereby incorporated by reference. Those of skill in the art will appreciate that most microcontrollers, and many other independently powered digital integrated circuits, are rated for no more than a 5 Volt power source. The clock frequency of microcontroller IC 2 400 is set by crystal 480 , coupled through appropriate pins. Pin 490 is the microcontroller IC 2 400 ground reference.
Switch 600 is a twelve position dip switch that may be alterably and mechanically set to uniquely identify the microcontroller IC 2 400 . When individual ones is of the twelve mechanical switches within dip switch 600 are closed, a path is generated from corresponding pins 650 on microcontroller IC 2 400 to ground 690 . Twelve switches create 2 12 possible settings, allowing any microcontroller IC 2 400 to take on one of 4096 different IDs, or addresses. In the preferred embodiment, only nine switches are actually used because the DMX-512 protocol, discussed below, is employed.
Once switch 600 is set, microcontroller IC 2 400 “knows” its unique address (“who am I”), and “listens” on serial line 520 for a data stream specifically addressed to it. A high speed network protocol, preferably a DMX protocol, is used to address network data to each individually addressed microcontroller IC 2 400 from a central network controller 1000 , as shown for example in FIG. 2 A. The DMX protocol is described in a United States Theatre Technology, Inc. publication entitled “DMX512/1990 Digital Data Transmission Standard for Dimmers and Controllers,” incorporated herein by reference. Basically, in the network protocol used herein, a central controller creates a stream of network data consisting of sequential data packets. Each packet first contains a header, which is checked for conformance to the standard and discarded, followed by a stream of sequential bytes representing data for sequentially addressed devices. For instance, if the data packet is intended for light number fifteen, then fourteen bytes from the data stream will be discarded, and the device will save byte number fifteen. If as in the preferred embodiment, more than one byte is needed, then the address is considered to be a starting address, and more than one byte is saved and utilized. Each byte corresponds to a decimal number 0 to 255, linearly representing the desired intensity from Off to Full. (For simplicity, details of the data packets such as headers and stop bits are omitted from this description, and will be well appreciated by those of skill in the art.) This way, each of the three LED colors is assigned a discrete intensity value between 0 and 255. These respective intensity values are stored in respective registers within the memory of microcontroller IC 2 400 (not shown). Once the central controller exhausts all data packets, it starts over in a continuous refresh cycle. The refresh cycle is defined by the standard to be a minimum of 1196 microseconds, and a maximum of 1 second.
Microcontroller IC 2 400 is programmed continually to “listen” for its data stream. When microcontroller IC 2 400 is “listening,” but before it detects a data packet intended is for it, it is running a routine designed to create the square wave signal outputs on pins 434 , 454 and 474 . The values in the color registers determine the duty cycle of the square wave. Since each register can take on a value from 0 to 255, these values create 256 possible different duty cycles in a linear range from 0% to 100%. Since the square wave frequency is uniform and determined by the program running in the microcontroller IC 2 400 , these different discrete duty cycles represent variations in the width of the square wave pulses. This is known as pulse width modulation (PWM).
The PWM interrupt routine is implemented using a simple counter, incrementing from 0 to 255 in a cycle during each period of the square wave output on pins 434 , 454 and 474 . When the counter rolls over to zero, all three signals are set high. Once the counter equals the register value, signal output is changed to low. When microcontroller IC 2 400 receives new data, it freezes the counter, copies the new data to the working registers, compares the new register values with the current count and updates the output pins accordingly, and then restarts the counter exactly where it left off. Thus, intensity values may be updated in the middle of the PWM cycle. Freezing the counter and simultaneously updating the signal outputs has at least two advantages. First, it allows each lighting unit to quickly pulselstrobe as a strobe light does. Such strobing happens when the central controller sends network data having high intensity values alternately with network data having zero intensity values at a rapid rate. If one restarted the counter without first updating the signal outputs, then the human eye would be able to perceive the staggered deactivation of each individual color LED that is set at a different pulse width. This feature is not of concern in incandescent lights because of the integrating effect associated with the heating and cooling cycle of the illumination element element. LEDs, unlike incandescent elements, activate and deactivate essentially instantaneously in the present application. The second advantage is that one can “dim” the LEDs without the flickering that would otherwise occur if the counter were reset to zero. The central controller can send a continuous dimming signal when it creates a sequence of intensity values representing a uniform and proportional decrease in light intensity for each color LED. If one did not update the output signals before restarting the counter, there is a possibility that a single color LED will go through nearly two cycles without experiencing the zero current state of its duty cycle. For instance, assume the red register is set at 4 and the counter is set at 3 when it is frozen. Here, the counter is frozen just before the “off” part of the PWM cycle is to occur for the red LEDs. Now assume that the network data changes the value in the red register from 4 to 2 and the counter is restarted without deactivating the output signal. Even though the counter is greater than the intensity value in the red register, the output state is still “on”, meaning that maximum current is still flowing through the red LEDs. Meanwhile, the blue and green LEDs will probably turn off at their appropriate times in the PWM cycle. This would be perceived by the human eye as a red flicker in the course of dimming the color intensities. Freezing the counter and updating the output for the rest of the PWM cycle overcomes these disadvantages, ensuring the flicker does not occur.
The network interface for microcontroller IC 2 400 will now be described. Jacks 800 and 900 are standard RJ-8 network jacks. Jack 800 is used as an input jack, and is shown for simplicity as having only three inputs: signal inputs 860 , 870 and ground 850 . Network data enters jack 800 and passes through signal inputs 860 and 870 . These signal inputs are then coupled to IC 3 500 , which is an RS- 485 /RS 422 differential bus repeater of the standard type, preferably a DS96177 from the National Semiconductor Corporation, Santa Clara, Calif. The teachings of the DS96177 datasheet are hereby incorporated by reference. The signal inputs 860 , 870 enter IC 3 500 at pins 560 , 570 . The data signal is passed through from pin 510 to pin 520 on microcontroller IC 2 400 . The same data signal is then returned from pin 540 on IC 2 400 to pin 530 on IC 3 500 . Jack 900 is used as an output jack and is shown for simplicity as having only five outputs: signal outputs 960 , 970 , 980 , 990 and ground 950 . Outputs 960 and 970 are split directly from input lines 860 and 870 , respectively. Outputs 980 and 990 come directly from IC 3 500 pins 580 and 590 , respectively. It will be appreciated that the foregoing assembly enables two network nodes to be connected for receiving the network data. Thus, a network may be constructed as a daisy chain, if only single nodes are strung together, or as a binary tree, if two nodes are attached to the output of each single node.
From the foregoing description, one can see that an addressable network of LED illumination or display units 2000 as shown in FIG. 2A can be constructed from a collection of power modules each connected to a respective light module. As long as at least two primary color LEDs are used, any illumination or display color may be generated simply by preselecting the light intensity that each color emits. Further, each color LED can emit light at any of 255 different intensities, depending on the duty cycle of PWM square wave, with a full intensity pulse generated by passing maximum current through the LED. Further still, the maximum intensity can be conveniently programmed simply by adjusting the ceiling for the maximum allowable current using programming resistances for the current regulators residing on the light module. Light modules of different maximum current ratings may thereby be conveniently interchanged.
The foregoing embodiment may reside in any number of different housings. A preferred housing for an illumination unit is described. Turning now to FIG. 3 , there is shown an exploded view of an illumination unit of the present invention comprising a substantially cylindrical body section 10 , a light module 20 , a conductive sleeve 30 , a power module 40 , a second conductive sleeve 50 and an enclosure plate 60 . It is to be assumed here that the light module 20 and the power module 40 contain the electrical structure and software of light module 100 and power module 200 , described above. Screws 62 , 64 , 66 , 68 allow the entire apparatus to be mechanically connected. Body section 10 , conductive sleeves 30 and 50 and enclosure plate 60 are preferably made from a material that conducts heat, most preferably aluminum. Body section 10 has an open end 10 , a reflective interior portion 12 and an illumination end 13 , to which module 20 is mechanically affixed. Light module 20 is disk shaped and has two sides. The illumination side (not shown) comprises a plurality of LEDs of different primary colors. The connection side holds an electrical connector male pin assembly 22 . Both the illumination side and the connection side are coated with aluminum surfaces to better allow the conduction of heat outward from the plurality of LEDs to the body section 10 . Likewise, power module 40 is disk shaped and has every available surface covered with aluminum for the same reason. Power module 40 has a connection side holding an electrical connector female pin assembly 44 adapted to fit the pins from assembly 22 . Power module 40 has a power terminal side holding a terminal 42 for connection to a source of DC power. Any standard AC or DC jack may be used, as appropriate.
Interposed between light module 20 and power module 40 is a conductive aluminum sleeve 30 , which substantially encloses the space between modules 20 and 40 . As shown, a disk-shaped enclosure plate 60 and screws 62 , 64 , 66 and 68 sad all of the components together, and conductive sleeve 50 is thus interposed between enclosure plate 60 and power module 40 . Once sealed together as a unit, the illumination apparatus may be connected to a data network as described above and mounted in any convenient manner to illuminate an area. In operation, preferably a light diffusing means will be inserted in body section 10 to ensure that the LEDs on light module 20 appear to emit a single uniform frequency of light.
From the foregoing, it will be appreciated that PWM current control of LEDs to produce multiple colors may be incorporated into countless environments, with or without networks. For instance, FIG. 8 shows a hand-held flashlight can be made to shine any conceivable color using an LED assembly of the present invention. The flashlight contains an external adjustment means 5 , that may be for instance a set of three potentiometers coupled to an appropriately programmed microcontroller 92 through respective A/D conversion means 15 . Each potentiometer would control the current duty cycle, and thus the illumination intensity, of an individual color LED on LED board 25 . With three settings each capable of generating a different byte from 0 to 255, a computer-controlled flashlight may generate twenty-four bit color. Of course, three individual potentiometers can be incorporated into a single device, such as a track ball or joystick, so as to be operable as a single adjuster. Further, it is not necessary that the adjustment means must be a potentiometer. For instance, a capacitive or resistive thumb plate may also be used to program the two or three registers necessary to set the color. A lens assembly 93 may be provided for reflecting the emitted light. A non-hand held embodiment of the present invention may be used as an underwater swimming pool light. Since the present invention can operate at relatively low voltages and low current, it is uniquely suited for safe underwater operation.
Similarly, the present invention may be used as a general indicator of any given environmental condition. FIG. 9 shows the general functional block diagram for such an apparatus. Shown within FIG. 9 is also an exemplary chart showing the duty cycles of the three color LEDs during an exemplary period. As one example of an environmental indicator 96 , the power module can be coupled to an inclinometer. The inclinometer measures general angular orientation with respect to the earth's center of gravity. The inclinometer's angle signal can be converted through an A/D converter 94 and coupled to the data inputs of the micro controller 92 in the power module. The microcontroller 92 can then be programmed to assign each discrete angular orientation a different color through the use of a lookup table associating angles with LED color register values. A current switch 90 , coupled to the microcontroller 92 , may be used to control the current supply to LEDs 120 , 140 , and 160 of different colors. The microcontroller 92 may be coupled to a transceiver 95 for transmitting and receiving signals. The “color inclinometer” may be used for safety, such as in airplane cockpits, or for novelty, such as to illuminate the sails on a sailboat that sways in the water. Another indicator use is to provide an easily readable visual temperature indication. For example, a digital thermometer can be connected to provide the microcontroller a temperature reading. Each temperature will be associated with a particular set of register values, and hence a particular color output. A plurality of such “color thermometers” can be located over a large space, such as a storage freezer, to allow simple visual inspection of temperature over three dimensions.
Another use of the present invention is as a lightbulb. Using appropriate rectifier and voltage transformation means, the entire power and light modules may be placed in an Edison-mount (screw-type) lightbulb housing. Each bulb can be programmed with particular register values to deliver a particular color bulb, including white. The current regulator can be pre-programmed to give a desired current rating and thus preset light intensity. Naturally, the lightbulb will have a transparent or translucent section that allows the passage of light into the ambient.
While the foregoing has been a detailed description of the preferred embodiment of the invention, the claims which follow define more freely the scope of invention to which applicant is entitled. Modifications or improvements which may not come within the explicit language of the claims described in the preferred embodiments should be treated as within the scope of invention insofar as they are equivalent or otherwise consistent with the contribution over the prior art and such contribution is not to be limited to specific embodiments disclosed. | Illumination methods and apparatus, in which a first number of first light sources are adapted to generate first radiation having a first spectrum, and a second number of second light sources are adapted to generate second radiation having a second spectrum different than the first spectrum. In one example, the first number of the first light sources and the second number of the second light sources are different. In another example, a first intensity of the first radiation and a second intensity of the second radiation are independently controlled so as to controllably vary at least an overall perceivable color of generated visible radiation. In yet another example, a first control signal controls all of the first light sources substantially identically, and a second control signal controls all of the second light sources substantially identically. | 5 |
FIELD OF THE INVENTION
This invention relates to an interrupt control system and more specifically to an interrupt control system suited for a data processing unit constructed by the application of semiconductor integrated circuit techniques.
DESCRIPTION OF THE PRIOR ART
In constructing a central processing unit (CPU) such as a microcomputer by applying large scale integration (LSI) techniques to semiconductor chips, CPU-constituting elements are sometimes divided into several LSI chips due to limitations imposed on the density of integration of the LSI chips or on the number of pins for the interconnection with external circuits. Especially in the case of a 16-bit microcomputer used for various control purposes, a CPU is frequently formed by dividing its constituents into the following two LSI chips.
The first LSI chip is a portion which incorporates therein various registers and arithmetic and logic unit (ALU) for arithmetic operations and principally carries out a processing operation. The second LSI chip is a portion which plays the roles of decoding instructions, controlling its run sequence and also controlling interrupt and input and output.
In the present specification, the first and second LSI chips will hereinafter be referred to as an "arithmetic chip" and a "control chip", respectively. Incidentally, in a microprogram control system, read only memory (ROM) is assigned an LSI chip which is different from the abovementioned two LSI chips. In such a case, the CPU is constructed by three LSI chips in total.
FIG. 1 diagrammatically shows the construction of a microcomputer system as an example of the prior art which has the above-described CPU construction. In the drawing, reference numeral 1 is an arithmetic chip; 2 is a control chip; 3 is a ROM for storing the microprogram; 4 is a main memory for storing user program and data; and 5, 6 and 7 are external input/output terminal units. These elements are interconnected to each other by an information bus 8. An interrupt request from a terminal unit is applied as an input to the control chip 2 via a bus 9 and when the interrupt request is received, an interrupt-receiving signal is produced as an output from the control chip 2 via a bus 10 to the corresponding terminal unit 5, 6 or 7.
The system of interrupt routine that has been conventionally carried out in the control chip 2 when the abovementioned system configuration is used will be explained with reference to FIG. 2. The control chip 2 includes two kinds of interrupt registers (flip-flops) 11 and 12 whereby one 11 of them receives interrupt request signals REQ0-REQ3 from input/output units connected to devices outside the CPU that require masking while the other flip-flop 12 receives interrupt signals having higher priority that are produced inside the CPU, such as remote console request CI/O, stop request STOP REQ, power-down interrupt POP INT and so on, for example.
An external interrupt request of the flip-flop 11 is passed through AND gates 13a-13d whereby an AND operation is made between it and the content of an interrupt mask 14 forming part of a status register and a receivable interrupt request is applied as input to a priority judging circuit 15. On the other hand, a CPU internal interrupt request of the flip-flop 12 does not require masking so that it is directly applied as an input to the priority judging circuit 15.
Of the interrupt requests input to it, the priority judging circuit 15 selects the one having the highest priority and produces a signal 15s, which instructs the jump to a head address of interrupt judging routine, to an address generating circuit 16 of the microprogram. When the interrupt to be run is from outside the CPU, an acknowledge signal ACQ0-ACQ3 is produced as an output to the corresponding input/output unit.
However, the control chip requires a number of signal input/output pins in order to perform various functions such as reading of instruction words from the main memory and microinstruction from the ROM, for input and output control and other functions. If reception and acknowledgement of various interrupt requests are made by means of the control chip as in the conventional interrupt control system mentioned above, a large number of signal pins are used for the interrupt routine whereby addition of new functions to the control chip and extension of performance of the control chip becomes remarkably difficult due to the shortage of the signal pins.
It is desired, on the other hand, that the interrupt mask data should form a status register together with a condition code representing the result of logical operation. In the conventional interrupt control system such as described above, however, the interrupt mask is provided on the control chip whereas the condition code is provided on the arithmetic chip on account of their functions so that the status register is divided into two LSI chips and their control is complicated.
SUMMARY OF THE INVENTION
The present invention contemplates to solve the above-mentioned problems encountered in the prior art and is directed to provide an interrupt control system which reduces the number of signal pins for the interrupt routine and which is suited for an LSI data processing unit.
In order to accomplish this object, in an interrupt control system for a microprogram control data processing unit having its processor constructed dividedly by an arithmetic chip and a control chip, the present invention includes memory means for storing a microprogram for interrupt source-judging routine and interrupt source-processing routine, said means being interconnected with said arithmetic chip and with said control chip; and gate means for receiving interrupt request signals from plural interrupt sources having higher priority to a job being run in said arithmetic chip, and for producing as output one interrupt signal to be applied to said control chip; said control chip having access to the microprogram of the interrupt source-judging routine in response to the interrupt signal from said gate means; and said arithmetic chip judging the interrupt sources in accordance with the microprogram read out and performing the respective processing routine corresponding to the interrupt source.
In the control system in accordance with the present invention, an interrupt request signal from an input/output unit outside the CPU that requires masking in accordance with an interrupt level is input to the arithmetic chip and is subjected to masking by means of mask data of a status register. The arithmetic chip produces as an output a signal representing the absence or presence of an interrupt to be made on the basis of the masking result. This signal is applied as an input to an external OR gate together with a signal having the top priority interrupt level such as an internal interrupt of a CPU, the output of the OR gate being given as a signal representative of the absence or presence of the interrupt request to the control chip. Judgement of the interrupt sources is made at the arithmetic chip by sequentially taking in the interrupt request signals from inside the CPU having the abovementioned top priority levels by means of the microprogram for the interrupt routine, and then sequentially taking in the interrupt requests from the external input/output units.
These and other objects and features of the present invention will be made apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the overall construction of the conventional LSI microcomputer;
FIG. 2 is a chart useful for explaining the conventional interrupt control system used for the microcomputer having the abovementioned construction;
FIG. 3 is a chart useful for explaining the principle of the interrupt control system in accordance with the present invention;
FIG. 4 is a time chart showing an example of the time chart of signals in the abovementioned interrupt control system;
FIG. 5 is a diagrammatic flow chart of a microprogram for the interrupt routine;
FIG. 6 is a block diagram showing the overall construction of the CPU portion of a microcomputer in an embodiment of the present invention;
FIG. 7 is a block diagram showing the construction of the arithmetic chip; and
FIG. 8 is a block diagram showing the construction of the control chip.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 3 is a circuit diagram for explaining the principle of the present invention and FIG. 4 is a time chart of the signals in this circuit. The arithmetic chip 1 incorporates therein a status register 20 including mask data 20a and condition code 20b, and a flip-flop 21 for receiving as an input the interrupt request signals from the external input/output units at each level. The external interrupt request signals RQI0-RQI3 are sampled by clock signals of the arithmetic chip every one micro-cycle, are applied as an input to the interrupt-receiving flip-flop 21 and are then subjected to AND operation between them and the abovementioned mask data 20a at AND gates 22a-22d at each interrupt level. The output of the AND gates 22a-22d is then passed through an OR gate 23 to determine the logical OR and its result is produced from the arithmetic chip 1 as the output signal IREQ. In other words, the arithmetic chip 1 produces as its output the signal IREQ which represents the absence or presence of the external interrupt request.
The abovementioned signal IREQ is input to an OR gate 25 outside the LSI chip together with interrupt request signals from inside the CPU that are to be received with higher priority, and the output of this OR gate is input to a signal pin IRQ of the control chip 2 for receiving an interrupt input.
Examples of the internal interrupt request signals of the CPU include internal interrupt request from the console C I/O, stop interrupt request STOP INT and power-down interrupt request POP INT, for example.
The control chip 2 samples the interrupt request signals IRQ from the abovementioned OR gate 25 by means of its internal clocks and takes them into the interrupt-receiving circuit incorporated therein such as a flip-flop 26, for example. As a result, it receives a request, if any, at the timing of the interval of the instruction which is being run, produces from a microprogram address-generating circuit 27 a ROM address 28 representing the head of the interrupt routine program and applies it to an address counter 3'.
The interrupt processing program of ROM 3 is programmed in micro instruction language, as represented by 30-35 in FIG. 5, so as to judge the interrupt sources in accordance with priority and to perform the processing routines 30J-36J corresponding to the respective interrupt sources.
In the running process of the abovementioned interrupt processing program, the arithmetic chip 1 performs its control function in such a fashion that it sequentially takes the internal interrupt signals of the CPU, that is, the conditions of C I/O, STOP REQ and POP INT, from the terminal TB into a priority-judging circuit 24 and if there is no interrupt request among them, it then takes the output signals of the AND gates 22a-22d into the priority-judging circuit 24. When detecting an interrupt source, the priority-judging circuit 24 outputs a signal LREQ to the address counter 3'. The address counter 3' is response to the abovementioned signal LREQ to perform an incremental action or a load action, loads the address 28 from the circuit 27 when the signal is fed thereto and jumps it to the predetermined processing routine 30-36J.
Next, an embodiment of the microcomputer employing the interrupt control system in accordance with the present invention will be explained with reference to FIGS. 6-8.
FIG. 6 shows the overall construction of the CPU board which includes the arithmetic chip 1, the control chip 2, the ROM chip 3 for storing the microprogram, the ROM address counter 3' and the main memory 4 for storing the program. Reference numerals 30 and 30' represent clock pulse generators, respectively, that produce as their output fundamental clocks required for the arithmetic chip, the control chip and other circuit elements. Reference numeral 8a represents an address bus and 8b a data bus. The arithmetic chip 1, the control chip 2 and the main memory 4 are interconnected to the address bus or to the data bus through the intermediary of interface circuits 31, 32, 33, respectively.
Reference numeral 35 represents an address over detecting circuit; 36 is a parity error detecting circuit; 37 is a time-out detecting circuit and 38 is a power-off detecting circuit. The output signals from these detecting circuits are applied as input to a test bit selector 39.
Reference numeral 40 represents a console controlling circuit which produces, as its output, interrupt request signals to a STOP flip-flop 41 and to a C I/O flip-flop 42 in response to the input signal 40i from the console and also produces as output a data representing signal 40s to the console. Reference numeral 43 represents an input/output control register and 44 a register for storing an acknowledge signal to the external input or output device which generates the interrupt request.
In the system described above, machine instructions and data, that form the user program stored in the main memory 4, are read out in accordance with the address generated as an output from the control chip 2 and are taken into the chips 1 and 2 via the interfaces 33 and 31. The control chip 2 decodes the machine instruction and gives the ROM address from the terminal MI to the ROM address counter 3' to read out the corresponding microprogram. The microinstruction read out from ROM 3 is input to the arithmetic chip 1 and to the control chip 2 through their MI terminals and controls the operation inside each chip.
The interrupt request signals RQI0-RQI3 from the external input/output units are masked at the arithmetic chip 1, which produces a signal IREQ and outputs it to the OR gate 25. On the other hand, STOP REQ, C I/O and POP INT as the internal interrupt request signals from inside the CPU are output from the flip-flops 41, 42 and from the power-off detecting circuit 38 and are input to the above-mentioned OR gate 25.
When the interrupt request signal IRQ from the abovementioned OR gate 25 is taken into the control chip 2, the microinstructions for the interrupt processing program are sequentially read out from ROM 3. The microinstruction for determining whether or not a given interrupt request is from inside the CPU produces a selection signal and applies it to the test bit selector 39 through a signal line 39i. Since the internal interrupt signals STOP REQ, C I/O and POP INT each are one of the input signals of the test bit selector 39, they are sequentially input to the arithmetic chip 1 in accordance with the microinstruction read out from ROM 3.
In this embodiment, the interrupt acknowledegment to the external input/output units is made from a register 44 in order to restrict the increase in the number of signal pins for the purpose of processing the interrupt at the arithmetic chip 1. When the external interrupt request is received, the operand "1" is set to the bit corresponding to the interrupt of the register 44 by means of the microinstruction of the interrupt processing program, and "0" is set to the bit when the interrupt routine is completed.
FIG. 7 shows the internal construction of the abovementioned arithmetic chip 1. Its principal portion is a data construction portion 50, which consists of an ALU 51, a buffer register 52, a general purpose register 53, a temporary register 54a, a temporary register for extension 54b, a status register 55, shift registers 56a, 56b, a loop counter 57, a flag register 58 and a logic array 59, all being the elements required for the data operation.
In addition to these elements, the arithmetic chip 1 further includes a clock control circuit 60 for generating internal clocks by means of clock pulses given from the outside and of reset signals RST, a counter circuit 61 for counting the clock pulses φ 0 and producing the timing pulses and a decoder circuit 62 for decoding the microinstruction MI and producing various control signals for LSI internal circuits as its output. In this embodiment, the decoder circuit 62 consists of two portions whereby the first portion comprises a programmable logic array (PLA) 63 for immediately decoding the fetched microinstruction and producing a control signal S o at a quick timing and a register 64 while the second portion comprises a register 65 and PLA 66 for producing a control signal S 1 at a timing slower than the abovementioned signal S o . The former control signal S o includes, for example, a signal designating a register as the object of the logical operation and the latter S 1 includes, for example, a signal designating a register for storing the result of the logical operation by ALU 51.
The external interrupt request signals REQ0-REQ3 are taken into an interrupt flip-flop 70 and are masked in a masking circuit 71 consisting of the AND gate and the OR gate that have been explained with reference to FIG. 3. To this masking circuit 71 is supplied mask data from the mask data portion 55a of the status register 55 and if the interrupt request is a receivable interrupt request, a signal IREQ is produced as an output outside LSI through the OR gate 72. The OR gate 72 also produces, as the signal IREQ, a timer interrupt request signal to be produced from the counter circuit 61.
Reference numeral 73 represents a test bit selector circuit for judging the absence or presence of an interrupt request which selectively outputs any of various input signals in accordance with the microinstruction to a test flip-flop 74. The input signals include bit signals TB from inside CPU, and bit signals corresponding to the external interrupt request signals REQ0-REQ3 given from the masking circuit 73. As explained already, in the running process of the interrupt routine program, a bit signal representing the interrupt request is selected from the selector circuit 73 and when it corresponds to the interrupt source, a signal LREQ is produced from a jump control circuit 75.
FIG. 8 diagrammatically shows the internal construction of the control chip 2. The control chip 2 includes a real address calculating circuit 80 of the main memory 4, an address generating circuit 81 for designating the address of the microprogram of ROM 3, a microinstruction processing circuit 82 and a clock bus 90. The real address calculating circuit 80 has various registers such as memory registers and program counters, takes thereinto the machine instruction on the main memory designated by the program counter through a bidirectional bus AB and calculates the real address for data reading. The address generating circuit 81 generates the head address of the microprogram for performing the machine instruction which is taken into the real address calculating circuit 80. This address is given to the microinstruction processing unit 82 and is output to a bidirectional bus MI connected to ROM 3 as well as to the ROM address counter 3'. The microinstruction processing circuit 82 has a register 83 for storing the microinstruction read out from ROM and the microinstruction taken into this register is decoded and converted into an operation control signal S for the control chip by means of PLA 84.
Reference numeral 85 represents a circuit (staticizing circuit) for controlling the read-out operation of the instruction from the main memory and the performance of the decoding operation of the instruction. When it is input with an interrupt signal INT, the circuit gives a signal to the address generating circuit 81 so that it generates the head address of the interrupt program. The interrupt signal IRQ from the OR gate 25 disposed outside the control chip is input to the abovementioned staticizing circuit through the AND gate 86, which is subject to the conductivity control by means of an interrupt-inhibiting flip-flop 87. Reference numeral 88 represents an input/output control circuit. Since this circuit has nothing to do directly with the gist of the invention, the explanation of this circuit is hereby omitted.
As can be appreciated from the foregoing explanation, in accordance with the present invention, the interrupt request of the top priority which does not require masking is first subjected to the AND operation outside both chips and is then applied as an input to the control chip so that the interrupt signal input pins have only to be allotted to the interrupt requests of lower order of priority which need masking. It is therefore possible to reduce the number of the interrupt processing pins in the LSI chips as a whole. The present invention uses the system in which the acknowledgement to an input/output device requesting the interrupt is made through the register disposed outside the LSI chips so that the acknowledgement data is given to this register by means of the microprogram control through the intermediary of the data bus. Accordingly, it is also possible to further reduce the number of the interrupt control pins on the arithmetic chip. Thus, the interrupt control system in accordance with the present invention is extremely effective for the large scale integration of CPU of a data processing unit. | In an interrupt control system for a data processing unit for microprogram control including a processor constructed dividedly between an arithmetic unit and a control unit, a signal representing the absence or presence of an interrupt request to be performed is applied to the control unit so that said control unit reads a microprogram for the interrupt processing from a memory in response to said signal, and said arithmetic unit judges an interrupt source on the basis of the microprogram read out from said memory and performs processing in accordance with the interrupt source. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a Continuation In Part of U.S. patent application Ser. No. 11/777,831 filed Jul. 13, 2007; a Continuation In Part of U.S. patent application Ser. No. 12/610,181 filed Oct. 30, 2009; and a Continuation In Part of U.S. patent application Ser. No. 12/620,584 filed Nov. 17, 2009, which applications are incorporated in their entirety herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to single serving coffee makers and in particular to a single serving reusable brewing material holder including a reusable mesh material to retain the brewing material in the holder.
Coffee is prepared in a coffee maker by measuring an amount of ground coffee into a coffee filter, closing a lid over the ground coffee, and providing a stream of hot water through the ground coffee. In recent years, single serving coffee makers have become very popular, for example, KEURIG® coffee makers. U.S. Pat. Nos. 5,325,765 and 6,708,600 disclose a housing and cooperating filter cartridge for use in a KEURIG®. coffee maker. While the housing and cartridge of the '765 patent are very popular, the cost of single use cartridges far exceeds the cost of the brewing material contained in the cartridges. The '765 and '600 patents are herein incorporated by reference in their entirety.
SUMMARY OF THE INVENTION
The present invention addresses the above and other needs by providing a single serving beverage filter cartridge which is formed by placing a single serving portion of brewing material into a reusable coffee holder having a lid and a base. The reusable coffee holder includes a recessed region at the bottom of a base of the holder and is insertable into a cartridge housing of a single serving coffee maker having an offset needle reaching up vertically from the base of the housing, the recessed region may be a large annular recessed region or a smaller off-center recessed region, thereby avoiding the offset bottom needle. The coffee holder defines a frustoconical exterior and includes mesh filtering material for retaining brewing material inside the coffee holder. The mesh material may be a metal mesh or plastic mesh. The reusable coffee holder is configured for use in single serving coffee makers having the offset bottom needle and designed for single use cartridges.
In accordance with one aspect of the invention, there is provided a coffee holder including a metal mesh filter material interposed between an interior and exterior of the holder to retain brewing material in the holder. The mesh filter material may be a metal or plastic mesh.
In accordance with another aspect of the invention, there is provided a coffee holder having a bottom with an annular recess. The holder fits into existing single serving coffee makers having an offset bottom needle and the annular recess provides clearance for the offset bottom needle.
In accordance with still another aspect of the invention, there is provided a coffee holder having a bottom with an offset recess. The holder fits into existing single serving coffee makers having an offset bottom needle and the offset recess provides clearance for the offset bottom needle.
In accordance with yet another aspect of the invention, there is provided a method for using a reusable coffee holder in a single serving coffee maker. The method includes opening a lid of the reusable coffee holder, placing a single serving portion of brewing material into a holder base, closing the lid of the coffee holder, opening a coffee cartridge housing of the single serving coffee maker to expose the interior of the coffee cartridge housing, the base of the coffee cartridge housing including a upward reaching offset needle, placing the coffee holder in the coffee cartridge housing, positioning a recessed area in the bottom of the holder base over the offset needle, closing the coffee cartridge housing, and brewing a brewed beverage. The reusable coffee holder includes a holder lid, a frustoconical shaped coffee holder base, a metal mesh filter material attached to the coffee holder base and interposed between the interior and the exterior of the holder base and retaining brewing material deposited into the holder base through the holder top, and a holder lid closeable over the top of the holder base. The metal mesh filter material may be fixed to the holder base, or removable from the holder base. The holder lid may include a center mating portion of the holder lid including a downward concave cavity for receiving a nozzle of a coffee maker and sealing against the coffee maker to prevent the escape of heated liquid during brewing. The frustoconical shaped coffee holder base includes a smaller diameter bottom, a larger diameter top, an interior, an exterior, and a upward recessed area in the bottom of the holder base.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
FIG. 1 shows a prior art coffee cartridge housing of a single serving coffee maker, with a filter cartridge residing in the coffee cartridge housing.
FIG. 2 is a perspective view of a first single serving coffee holder according to the present invention.
FIG. 3 is a cross-sectional side view of the first single serving coffee holder containing coffee restrained in a holder base by mesh filter material and having an annular recess in the bottom of the holder base, according to the present invention.
FIG. 4 is a cross-sectional side view of the first single serving coffee holder according to the present invention in the prior art single serving coffee cartridge housing.
FIG. 5A shows a cross-sectional side view of a tamping single serving coffee holder having a lid including a tamper which enters the holder base to tamp coffee restrained in the holder base by mesh filter material, and having an annular recess in the bottom of the holder base, according to the present invention.
FIG. 5B shows a cross-sectional side view of the tamping single serving coffee holder having the lid including the tamper attached to the holder base and tamping the coffee restrained in the holder base by the mesh filter material, according to the present invention.
FIG. 6 is a cross-sectional side view of a second single serving coffee holder containing coffee restrained in a holder base by mesh filter material and having an annular recess in the bottom of the holder base, according to the present invention.
FIG. 7 is a cross-sectional side view of the second single serving coffee holder according to the present invention in the prior art single serving coffee cartridge housing.
FIG. 8 is a cross-sectional side view of a third single serving coffee holder containing coffee restrained in a holder base by mesh filter material and having an offset recess in the bottom of the holder base, according to the present invention.
FIG. 8A is a cross-sectional view of the holder base taken along line 8 A- 8 A of FIG. 8 .
FIG. 9 is a cross-sectional side view of the third single serving coffee holder according to the present invention in the prior art single serving coffee cartridge housing.
FIG. 10 shows a side view of a holder 70 having a hinged holder lid 32 ″
FIG. 11 shows a side view of a threaded holder and threaded holder lid according to the present invention.
Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.
A prior art single serving cartridge housing 10 of a coffee maker, and a single use filter cartridge 12 residing in a brewing chamber 11 of the coffee maker, disclosed in U.S. Pat. Nos. 5,325,765 and 6,708,600 (incorporated by reference above) are shown in FIG. 1 . The filter cartridge 12 includes a pierceable shell 14 and contains brewing material 16 . An upper needle 20 penetrates the top of the shell 14 to inject heated water into the cartridge 12 and an offset bottom needle 22 penetrates the bottom of the shell 14 and receives the brewed drink produced in the cartridge 12 and carries the brewed drink from the brewing chamber, when the housing 10 is closed on the cartridge 12 . A filter cartridge sold under the trademark K-CUP® has a top edge with a diameter of about 1.8 inches, a height of about 1¾ inches, and a frustoconical shape with a base smaller than the top edge. The base of the K-CUP® cartridge is generally being about 1.45 inches in diameter.
A perspective view of a first single serving coffee holder 30 according to the present invention is shown in FIG. 2 . The coffee holder 30 includes a lid 32 and a base 34 . The base 34 includes a larger diameter top 34 a and a smaller diameter bottom 34 b and is generally frustoconical in shape. A passage 40 in the lid 32 is provided for the needle 20 . The bottom 34 b of the base 34 includes an annular recessed region 38 surrounding a stem 36 generally centered in the bottom 34 b of the base 34 . The stem 36 extends downward in the bottom 34 b of the base 34 . Lid 32 may be removably attachable to the base 34 , or hingedly attached to the base 34 . The removable lid 32 may be an interference fit to the base 34 , or the lid 32 and base 34 may have cooperating threads to threadably attach, or the lid 32 may be otherwise attached to the base 34 . The coffee holder 30 defines an interior region 30 a and an exterior region 30 b and a mesh filter 42 resides in the base 34 to restrain brewing material in the interior region 30 a.
A cross-sectional side view of the first single serving coffee holder 30 containing coffee 16 restrained in the holder base 34 by the mesh filter material 42 and having an annular recess 38 a in the bottom of the holder base 34 is shown in FIG. 3 and a cross-sectional side view of the first single serving coffee holder 30 in the prior art single serving coffee cartridge housing 10 is shown in FIG. 4 . The mesh filter 42 holds the brewing material 16 , and retains the brewing material 16 in the interior region 30 a of the coffee holder 30 separating the brewing material 16 from the exterior region 30 b of the coffee holder 30 . The mesh filter 42 may be a fixed filter not removable from the holder base 34 or a removable filter, and may be constructed of nylon mesh or metal mesh, or any reusable material capable of holding the coffee while allowing a flow of heated water through the coffee. Unlike filter paper, the mesh filter 42 may be cleaned and reused. The needle 20 reaches through the passage 40 in the lid 32 to inject hot liquid into the brewing material 16 to make a brewed drink. The annular recess 38 a provides clearance D for the lower needle 22 of the coffee maker without requiring aligning the annular recessed area 38 a with the offset bottom needle 22 , and the opening 39 in the bottom of the holder base 34 allows brewed beverage to escape from the coffee holder into the brewing chamber 11 of the coffee maker. The clearance D is preferably between one and twenty mm and more preferably about ten mm to a ceiling 38 b of the annular recessed area 38 a . A compliant ring 33 may be included to seal against the coffee maker.
The housing 30 is disclosed in FIG. 2 of U.S. patent application Ser. No. 11/777,831 filed Jul. 13, 2007 by the present applicant, which this application is a Continuation In Part thereof.
The mesh filter 42 is disclosed in paragraph 0005 of the summary in U.S. patent application Ser. No. 12/620,584 filed Nov. 17, 2009, by the present applicant, which this application is a Continuation In Part thereof, as a fixed or removable nylon mesh, metal mesh, or any material capable of holding the coffee while allowing a flow of heated water through the coffee.
A cross-sectional view of a tamping single serving coffee holder 30 ′ having a lid 32 ′ including a tamper 31 , is shown in FIG. 5A , and a cross-sectional view of the tamping single serving coffee holder 30 ′ having the lid 32 ′ attached to the holder base 34 is shown in FIG. 5B . When the lid 32 ′ is attached to the holder base 34 , the tamper 31 enters the holder base 34 to tamp coffee 16 a restrained in the holder base 34 by the mesh filter material 42 . Tamping the coffee reduces or prevents channeling and generally provides a stronger brew. The coffee holder 30 ′ is otherwise similar to the coffee holder 30 .
A cross-sectional side view of a second single serving coffee holder 50 containing coffee 16 is shown in FIG. 6 and a cross-sectional side view of the second single serving coffee holder 50 in the prior art single serving coffee cartridge housing 10 is shown in FIG. 7 . The coffee holder 50 includes the lid 32 and a holder base 52 . The coffee 16 is restrained in the holder base 52 by the mesh filter material 42 . A second annular recess 38 b in the bottom 52 b of the holder base 52 is provided to clear the bottom needle 22 and the passage 40 in the lid 32 is provided for the needle 20 and opening 39 b in the bottom of the coffee holder 50 allows brewed beverage to escape from the coffee holder into the brewing chamber 11 of the coffee maker.
The coffee holder 50 defines an interior region 50 a and an exterior region 50 b (similar to the regions 30 a and 30 b in FIG. 2 ). The mesh filter 42 holds the brewing material 16 , and retains the brewing material 16 in the interior region 50 a of the coffee holder 50 separating the brewing material 16 from the exterior region 50 b of the coffee holder 50 . The needle 20 reaches through the passage 40 in the lid 32 to inject hot liquid into the brewing material 16 to make a brewed drink. The second annular recess 38 b is provided by a large circular opening 54 in the bottom 52 b of the base 52 . The annular recess 38 b provides clearance for the lower needle 22 without aligning the annular recess 38 b with the needle 22 . The coffee holder 50 is otherwise similar to the coffee holder 30 .
The housing 50 is disclosed in FIG. 6 of U.S. patent application Ser. No. 11/777,831 filed Jul. 13, 2007 by the present applicant, which the present application is a Continuation In Part thereof.
A cross-sectional side view of a third single serving coffee holder 60 containing coffee 16 restrained in a holder base 64 by the mesh filter material 42 is shown in FIG. 8 , a cross-sectional view of the holder base 64 taken along line 8 A- 8 A of FIG. 8 is shown in FIG. 8A , and a cross-sectional side view of the third single serving coffee holder 60 in the coffee cartridge housing 10 is shown in FIG. 9 . An offset recess 68 in the bottom 64 b of the holder base 64 provides clearance for the lower needle 22 . The coffee holder 60 defines an interior region 60 a and an exterior region 60 b separated by the mesh filter material 42 . The offset recess 68 is offset from a centerline CL of the coffee holder 60 and is not an annular recess (i.e., is a vertical passage somewhat larger than the needle 22 ) and requires aligning the offset recess 68 with the needle 22 . While the offset recess 68 is shown as having a round cross-section, the offset recess 68 may have any cross-section suitable to provide clearance for the needle 22 and opening 39 c in the bottom of the coffee holder 60 allows brewed beverage to escape from the coffee holder into the brewing chamber 11 of the coffee maker. The coffee holder 60 is otherwise similar to the coffee holder 30 .
The offset recess 68 in the bottom 64 b of the holder base 64 is disclosed in FIG. 5 of U.S. patent application Ser. No. 11/777,831 filed Jul. 13, 2007 by the present applicant, which the present application is a Continuation In Part thereof.
FIG. 10 shows a side view of a holder 70 having a hinged holder lid 32 ″ hingedly attached to the holder by a hinge 72 .
FIG. 11 shows a side view of a threaded holder 80 having a threaded holder lid 32 ′″. The holder lid 32 ′″ has male threads 82 and the holder base
A method for using a reusable coffee holder in a single serving coffee maker having an offset bottom needle includes the steps of: placing a single serving portion of brewing material into the holder base; attaching the holder lid to the top of the holder base; opening a brewing chamber of the single serving coffee maker; placing the coffee holder into the brewing chamber causing the offset bottom needle to reside in the recess in the bottom of the holder base and not puncture any part of the coffee holder; closing the coffee cartridge housing; brewing a brewed beverage; and creating a flow of the brewed beverage through the mesh filter and into the brewing chamber, the flow of the brewed beverage avoiding flowing through the bottom needle. The reusable coffee holder includes a coffee holder base and a holder lid. the holder base includes a smaller diameter holder bottom; a larger diameter holder top; an interior; an exterior, a recess in the bottom of the holder base configured to provide clearance for a bottom needle of the coffee maker; and a metal mesh filter fixed to the coffee holder base and interposed between the interior and the exterior of the holder base and retaining brewing material deposited into the holder base through the holder top. The holder lid is attachable to the top of the holder base and including a passage for receiving a nozzle of the coffee maker.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | A single serving beverage filter cartridge is formed by placing a single serving portion of brewing material into a reusable coffee holder having a lid and a base. The reusable coffee holder includes a recessed region at the bottom of a base of the holder and is insertable into a cartridge housing of a single serving coffee maker having an offset needle reaching up vertically from the base of the housing, the recessed region may be a large annular recessed region or a smaller off-center recessed region thereby avoiding the offset bottom needle. The coffee holder defines a frustoconical exterior and includes mesh filtering material for retaining brewing material inside the coffee holder. The mesh material may be a metal mesh or plastic mesh. The reusable coffee holder is configured for use in single serving coffee makers having the offset bottom needle and designed for single use cartridges. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based upon, claims the benefit of priority of, and incorporates by reference, the contents of Japanese Patent Application No. 2002-159747 filed May 31, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field of the Invention
[0003] The present invention relates to ignition coils, and more particularly, to an ignition coil which incorporates an igniter to apply a high voltage to an ignition plug.
[0004] 2. Description of Related Art
[0005] For example, as an ignition coil of the type incorporating an igniter, an ignition coil which employs electrically insulating oil to ensure insulation is introduced in Japanese Patent Laid-Open Publication No. Hei 7-153636. A circuit module containing a power transistor, a primary coil portion, a secondary coil portion, and the like are accommodated inside the housing of the ignition coil in the publication. The housing also has a liquid electrical insulating oil injected therein. The electrical insulating oil ensures insulation between the aforementioned members.
[0006] On the other hand, an ignition coil which employs an epoxy resin to ensure insulation is introduced in Japanese Patent Laid-Open Publication No. Hei 2001-127239. An igniter, a primary coil portion, a secondary coil portion, and the like are accommodated inside the housing of the ignition coil described in the publication. The igniter is also formed of a heat sink, a hybrid integrated circuit, a power transistor, and the like, which are encapsulated in a molding resin.
[0007] [0007]FIG. 8 is an enlarged cross-sectional view showing the vicinity of the igniter in the ignition coil described in the publication. An igniter 100 comprises a heat sink 101 , a power transistor 102 , a hybrid integrated circuit 103 , and an igniter terminal 104 . The igniter 100 is placed on a mount 113 . The power transistor 102 and the hybrid integrated circuit 103 are secured to the heat sink 101 . An aluminum wire 106 electrically connects between the power transistor 102 and the hybrid integrated circuit 103 . An aluminum wire 107 electrically connects the hybrid integrated circuit 103 and the igniter terminal 104 . The hybrid integrated circuit 103 is covered with silicone rubber 105 . These members are encapsulated in a molding resin 108 with the top end of the igniter terminal 104 protruded. The molding resin 108 forms an outer shell of the igniter 100 . The igniter terminal 104 is jointed to a connector terminal 110 , which lies in a connector 109 . The connector terminal 110 is electrically connected to an engine control unit ECU. A housing 112 forming the outer shell of the ignition coil has an epoxy resin 111 injected therein to ensure insulation between the members accommodated inside the housing 112 and to secure each member. The housing 112 has the epoxy resin 111 filled and hardened in between the members therein.
[0008] However, the ignition coil described in Japanese Patent Laid-Open Publication No. Hei 7-153636, which ensures insulation by using the electrically insulating oil, raises the following problems. That is, the electrically insulating oil is a liquid. For this reason, a robust sealing mechanism is required to prevent the electrically insulating oil from leaking out of the ignition coil. This causes an increase in complexity of the structure of the ignition coil due to the sealing mechanism. This also causes an increase in the size of the ignition coil. This further causes an increase in manufacturing costs.
[0009] On the other hand, the ignition coil described in Japanese Patent Laid-Open Publication No. Hei 2001-127239, which ensures insulation by using the epoxy resin, raises the following problems. That is, double layers of a resin cover the heat sink 101 , the power transistor 102 , the hybrid integrated circuit 103 , the silicone rubber 105 , the aluminum wire 106 , the aluminum wire 107 , and part of the igniter terminal 104 . That is, these members are doubly covered with the molding resin 108 and the epoxy resin 111 . Accordingly, upon fabrication of the ignition coil, this requires the additional and independent steps of encapsulating the aforementioned members in the molding resin 108 to fabricate the igniter 100 , and placing the fabricated igniter 100 on the mount 113 to inject and harden the epoxy resin 111 . Accordingly, this increases the complexity of the fabrication process. This also causes an increase in manufacturing costs. This further causes an increase in complexity of the structure of the ignition coil due to the provision of the double resin layers. This further causes double electrical connections with the outside.
[0010] The ignition coil according to the present invention was completed in view of the aforementioned problems. It is therefore an object of the present invention to provide an ignition coil that can be fabricated at low costs in a simple structure and reduced in size.
SUMMARY OF THE INVENTION
[0011] (1) To solve the aforementioned problems, the ignition coil of the present invention has a connector electrically connected to an external circuit, an igniter having a switching element for causing a current supplied from the connector to be intermittent, a primary coil portion for generating a predetermined voltage by the intermittent current; a secondary coil portion for stepping up the generated voltage and applying the resulting voltage to an ignition plug, and a resin insulating material which hardens in between the primary coil portion and the secondary coil portion to ensure insulation between the primary coil portion and the secondary coil portion. Also, with respect to the ignition coil, an outer shell of the igniter is formed by the resin insulating material.
[0012] That is, in the ignition coil of the present invention, the outer shell of the igniter is formed of the resin insulating material for ensuring insulation between the primary coil portion and the secondary coil portion. That is, for example, in FIG. 8 described above, the molding resin ( 108 ) is eliminated and the members accommodated in the igniter ( 100 ) are directly encapsulated in the epoxy resin ( 111 ).
[0013] According to the ignition coil of the present invention, the resin insulating material is in a solid state. This simplifies the sealing mechanism when compared with the electrically insulating oil used for insulation. Furthermore, according to the ignition coil of the present invention, the members to be accommodated in the igniter are covered with a single layer of the resin insulating material. For this reason, an additional step of encapsulating the members accommodated in the igniter in a molding resin is not necessary upon fabricating the ignition coil.
[0014] As described above, since the ignition coil of the present invention has a simple sealing mechanism and is covered with a single layer of the resin insulating material, the structure is simple. Additionally, the manufacturing process is simple, and the manufacturing cost is low.
[0015] Furthermore, since the ignition coil of the present invention has a simple sealing mechanism, it is easy to reduce its size. Accordingly, the ignition coil is preferably embodied as a stick-type ignition coil with a limited outer diameter (circumferential) due to its direct loading into a plughole.
[0016] (2) Preferably, the ignition coil has positioning means for positioning said igniter relative to said connector. The igniter is wired to the connector. According to this arrangement, the positioning means allows the igniter to be fixedly positioned relative to the connector. This facilitates the wiring operation. Furthermore, according to this arrangement, it is possible to prevent the igniter from rattling upon injecting the resin insulating material.
[0017] (3) Preferably, said igniter has a heat sink to which said switching element is secured, and said positioning means is a joint member for joining the heat sink and said connector together. The heat sink is relatively robust and has a large volume. For this reason, retaining and positioning the heat sink with the joint member allows the fixability of the igniter to be improved. It is therefore possible to prevent the igniter from rattling upon wiring and injecting the resin insulating material.
[0018] On the other hand, the joint member joints the igniter and the connector together. For this reason, this arrangement allows the igniter and the connector to be handled in one piece. Accordingly, upon fabrication of the ignition coil, the igniter and the connector can be first jointed together, the igniter and the connector can then be wired under this condition, and both the wired members can be loaded into the ignition coil. That is, after the wiring has been carried out in advance, the igniter can be loaded into the ignition coil. Accordingly, this arrangement facilitates the wiring operation.
[0019] (4) Preferably, said igniter further accommodates a control circuit for controlling said switching element. According to this arrangement, not only the switching element but also the control circuit are accommodated in the igniter and encapsulated in the resin insulating material. This eliminates additional wiring for connecting between the control circuit and the igniter when compared with the control circuit being solely placed. This improves the handleability of the ignition coil.
[0020] (5) Preferably, a coefficient of linear expansion of said resin insulating material is set at 750% or less, assuming that a coefficient of linear expansion of a material having the lowest coefficient of linear expansion, of materials forming said igniter, is 100%. The coefficient of linear expansion of the resin insulating material is set at 750% or less, assuming that the coefficient of linear expansion of a material having the lowest coefficient of linear expansion, of materials forming said igniter, is 100%. This is because thermal stress may cause a problem to the resin insulating material or the igniter at greater than 750%.
[0021] That is, suppose that the coefficient of linear expansion of the resin insulating material is significantly different from the coefficients of linear expansion of the materials forming the igniter. In this case, a significant thermal stress may be applied to the resin insulating material and the igniter due to thermal expansion or contraction caused by variations in ambient temperature. For example, thermal stress may cause problems such as cracking.
[0022] According to this arrangement, the difference in coefficient of linear expansion between the resin insulating material and the material forming each of the members constituting the igniter is small. Thus, it is possible to relieve the thermal stress applied to the resin insulating material and the igniter. This allows the ignition coil configured in this arrangement to be more reliable and longer-lasting.
[0023] (6) Preferably, the coefficient of linear expansion of said resin insulating material is set at 25 ppm/K or less. The reason why the coefficient of linear expansion of the resin insulating material is set at 25 ppm/K or less is because thermal stress may cause a problem to the resin insulating material or the igniter at greater than 25 ppm/K.
[0024] That is, for example, of each of the members constituting the igniter, Si used for semiconductors has a relative coefficient of linear expansion as low as 3.5 ppm/K. Thus, the coefficient of linear expansion of the resin insulating material being exceedingly higher than the coefficient of linear expansion of Si may cause a significant thermal stress to be applied to the resin insulating material and the igniter.
[0025] According to this arrangement, the difference in coefficient of linear expansion between the resin insulating material and the Si is small. Thus, it is possible to relieve the thermal stress applied to the resin insulating material and the igniter. This allows the ignition coil configured in this arrangement to be more reliable and have a longer life.
[0026] Therefore, according to the present invention, it is possible to provide an ignition coil that can be fabricated at low costs in a simple structure and reduced in size. Additionally, further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0027] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0028] [0028]FIG. 1 is an axial, cross-sectional view showing an ignition coil according to a first embodiment;
[0029] [0029]FIG. 2 is an external view showing the ignition coil according to the first embodiment;
[0030] [0030]FIG. 3 is an enlarged cross-sectional view showing the vicinity of an igniter in the ignition coil according to the first embodiment;
[0031] [0031]FIG. 4 is a view showing a state where the igniter in the ignition coil according to the first embodiment is assembled to a joint member;
[0032] [0032]FIG. 5 is a view showing a state where the igniter in the ignition coil according to the first embodiment is wired to a connector;
[0033] [0033]FIG. 6 is an enlarged cross-sectional view showing the vicinity of an igniter in an ignition coil according to a second embodiment;
[0034] [0034]FIG. 7 is an axial, cross-sectional view showing an ignition coil according to a third embodiment; and
[0035] [0035]FIG. 8 is an enlarged cross-sectional view showing the vicinity of an igniter in a prior art ignition coil.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. Now, an ignition coil of the present invention will be explained below in accordance with the embodiments.
[0037] (1) First Embodiment
[0038] The structure of the ignition coil according to this embodiment will first be described. FIG. 1 is an axial cross-sectional view showing the ignition coil according to this embodiment. FIG. 2 is an external view showing the ignition coil according to this embodiment. FIG. 2 is a view showing components through an epoxy resin. An ignition coil 1 of a stick type is accommodated in a plughole (not shown) formed in each cylinder on the upper portion of an engine block. As will be described later, the ignition coil 1 is connected to an ignition plug (not shown) at a lower side in the figure.
[0039] The ignition coil 1 comprises a housing 2 . The housing 2 is made of a resin and takes the shape of a cylinder with a shoulder that is increased in diameter at an upper end. The portion below the shoulder is cylindrically shaped. On the other hand, the portion above the shoulder is rectangular shaped. Additionally, there is formed a wide opening 20 on the upper end portion of the housing 2 . There is also formed a notched window 21 on part of a sidewall of the wide opening 20 . A center core portion 5 , a primary spool 3 , a primary coil portion 30 , a secondary spool 4 , a secondary coil portion 40 , a core alignment member 61 , an igniter 9 , and a joint member 10 , which are each accommodated inside the housing 2 .
[0040] In this arrangement, the center core portion 5 comprises a center core 54 , an elastic member 50 , and a heat-shrinkable tube 52 . The center core 54 is formed of strip-shaped silicon steel plates 540 , having different widths, stacked in the axial direction of the ignition coil 1 , and takes the shape of a bar. The elastic member 50 is made of closed-cell sponge and takes a cylindrical shape. The elastic member 50 is placed on both the upper and lower ends of the center core 54 . The heat-shrinkable tube 52 is made of a resin that shrinks by heating. The heat-shrinkable tube 52 covers the center core 54 and the elastic member 50 from the outer circumferential side.
[0041] The secondary spool 4 is made of a resin and is cylindrically shaped with a bottom. The secondary spool 4 is placed coaxially with the center core portion 5 and is adjacent to the outer circumference of the center core portion 5 . The secondary coil portion 40 includes conductive wires wound around the outer circumferential surface of the secondary spool 4 . There are vertically provided spool-side engagement pawls 41 on the upper end surface of the secondary spool 4 . The spool-side engagement pawls 41 , three in total, are spaced by 90 degrees in the circumferential direction.
[0042] The primary spool 3 is placed coaxially with the secondary spool 4 and adjacent to the outer circumference of the secondary spool 4 . The primary coil portion 30 includes conductive wires wound around the outer circumferential side of the primary spool 3 . Additionally, on the outer circumferential side of the primary coil portion 30 , there is an outer circumferential cylindrical core (not shown) comprising one or more silicon steel plates and having a slit penetrating in the longitudinal direction.
[0043] A connector 6 is made of a resin and takes a prismatic shape. The connector 6 is disposed to protrude outwardly from the housing 2 through the notched window 21 . The connector 6 has a plurality of connector terminals 600 insert molded therein. The core alignment member 61 takes a flat plate. The core alignment member 61 is placed generally at the center of the wide opening 20 . From the lower surface of the core alignment member 61 , there are, vertically provided, an alignment rib 63 and alignment-member-side engagement pawls 66 . The alignment rib 63 has an annular shape. The alignment rib 63 is inserted from above in between the center core portion 5 and the secondary spool 4 . The alignment-member-side engagement pawls 66 , three in total, are spaced by 90 degrees in the circumferential direction. The alignment-member-side engagement pawls 66 ate engaged with said spool-side engagement pawl 41 .
[0044] The igniter 9 accommodates a power transistor, a hybrid integrated circuit, a heat sink, and the like. The power transistor is included in a switching device of the present invention. The hybrid integrated circuit is also included in a control circuit of the present invention. The igniter 9 is electrically connected to an ECU (not shown) and the primary coil portion 30 . The ECU is included in an external circuit of the present invention. The igniter 9 will be described later. The joint member 10 joins (joints) the connector 6 and the heat sink together. The joint member 10 will also be described later.
[0045] An epoxy resin 8 is interposed between the aforementioned members placed inside the housing 2 . An epoxy pre-polymer and a hardening agent are injected through the wide opening 20 and into the housing 2 that has been vacuumed (evacuated), thereby allowing the epoxy resin 8 to penetrate between the aforementioned members and harden. The epoxy resin 8 has a coefficient of linear expansion adjusted at 10 ppm/K. The epoxy resin 8 is included in a resin insulating material of the present invention.
[0046] A high-voltage tower portion 7 is disposed at a downward portion of the housing 2 . The high-voltage tower portion 7 comprises a tower housing 70 , a high-voltage terminal 71 , a spring 72 , and a plug cap 73 . The tower housing 70 is made of a resin and takes a cylindrical shape. There is formed a boss portion 74 protruding upwardly generally at the midsection on the inner circumferential side of the tower housing 70 . The high-voltage terminal 71 is made of metal and takes the shape of a cup having a downwardly oriented opening 76 . The downwardly oriented opening 76 has the boss portion 74 inserted therein. That is, the boss portion 74 supports the high-voltage terminal 71 . There is placed a convex portion 75 protruding upwardly from the center of the upper end surface of the high-voltage terminal 71 . The convex portion 75 is inserted into a lower end opening 42 of said secondary spool 4 . The convex portion 75 is electrically connected to the secondary coil portion 40 .
[0047] The spring 72 is spiral shaped. The upper end of the spring 72 is secured to the opening 76 of the high-voltage terminal 71 . The spring 72 is in elastic contact with the ignition plug. The plug cap 73 is made of rubber and takes a cylindrical shape. The plug cap 73 is annularly installed at the lower end portion of the tower housing 70 . The ignition plug is press fit into the inner circumferential side of the plug cap 73 and is in elastic contact therewith.
[0048] Now, a description will be made as to how the ignition coil 1 of this embodiment operates when energized. A control signal from the ECU is transmitted to the igniter 9 via the connector 6 . A current caused by the igniter 9 to be intermittent allows a predetermined voltage to be generated in the primary coil portion 30 due to a self-induction effect. A mutual induction effect between the primary coil portion 30 and the secondary coil portion 40 causes this voltage to be stepped up. The resulting stepped-up high voltage is transmitted from the secondary coil portion 40 to the ignition plug via the high-voltage terminal 71 and the spring 72 . This high voltage causes a spark to be generated in the gap of the ignition plug.
[0049] Now, a detailed explanation is made on the configuration of the igniter 9 . FIG. 3 is an enlarged cross-sectional view showing the vicinity of the igniter in the ignition coil of this embodiment. As shown, the igniter 9 comprises a heat sink 90 , a power transistor 91 , and a hybrid integrated circuit 92 . The heat sink 90 is made of copper having a coefficient of linear expansion of 17 ppm/K and has a flat shape. The heat sink 90 is press fit into a concave portion of the joint member 10 secured to the connector 6 . The power transistor 91 is soldered to the heat sink 90 . The hybrid integrated circuit 92 comprises a circuit board 920 and an element 921 . The element 921 is mainly formed of Si having a coefficient of linear expansion of 3.5 ppm/K.
[0050] The circuit board 920 is made of a ceramic and is of a flat shape. The circuit board 920 is adhered to the heat sink 90 . The circuit board 920 has a plurality of elements 921 soldered thereto. An aluminum wire 93 connects between the power transistor 91 and the hybrid integrated circuit 92 . An aluminum wire 94 connects between the hybrid integrated circuit 92 and the connector terminal 600 . The hybrid integrated circuit 92 is covered with silicone rubber 95 . The silicone rubber 95 serves to relieve thermal stress between the epoxy resin 8 and the hybrid integrated circuit 92 . These members are encapsulated in the epoxy resin 8 in conjunction with said primary coil portion 30 , the secondary coil portion 40 , and the like. In other words, as indicated by an alternate long and short dashed line, an outer shell 96 of the igniter 9 is formed of the epoxy resin 8 .
[0051] Now, a description will be made as to how the ignition coil of this embodiment is assembled. FIG. 4 is a view showing a state where the igniter is assembled into the joint member. As shown, the connector 6 is disposed upside down with respect to the one shown in FIG. 3. There is formed a concave portion 11 on the upper surface of the joint member 10 , which is disposed upside down.
[0052] For the assembly, the connector 6 is first prepared. The joint member 10 is then secured to the connector 6 . The connector 6 and the joint member 10 may be formed in one piece. The power transistor 91 and the hybrid integrated circuit 92 are also secured to the heat sink 90 . Subsequently, as shown by a hollow arrow in the figure, the heat sink 90 is press fit into the concave portion 11 .
[0053] [0053]FIG. 5 shows a state where the igniter is wired to the connector. The aluminum wire 94 then connects between the hybrid integrated circuit 92 and the connector terminal 600 . More specifically, the aluminum wire 94 is ultrasonically bonded onto the hybrid integrated circuit 92 and the connector terminal 600 . The aluminum wire 93 also connects between the hybrid integrated circuit 92 and the power transistor 91 . More specifically, the aluminum wire 93 is ultrasonically bonded onto the hybrid integrated circuit 92 and the power transistor 91 . In this manner, conduction between the connector terminal 600 and the hybrid integrated circuit 92 and the power transistor 91 is ensured. Thereafter, the upper surface of the hybrid integrated circuit 92 is sealed with silicone rubber (not shown).
[0054] An assembly of the igniter 9 and the connector 6 is assembled into a housing in which the primary coil portion and the secondary coil portion and the like have been accommodated in advance. More specifically, as previously shown in FIG. 2, the connector 6 is fitted into the notched window 21 , thereby assembling the assembly of the igniter 9 and the connector 6 into the housing 2 . While the housing 2 is being vacuumed (evacuated), the epoxy resin 8 is injected through the wide opening 20 . Finally, the injected epoxy resin 8 is allowed to penetrate in between each of the members and become hardened by heating. In this manner, the ignition coil of this embodiment is assembled.
[0055] Now, the effects of the ignition coil of this embodiment will be described. According to the ignition coil 1 of this embodiment, a solid-state epoxy resin 8 is used as a resin insulating material. This simplifies the sealing mechanism.
[0056] Furthermore, according to the ignition coil 1 of this embodiment, the members accommodated in the igniter 9 such as the heat sink 90 , the power transistor 91 , and the hybrid integrated circuit 92 are covered with a single layer of the epoxy resin 8 . For this reason, an additional step of encapsulating the aforementioned members in a molding resin is not necessary upon fabricating the ignition coil.
[0057] The ignition coil 1 of this embodiment comprises the joint member 10 as positioning means. This allows the igniter 9 and the connector 6 to be handled in one piece. Accordingly, after the igniter 9 and the connector 6 have been wired, the assembly of both of these members can be placed in the housing 2 . That is, this provides handling advantages upon fabrication. Furthermore, the heat sink 90 is press fit into the concave portion 11 . This allows the igniter 9 to remain secure and not rattle with respect to the connector 6 . Accordingly, the wiring operation is easy to carry out. The epoxy resin 8 is also easy to inject.
[0058] The ignition coil 1 of this embodiment accommodates the power transistor 91 as well as the hybrid integrated circuit 92 in the igniter 9 . This provides a handling advantage to the ignition coil 1 over an ignition coil 1 having an external hybrid integrated circuit 92 .
[0059] The epoxy resin 8 of the ignition coil 1 according to this embodiment has a coefficient of linear expansion of 10 ppm/K. On the other hand, the copper forming the heat sink 90 has a coefficient of linear expansion of 17 ppm/K. The Si included in the elements 921 has a coefficient of linear expansion of 3.5 ppm/K. That is, the coefficient of linear expansion of the epoxy resin 8 is set at a substantially median value of the coefficients of linear expansion of the copper and Si. According to the ignition coil 1 of this embodiment, it is possible to relieve a thermal stress applied to the epoxy resin 8 and the igniter 9 . Thus, the ignition coil 1 of this embodiment is increased in reliability and life. On the other hand, the ignition coil 1 of this embodiment is not provided with the igniter terminal 104 as previously shown in FIG. 8. This reduces the number of parts required.
[0060] (2) Second Embodiment
[0061] This embodiment differs from the first embodiment in that the positioning means is secured to the housing, and as well the connector and the igniter are not handled in one piece. Accordingly, the description here will be made only with respect to the differences.
[0062] [0062]FIG. 6 is an enlarged cross-sectional view showing the vicinity of the igniter in the ignition coil according to this embodiment. The components corresponding to those of FIG. 3 are indicated with the same symbols. As shown, positioning means 12 is secured to the wide opening 20 of the housing. The upwardly-oriented concave portion 11 is formed on the upper surface of the positioning means 12 . The heat sink 90 of the igniter 9 is press fit from above into the concave portion 11 . That is, the igniter 9 and the positioning means 12 of this embodiment are placed upside down with respect to those of the first embodiment.
[0063] The ignition coil 1 of this embodiment is assembled in the following steps. First, the members such as the primary coil portion and the secondary coil portion are accommodated inside the housing. Then, the connector 6 is fitted into the notched window of the wide opening 20 . The igniter 9 is also press fit into the concave portion 11 . Thereafter, the aluminum wire 94 connects between the connector terminal 600 and the hybrid integrated circuit 92 . The aluminum wire 93 also connects between the hybrid integrated circuit 92 and the power transistor 91 . The hybrid integrated circuit 92 is then covered with the silicone rubber 95 . Finally, the epoxy resin 8 is injected through the wide opening 20 into the housing that has been vacuumed (evacuated) and then allowed to harden.
[0064] According to the ignition coil 1 of this embodiment, the igniter 9 is press fit into the concave portion 11 on the upper surface of the positioning means 12 . This prevents the igniter 9 from falling off from the positioning means 12 upon injecting the epoxy resin 8 . As the ignition coil 1 of this embodiment, even when the positioning means 12 is secured to the wide opening 20 of the housing, it is possible to position the igniter 9 relative to the connector 6 . This facilitates the wiring and the injection operations of the epoxy resin 8 .
[0065] (3) Third Embodiment
[0066] This embodiment differs from the first embodiment in that the present invention is embodied in an ignition coil other than one of the stick type. Accordingly, the description here will be made only on the differences.
[0067] [0067]FIG. 7 is an axial cross-sectional view showing the ignition coil of this embodiment. In FIGS. 1 and 3, the same components are indicated with the same symbols. The ignition coil 1 comprises the housing 2 made of a resin. There are cores 55 , a primary spool (not shown), a primary coil portion (not shown), the secondary spool 4 , the secondary coil portion 40 , the joint member 10 , the high-voltage terminal 71 , and a partition plate 22 ., each of which are accommodated inside the housing 2 .
[0068] The core 55 takes the shape of an oval in cross section with the “C”-shaped cores being assembled together. The primary spool is made of a resin and is prismatic in shape. The primary spool is placed on the outer circumference side of the core 55 . The primary coil portion includes conductive wires wound around the outer circumference surface of the primary spool. The secondary spool 4 is made of a resin and is prismatic shaped. The secondary spool 4 is placed on the outer circumference side of the primary coil portion. The secondary coil portion 40 includes conductive wires wound around the outer circumference surface of the secondary spool 4 .
[0069] The connector 6 is made of a resin and takes a prismatic shape. The connector 6 is disposed to protrude outwardly from the housing 2 . The connector 6 has a plurality of connector terminals 600 insert molded therein. The joint member 10 is formed integrally with the connector 6 . The igniter 9 accommodates the power transistor 91 , the hybrid integrated circuit 92 , the heat sink 90 , and the like. The heat sink 90 is fixedly press fit into the concave portion of the joint member 10 .
[0070] The epoxy resin 8 is interposed between the aforementioned members placed inside the housing 2 . An epoxy pre-polymer and a hardening agent are injected into the housing 2 , thereby allowing the epoxy resin 8 to penetrate between the aforementioned members and harden. The high-voltage terminal 71 is electrically connected to the secondary coil portion 40 .
[0071] The ignition coil of this embodiment is assembled in the following steps. First, the connector 6 and the joint member 10 are fabricated in one piece. The power transistor 91 and the hybrid integrated circuit 92 are also secured to the heat sink 90 . Then, the heat sink 90 of the igniter 9 is press fit into the concave portion of the joint member 10 (see FIG. 4). Subsequently, the power transistor 91 and the hybrid integrated circuit 92 are wired. The hybrid integrated circuit 92 and the connector terminal 600 are also wired (see FIG. 5). Thereafter, an assembly of the igniter 9 and the connector 6 is assembled into a space above the partition plate 22 of the housing 2 in which the primary coil portion and the secondary coil portion 40 are accommodated, and the C-shaped cores are fitted from both sides thereby allowing the cores 55 to be assembled. The epoxy resin 8 is then injected into the housing 2 . Finally, the epoxy resin 8 is allowed to penetrate between the members and harden by heating.
[0072] The ignition coil 1 of this embodiment can provide the same effects as those of the ignition coil of the first embodiment. That is, the ignition coil 1 requires no sealing mechanism for electrically insulating oil. Furthermore, an additional step of encapsulating the members to be accommodated in the igniter 9 in a molding resin is not necessary upon fabricating the ignition coil.
[0073] Furthermore, since the joint member 10 is provided as positioning means, the igniter 9 and the connector 6 can be handled in one piece. Accordingly, this provides handling advantages upon fabrication. Furthermore, the heat sink 90 is press fit into the concave portion. This makes wiring operations easy to carry out. This also facilitates the injection operation of the epoxy resin 8 . Furthermore, the hybrid integrated circuit 92 is accommodated in the igniter 9 . This provides handling advantages to the ignition coil 1 .
[0074] The epoxy resin 8 of the ignition coil 1 according to this embodiment has a coefficient of linear expansion of 10 ppm/K. On the other hand, the copper forming the heat sink 90 has a coefficient of linear expansion of 17 ppm/K. The Si included in the elements 921 has a coefficient of linear expansion of 3.5 ppm/K. That is, the coefficient of linear expansion of the epoxy resin 8 is set at a substantially median value of the coefficients of linear expansion of the copper and Si. It is thus possible to relieve a thermal stress applied to the epoxy resin 8 and the igniter 9 .
[0075] Furthermore, the joint member 10 in the ignition coil 1 according to this embodiment is formed integrally with the connector 6 . For this reason, this embodiment eliminates the need for an additional step of securing the joint member 10 to the connector 6 upon assembly of the ignition coil. This simplifies the fabrication process.
[0076] (4) Others
[0077] The embodiments of the ignition coil according to the present invention have been described in the foregoing. However, the embodiments are not limited to any of the aforementioned forms. It is also possible to implement various modifications and improvements that can be made by those skilled in the art. For example, the method for adjusting the coefficient of linear expansion of the epoxy resin 8 is not limited to any particular one. For example, filler may be dispersed in the epoxy resin 8 to thereby adjust the coefficient of linear expansion thereof. It is not necessary to set the coefficient of linear expansion of the epoxy resin 8 at a generally median value of the coefficients of linear expansion of the copper forming the heat sink 90 and the Si included in the elements 921 . For example, it is also acceptable to employ a value close to the coefficient of linear expansion of the Si that has a lower coefficient of linear expansion. On the other hand, it is also acceptable to employ a value close to the coefficient of linear expansion of the copper in view of the heat sink 90 having a relatively large volume. Furthermore, the connector 6 doesn't need to have the connector terminal 600 . For example, the connector 6 may be a simple wire. That is to say, it is only required to be able to electrically connect between the igniter 9 and an external circuit. Furthermore, the igniter 9 does not need to have the heat sink 90 and the control circuit 92 . For example, it may be formed only of the switching element 91 . It also does not need to have the silicone rubber 95 .
[0078] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | An ignition coil has a connector electrically connected to an external circuit, an igniter for accommodating a switching element adapted to cause a current supplied from the connector to be intermittent, a primary coil portion for generating a predetermined voltage by the intermittent current, a secondary coil portion for stepping up the generated voltage and applying the resulting voltage to an ignition plug, and a resin insulating material which hardens in between the primary coil portion and the secondary coil portion to ensure insulation between the primary coil portion and the secondary coil portion. An outer shell of the igniter is formed of the resin insulating material. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority, under 35 U.S.C. §119, of German application DE 10 2007 028 163.5, filed Jun. 20, 2007; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a rear lid for closing a rear compartment of a passenger vehicle. The rear lid, when fitted, being attached to the vehicle and being composed of an inner part and an outer part. The rear lid contains a spoiler device which can be displaced between an inoperative position and an operative position and interacts with an adjustment device.
European patent EP 0 250 716 B1 discloses a rear lid which contains a lid body of shell-type construction, with an inner shell which faces the rear compartment which is to be closed and with an outer shell which faces away from the rear compartment and completely covers or clads the inner shell. The lid body contains a cutout which is enclosed on all sides and in which a spoiler device is disposed. The latter is attached to the lid body in a manner such that it can be adjusted between an inoperative position and an operative position. Furthermore, an adjustment device is provided for adjusting the spoiler device which is attached to the inner shell and therefore to the lid body via an auxiliary frame. The production of a vehicle which has a rear compartment and a rear lid of this type can be carried out, for example, in such a manner that first of all the lid body, i.e. the inner shell and the outer shell which is fastened thereto are fastened to the vehicle body via hinges. The vehicle body together with the lid body attached thereto is subsequently painted. After the painting, the remaining components of the rear lid, i.e. in particular the spoiler device and the adjustment device and, if appropriate, a fan and a locking clamp, are attached to the lid body.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a rear lid that overcomes the above-mentioned disadvantages of the prior art devices and methods of this general type, which is distinguished in particular by simplified producibility.
With the foregoing and other objects in view there is provided, in accordance with the invention, a rear lid for closing a rear compartment of a passenger vehicle, the rear lid, when fitted, being attached to the passenger vehicle. The rear lid contains an inner part being an assembly carrier forming a supporting structure of the rear lid; an adjustment device fastened to the assembly carrier; and an outer part having a panel device and a spoiler device. The spoiler is displaced by the adjustment device between an inoperative position and an operative position.
The invention is based on the general concept of equipping the rear lid with a self-supporting assembly carrier to which all of the remaining components of the rear lid are fitted. A preassemblable unit is thereby formed, which simplifies the production of the vehicle equipped with the rear lid. In particular, the unit which is preassembled in this manner can be fitted to the already painted vehicle body. In order to be able better to adapt the visual impression of the rear lid here to the painted vehicle body, the spoiler device extends over the entire width of the rear lid, as measured transversely with respect to the longitudinal direction of the vehicle. The spoiler device therefore covers the outer side of the assembly carrier over the entire width, and therefore painting of the assembly carrier is not required. The remaining region of the outer side of the assembly carrier is covered in this case by a panel device which likewise extends over the entire width of the rear lid.
This construction results in a further simplification of the assembly, since the spoiler device, when fitted, only has to be aligned in relation to the vehicle body in order to produce the desired gap sizes. In the case of the known rear lid which is described further above, the spoiler device has to be aligned in relation to the lid body. In addition, the lid body has to be aligned in relation to the vehicle body in order to obtain the desired gap sizes.
According to a particularly advantageous embodiment, the panel device can have a panel carrier which is fastened to the assembly carrier, and at least one panel body which is fastened to an outer side of the panel carrier, which outer side faces away from the assembly carrier. The use of different panel bodies therefore enables different variants of the panel device to be realized. The panel carrier remains identical, as a result of which the diversity of parts can be reduced and the costs for forming variants can be lowered.
In accordance with an added feature of the invention, at least one of the panel bodies is configured as a luminous band.
In accordance with an additional feature of the invention, the adjustment device is directly fastened to the assembly carrier. In addition, a fan is directly fastened to the assembly carrier. Furthermore, a locking clamp is directly fastened to the assembly carrier. Hinges are also directly fastened to the assembly carrier.
In accordance with another feature of the invention, the assembly carrier is a single-piece diecast part made from a metal alloy such as aluminum or magnesium alloy.
With the foregoing and other objects in view there is provided, in accordance with the invention, a method for producing a passenger vehicle with a tailgate. The methods includes the steps of preassembling an adjustment device on an assembly carrier resulting in a preassembled assembly carrier; fitting the preassembled assembly carrier to a painted vehicle body; and fitting a spoiler device to the preassembled assembly carrier fitted to the painted vehicle body.
In accordance with a concomitant mode of the invention, during the preassembling of the assembly carrier step, there is the step of fitting at least one of a panel device, a panel carrier, panel bodies, a fan, a locking clamp and hinges to the assembly carrier.
It goes without saying that the features mentioned above and those which have yet to be explained below can be used not only in the respectively stated combination but also in different combinations or on their own without departing from the scope of the present invention.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a rear lid, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. The same reference numbers referring to identical or similar or functionally identical components throughout the drawing.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a diagrammatic, perspective view of a rear lid according to the invention;
FIG. 2 is a diagrammatic, perspective view of the rear lid without a spoiler device;
FIG. 3 is a diagrammatic, perspective view of the spoiler device;
FIG. 4 is a diagrammatic, perspective view of the rear lid with a panel device pulled out and enlarged;
FIG. 5 is a diagrammatic, perspective view as shown in FIG. 4 , but with a different embodiment of the panel device;
FIG. 6 is a diagrammatic, perspective view of a panel carrier of the panel device;
FIG. 7 is a diagrammatic, plan view view of a panel body for the panel device shown in FIG. 4 ;
FIGS. 8 and 9 are diagrammatic, plan views of panel bodies for the panel device shown in FIG. 5 ;
FIG. 10 is a diagrammatic, perspective view as in FIG. 2 ;
FIG. 11 is a diagrammatic, perspective view of an assembly carrier;
FIG. 12 is a diagrammatic, perspective view of the panel device;
FIG. 13 is a diagrammatic, perspective view of a fan; and
FIG. 14 is an illustration of an adjustment device.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures of the drawing in detail and first, particularly, to FIGS. 1-3 thereof, there is shown a rear lid 1 , with the aid of which a non-illustrated rear compartment of a passenger vehicle, in particular a sports car, can be closed. The rear lid contains a spoiler device 2 , a panel device 3 and an assembly carrier 4 which can be seen in FIG. 2 . The assembly carrier 4 forms, as it were, an inner side of the rear lid 1 , which inner side, when the rear lid 1 is fitted, faces the rear compartment which is to be closed. In contrast thereto, the spoiler device 2 and the panel device 3 form an outer side of the rear lid 1 , which outer side, when the rear lid is fitted, faces away from the rear compartment. As can be seen, the spoiler device 2 and the panel device 3 each extend over the entire width of the rear lid 1 , as measured transversely with respect to a longitudinal direction 5 of the vehicle, which direction is illustrated symbolically in FIG. 1 by an arrow.
Furthermore, the panel device 3 is disposed on a rear side, i.e. to the rear with respect to the direction of travel of the vehicle, adjacent to the spoiler device 2 on the assembly carrier 4 . However, the panel device 3 may also be disposed in front of the spoiler device 2 .
In the fitted state, the assembly carrier 4 is attached to the vehicle in a manner such that it can be pivotably adjusted. For this purpose, non-illustrated hinges are attached to the assembly carrier 4 . The assembly carrier 4 has an outer side 6 which, in the fitted state, faces away from the rear compartment and, in FIGS. 2 , 10 and 11 , faces an observer. The assembly carrier 4 may be produced as a cast component. For example, it may here be a diecast part made from a light metal alloy, preferably from an aluminum or magnesium alloy. Similarly, the assembly carrier 4 may be configured as a plastic injection molded component or as a pressed component. Furthermore, it is possible to configure the assembly carrier 4 as a sheet-metal shaped part, preferably made from a light metal sheet.
The spoiler device 2 is disposed on the outer side 6 of the assembly carrier 4 , to be precise in such a manner that it can be adjusted between an inoperative position, shown in FIGS. 1 , 4 and 5 , and an operative position. In the inoperative position, the spoiler device 2 is integrated into the contour of the rear lid 1 and, when the rear lid 1 is closed, into the contour of the vehicle body. In the operative position, the spoiler device 2 is deployed. For example, the spoiler device 2 extends essentially horizontally in its operative position on the vehicle when the rear lid 1 is closed. The spoiler device 2 forms a spoiler in its operative position. In order to be able to adjust the spoiler device 2 between the inoperative position and the operative position, an adjustment device 7 (illustrated in FIG. 14 ) which is likewise attached to the assembly carrier 4 is provided. The adjustment device 7 can have, for example, an adjustment drive 8 which is coupled via suitable connecting elements 9 , such as, for example, Bowden cables or flexible rotary shafts, to actuating elements 10 to which the spoiler device 2 is fixedly connected.
The spoiler device 2 has, in the customary manner, air inlet openings (not referred to specifically) in order to be able to introduce air through the spoiler device 2 and through the rear lid 1 into the rear compartment in which, for example, a driving unit of the passenger vehicle may be disposed. In this case, the assembly carrier 4 has at least one passage opening 11 . In the example shown, the assembly carrier 4 has at least three relatively large passage openings 11 . Furthermore, a fan 12 which makes the desired circulation of air possible is fastened here to the assembly carrier 4 . In this case, the fan 12 is fastened directly to the assembly carrier 4 and is disposed on an inner side of the assembly carrier 4 , which inner side faces the rear compartment.
Since both the spoiler device 2 and the panel device 3 extend over the entire width of the assembly carrier 4 , the latter is completely covered on its outer side 6 by the spoiler device 2 and by the panel device 3 at least in the inoperative position of the spoiler device 2 . Painting of the assembly carrier 4 in line with the color of the vehicle body is therefore not required.
The panel device 3 is configured in such a manner that it can be produced as simply as possible in a plurality of variants in order also to be able to realize different variants of the rear lid 1 . Accordingly, FIG. 4 shows the variant, which is already shown in FIGS. 1 to 3 , of the rear lid 1 and of the panel device 3 while FIG. 5 shows a different embodiment of the rear lid 1 which is referred to below by 1 ′, and of the panel device 3 , which is referred to below by 3 ′. According to FIGS. 3 to 9 , the panel device 3 or 3 ′ contains a panel carrier 13 which is fastened to the assembly carrier 4 , to be precise to the outer side 6 thereof. Furthermore, the panel device 3 or 3 ′ contains at least one panel body 14 or 15 and 16 . In the embodiment shown in FIG. 4 , only one panel body 14 is provided. In contrast thereto, the embodiment reproduced in FIG. 5 shows two panel bodies 15 and 16 . The particular panel body 14 , 15 , 16 is fastened to the panel carrier 13 on an outer side 17 which faces away from the assembly carrier 4 .
FIG. 7 shows the one panel body 14 which is used in order to realize the embodiment shown in FIG. 4 . The single panel body 14 used in this case extends over the entire width of the rear lid 1 and, as a result, clads the entire panel carrier 13 and that section of the assembly carrier 4 which is assigned to the panel device 3 .
The variant shown in FIG. 5 has precisely two panel bodies 15 , 16 . It is clear that, in principle, three or more panel bodies may also be provided. The two panel bodies 15 , 16 extend in each case over the entire width of the rear lid or tailgate 1 and, accordingly, are disposed adjacent to each other in the longitudinal direction 5 of the vehicle. FIG. 8 shows the panel body 15 which, in the fitted state, is directly adjacent to the spoiler device 2 while FIG. 9 shows the panel body 16 which is disposed at a distance from the spoiler device 2 . The panel body 16 may be, for example, a luminous band which, for example, is configured to be reflective.
In the same manner as the panel carrier 13 , the panel bodies 14 , 15 , 16 may be produced from plastic. The spoiler device 2 may also be produced from plastic.
In the same manner as FIG. 2 , FIG. 10 shows the assembly carrier 4 in a preassembled state with the spoiler device 2 missing. In the assembly state, the assembly carrier 4 together with the components attached thereto forms a preassembled unit 18 which can be fitted in its entirety to the vehicle body. In order to produce the unit 18 , the assembly carrier 4 according to FIG. 11 is equipped with the individual components which are reproduced by way of example in FIGS. 12 to 14 . The assembly carrier 4 according to FIG. 11 is therefore provided with the panel device 3 which is shown in FIG. 12 and, for its part, can form a preassemblable unit. Furthermore, the fan 12 according to FIG. 13 can also be fastened to the assembly carrier 4 . Furthermore, the adjustment device 7 shown in FIG. 14 can be attached to the assembly carrier 4 . Moreover, a non-illustrated locking clamp can be attached to the assembly carrier 4 and can be used to lock the tailgate 1 to the vehicle body in the closed position. In addition, the hinges already mentioned further above can be attached to the assembly carrier 4 and are used to mount the tailgate 1 pivotably on the vehicle body.
When the tailgate 1 presented here is used, the vehicle to be equipped therewith can preferably be produced as follows. First of all, the unit 18 which generally contains the entire tailgate 1 without the spoiler device 2 is preassembled. The preassembled unit 18 is subsequently fitted on the vehicle which has already been painted previously or on the vehicle body which has been painted in advance. The spoiler device 2 is subsequently fitted to the assembly carrier 4 which is already fitted on the vehicle.
It is likewise possible to preassemble the spoiler device 2 on the unit 18 and then to fit the complete rear lid to the painted vehicle.
Painting of the tailgate 1 or of part of the tailgate 1 together with the vehicle body is not required. It is clear that those components of the tailgate which form the outer side of the tailgate 1 , i.e. the spoiler device 2 and the panel device 3 or at least one of the panel bodies 14 or 15 , can likewise be painted in the color of the vehicle. | A rear lid closes a rear compartment of a passenger vehicle. The rear lid, when fitted, is attached to the vehicle and is composed of an inner part and an outer part. The rear lid contains a spoiler device which can be displaced between an inoperative position and an operative position and interacts with an adjustment device. In order to simplify producibility of the rear lid, the inner part is formed by an assembly carrier which forms the supporting structure of the rear lid and to which at least the adjustment device of the spoiler device is fastened. The outer part is formed by the spoiler device and a panel device. | 1 |
RELATED APPLICATIONS
[0001] This application claims the Aug. 20, 2011 priority date benefit of Provisional Application No. 61/575,472.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] Normal hydrocarbon well perforating operations require shutting down radio frequency (RF) transmitters and eliminating stray voltage sources before arming explosive equipment such as perforating guns at the surface of an oil or gas well. The exception is for certain qualified high voltage initiators as recommended by the American Petroleum Institute (API Recommended Practice 67 (RP67), 2 nd Edition, 2007) where explosive preparations are allowed in the presence of uncontrolled external voltages. High voltage initiators (HVI) include devices that utilize exploding foil initiation (EFI) and exploding bridge wire (EBW) as the initiating elements. An HVI that uses an semi-conductor bridge (SCB) is safer than a hot-wire detonator but more restrictive than HVIs using EFIs and EBWs.
[0003] These technologies were adapted for downhole during the last two decades. The first commercial EFI device for downhole use is described in U.S. Pat. No. 5,088,413 by Huber et al. The efficiency of such devices is determined in part by the overall inductance of a current loop that connects a capacitor, a switch and an EFI or EBW. One simple version was designed in the 1980s by Meyers, Application of Slapper Detonation Technology to the Design of Special Detonation Systems, Los Alamos Report LA-UR-87-391 that used a two conductor flexible cable that incorporated a small hole in the flex cable that served as a barrel between the EFI and the explosive pellet. The capacitor, switch, EFI and flex cable with a hole, used as an EFI infinite flyer barrel, were all part of the same current loop that reduced total resistance and inductance. This concept was followed in another design in the presentation of Lerche and Brooks, “Efficiencies of EFI Firing Systems,” 43 rd NDIA Fuze Conference, April, 1999.
[0004] The present high voltage devices for downhole explosive detonations are physically larger than conventional low voltage detonators (commonly called hot-wire detonators that utilize primary explosive), which normally have a slim profile. Low voltage detonators typically are about 0.3-inch diameter and less than 3 inches long. One advantage in using a low voltage detonator is afforded by its small size which allows its insertion into a perforating gun or firing head housing sub-assembly through a relatively small port plug, typically 13/16-inch or 1⅜-inch diameter, permitting easy attachment outside the gun housing of the detonator to the wireline and then to the detonating cord, for example, before inserting the armed detonator back through the port plug hole into the gun housing. High voltage devices, on the other hand, typically do not fit through port plug openings, requiring insertion through one end of a separate arming sub or a special sub, for example, making the arming operation more difficult and adds cost and preparation time at the job site.
[0005] A high-voltage device that fits through a port plug opening is needed to reduce cost, improve reliability and improve well-site safety and efficiency. Added safety is afforded by a feature that only allows electrical power to initiate the device by sending a prescribed activation signal.
SUMMARY OF THE INVENTION
[0006] The present invention disclosure describes an assembly for initiating explosives downhole using an exploding foil initiator, consisting of an input power supply, a flexible electrical link, a capacitor discharge unit and a secondary explosive transfer to a detonating cord. In one version, the explosive is initiated in a direction approximately parallel to the capacitor discharge unit and in another version the explosive is initiated in a direction approximately perpendicular to the capacitor discharge unit. The unique configurations and construction of the assembly allow installation through a small port plug hole in the gun housing structure for more efficient gun arming.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The advantages and further features of the invention will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout.
[0008] FIG. 1 schematically shows a well perforating gun operating assembly with a wireline cable and detonator.
[0009] FIG. 2 is a sectional view of a prior art high voltage initiator.
[0010] FIG. 3 a is a block diagram of a first invention embodiment.
[0011] FIG. 3 b is a block diagram of a second invention embodiment
[0012] FIG. 4 is a flow chart of the present invention arming procedure
[0013] FIG. 5 is a preferred voltage multiplier schematic with low impedance shunt
[0014] FIG. 6 is a flyback concept for stepping up the input voltage with the addition of low impedance shunt.
[0015] FIG. 7 a is a first preferred invention embodiment showing a capacitance discharge unit configuration corresponding to FIG. 3 a.
[0016] FIG. 7 b is a second preferred invention embodiment showing a capacitance discharge unit configuration corresponding to FIG. 3 b.
[0017] FIG. 8 a is another preferred invention embodiment showing a capacitance discharge unit configuration corresponding to FIG. 3 a.
[0018] FIG. 8 b is another preferred invention embodiment showing a capacitance discharge unit configuration corresponding to FIG. 3 b.
[0019] FIG. 9 is an explosive transfer holder schematic.
[0020] FIG. 10 is a block diagram that shows modified circuit to permit powering with an activation signal from the surface.
[0021] FIG. 11 is a schematic that show a circuit that detects downhole voltage and uplinks real time downhole measured voltages.
[0022] FIG. 12 is a signal format for uplink signal pulses corresponding to FIG. 11
[0023] FIG. 13 is an alternative embodiment of FIG. 11
[0024] FIG. 14 is a signal format for uplink signal pulses corresponding to FIG. 13
[0025] FIG. 15 is a circuit schematic for integrating a voltage detector with a detonator having a voltage multiplier as part of its power supply.
[0026] FIG. 16 is a schematic for one embodiment of the overall assembly detonator.
[0027] FIG. 17 is a circuit schematic of the CDU with separate flexible cable containing an EFI
[0028] FIG. 18 a shows a CDU where the spark gap and bleed resistor are mounted on the capacitor with a separate flexible cable with EFI aligns vertically
[0029] FIG. 18 b shows a CDU where the spark gap and bleed resistor are mounted on the capacitor with a separate flexible cable with EFI aligns horizontally
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] In a typical wireline perforating operation, the perforating gun 10 is lowered into a well by way of an electrical cable 12 to position the gun at the desired portion in the reservoir ( FIG. 1 ). Conveyance from a truck-mounted reel 14 may be by means of gravity, by fluid pressure, by pushing the gun with small-diameter tubing, or by pushing the gun down with a downhole tractor. Once the gun is positioned at the specified depth, electrical detonation power 16 connected to the cable by means of a wireline cable connector 20 to “fire” the gun by powering a detonator 11 . “Firing” of the gun is represented by the detonation of specialized high explosives such as shaped charges that are radially aligned in the gun housing to produce holes in the well casing and/or reservoir to allow a flow of in situ hydrocarbons from the surrounding formation into the well.
[0031] In prior art low voltage perforating operations using hot wire detonators with primary explosive, typically with 50 Ohm input resistance, the shooting power supply 16 produces sufficient voltage, in the range of 10V to 50V at the input of the detonator, to directly initiate these types of explosive devices. However, electro-explosive initiators such as EBW (exploding bridge wire) and EFI (exploding foil initiator) detonators require a discharge voltage in the range of 1000V to 3000V for reliable initiation of a secondary explosive. Because most power supplies are limited to below 500V output, it becomes necessary to provide an integral step-up voltage power supply downhole for the EBW and EFI type detonators.
[0032] A basic configuration of such a prior art EFI detonator as described by U.S. Pat. No. 6,752,083 by Nolan C. Lerche et al, is represented by FIG. 2 , and may be composed of three sections: circuitry 22 to boost downhole voltage (first section), a capacitor discharge unit (CDU) 24 (second section) and an explosive housing 26 (third section) which includes a small explosive pellet 112 . A support structure 100 consolidates and houses the cooperative components of the first and second sections. An electric cable connector 104 connects a power source 16 to the active elements of the voltage multiplier circuit 22 within the support structure. A bore 162 within the explosive housing is sized to receive a booster explosive 164 proximate of the explosive pellet 112 . In intimate contact with the booster 164 , the end of a detonating cord 166 is clamped within the bore 162 by a threaded collet mechanism 168 .
[0033] The prior art example of the FIG. 2 of an EFI detonator device typically assembles the three sections 22 , 24 , and 26 in rigid alignment along a common axis making a total length of about 5 inches or greater which is too long to fit through the gun housing service ports of most gun systems. Sections 22 and 24 contain close-coupled, high voltage electronic components that are arranged on the same circuit support structure which determines in large part the overall length of the assembly, making it impossible to fit the detonator through a small port plug hole of most guns.
[0034] The present invention, represented schematically by FIGS. 3 a and 3 b are the embodiments of designs that overcome the length disadvantage of prior art such as that of FIG. 2 . In its simplest form, the present invention also has three sections including the voltage multiplier section 30 , a capacitive discharge unit coupled to an EFI 32 and an explosive housing 34 which contains one or more small explosive pellets 164 ( FIG. 9 ), where sections 32 and 34 are rigidly attached. Distinctively, the voltage multiplying section 30 and the capacitive discharge section 32 are joined by a short section of flexible electrical link 36 about 1 inch in length, for example, capable of carrying high voltage. The prior art contained its electronics on a flex cable for single unit assembly. A flex cable is unnecessary for the section 30 because, unlike section 32 , there is no need for low inductance for the voltage step-up section. Moreover, a sturdy circuit board is more robust for handling.
[0035] In one version of the invention, FIG. 3 a , the explosive housing section 34 is physically angled relative to the capacitive discharge section 32 a. The flexible link 36 allows the first section 30 to pivot relative to the second section 32 a while maintaining electrical connection through two wires. The width (less than 0.70 inch) of the two sections 30 and 32 a is less than the 13/16-inch diameter opening of a standard perforating gun service port, and fits easily through the opening. The individual lengths of the two sections 30 and 32 a are less than the allowed clearance inside a small diameter 2⅞ inch gun, for example, and are easily placed inside the gun section through a standard service port. By the third section being angled approximately perpendicular to the second section, it too, fits easily inside the gun section, after it is affixed outside the gun to a booster that is connected to flexible detonating cord.
[0036] FIGS. 3 b and 16 show another embodiment of the invention that is suited for larger service ports, such as the common 1⅜-inch diameter port plug used with a small diameter 2⅞ inch gun. The capacitive discharge section 32 b is in-line with the explosive housing 34 . The larger diameter service port allows easy insertion of an in-line 34 and 32 b with flexible link 36 and voltage multiplier 30 following.
[0037] Partitioning the rigid voltage multiplier section 30 from the rigid unit of sections 32 and 34 is the simplest configuration of the invention and the presently preferred embodiment. However, three or more rigid sections with pivoting electrical connections is also possible, and would allow for more electronic features to fit through a service port.
[0038] A flow chart of the loading procedure is given in FIG. 4 . A typical loading procedure at the well site would have the assembly of FIG. 3 a or 3 b connected to wireline wires that have been routed from inside of the gun through the service port hole. The electrical connection is normally done with the assembly inside a safety tube to prevent bodily injury in case of accidental firing. After the electrical connection is made, the end of the detonating cord, also routed through the service port from inside the gun, is capped with a booster-shelled explosive, inserted into the explosive housing section 34 and secure by a collet clamp. Once the assembly is attached to the booster/detonating cord, the linking cord and explosive housing section of the assembly is inserted through the port plug and rotated until sections 34 and 32 are inside the gun section. Finally, section 30 and its connection wires are inserted, enabled by the flexible link that allows section 30 to pivot relative to section 32 . The port plug is then secured to the gun section.
[0039] A more detailed description of alternative embodiments of a voltage multiplier and accompanying electronics 30 is shown by FIGS. 5 and 6 . The electronic components are mounted on a hard circuit board. Two input wires 104 A and 104 B are attached to the board and used to make electrical connection to the wireline 12 . A commutating diode allows only positive voltage to power the circuit. A flexible link 36 unsupported by the board attaches to the output side and connects to section 32 . In one embodiment, the link is composed of two short wires; in another embodiment, the link connects to the second section 32 by an unsupported flexible cable.
[0040] A unique feature of the FIGS. 5 and 6 embodiments is the inclusion of a low-impedance shunt 31 that is electrically in parallel with the input wires, and having a value in the range of 10 to 500 Ohms, for example, 50 Ohms. For low voltage applications, the first section 30 presents low input impedance onto the wireline. At higher voltages the low impedance shunt 31 opens or maintains a constant current load, presenting higher input impedance for section 30 at higher input voltages. Existing high-voltage detonators have high input impedance, typically between 2,000 and 50,000 Ohms, depending on the device. The resulting charging current is therefore much smaller than that presented to a 50 Ohm hot-wire detonator, for example. The lower current typical for high-voltage detonators makes it difficult to detect the presence of these types of detonators by monitoring current change at the surface when they are switched onto the wireline. The low impedance shunt 31 allows current to be more easily detected at the surface at low voltages during normal firing sequences, as is now common for conventional hot-wire detonators with 50 Ohm resistance. This shunt feature is particularly advantageous when using electronic downhole switches with the present invention to detect a failed or shorted downhole electronic switch when used with high voltage detonators. Some typical electronic downhole switches are described in U.S. Pat. No. 6,283,227 by Lerche et al and U.S. Patent Publication No. 2011/0066378 filed Nov. 3, 2010 by Lerche et al.
[0041] One embodiment of a low-impedance shunt is a fusing resistor. Another embodiment would be a depletion mode field effect transistor (DFET) in series with a 50 Ohm resistor, as an example. The DFET and series 50 ohm resistor is again placed in parallel with the input wires of the detonator. A current sense resistor also in series with the DFET and limits the current through the DFET to a predetermined level.
[0042] There are other embodiments where a high voltage, high impedance detonator presents a low impedance with low wireline voltages typical during downhole communication of electronic perforating switches. The low impedance shunt can be part of the electronic switch or anywhere between the switch and the detonator.
[0043] Two embodiments of the present invention second section 32 are represented schematically by FIGS. 7 a and 8 a and correspond to FIG. 3 a (perpendicular alignment with section 34 ). A CDU circuit including a ceramic capacitor 42 and switching component 44 (spark gap) mounted on a thin, low inductance flex cable, which may or may not include a more rigid composite section. The circuit is supported along a rigid mechanical support 40 underneath. In one embodiment, a controlled gap 48 of between 0.005-0.015 inches separates the top of an EFI 46 and the bottom of an explosive pellet 50 , The FIG. 7 a embodiment engages a small insulated spacer 52 between the EFI 46 and the explosive pellet to control the gap 48 spacing. In the FIG. 8 a embodiment, the control gap 48 is a perforation in the flexible cable and support structure between the EFI 46 and the explosive pellet 50 abutting the flexible cable/support structure 40 .
[0044] It is clear to one skilled in the art that other electro-explosive initiators besides an EFI can be used, such as an EBW or an SCB.
[0045] Two other embodiments of the present invention section 32 are represented schematically by FIGS. 7 b and 8 b and correspond to FIG. 3 b (parallel alignment with section 34 ). Here the rigid support 40 only supports the low inductance cable up to the EFI 46 , allowing that portion of the cable to be bent as shown.
[0046] Two more embodiments of the present invention section 32 are shown in FIG. 18 which uses a portion of the structural surface of the firing capacitor 42 as an substrate for supporting the bleed resistor 41 and the switching component 44 , all in an integrated CDU (see FIG. 17 for circuit schematic). Advanced Monolythic Ceramics, for example, offers such construction. This eliminates the need for the cable support 40 . A separate section of flexible cable, such as a ribbon cable, 43 with an EFI 46 is soldered to the firing capacitor surface to attach the CDU to the initiator element. The flexible cable with the EFI is coupled, in turn, to the explosive section 34 as in FIG. 3 a and FIG. 18 a . or when after bending as in FIG. 3 b and FIG. 18 b.
[0047] The most common cause of perforating fatalities is the accidental application of power to the detonator at the surface. Sending and correctly detecting an activation signal at the detonator before firing provide an extra degree of safety. An embodiment of the voltage multiplier section 30 is shown in Fig, 10 that adds this extra margin of safety. FIG. 10 differs from FIGS. 5 and 6 by the inclusion of a receiver and microprocessor for one-way communication from the surface tool control computer 18 ( FIG. 1 ) to the voltage multiplier section 30 of the detonator. A low voltage is applied at the surface to energize the power supply 35 . Next, a downlink activation signal is received and processed by the microprocessor using FSK communication. The microprocessor verifies that it has received the correct activation signal and only then allows the internal high voltage power supply to activate. Finally, shooting voltage is applied at the surface to complete the firing sequence, making for safer operations.
[0048] FIG. 11 is a schematic of an additional feature for the detonator that detects downhole voltage and then uplinks real time voltage levels to the surface computer 18 . The voltage detect feature is on a separate circuit board in front of the voltage multiplier 30 ( FIG. 5 and FIG. 6 ), but could also be incorporated as part of section 30 on a common board as depicted in FIG. 3 and schematically shown in FIG. 15
[0049] Referring to FIG. 11 , the downhole voltage level is detected and the resulting analog signal is sent to an A/D input of a microprocessor. The microprocessor then sends a digital signal to the surface computer 18 in the form of a current induced signal that rides on top of the shooting power supply voltage 16 , known as current loop power line carrier. At the surface, a current viewing resistor (CVR) is placed in series with the wireline in order to detect the current deflection. This signal is then processed and the results are displayed in a plot format or as a digital value. The detector unit would automatically send a series of pulses at a selected predetermined interval.
[0050] One type of uplink signal is a binary weighted Manchester represented by FIG. 12 . When surface power supply (SPS) voltage is detected downhole, a 3 bit preamble, 3 null bits and 8 bit data word is sent uplink as a power line carrier on top of the SPS voltage using the Manchester format. The bit rate can be chosen to give reliable uplink detection for a given wireline resistance and capacitance values. Typically a 100 bits/sec would work for all wirelines. The downhole signal would be an induced current in the range of (10-100) ma. Using an 8 bit word, the advantage is a high resolution signal.
[0051] In another embodiment variation of FIG. 11 , the FIG. 13 embodiment provides a series of diodes, each with a different breakdown voltage. As the downhole voltage from the power supply 16 increases, sequential signals are sent to a microprocessor which tracts the number of such signals. Each time a signal is detected a designated pulse sequence corresponding to the particular voltage is transmitted up the wireline and recorded at the surface by a computer 18 . The presence of the detonator is confirmed by monitoring these received signals and the last signal corresponding to the last voltage change gives an approximation to the firing voltage of the detonator. Unless there are special provisions, whenever an electronic perforating switch is integrated into a high voltage detonator there is no surface feedback indicating that the detonator is functioning. Instrumentation of the following two methods would provide surface status for operation of a high voltage detonator.
[0052] A simple method for the uplink corresponding to FIG. 13 is shown in FIG. 14 . A series of pulses is uplinked, each pulse having a predetermined weighted value. As an example each pulse could represent 50 volts, and 3 pulses would indicate 150 volts. The disadvantage is that the resolution is not as precise while the advantage would be to only count pulses at the surface.
[0053] The third section 34 of the invention assembly as schematically illustrated by FIG. 9 attaches the output side of the explosive pellet 50 to an explosive booster 54 that is attached later and is all contained within a housing 56 . The length of section 34 is short enough to fit inside a safety loading tube not shown.
[0054] The explosive pellet 50 is normally fine particle HNS (IV) or NONA, both commercially available and has been shown to work with EFIs. A stack of two explosive pellets, one of fine particle HNS at the EFI interface, topped with HMX or coarser particle HNS, for example, is also a variation. Furthermore, the explosive pellet can be included as part of section 32 or as part of section 34 .
[0055] The assembly may also be configured without the explosive pellet. The explosive pellet could be incorporated into the booster and attached separately in the field.
[0056] Although the invention disclosed herein has been described in terms of specified and presently preferred embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto. Alternative embodiments and operating techniques will become apparent to those of ordinary skill in the art in view of the present disclosure. Accordingly, modifications of the invention are contemplated which may be made without departing from the spirit of the claimed invention. | A downhole explosive detonation comprises a high voltage electro-explosive initiator comprising an input high voltage power supply with a low impedance shunting fuse, a flexible electrical link and a capacitor discharge unit. Explosive is initiated in a direction approximately parallel, or in another version perpendicular to the capacitor discharge unit. A unique configuration and construction of the assembly allows installation through a small service port in the gun housing structure for more efficient gun arming. A real time downhole voltage monitoring is described that transmits voltage readings to the surface during a firing sequence. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to network device management and more particularly to displaying network indicators in a window title bar.
[0003] 2. Description of the Related Art
[0004] Network management software provides network administrators a way of tracking the various characteristics of network devices, such as switches, routers, and the like, in a data communication network. Examples of these characteristics are the CPU utilization, memory utilization, unused ports, and number of events on devices in a network. Network management software, such as Brocade Network Advisor by Brocade Communication Systems, Inc., generally has a graphic user interface (GUI) that allows a network administrator to monitor numerous types of network characteristics in a single display. Each characteristic may be monitored in its own individual window called a widget. However, because there are so many types of network characteristics to monitor it is often necessary for the network administrator to minimize some of the widgets. When minimized, none of the network information being tracked by a particular widget may be seen in the GUI by an administrator. Instead, only the widget's title bar is displayed, which simply tells a network administrator which type of characteristic is being tracked by the widget. If, for example, the minimized widget monitors the memory utilization of devices in the network, and a monitored network device suddenly reaches its maximum memory utilization, a network administrator has no way of knowing that situations exists. Therefore, a method and system is needed to alert a network administrator.
SUMMARY OF THE INVENTION
[0005] Network management software displays a widget for tracking a particular characteristic of a network. The widget title bar contains a first and second indicator. The first indicator represents the severity of the most severe alert for the particular characteristic being tracked by the widget, such as by a color code. The second indicator is a numerical value for the characteristic that caused the alert.
[0006] This technique can be used on any telecommunication network.
BRIEF DESCRIPTION OF THE FIGURES
[0007] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of apparatus and methods consistent with the present invention and, together with the detailed description, serve to explain advantages and principles consistent with the invention.
[0008] FIG. 1 is a diagram illustrating a local area network (LAN) and wide area network (WAN) as may be incorporated together with the present invention.
[0009] FIG. 2 is a diagram of an Ethernet Switch that may be incorporated together with the present invention.
[0010] FIG. 3 is a diagram illustrating Fibre Channel (FC) storage area network (SAN) fabrics interconnected via a wide area network (WAN) as may be incorporated together with the present invention.
[0011] FIG. 4 is a diagram of a Fibre Channel Switch that may be incorporated together with the present invention.
[0012] FIG. 5 is a block diagram of a management station connected to a communications network for operating in accordance with the present invention.
[0013] FIG. 6 is a screenshot of an example graphical user interface (GUI) illustrating aspects according to the prior art.
[0014] FIGS. 7 a, 7 b, and 7 c are screenshots of an example of a GUI according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Referring to FIG. 1 , an Ethernet network 100 is shown wherein a LAN 102 is interconnected to a remote campus 130 via WAN 104 . The campus core 106 includes a plurality of interconnected core switches 108 . The core switches 108 are connected to a data center (not shown). A router no is connected to the core switches and the WAN 104 . The core switches 108 are connected to switches 114 and 116 of an aggregation campus 112 . The aggregation campus switches 114 and 116 are connected to switches 120 of large network 118 and provide data communication services to the large network's telephone 122 , computer 124 , and wireless access 126 devices. The aggregation network switches 114 and 116 may also be connected to additional campuses (not shown) in order to provide additional data communication services. The LAN 102 is connected to the WAN 104 via router 110 . The WAN 104 is comprised of a plurality of interconnected Ethernet switches 128 and other networking devices (not shown). WAN 104 is connected to remote campus 130 via a router 132 . Router 132 provides data communication services to computers 134 and telephone devices 136 . It is understood that this is an exemplary network and numerous other network topologies can be monitored according to the present invention.
[0016] In an embodiment of the present invention a management station 138 is connected to router no of the campus core 106 . As will be appreciated by one having ordinary skill in the art, the management station 138 allows a network administrator to monitor the data traffic, port utilization, and various other networking characteristics of each switching device in the Ethernet network 100 .
[0017] Turning next to FIG. 2 , a block diagram of an Ethernet switch or router 200 that may be utilized in Ethernet network 100 is shown. The Ethernet switch 200 comprises a switch software environment 202 and switch hardware environment 204 . The software environment 202 includes a diagnostics and statistics module 203 to allow management software access to the various statistical counters in the switch 200 , such as receive and transmit rate counters for each port 226 , 228 , 230 , 232 . The switch hardware environment 204 has a processor complex 206 that consists of processors as defined. The processor complex 206 is connected to a switch fabric 208 , which provides the basic switching operations for the switch 200 . The switch fabric 208 is connected to a plurality of packet processors 210 , 212 , 214 , 216 . Each packet processor 210 , 212 , 214 , 216 has its own respective policy routing table 218 , 220 , 22 , 224 to provide conventional packet analysis and routing. Each packet processor 210 , 212 , 214 , 216 is connected to its own respective port or ports 226 , 228 , 230 , 232 . When the Ethernet switch 200 is implemented in a network such as network 100 , the data value of each port 226 , 228 , 230 , and 230 may be monitored and analyzed using management software on a management station, such as management station 136 . Again, it is understood that this is an exemplary Ethernet switch architecture and numerous other architectures can be used according to the present invention.
[0018] FIG. 3 illustrates a SAN network 300 utilizing the Fibre Channel (FC) protocol. As shown, a plurality of FC SAN fabrics 302 a and 302 b are interconnected via WAN 304 . The SAN fabrics 302 a and 302 b are comprised of a plurality of FC switches 306 a and 306 b, respectively. SAN fabric 302 a is connected to a plurality of storage devices 308 a. Likewise, SAN fabric 302 b is connected to a plurality of storage devices 308 b. Each SAN fabric 302 a and 302 b connect their respective storage devices 308 a and 308 b to application servers 310 a and 310 b, which are in turn connected to computers 312 a and 312 b. This configuration allows for computer 312 a to access storage devices 308 b and for computer 312 b to access storage devices 308 a. As above, this is an exemplary FC SAN architecture and numerous other FC architectures can be managed according to the present invention.
[0019] In an embodiment of the present invention a management station 314 is connected to Ethernet LAN 301 a, which is connected directly to SAN network 302 a and indirectly to Ethernet LAN 301 b via WAN 304 . Ethernet LANs 301 a and 301 b are connected to the Ethernet management ports of the switches 306 a and 306 b to provide a management network for the switches 306 a and 306 b. As will be appreciated by one having ordinary skill in the art, the management station 314 allows a network administrator to monitor the data traffic, port utilization, and various other networking characteristics using network management software, such that any data congestion may be alleviated.
[0020] FIG. 4 illustrates a block diagram of a FC switch 400 that may be utilized in accordance with the SAN network 300 . A control processor 402 is connected to a switch ASIC 404 . The switch ASIC 404 is connected to media interfaces 406 which are connected to ports 408 . Generally the control processor 402 configures the switch ASIC 404 and handles higher level switch operations, such as the name server, the redirection requests, and the like. The switch ASIC 404 handles the general high speed inline or in-band operations, such as switching, routing and frame translation. The control processor 402 is connected to flash memory 410 to hold the software, to RAM 412 for working memory and to an Ethernet PHY 414 used for management connection and serial interface 416 for out-of-band management.
[0021] The switch ASIC 402 has four basic modules, port groups 418 , a frame data storage system 420 , a control subsystem 422 and a system interface 424 . The port groups 418 perform the lowest level of packet transmission and reception, and include a statistical counter module 426 to allow management software to access the various statistical counters of the switch 400 , such as receive and transmit rate counters for each port. Generally, frames are received from a media interface 406 and provided to the frame data storage system 420 . Further, frames are received from the frame data storage system 420 and provided to the media interface 406 for transmission out a port 408 .
[0022] FIG. 5 illustrates a block diagram of a management station 500 , similar to management stations 138 and 314 , that may be utilized in accordance with the present invention. As shown, the management station 500 is comprised of a central processing unit (CPU) 502 , random access memory (RAM) 504 , network interface card (NIC) 506 , system interconnect 508 , storage component 510 , input component 512 , and output component 518 which are all interconnected via the system interconnect 508 . The input component 512 may be connected to an input device such as a keyboard 514 and mouse 516 . The output component 518 is connected to a display device 520 , such as an LCD monitor. Storage component 510 stores software 522 , which typically includes an operating system 524 and network management software 526 . The NIC 506 allows the management station 500 to communicate with a network. As understood by those skilled in the art, network management software is typically designed to allow a network administrator to quickly and efficiently monitor and manage a large network via a user interface, often a graphical user interface (GUI). The network management software 526 could be, for example, Brocade Network Advisor by Brocade Communication Systems, Inc. Once booted, the management station 500 loads the operating system 524 from the storage 510 into the RAM 504 . From the operating system 524 a user may run the network management software 526 , which is then also loaded into the RAM 504 . The interface of the network management software 526 is then displayed on the display 520 via the output component 518 . The network management software 526 allows a user to monitor numerous network characteristics, such as the number events on the network, number of unused ports of network devices, memory utilization of network devices, bandwidth utilization of network devices, and CPU utilization of network devices. It is understood that this is an exemplary computer system architecture and numerous other computer architectures can be used according to the present invention.
[0023] FIG. 6 illustrates an example of the graphic user interface (GUI) 600 of network management software 526 in partial accordance with the prior art. As shown, widgets 602 , 604 , 606 all track particular characteristics 608 , 610 , 612 of a data communication network. As understood by those having skill in the art, network management software accumulates the particular characteristics of a network by either: (1) polling switches via application programming interface (API), command line interface (CLI) or simple network management protocol (SNMP); or (2) receiving warnings from switches on the network via API or SNMP. The network management software then displays the particular characteristics being tracked in a window, such as a widget, for the network administrator. Widget 602 tracks the number of events 608 in the network. Widget 604 tracks the top product memory utilization 610 of devices, such as routers and switches, in the network. Widget 606 tracks the top products with unused ports 612 in the network. Widget 606 is shown expanded or maximized, as indicated by upward pointing chevron symbol 622 , in embodiments according to the present invention, and displays the number of unused ports 616 for each device 614 in the network. Widgets 602 and 604 are minimized, as indicated by downward pointing chevron symbols 618 , 622 in embodiments according to the present invention. In embodiments according to the present invention, when a chevron symbol that indicates a widget is minimized is clicked by a user, the widget expands or maximizes as shown by widget 606 . Conversely, when a chevron symbol that indicates a widget is maximized is clicked by a user, the widget minimizes as shown by widgets 602 and 604 . Illustrating the prior art, minimized widgets 602 and 604 only display the widget title bar, which contains only the name of the specific characteristic 608 , 610 tracked by widgets 602 and 604 . Consequently, a network administrator has no way of knowing the number of events 608 on the network based on widget 602 or the top product memory utilization 610 based on widget 604 because both widgets 602 and 604 are minimized. Likewise, when widget 606 is minimized an administrator will no longer be able to see the number of unused ports 616 for any device 614 on the network using the widget. Therefore, there remains a need for a solution that allows a network administrator to monitor a network characteristic tracked by a widget, even when the widget is minimized.
[0024] FIG. 7A illustrates an example of the GUI 700 of management software 526 in accordance with the present invention. As shown, there are three widgets 702 , 704 , 706 . Widgets 702 , 704 , 706 track a particular characteristic 708 , 710 , 712 of a data communication network. Widget 702 tracks the number of events 708 in the network. Widget 704 tracks the top product memory utilization 710 in the network. Widget 706 tracks the top products with unused ports 712 in the network. Widgets 702 and 704 are minimized, as indicated by downward pointing chevron symbols 736 , 738 , while widget 706 is fully expanded, as indicated by upward pointing chevron symbol 740 . The expanded view of widget 706 displays the number of ports not in use 716 for each device 714 in the network with the devices sorted by decreasing number of unused ports.
[0025] The title bars of widgets 702 , 704 , 706 all contain the name of the specific characteristic being tracked by each widget, such as “Events” 708 , “Top Product Memory Utilization” 710 , and “Top Products with Unused Ports” 712 , as done in the example of FIG. 6 . The title bar for each widget 702 , 704 , 706 further includes a color coded indicator 718 , 720 , 722 that indicates the severity level of the most severe alert triggered by the specific characteristic 708 , 712 , 710 being monitored by the widget. The color of the color coded indicators 718 , 720 , 722 tracks the severity level. For example, for the most severe alerts the color may be red. As the severity decreases the color may change to orange then yellow and then green, for example. The title bar for each widget 702 , 704 , 706 also includes a count indicator 724 , 726 , 728 representative of the value of specific characteristic causing the alert. The color coded indicators 718 , 720 , 722 and count indicators 724 , 726 , 728 allow an administrator to monitor network characteristics even when widgets 702 , 704 , 706 are minimized.
[0026] For example, widget 706 has a color coded indicator 722 with a red color, which indicates a high severity alert related to the number of unused ports on the network. The count indicator 728 represents the number of ports not in use 716 on device 714 , which is the device having the highest number of unused ports. Consequently, even when widget 706 is minimized as shown in FIGS. 7B and 7C , an administrator will be able to identify the most severe alarm relating to the number of unused ports based on color coded indicator 722 and the count indicator 728 . This allows an administrator to minimize multiple widgets, such as widgets 702 , 704 , 706 , and still monitor specific characteristics of the network.
[0027] Turning to FIG. 7B , the same GUI 700 of network management software 526 is shown except that widget 706 has been minimized, as indicated by downward pointing chevron symbol 740 , and widget 704 has been maximized, as indicated by upward pointing chevron symbol 738 , to show memory utilization of the devices in decreasing order. Consequently, specific details relating to the memory utilization 732 of each device 730 on the network are now shown by widget 704 , while only the title bar of widget 706 is now shown. Widget 704 has a color coded indicator 720 with a yellow color, indicating a low level alert. The count indicator 726 represents the memory utilization 732 of a single device 730 in the network having the highest memory utilization. Consequently, even when widget 704 is minimized as shown in FIGS. 7A and 7C , an administrator will be able to identify the highest alarm level relating to the memory utilization of products on the network based on color coded indicator 720 and the count indicator 726 .
[0028] Turning to FIG. 7C , the same GUI 700 from FIG. 7B is shown except that widget 704 has been minimized, as indicated by downward pointing chevron symbol 738 , and widget 702 has been maximized, as indicated by upward pointing chevron symbol 736 , to show errors, warning and general information messages. Consequently, specific details relating to the number of events 708 on the network are now shown by widget 702 , while only the title bar of widget 704 is now shown. Widget 702 has a color coded indicator 718 with an orange color, indicating a more severe alert level but not the highest level. The count indicator 724 corresponds to the number of errors 734 in the network. Consequently, even when widget 702 is minimized as shown in FIGS. 7A and 7B , an administrator will be able to identify the most severe alarm relating to the number of events on a network based on color coded indicator 718 and the count indicator 724 .
[0029] It is understood that the present invention is not limited to using color coded indicators, but instead any object sufficient to indicate the severity of an alarm may be used. For example, differently shaped objects could be used, such as an octagonal stop sign, a triangular warning sign and a round acceptable sign.
[0030] The above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments may be used in combination with each other. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” | What is disclosed is network management software which displays a widget for tracking a particular characteristic of a network. The widget title bar contains a first and second indicator. The first indicator represents the severity of the most severe alert for the particular characteristic being tracked by the widget. The second indicator is a numerical value of the characteristic that caused the alert. | 7 |
FIELD OF THE INVENTION
This invention relates to a method and apparatus for evaluating test samples and more particularly, for accepting a sample of a liquid specimen on an extendable wick and transporting the sample to a multitude of test membranes.
BACKGROUND OF THE INVENTION
Various devices have been used to accept liquid biological samples, evaluate the sample and display test results by color change such as detecting AIDS, glucose, alcohol abuse, drug abuse, viruses and the like. The simplest of such are single test strips that have a chemical strip that, after dipped in a sample, undergoes a chemical reaction when exposed to the target substance. These test strips are limited in the number of tests that can be performed at one time, limit privacy and create a biological disposal issue. If a series of tests need be performed, multiple test strips are exposed to the same sample, creating a potential for confusion between the different tests and requiring disposal or storage of multiple strips. If the strips have to be retained for evidence or transported to another location, they need to be sealed in a container to prevent contamination and prevent exposure to potentially biologically hazardous materials.
Other devices have extension portions that extend into the sample, and then retract after making contact. One such device is described in U.S. Pat. No. 6,150,178 to Cesarczyk and Phildius, which is hereby incorporated by reference. This patent describes a specimen collecting and testing device that slides out of a plastic holder by pushing a shaft, passing the test membrane and exposing it to the sample. The described device is limited to one particular test. Furthermore, once the sample is collected, there is no seal to prevent leakage if this device is to be stored or transported to another location.
What is needed is a method and apparatus for specimen collecting that provides for multiple tests that are easy to read, yet are optionally protected for privacy purposes. Also needed is a specimen collecting device that is self-sealing for mailing, storage and to reduce exposure to biologically hazardous materials.
SUMMARY OF THE INVENTION
Accordingly, an objective of the present invention is to provide a specimen tester that performs multiple tests from the same sample, concurrently.
Another objective of the present invention is to provide a specimen tester that organizes multiple tests in an easy to read format.
Another objective of the present invention is to provide a specimen tester that includes a cover for preventing unwanted exposure to contaminants before the tester is exposed and prevents leakage of potentially biologically hazardous liquids after it is exposed to a specimen.
In a first embodiment, an apparatus for testing a specimen is disclosed including an outer case having a bottom end that is open with an extendable carrier adapted within it. A wick is affixed to a bottom end of the extendable carrier for accepting the specimen and a knob is rotatably coupled to a top surface of the outer case. The knob has a screw extending though threads in a top portion of the extendable carrier for extending and retracting the extendable carrier. The is at least one test membrane affixed to the carrier, visible through the outer case and interfaced with the wick member whereby the wick member is coupled to the at least one test membrane so as to transfer the specimen from the wick member to the at least one test membrane.
In another embodiment, a method for collecting and testing a specimen is disclosed including providing a test kit having an outer case, an extendable carrier adapted within the outer case, at least one test membrane affixed to the carrier and a knob rotatably coupled to a top surface of the outer case. A wick member affixed to a bottom end of the extendable carrier for accepting the specimen. The at least one test membrane is visible through the outer case and is interfaced with the wick member. The knob has a screw extending though threads in a top portion of the extendable carrier for extending and retracting the extendable carrier. The method proceeds with rotating the knob, thereby extending the wick beyond a bottom edge of the outer case, the exposing the wick to the specimen by dipping the wick into the specimen, thereby transferring the specimen from the wick to the at least one test membrane using capillary action. Finally, rotating the knob in an opposite direction, thereby retracting the wick into the carrier.
In another embodiment, an apparatus for collecting and testing a specimen is disclosed including an enclosure and an extendable carrier adapted within the enclosure. A wick is affixed to a bottom end of the extendable carrier for accepting the specimen. There is a mechanism for extending and retracting the extendable carrier and at least one test membrane is affixed to the carrier and visible through the enclosure and interfaced with the wick. The wick is coupled to the at least one test membrane so as to transfer the specimen from the wick to the at least one test membrane.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a perspective view of the device of the present invention.
FIG. 2 illustrates a perspective view of the device of the present invention.
FIG. 3 illustrates a perspective view of the device of the present invention.
FIG. 4 illustrates a perspective view of the device of the present invention.
FIG. 5 illustrates a sectional view along lines 1 - 1 of FIG. 4 of the device of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
Referring to FIG. 1 , a perspective view of the device of the present invention is shown. In the preferred embodiment, the tester 10 is of cylindrical shape, but in other embodiments, the tester is, for example, of square, rectangular, hexagonal, octagonal, pentagonal or triangular shape as the overall shape is exemplary. The tester 10 has an outer case 12 that is preferably clear or translucent to provide visibility to the individual test membranes 50 . The test membranes 50 are affixed to an extendable carrier 22 and interface to the wick 36 located at the bottom of the extendable carrier 22 . It is preferred that the extendable carrier 22 is shaped to match the outer case 12 . For example, if the outer case 12 is hexagonal, the extendable carrier 22 is also hexagonal. In some embodiments, the shape of the extendable carrier 22 is different from the shape of the outer case 12 . For example, the extendable carrier 22 is hexagonal and the outer case 12 is cylindrical.
In some embodiments, the test membranes 50 are affixed to an inside surface of the extendable carrier 22 and the extendable carrier 22 is made of a transparent or translucent material, making the test membranes 50 visible from the outside of the tester 10 . In other embodiments, the test membranes 50 are inserted into bores within the extendable carrier 22 and are visible through the bores.
In some embodiments, the test membranes 50 comprise a hydrophilic microporous membrane that is treated with an agent that reacts to the presence of specific matter in the test specimen by changing color. For example, a test membrane 50 is treated with an agent that changes color upon exposure to glucose, thereby when exposed to a urine sample containing glucose, that specific test membrane changes color. Many test membranes are known in the industry and the present invention is not limited to any particular test membrane, chemical compound or test membrane construction. For an example, several test membranes are disclosed in U.S. Pat. No. 6,150,178 to Cesarczyk and Phildius. In some embodiments, the test membranes 50 include a filter layer and a drying layer, as known in the industry.
In some embodiments, the test membranes 50 are obstructed, preventing the technician who obtained the sample from seeing the results. In that embodiment, the tester is transferred to another person for evaluation, whereby the obstruction is defeated. In some embodiments, the obstruction is a layer of opaque security tape. In some embodiments, the obstruction is part of the tester and a mechanical operation must be performed to obtain access to the results. For example, the carrier 22 is moved beyond a detent that locks it in place and provides visibility to the test membranes 50 .
The extendable carrier 22 is movably positioned within the outer case 12 allowing it to adjustably extend beyond the bottom edge of the outer case 12 for obtaining a biological sample. The extendable carrier 22 is extended by rotating a knob 20 whereas the knob 20 is rotatably coupled to the top of the outer case 12 and coupled to a screw or threaded shaft 30 that passes through threads 32 in the top of the carrier 22 . In FIG. 1 , the extendable carrier 22 is retracted so the wick 36 is above the bottom edge of the outer case 12 . In a preferred embodiment, the wick 36 is made from an absorbent foam material. The wick 36 extends into the extendable carrier 22 and is in contact with the test membranes 50 so that when the wick 36 contacts a biological sample (liquid), capillary action transfers a portion of the sample to each of the test membranes 50 .
A cover or lid 40 is provided to protect the test membranes from exposure to contaminations and in some embodiments, a seal 60 is provided at the interface between the outer case 12 and the cover 40 to provide a tight seal and prevent liquids from flowing into or out of the tester 10 . Therefore, in some embodiments, the extendable carrier 22 is sealed by attaching the cover 40 , protecting from the release of biologically hazardous materials. Once sealed, the tester can be mailed without the need for further sealing. Some testing requires the tester to be transported and retained for further testing, analysis and evidence. Additionally, in some embodiments, the top portion of the tester may also have a seal (not shown), for example, a rubber o-ring, to prevent leakage through the knob assembly. In the disclosed embodiment, the cover 40 is held in place by friction, requiring a tight fit. Any type of cover retaining mechanism is possible and the present invention is not limited to the described cover. Examples of cover retention mechanisms include a cover that is held in place by ridges, a screw cover, a hinged cover and a twist-and-lock cover. Cover attaching mechanisms are well known in the industry.
In some embodiments, the wick comprises absorbent foam. Although the foam can be molded, it is desirable that it be cut from a larger stock to preserve the cell structure. Preferred foam materials include polyethylene foam, polyvinylchloride foam, polyurethane foam, ethyl vinyl acetate foam, polyester foam, polyether foam and the like.
Referring to FIG. 2 , an a perspective view of the device of the present invention is shown. As in FIG. 1 , the tester 10 has an outer case 12 that is preferably clear or translucent to provide visibility to the individual test membranes 50 . The test membranes 50 are affixed to an extendable carrier 22 and interface with the wick 36 . The extendable carrier 22 is movably positioned within the outer case 12 allowing it to adjustably extend the wick 36 beyond the bottom edge of the outer case 12 for obtaining a sample. The extendable carrier 22 is extended by rotating a knob 20 whereas the knob 20 is rotatably coupled to the top of the outer case 12 and coupled to a threaded shaft or screw 30 that passes through threads 32 in the top of the carrier 22 . In FIG. 2 , the knob has not been rotated, thereby leaving the extendable carrier 22 retracted so that a wick 36 is contained within the outer case 12 and the optional cover or lid 40 is shown affixed to the tester 10 . In this example, a seal 60 between the outer case 22 and the cover 40 helps prevent leakage of the specimen and helps prevent outside contamination during storage and shipping.
Referring to FIG. 3 , a perspective view of the device of the present invention is shown. The tester 10 has an outer case 12 that is preferably clear or translucent to provide visibility to the individual test membranes 50 . The test membranes 50 are affixed to an extendable carrier 22 and extendable carrier 22 is movably positioned within the outer case 12 allowing it to adjustably extend beyond the bottom edge of the outer case 12 for obtaining a sample. The extendable carrier 22 is extended by rotating a knob 20 whereas the knob 20 is rotatably coupled to the top of the outer case 12 and coupled to a screw or threaded shaft 30 that passes through threads 32 in the top of the carrier 22 . In FIG. 3 , the cover 40 (not shown) is removed and the knob has been rotated, extending the extendable carrier 22 downward so that a wick 36 extends beyond the bottom edge of the outer case 12 . The wick 36 is partially submerged into a biological sample or specimen 70 , for example a urine sample. The specimen 70 at least partially saturates the wick 36 and is transferred to the test membranes 50 through capillary action. After the tester 10 is exposed to the sample 70 , the knob 20 is rotated to retract the extendable carrier 22 into the outer case 12 and the cover 40 (not shown in this figure) is attached, sealing the device and protecting it from contamination as well as preventing leakage of biological materials during storage or shipping of the tester 10 .
Referring to FIG. 4 , a perspective view of the device of the present invention is shown. In this embodiment, the tester 10 is of hexagonal shape having flat sides. The tester 10 has an outer case 12 that is preferably clear or translucent to provide visibility to the individual test membranes 50 . The test membranes 50 are affixed to flat sides of an extendable carrier 22 and interface to the wick 36 located at the bottom of the extendable carrier 22 . It is preferred that the extendable carrier 22 is shaped to match the outer case 12 . In this embodiment, the outer case 12 is hexagonal and therefore, the extendable carrier 22 is also hexagonal. In some embodiments, the shape of the extendable carrier 22 is different from the shape of the outer case 12 . An example of this would be if the extendable carrier 22 is hexagonal and the outer case 12 is cylindrical.
In some embodiments, the test membranes 50 are affixed to an inside surface of the extendable carrier 22 and the extendable carrier 22 is made of a transparent or translucent material, making the test membranes 50 visible from the outside of the tester 10 . In other embodiments, the test membranes 50 are inserted into bores within the extendable carrier 22 and are visible through the bores. In some embodiments, there is a non-porous fill material (not shown) within the carrier 22 and behind the test membranes 50 .
In some embodiments, the test membranes 50 comprise a hydrophilic microporous membrane that is treated with an agent that reacts to the presence of specific matter in the test specimen by changing color. For example, a test membrane 50 is treated with an agent that changes color upon exposure to glucose, thereby when exposed to a urine sample containing glucose, that specific test membrane changes color. Many test membranes are known in the industry and the present invention is not limited to any particular test membrane, chemical compound or test membrane construction. For an example, several test membranes are disclosed in U.S. Pat. No. 6,150,178 to Cesarczyk and Phildius. In some embodiments, the test membranes 50 include a filter layer and a drying layer, as known in the industry.
In some embodiments, the test membranes 50 are obstructed, preventing the technician who obtained the sample from seeing the results. In that embodiment, the tester is transferred to another person for evaluation, whereby the obstruction is defeated. In some embodiments, the obstruction is a layer of opaque security tape. In some embodiments, the obstruction is part of the tester and a mechanical operation must be performed to obtain access to the results. For example, the carrier 22 is moved beyond a detent that locks it in place and provides visibility to the test membranes 50 .
The extendable carrier 22 is movably positioned within the outer case 12 allowing it to adjustably extend beyond the bottom edge of the outer case 12 for obtaining a biological sample. The extendable carrier 22 is extended by rotating a knob 20 whereas the knob 20 is rotatably coupled to the top of the outer case 12 and coupled to a screw or threaded shaft 30 that passes through threads 32 in the top of the carrier 22 . In FIG. 1 , the extendable carrier 22 is retracted so the wick 36 is above the bottom edge of the outer case 12 . In a preferred embodiment, the wick 36 is made from an absorbent foam material. The wick 36 extends into the extendable carrier 22 and is in contact with the test membranes 50 so that when the wick 36 contacts a biological sample (liquid), capillary action transfers a portion of the sample to each of the test membranes 50 .
A cover or lid 40 is provided to protect the test membranes from exposure to contaminations and in some embodiments, a seal 60 is provided at the interface between the outer case 12 and the cover 40 to provide a tight seal and prevent liquids from flowing into or out of the tester 10 . Therefore, in some embodiments, the extendable carrier 22 is sealed by attaching the cover 40 , protecting from the release of biologically hazardous materials. Once sealed, the tester can be mailed without the need for further sealing. Additionally, in some embodiments, the top portion of the tester may also have a seal (not shown), for example, a rubber o-ring, to prevent leakage through the knob assembly. In the disclosed embodiment, the cover 40 is held in place by friction, requiring a tight fit. Any type of cover retaining mechanism is possible and the present invention is not limited to the described cover. Examples of cover retention mechanisms include a cover that is held in place by ridges, a screw cover, a hinged cover and a twist-and-lock cover. Cover attaching mechanisms are well known in the industry.
Equivalent elements can be substituted for the ones set forth above such that they perform in substantially same manner in substantially the same way for achieving substantially the same result.
It is believed that the system and method of the present invention and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes. | A specimen testing apparatus includes an outer case and an inner case that adjustably extends beyond the bottom end of the outer case. The inner case has a plurality of test strips for biologically testing a specimen, whereby a wick affixed to the bottom end of the inner case draws the specimen into each of the test strips after the inner case is extended and the wick is exposed to the specimen. A cover is provided to protect the apparatus from contamination and to seal the apparatus after exposure to the specimen. | 0 |
This application is a continuation-in-part application of U.S. application Ser. No. 10/334,052 filed Dec. 30, 2002, now abandoned, which is a continuation of U.S. application Ser. No. 09/971,167 filed Oct. 4, 2001, now U.S. Pat. No. 6,500,454. Each of the foregoing applications, each document cited or referenced in each of the foregoing applications and during the prosecution of each of the foregoing applications (“application cited documents”), each document referenced or cited in each of the application cited documents, each document cited or referenced in this application (“herein cited documents”) and each document cited or referenced in each of the herein cited documents are all incorporated herein by reference.
TECHNICAL FIELD
A major objective of chronotherapy for cardiovascular diseases is to deliver the drug in higher concentrations during the time of greatest need, typically during the early morning hours, and in lesser concentrations when the need is less, such as during the late evening and early sleep hours. This can be accomplished by administration of the release dosage form of the present invention, which relates to a controlled absorption of propranolol from dosage forms. The release dosage form of the present invention, which relates to a controlled absorption of propranolol from dosage form, comprises an assembly of Timed, Sustained Release (TSR) Beads, each of which is designed to release as a sustained release pulse after a predetermined delay (“time-controlled” drug delivery instead of “rate-controlled”) with resulting plasma concentration(s) of propranolol varying in a circadian rhythm fashion following administration of a single dosage form at bedtime, thereby minimizing potential risks of a cardiovascular disease, such as stroke, heart attack and myocardial infarction, decreasing systolic blood pressure, or reducing hypertension or beta-adrenergic stimulation, treating cardiac arrhythmia, hypertrophic subaortic stenosis or angina, or preventing migraine and thus enhancing patient compliance and therapeutic efficacy, while reducing cost of treatment.
BACKGROUND OF THE INVENTION
Many therapeutic agents are most effective when made available at a constant rate at or near the absorption site. The absorption of therapeutic agents thus made available generally results in desired plasma concentrations leading to maximum efficacy and minimum toxic side effects. Much effort has been devoted to developing sophisticated drug delivery systems, such as osmotic devices, for oral application. However, there are instances where maintaining a constant blood level of a drug is not desirable. For example, a “position-controlled” drug delivery system (e.g., treatment of colon disease or use of colon as an absorption site for peptide and protein based products) may prove to be more efficacious. A pulsatile delivery system is capable of providing one or more immediate release pulses at predetermined time points after a controlled lag time or at specific sites. However, there are only a few such orally applicable pulsatile release systems due to the potential limitation of the size or materials used for dosage forms. Ishino et al. disclose a dry-coated tablet form in Chemical Pharm. Bull. Vol. 40 (11), 3036-041 (1992). U.S. Pat. No. 4,851,229 to Magruder et al., U.S. Pat. No. 5,011,692 to Fujioka et al., U.S. Pat. No. 5,017,381 to Maruyama et al., U.S. Pat. No. 5,229,135 to Philippon et al., and U.S. Pat. No. 5,840,329 to Bai disclose preparation of pulsatile release systems. Some other devices are disclosed in U.S. Pat. No. 4,871,549 to Ueda et al. and U.S. Pat. Nos. 5,260,068; 5,260,069; and 5,508,040 to Chen. U.S. Pat. Nos. 5,229,135 and 5,567,441 both to Chen disclose a pulsatile release system consisting of pellets coated with delayed release or water insoluble polymeric membranes incorporating hydrophobic water insoluble agents or enteric polymers to alter membrane permeability. U.S. Pat. No. 5,837,284 to Mehta et al. discloses a dosage form which provides an immediate release dose of methylphenidate upon oral administration, followed by one or more additional doses spread over several hours.
There is a well-established circadian variation in frequency of onset of cardiovascular events including ventricular arrhythmias, stroke, angina, and myocardial infarction. The peak frequency of such events is exhibited in the morning hours, theoretically in conjunction with the morning surge in systolic blood pressure and heart rate. There is also some evidence of a secondary peak in frequency of such events in the late afternoon or evening hours. Although there is some evidence which suggests that long acting propranolol may blunt the circadian variability of sudden cardiac death, it does not appear to attenuate early morning increases in blood pressure observed in hypertensive patients. Thus it would be physiologically advantageous to tailor plasma concentrations of propranolol to the typical circadian patterns of blood pressure and heart rate.
Chronotherapeutics is a means of proportioning plasma drug concentrations during a 24 hour period, relative to the biological rhythm determinates of disease activity. The objective of chronotherapy is to deliver the drug in higher concentrations during the time of greatest need, and in lesser concentrations when the need is less. The dosage forms disclosed in the prior arts above are not specifically designed to provide drug release profiles varying predictably in time over 24 hours, i.e., in a circadian rhythm fashion to effectively treat cardiovascular diseases. The dosage forms of the present invention, Propranolol Hydrochloride ER Capsules, 80, 120, and 160 mg), which are typically administered at bedtime, i.e., at about 10:00 PM, are novel formulations designed to provide reductions in blood pressure and heart rate over 24 hours, including optimal protection in the early morning hours when patients are most vulnerable to cardiovascular events. At steady state, blood levels of propranolol begin to increase approximately 4 hours after bedtime administration of these capsules and rise progressively over the early morning hours to reach peak plasma concentrations approximately 14 hours after dosing. These capsules produce peak plasma propranolol levels that rise slowly to attenuate the rapid increase in blood pressure and heart rate that precedes and follows waking. This increase is associated with circadian variation in catecholamine secretion and in rennin release. The rise in plasma propranolol concentration after dosing with these capsules parallel the circadian rise in morning blood pressure associated with target organ damage in patients with hypertensive and ischemic cardiovascular disease.
Propranolol [1-(isopropyl amino)-3-(1-naphthyloxy)-2-propanol] is a betaadrenergic blocking agent and as such is a competitive inhibitor of the effects of catecholamines at beta-adrenergic receptor sites. The principal effect of propranolol is to reduce cardiac activity by diminishing or preventing beta-adrenergic stimulation. By reducing the rate and force of contraction of the heart, and decreasing the rate of conduction of impulses through the conducting system, the response of the heart to stress and exercise is reduced. These properties are used in the treatment of angina in an effort to reduce the oxygen consumption and increase the exercise tolerance of the heart. Propranolol is also used in the treatment of cardiac arrhythmias to block adrenergic stimulation of cardiac pacemaker potentials. Propranolol is also beneficial in the long term treatment of hypertension. Other uses of propranolol are in the treatment of migraine and anxiety.
SUMMARY OF THE INVENTION
The preparation of the dosage form of the present invention is fully described in U.S. Pat. No. 6,500,454 assigned to Eurand Pharmaceuticals, Ltd., which is incorporated here by reference in its entirety. The dosage form, a hard gelatin capsule, is a timed, sustained release multi-particulate dosage form comprising a propranolol core having a first membrane of a sustained release polymer and a second membrane of a mixture of water insoluble polymer and an enteric polymer (2 nd or outer coating), wherein the water insoluble polymer and the enteric polymer may be present at a weight ratio of from 10:1 to 1:2, and the total weight of the coatings is 10 to 60 weight % based on the total weight of the coated beads. In some cases depending on the type of drug release profile needed, an immediate release component may be included to provide a modified, timed, sustained release dosage form. When administered at bedtime, the dosage form comprising Timed, Sustained Release Capsule, commercially known as TSR Formulation XL, is designed to provide reductions in blood pressure and heart rate over 24 hours, including optimal protection in the early morning hours when patients are most vulnerable to cardiovascular events. At steady state, blood levels of propranolol begin to increase approximately 4 hours after bedtime administration of TSR Formulation XL and rise progressively over the early morning hours to reach peak plasma concentrations approximately 14 hours after dosing. TSR Formulation XL produces peak plasma propranolol levels that rise slowly to attenuate the rapid increase in blood pressure and heart rate that precedes and follows waking. This increase is associated with circadian variation in catecholamine secretion and in rennin release. The rise in plasma propranolol concentration after dosing with TSR Formulation XL parallels the circadian rise in morning blood pressure associated with target organ damage in patients with hypertensive and ischemic cardiovascular disease.
BRIEF DESCRIPTION OF THE FIGURES
The invention will be described in further detail with reference to the accompanying Figures wherein:
FIG. 1 shows in vitro drug release profiles from Propranolol HCl TSR Capsules, 80, 120, and 160 mg, used in the pivotal clinical studies.
FIG. 2 shows mean propranolol concentration versus time plots for 80 mg, 120 mg and 160 mg dosage strengths of TSR Formulation following a single administration of the drug product.
FIG. 3 a shows the mean propranolol plasma concentration over time (0-80 hours) during multiple dosing of either Inderal® LA 160 mg or TSR Formulation 160 mg (i.e., at steady state).
FIG. 3 b shows the mean propranolol plasma concentration over time (24 hours) during multiple dosing of either Inderal® LA 160 mg or TSR (RelPro) Formulation 160 mg (i.e., at steady state).
DETAILED DESCRIPTION OF THE INVENTION
The active core of the novel dosage form of the present invention may comprise an inert particle or an acidic or alkaline buffer crystal, which is coated with a propranolol-containing film-forming formulation and preferably a water-soluble film forming composition to form a water-soluble/dispersible particle. Alternatively, the active core may be prepared by granulating and milling and/or by extrusion and spheronization of a polymer composition containing propranolol. Generally, the individual polymeric coating on the active core will be from 1 to 50% based on the weight of the coated particle. Those skilled in the art will be able to select an appropriate amount of propranolol for coating onto or incorporating into the core to achieve the desired dosage. In one embodiment, the inactive core may be a sugar sphere, a buffer crystal or an encapsulated buffer crystal, such as calcium carbonate, sodium bicarbonate, fumaric acid, tartaric acid, etc. Buffer crystals are useful to alter the microenvironment.
In accordance with one embodiment of the present invention, the water soluble/dispersible drug-containing particle is first coated with a water insoluble polymer (1 st or inner coating), and further coated with a mixture of a water insoluble polymer and an enteric polymer (2 nd or outer coating). The water insoluble polymer and enteric polymer may be present at a weight ratio of from 10:1 to 1:2, more preferably 2:1 to 1:1, and the total weight of the coatings is 10 to 60 weight % based on the total weight of the coated beads. The polymeric coatings typically contain plasticizers and may be applied from aqueous and/or solvent based systems.
The composition of the outer layer and the individual weights of the inner and outer layers of the polymeric membrane are optimized for achieving desired drug release profiles. The unit dosage form according to certain embodiments of the present invention may comprise an immediate release bead population which provides an immediate release component of propranolol to act as a bolus dose.
The invention also provides a method of making a timed, sustained release dosage form comprising the steps of:
1. preparing an active-containing core by coating an inert particle such as a nonpareil seed, an acidic buffer crystal or an alkaline buffer crystal, with propranolol and polymeric binder or by granulation and milling or by extrusion/spheronization to form an immediate release (IR) bead;
2. coating the core with a plasticized solution or suspension of a water insoluble polymer to form sustained release (SR) coated drug particle;
3. coating the SR coated particle with a mixture of plasticized water insoluble and enteric polymers to form a Timed Sustained Release (TSR) coated drug particle; and filling capsules with TSR particles to produce Timed, Sustained Release (TSR) capsules.
The release profile for TSR beads can be determined according to the following procedure:
Dissolution testing is conducted with a USP Apparatus 2 (Paddles at 50 rpm) using a two-stage dissolution medium (first 2 hours in 700 mL 0.1N HC1 at 37° C. followed by dissolution at pH=6.8 obtained by the addition of 200 mL of pH modifier). Drug release with time is determined by HPLC on samples pulled at selected intervals.
The TSR Beads prepared in accordance with present invention release not more than 20%, more preferably not more than 10%, and most preferably not more than 5% in 2 hours, about 5-35%, more preferably about 5-25%, and most preferably about 5-15% in 4 hours, about 10-60%, more preferably about 20-45%, and most preferably about 25-35% in 6 hours, about 4090%, more preferably about 50-80%, and most preferably about 55-70% in 10 hours, and not less than 60%, more preferably not less than 70%, and most preferably not less than 75% in 16 hours.
In accordance with the present invention, the desired release properties are obtained as a result of the different characteristics of the two coating layers. The inner layer membrane provides sustained or extended drug release over several hours, while the second or outer membrane provides a lag time of three to four hours. Typical release profiles for SR beads (ethylcellulose coated drug particle) and TSR beads when tested by the two-stage dissolution medium are provided in Table 1, below:
TABLE 1
SR Beads
TSR Beads
Time
(% Propranolol Released)
1 hr
11.2
0.0
2 hr
32.1
0.1
3 hr
39.8
1.1
4 hr
52.3
8.6
5 hr
62.3
18.3
6 hr
69.2
27.4
8 hr
79.4
44.5
10 hr
84.6
58.4
12 hr
90.0
68.8
16 hr
95.6
90.0
It is also possible that the TSR Capsule may optionally also contain a population of Immediate Release (IR) beads or particles to provide an immediate release component of active to act as a bolus dose in addition to the timed, sustained release of active provided by the TSR beads. These dosage forms provide a Modified Timed Sustained Release (MTSR) profile.
An aqueous or a pharmaceutically acceptable solvent medium may be used for preparing drug containing core particles. The type of film forming binder that is used to bind propranolol to the inert sugar sphere is not critical but usually water-soluble, alcohol-soluble or acetone/water soluble binders are used. Binders such as polyvinylpyrrolidone (PVP), polyethylene oxide, hydroxypropyl methylcellulose (HPMC), hydroxypropylcellulose (HPC), polysaccharides, such as dextran, and corn starch may be used at concentrations of from about 0.5 to 10 weight %. Propranolol may be present in the coating formulation in solution form or may be suspended at a solids content up to about 35 weight % depending on the viscosity of the coating formulation.
Dissolution rate controlling polymers suitable for incorporating in the formulation for producing granules by high shear or fluid bed granulation or by dry granulation include high molecular weight hydroxypropyl methylcellulose, hydroxypropyl cellulose, ethyl cellulose, sodium carboxymethyl cellulose, alginic acid, polymethylmethacrylate copolymers and polyvinyl acetate/crotonic acid copolymer or combinations thereof. Acidic buffers, which help maintain an acidic microenvironment within drug containing particles, include fumaric acid, tartaric acid, maleic acid, succinic acid and mixtures thereof. An acidic microenvironment helps dissolve basic drugs with poor solubility at the intestinal pHs and become available for absorption. Examples of alkaline buffers include sodium bicarbonate, calcium carbonate, and sodium dihydrogen phosphate.
Propranolol, a binder such as PVP, a buffer, a dissolution rate controlling polymer (if used), and optionally other pharmaceutically acceptable excipients are blended together in a high shear granulator such as Fielder or a fluid bed granulator such as Glatt GPCG 5 and granulated to form agglomerates by adding/spraying a granulating fluid such as water or alcohol and dried. The wet mass can be extruded and spheronized to produce spherical particles (beads) using an extruder/marumerizer. In these embodiments, the drug load could be as high as 90% by weight based on the total weight of the extruded/spheronized core. The blend can also be used to produce dry granules by slugging in a tablet press or a chilsonator, without the addition of any granulating fluid.
The active containing cores (beads, pellets or granular particles) thus obtained may be coated with one or two layers of polymers to obtain desired release profiles with or without a lag time. The inner layer membrane, which largely controls the rate of release following imbibition of water or body fluids into the core, comprises a water insoluble polymer, such as ethylcellulose, at a thickness of from 1 weight % up to 6 weight %, preferably from 1.5 to 4% and most preferably about 2%, depending on the solvent or latex suspension based coating formulation used.
The outer membrane, which largely controls the lag time of up to 6 hours, comprises an enteric polymer and a water insoluble polymer at a thickness of 10 to 60, preferably from 10 to 56 weight % based on the total weight of the coated beads. The ratio of water insoluble polymer to enteric polymer may vary from 10:1 to 1:2, preferably from 2:1 to 1:1.
Representative examples of water insoluble polymers useful in the invention include cellulose derivatives (e.g. ethylcellulose), polyvinyl acetate (Kollicoat SR30D from BASF), neutral copolymers based on ethyl acrylate and methylmethacrylate, copolymers of acrylic and methacrylic acid esters with quaternary ammonium groups, such as Eudragit NE, RS or RS30D, RL or RL30D and the like.
Representative examples of enteric polymers useful in the invention include esters of cellulose and its derivatives (cellulose acetate phthalate, hydroxypropyl methylcellulose phthalate, hydroxypropyl methylcellulose acetate succinate), polyvinyl acetate phthalate, pHsensitive methacrylic acid-methamethacrylate copolymers and shellac. These polymers may be used as a dry powder or an aqueous dispersion. Some commercially available materials that may be used are methacrylic acid copolymers sold under the trademark Eudragit (L100, S100, L30D) manufactured by Rhom Pharma, Cellacefate (cellulose acetate phthalate) from Eastman Chemical Co., Aquateric (cellulose acetate phthalate aqueous dispersion) from FMC Corp. and Aqoat (hydroxypropyl methylcellulose acetate succinate aqueous dispersion) from Shin Etsu K.K.
Both enteric and water insoluble polymers used in forming the membranes are usually plasticized. Representative examples of plasticizers that may be used to plasticize the membranes include triacetin, tributyl citrate, triethyl citrate, acetyl tri-n-butyl citrate diethyl phthalate, castor oil, dibutyl sebacate, acetylated monoglycerides and the like or mixtures thereof. The plasticizer may comprise about 3 to 30 wt. % and more typically about 10 to 25 wt. % based on the polymer. The type of plasticizer and its content depends on the polymer or polymers, nature of the coating system (e.g., aqueous or solvent based, solution or dispersion based and the total solids).
In general, it is desirable to prime the surface of the particle before applying the pulsatile release membrane coatings or to separate the different membrane layers by applying a thin hydroxypropyl methylcellulose (HPMC) (Opadry Clear) film. While HPMC is typically used, other primers such as hydroxypropylcellulose (HPC) can also be used.
The membrane coatings can be applied to the core using any of the coating techniques commonly used in the pharmaceutical industry, but fluid bed coating is particularly useful.
The present invention is applied to multi-dose forms, i.e., drug products in the form of multi-particulate dosage forms (pellets, beads, granules or mini-tablets) or in other forms suitable for oral administration.
The following non-limiting examples illustrate the capsule dosage forms manufactured in accordance with the invention, which exhibit in vitro drug release profiles, similar to that predicted by performing modeling exercises, and in vivo plasma concentrations following circadian rhythm pharmaco-dynamic profile of angina attacks. Such dosage forms when administered at bed time, would enable maintaining drug plasma concentration at a level potentially beneficial in minimizing the occurrence of heart attacks in the early hours of the morning.
EXAMPLES
Modified Timed, Sustained Release (MTSR) capsules of Propranolol Hydrochloride may contain a mixture of two sets of beads: The first set is referred to as immediate release (IR) Beads and are designed to provide a loading dose by releasing all of the drug within the first hour, preferably within the first 30 minutes. The second set is referred to as Timed Sustained Release (TSR) Beads and are designed to release the remainder of the dose slowly over a period of 12-15 hours after a 3-5-hour lag time. The TSR Beads are produced by applying an inner layer of sustained release coating (with a dissolution rate controlling polymer such as ethylcellulose) (producing IntR Beads, intermediate release beads) and then an outer layer of pulse coating (with a blend of an enteric polymer such as HPMCP and a water-insoluble polymer such as ethylcellulose) on IR Beads. The two sets of beads (IR and TSR) when filled into capsule shells at an appropriate ratio will produce the target circadian rhythm release profile required for maintaining drug plasma concentrations at potentially beneficial levels in minimizing the occurrence of heart attacks. Alternatively, the capsules may comprise only the TSR Beads, the capsules containing only the TSR Beads are referred to as TSR Formulation. It is well known that the blood pressure begins to drop as the night advances, and consequently, only the Formulations containing only the TSR beads for oral administration are described below.
Example 1
Propranolol HCl (45.2 kg) was slowly added to an aqueous solution of polyvinylpyrrolidone (2.34 kg Povidone K-30) and mixed well. # 25-30 mesh sugar spheres (31.6 kg) were coated with the drug solution in a Glatt fluid bed granulator. The drug containing pellets were dried, and a seal coat of Opadry Clear (2% w/w) was first applied (batch size: 80.75 kg). The inner sustained release coating was applied to the active particles (73.7 kg) by spraying a solution of ethylcellulose and diethyl phthalate in 98/2 acetone/water. The outer coating of a blend of ethylcellulose and HPMCP plasticized with diethyl phthalate was sprayed onto the active particles having the inner coating to produce TSR Beads (batch size: 82.5 kg). These TSR Beads were filled into hard gelatin capsules using an MG capsule filling equipment to produce Propranolol hydrochloride TSR Capsules, 80, 120, and 160 mg.
These Propranolol TSR Capsules were tested for drug release profiles by the two-stage dissolution method, wherein capsules were dissoluted at pH 1.5 in 700 mL 0.1N HCl for two hours followed by testing at pH 6.8 in 900 mL obtained by adding 200 mL of concentrated buffer modifier. FIG. 1 presents the drug release profiles from Propranolol Hydrochloride TSR Capsules, 80, 120, and 160 mg, used in the pivotal clinical studies.
Example 2
A double-blind, randomized, placebo-controlled, 4-period crossover study to assess the efficacy and dose proportionality of TSR Formulation 80 mg, 120 mg, and 160 mg in 39 healthy male and female subjects of ages 18 to 40 was carried out. In each study period a single dose of one strength of TSR Formulation or placebo was administered at approximately 10:00 PM. There was a minimum of 7 days between the administration of each dose of TSR Formulation or placebo. Efficacy was assessed by the mean change in post-exercise heart rate, heart rate pressure product, and systolic blood pressure from pre-dose to Hour 24 post-dose (trough) assessments. The secondary efficacy variable was the mean change in post-exercise heart rate from pre-dose to Hour 12. Post-exercise heart rate was used as a surrogate marker for antianginal efficacy.
Analyses for concentrations of total plasma propranolol (conjugated and unconjugated) on the blood samples collected were carried out using a validated high performance liquid chromatography (HPLC) method. Plasma samples were collected pre-dose and up to 72 hours post-dose. The limit of quantitation was 2 ng/mL. FIG. 2 displays mean propranolol concentration versus time plots for 80 mg, 120 mg and 160 mg dosage strengths of TSR Formulation following a single administration of the drug product. Maximum plasma propranolol concentrations (C max ) occurred at about 12 hours post-dose for the 80 mg, 120 mg, and 160 mg dose groups. After 12 hours post-dose, plasma propranolol concentrations decreased at a consistent and similar rate in all dose groups. The absorption lag time (T lag ) and time to maximum drug concentration (T max ) were similar across all TSR Formulation dose groups. Table 2 summarizes the pharmacokinetic parameters for this study.
TABLE 2
Summary of Pharmacokinetic Parameters—Pharmacokinetic Population
TSR Formulation
80 mg
120 mg
160 mg
Parameter/Statistic
(N = 36)
(N = 36)
(N = 36)
AUC( 0–T )(ng · hr/mL) a
N
36
36
36
Mean
1442.6
2270.1
3417.1
SD
844.19
1230.62
2047.40
Median
1220.8
2102.2
3047.2
Minimum
551.8
594.3
1211.1
Maximum
3792.1
5928.7
11596.2
AUC( 0–∞ )(ng · hr/mL)
N
36
36
36
Mean
1568.5
2412.6
3589.0
SD
865.20
1287.41
2080.77
Median
1422.9
2180.1
3199.5
Minimum
605.1
646.6
1291.1
Maximum
3994.0
6660.0
12157.2
C max (ng/mL)
N
36
36
36
Mean
80.5
130.0
177.2
SD
31.53
52.30
70.62
Median
75.8
117.0
171.0
Minimum
30.1
41.5
72.4
Maximum
155.0
249.0
426.0
t 1/2 (hr)
N
36
36
36
Mean
9.5
8.5
9.1
SD
5.05
4.7
4.35
Median
8.1
7.1
8.8
Minimum
3.3
3.2
2.8
Maximum
22.7
20.2
21.3
T max (hr)
N
36
36
36
Mean
12.2
12.8
12.8
SD
1.93
2.46
2.72
Median
12.0
12.0
12.0
Minimum
8.0
10.0
8.0
Maximum
20.0
20.0
24.0
T lag (hr)
N
36
36
36
Mean
2.2
2.1
1.9
SD
1.05
0.89
0.67
Median
2.0
2.0
2.0
Minimum
0.0
0.0
0.0
Maximum
4.0
4.0
4.0
K el (1/hr)
N
36
36
36
Mean
0.0965
0.1076
0.0958
SD
0.05090
0.05384
0.05125
Median
0.0862
0.0987
0.0788
Minimum
0.0305
0.0343
0.0326
Maximum
0.2107
0.2193
0.2517
a t is the last time point with measurable propranolol concentration
Linear regression analyses on untransformed pharmacokinetic parameters showed dose proportionality and a linear dose-response relationship between the TSR Formulation dosage strengths and the pharmacokinetic parameters AUC 0-T (area under the concentration-time curve to the last measurable time point calculated by the linear trapezoidal rule), AUC 0-∞ (are under the concentration-time curve to infinity), and C max . Results of linear regression and ANOVA after log-transformation and dose-normalization confirmed a dose proportional relationship between AUC 0-T , AUC 0-∞ , and C max and TSR Formulation 80 mg, 120 mg, and 160 mg doses.
Regarding efficacy, maximum decreases in systolic blood pressure were noted at 8-10 hours post-dose in all treatment groups. Maximum decreases in diastolic blood pressure were noted at 8-10 hours post-dose in the TSR Formulation 120 mg and placebo groups and at 14 hours post-dose in the TSR Formulation 80 mg and 160 mg groups. Maximum decreases in heart rate were observed at 10 hours post-dose in all treatment groups. Mean changes in systolic and diastolic blood pressure and heart rate showed increases from pre-dose values at 72 hours post-dose in all treatment groups. No subject experienced postural hypotension during the study.
Only the TSR Formulation 80 mg dose group showed a statistically significant decrease in the adjusted mean change in exercise-induced heart rate from baseline at 24 hours post-dose, relative to placebo (primary end point) and in 12-hour post-exercise heart rate (secondary end point). No dose response was observed for heart rate. Statistically significant changes, relative to placebo, were observed for two primary end points: hour 24 heart rate-pressure product seen for the lowest and highest doses and hour 24 heart rate at the lowest dose of TSR Formulation; these data support the efficacy of TSR formulations in the prevention and treatment of angina. Demonstration of blunting of exercise response to beta blockade for the 12-hour post p.m. dosing exercise challenge also supports the efficacy of the TSR Formulation in protection against morning ischemic events.
Example 3
A randomized, open-label, two-period crossover study to evaluate the single and multiple dose bioavailability and safety of TSR Formulation 160 mg compared to Inderal® LA 160 mg capsules was carried out. The primary objective of this study was to evaluate the relative bioavailability of TSR Formulation 160 mg to Inderal® LA 160 mg as assessed by an ANOVA on AUCs after single and multiple dose administrations. The secondary objective was to explore the pharmacokinetics of TSR Formulation and Inderal® LA after single and multiple dose administrations. Safety and tolerability were measured by evaluating adverse events, laboratory values, physical examinations, electrocardiograms, and vital signs.
Subjects were healthy, adult, males between 18 and 45 years of age who met the study eligibility criteria. In Period 1 of the study, following a 4-hour fasting period on Day 1 , subjects received a single dose of the study drug (TSR Formulation or Inderal® LA) between 9:30 and 10:30 PM. Serial blood samples for plasma total propranolol determinations were collected for 72 hours. Subjects received a daily dose of their Period 1 drug on Days 4 to 8 and 24-hour trough blood samples were collected. A seven-day washout period followed, and the same procedures were followed for Period 2 with the other study drug as determined by the sequence to which the subjects were randomized. Analyses for concentrations of total plasma propranolol (conjugated and unconjugated) on the blood samples collected were carried out using a validated high performance liquid chromatography (HPLC) method. The limit of quantitation was 2 ng/mL.
Plots of the mean propranolol plasma concentration over time following a single dose of 160 mg propranolol TSR Formulation or 160 mg Inderal® LA are presented in FIG. 3 a . Following a single dose of TSR Formulation 160 mg there was a delayed release of propranolol for 2 to 4 hours, whereas release of propranolol following a single dose of Inderal® LA 160 mg was almost immediate. Within 3 hours after administration of Inderal® LA, mean plasma propranolol concentrations increased to approximately 50% of the mean maximum propranolol concentration. In contrast, following administration of TSR Formulation, 50% of the mean maximum plasma propranolol concentration was not reached until approximately 7 hours post administration. Between 10 hr and 12 hr post dose, mean plasma concentrations in the Inderal® LA group remained relatively constant (range 122.8 ng/mL to 128.2 ng/mL) while mean plasma concentrations in the TSR Formulation group steadily increased (range 146.9 ng/mL to 174.8 ng/mL). The time to maximum plasma levels of propranolol (T max ) was 10.5 hr and 11.9 hr for subjects administered Inderal® LA and TSR Formulation, respectively. The C max values were 149.1 ng/mL for Inderal® LA and 186.5 ng/mL for TSR Formulation, respectively. At 24 hr post-dose, the mean plasma concentrations were 51.8 ng/mL and 67.3 ng/mL in the Inderal® LA and TSR Formulation groups, respectively. After 24 hr post-dose, plasma concentrations decreased at a consistent and similar rate in both groups. The elimination half-life (t 1/2 ) was similar for both formulations.
A summary of the single dose pharmacokinetic parameters of AUC 0-T , AUC 0-∞ and C max following an Analysis of Variance (ANOVA) is given in Table 3. The adjusted mean C max values were 131.0 ng/mL and 171.3 ng/mL for subjects administered Inderal® LA and TSR Formulation, respectively.
TABLE 3
Summary of Analysis of Variance on
Single Dose Pharmacokinetic Parameters
Ratio (TSR
Formulation/
Inderal ®
Parameter/
Inderal ® LA
TSR Formulation
LA)
Statistic 1
160 mg (N = 35)
160 mg (N = 35)
(N = 35)
AUC 0–T
(ng · hr/mL)
Adjusted Mean
2588.7
2943.9
1.1
90% CI
(2399.77, 2792.44)
(2729.06, 3175.62)
(1.02, 1.27)
AUC 0–∞
(ng · hr/mL)
Adjusted Mean
2604.8
2962.7
1.1
90% CI
(2415.90, 2808.43)
(2747.90, 3194.37)
(1.02, 1.27)
C max (ng/mL)
Adjusted Mean
131.0
171.3
1.3
90% CI
(117.52, 146.12)
(153.66, 191.04)
(1.12, 1.53)
1 Adjusted mean and 90% CI calculated from ANOVA on log-transformed parameter with subject, period, sequence, and treatment as fixed effects. Adjusted means and CIs displayed have been transformed from the log to the arithmetic scale.
CI: Confidence Interval
FIG. 3 b displays the mean propranolol plasma concentration over time during multiple dosing of either Inderal® LA 160 mg or TSR Formulation 160 mg (i.e., at steady state). Following multiple doses of TSR Formulation 160 mg, there was a delayed release of propranolol for 2 to 6 hours, whereas the release of propranolol for Inderal® LA occurred after a slight delay of less than 1 hour. At steady state, the mean maximum plasma propranolol concentrations (C max SS ) were 229.9 ng/mL and 248.3 ng/mL for subjects administered Inderal® LA and TSR Formulation, respectively. Mean minimum plasma propranolol concentrations (C min ) at steady state were 56.3 ng/mL and 58.9 ng/mL for subjects administered Inderal® LA and TSR Formulation, respectively. The mean time to observed maximum propranolol concentration at steady state (T max SS ) was approximately 2 hours greater for TSR Formulation (12.6 hr) than for Inderal® LA (10.9 hr). Similarly, the mean time to the observed minimum plasma propranolol concentration at steady state (T min ) was approximately 2 hours greater for TSR Formulation (7.3 hr) than for Inderal® LA (5.1 hr). Steady state plasma propranolol concentrations for both TSR Formulation and Inderal® LA were attained after 2 days of dosing during the multiple dosing period. Both formulations showed similar accumulation at steady state and propranolol concentrations fluctuated in a similar manner over the dosing interval.
Table 4 describes a summary of the results of the ANOVA performed on the pharmacokinetic parameters AUC o-TSS , C AV SS , R ac SS , and Fi SS .
TABLE 4
Summary of Analysis of Variance on
Steady State Pharmacokinetic Parameters
Ratio
(Formulation
TSR/
Inderal ®
Parameter/
Inderal ® LA
Formulation TSR
LA)
Statistic 1
160 mg (N = 35)
160 mg (N = 35)
(N = 35)
AUC 0–τSS
(ng · hr/mL)
Adjusted Mean
3115.0
3325.6
1.1
90% CI
(2928.62, 3313.28)
(3126.56, 3537.22)
(.98, 1.16)
C AV SS (ng/mL)
Adjusted Mean
128.7
137.5
1.1
90% CI
(121.02, 136.92)
(129.22, 146.20)
(.98, 1.17)
R ac SS
(AUC 0–τSS /
AUC 0–τ DAY 1 )
Adjusted Mean
1.7
1.7
1.0
90% CI
(1.54, 1.94)
(1.47, 1.86)
(0.81, 1.13)
Fi SS (C max −
C min /C av )
Adjusted Mean
114.3
126.7
1.1
90% CI
(105.38, 123.93)
(116.87, 137.45)
(0.99, 1.24)
1 Adjusted mean and 90% CI calculated from ANOVA on log-transformed parameter with subject, period, sequence, and treatment as fixed effects. Adjusted means and CIs displayed have been transformed from the log to the arithmetic scale.
CI: Confidence Interval
Example 4
A randomized, double-blind, parallel, placebo-controlled, multicenter trial to study the efficacy, safety and steady state pharmacokinetics of 80 mg, 120 mg, 160 mg, and 640 mg TSR Formulation in patients with essential hypertension was carried out. The primary objective of this study was to assess the efficacy of the TSR Formulation in subjects with essential hypertension by evaluating the mean change from Baseline to Week 8 in morning sitting diastolic pressure. Subjects were randomized to one of the five double-blind treatment groups: placebo, TSR Formulation 80 mg/day, TSR Formulation 120 mg/day, TSR Formulation 160 mg/day, and TSR Formulation 640 mg/day taken once daily before bedtime. During Week 1 and Week 2 subjects were up titrated to the appropriate dose for 6 weeks, and then they were down titrated for the last two weeks of the study.
Morning sitting diastolic pressure, the measure of primary efficacy, decreased from Baseline to Endpoint for the placebo and all four TSR Formulation groups. Statistically significant differences in the magnitude of the decrease between the placebo group and the 120 mg, 160 mg, and 640 mg TSR Formulation groups were observed. Statistical trends were observed for the 80 mg TSR Formulation dose group. These results demonstrate that the TSR Formulation, administered once daily at bedtime in dosage strengths of 80 mg to 640 mg propranolol is an effective antihypertensive agent. | A unit dosage form, such as a capsule or the like for delivering drugs into the body in a circadian release fashion, is comprising of one or more populations of propranolol-containing particles (beads, pellets, granules, etc.). Each bead population exhibits a pre-designed rapid or sustained release profile with or without a predetermined lag time of 3 to 5 hours. Such a circadian rhythm release cardiovascular drug delivery system is designed to provide a plasma concentration—time profile, which varies according to physiological need during the day, i.e., mimicking the circadian rhythm and severity/manifestation of a cardiovascular disease, predicted based on pharmaco-kinetic and pharmaco-dynamic considerations and in vitro/in vivo correlations. | 0 |
FIELD OF THE INVENTION
The present invention relates to a process for the stereoselective preparation of phenylisoserine derivatives of the general formula ##STR1## in which R is a phenyl radical or a tert-butoxy radical and R 1 is a protecting group for the hydroxyl group.
DESCRIPTION OF THE INVENTION
In general formula (I), R 1 is more particularly a methoxymethyl, 1-ethoxyethyl, benzyloxymethyl, (β-trimethylsilylethoxy)methyl, tetrahydropyranyl or 2,2,2-trichloroethoxycarbonyl radical. The radical R 1 is preferably the 1-ethoxyethyl radical.
The procedure of general formula (I) are useful for preparing the baccatin III and 10-deacetylbaccatin III derivatives of the general formula ##STR2## in which R is a phenyl radical or a tert-butoxy radical and R 2 is a hydrogen atom or an acetyl radical.
The products of general formula (II) in which R is a phenyl radical correspond to taxol and 10-deacetyltaxol and the products of general formula (II) in which R is a tert-butoxy radical correspond to those described in European patent 253 738.
The products of general formula (II), and in particular the product of general formula (II) in which R 2 is a hydrogen atom and which is in the 2'R,3'S form, have particularly valuable antitumoral and antileukaemic properties.
The products of general formula (II) can be obtained by reacting a product of general formula (I) with a taxane derivative of the general formula ##STR3## in which R 3 is an acetyl radical or a protecting group for the hydroxyl group and R 4 is a protecting group for the hydroxyl group, and then replacing the protecting groups R 1 and R 4 and, if appropriate, R 3 with a hydrogen atom under the conditions described by J-N. DENIS et al., J. Amer. Chem. Soc., 110(17) 5917-5919 (1988).
It is possible to react the racemic product of general formula (I) and subsequently to separate the diastereoisomers of the product of general formula (II), or else to react each of the enantiomers of the product of general formula (I) separately with the product of general formula (III).
According to the present invention, the acid of general formula (I) (syn form, racemic mixture) can be obtained from benzylamine.
By reaction with an agent for introducing a benzoyl or t-butoxycarbonyl group, benzylamine is converted to a product of the general formula ##STR4## in which R is as defined above, which, after double anionisation, is reacted with acrolein to give the alcohol of the general formula ##STR5## in which R is as defined above, in the form of a syn and anti mixture containing essentially the syn form: ##STR6##
The alcohol of general formula (Va), previously separated from the mixture of the syn and anti forms, is oxidized to the acid of general formula (I) after protection of the hydroxyl group.
The product of general formula (IV) is generally obtained by reaction with an agent for introducing a benzoyl or t-butoxycarbonyl group, preferably benzoyl chloride or di-t-butyl dicarbonate, as the case may be. The reaction is generally carried out in an organic solvent such as methylene chloride, in the presence of an inorganic base such as sodium hydroxide or sodium bicarbonate or carbonate, or an organic base such as triethylamine or 4-dimethylaminopyridine, at a temperature of between 0° and 50° C.
The double anionization of the product of general formula (IV) is generally carried out using equivalents of an organolithium derivative such as s-butyllithium, in an anhydrous organic solvent such as tetrahydrofuran, at a temperature below -50° C. and preferably of about -78° C.
The reaction of acrolein with the dianion of the product of formula (IV) is generally carried out by adding acrolein, preferably freshly distilled, to the solution of the dianion, previously cooled to about 100° C. After hydrolysis, the product of general formula (V) is obtained in the form of a mixture of the syn and anti diastereoisomers, from which the syn form of formula (Va) is separated by chromatography.
Protection of the hydroxyl group of the alcohol of general formula (Va) is effected under the normal conditions for the preparation of ethers and acetals, for example in accordance with the processes described by J-N. DENIS et al., J. Org. Chem., 51, 46-50 (1986).
Oxidation of the protected alcohol of general formula (Va) is preferably carried out by means of an alkali metal periodate (sodium periodate), in the presence of a catalytic amount of a ruthenium salt (RuCl 2 ) and sodium bicarbonate, in an aqueous-organic medium such as, for example, a carbon tetrachloride/acetonitrile/water mixture. The reaction is generally carried out at a temperature of about 20° C.
Oxidation can also be carried out by means of potassium permanganate, for example in the presence of adogen in a pentane/water mixture, or in the presence of aliquat or dicyclohexyl-18 crown-6 in methylene chloride or in a pyridine/water mixture. It is also possible to use triethylbenzylammonium permanganate in the presence of pyridine in methylene chloride.
The product of general formula (I) (syn form, racemic mixture) can be resolved into its enantiomers, and in particular into its 2R,3S enantiomer, for example in accordance with the process described by D. Petterson, Thesis at the University of Lund (Sweden), pages 27-28 (1989).
EXAMPLES
The following Examples, which are given without implying a limitation, show how the invention can be put into practice.
EXAMPLE 1
218.5 μl (214.3 mg, 2 mmol) of benzylamine and 10 cm 3 of dry methylene chloride are introduced under argon into a 50 cm 3 single-necked flask surmounted by a condenser and equipped with a magnetic stirring system. 418 μl (303 mg, 3 mmol) of triethylamine and, in small portions (exothermic reaction), 524 mg (2.4 mmol) of pure di-t-butyl dicarbonate are added to the solution obtained. When the addition is complete, the reaction is left to proceed for 4 hours at a temperature of about 20° C. and the resulting reaction mixture is then diluted with 40 cm 3 of methylene chloride. The organic phase is washed 4 times with 5 cm 3 of water and once with 5 cm 3 of a saturated aqueous solution of sodium chloride. The organic phase is dried over anhydrous sodium sulphate. After filtration, the methylene chloride is driven off under reduced pressure on a rotary evaporator. The residue obtained (505 mg) is purified by chromatography on a column of silica gel using an ethyl acetate/methylene chloride mixture (5/95 by volume) as the eluent. 406 mg (1.96 mmol) of t-butyl benzylcarbamate are thus obtained in the form of a white solid with a yield of 98%, said product having the following characteristics:
melting point: 55.5°-56.5° C. (hexane)
infrared spectrum (film): characteristic absorption bands at 3350, 3315, 3080, 3060, 3040, 3010, 2980, 2960, 2930, 1680, 1550, 1450, 1442, 1395, 1370, 1315, 1290, 1255, 1180, 1140, 1080, 1055, 1035, 950, 930, 918, 865, 770, 750, 725 and 700 cm -1
proton nuclear magnetic resonance spectrum (300 MHz; CDCl 3 ; chemical shifts in ppm; coupling constants J in
Hz) 1.46 (s, 9H); 4.3 (d, J=5.7, 2H); 4.84 (s broad, 1H); 7.22-7.34 (m, 5H)
13 C nuclear magnetic resonance spectrum (CDCl 3 ): 28.38 (CH 3 ); 44.69 (CH 2 ); 79.43 (C); 127.27 (CH); 127.41 (CH); 128.54 (CH); 138.93 (C); 155.84 (C)
EXAMPLE 2
4.2 g (20.3 mmol) of t-butyl benzylcarbamate, 40 cm 3 of anhydrous tetrahydrofuran and 6.5 cm 3 (5.0 g, 43 mmol) of tetramethylethylenediamine (TMEDA) are introduced successively into a 250 cm 3 single-necked flask placed under argon and equipped with a magnetic stirring system. The solution obtained is cooled to 78° C. and 60 cm 3 (60 mmol) of a 1M solution of secondary butyllithium in hexane are then added dropwise. The reaction is left to proceed for 3 hours at this temperature and the mixture is then cooled to -100° C. 3 cm 3 (2.5 g, 44.9 mmol) of freshly distilled acrolein are then added and the reaction is left to proceed for 3 to 4 minutes at this temperature and then for 1 hour at -78° C. The resulting reaction mixture is hydrolyzed at -78° C. with 20 cm 3 of water and then extracted with 2 times 30 cm 3 of ether. The organic phases are combined and then washed twice with 20 cm 3 of water and once with 10 cm 3 of a saturated aqueous solution of sodium chloride. They are then dried over anhydrous sodium sulphate. After filtration, the solvents are driven off under reduced pressure. The residue obtained (11.6 g) is purified on a column of silica gel using a methylene chloride/ether mixture (95/5 by volume) as the eluent. 2.606 g (9.91 mmol) of 1-phenyl-1-t-butoxycarbonylamino-2-hydroxybut-3-ene are obtained with a yield of 49% in the form of a mixture of the syn and anti diastereoisomers in a ratio of 6/1.
The syn diastereoisomer is separated from the anti diastereoisomer by chromatography on a column of silica gel using an ether/hexane/methylene chloride mixture (5/45/50 by volume) as the eluent.
The syn diastereoisomer has the following characteristics:
melting point: 86.5°-88° C. (hexane)
infrared spectrum (film): characteristic absorption bands at 3400, 2975, 2920, 1690, 1500, 1450, 1390, 1365, 1250, 1175, 1080, 1050, 1020, 995, 920, 755 and 700 cm -1
proton nuclear magnetic resonance spectrum (300 MHz; CDCl 3 ; chemical shifts in ppm; coupling constants J in Hz): 1.40 (s, 9H); 1.9 (s broad, 1H); 4.38 (pst, J=4.6 and 4.8, 1H); 4.70 (s broad, 1H); 5.20 (dt, J=1.4 and 10.5, 1H); 5.26 (s broad, 1H); 5.34 (dt, J=1.4 and 17.2, 1H); 5.86 (ddd, J=54, 10.5 and 17.2, 1H); 7.24-7.37 (m, 5H)
13 C nuclear magnetic resonance spectrum (CDCl 3 ) 28.12 (CH 3 ); 58.74 (CH); 75.33 (CH); 79.58 (C); 116.36 (CH 2 ); 126.69 (CH); 127.26 (CH); 128.32 (CH); 137.17 (CH); 139.96 (C); 155.89 (C)
mass spectrum (c.i.) (NH 3 +isobutane): 321 (M + +isobutane); 281 (MH + +NH 3 ); 264 (MH + , parent peak); 246, 225, 208, 190, 164, 124, 106
elemental analysis:
calculated % C 68.41 H 8.04 N 5.32
measured % C 68.15 H 7.98 N 5.34
The anti diastereoisomer has the following characteristics:
infrared spectrum (film): characteristic absorption bands at 3370, 3060, 2975, 2920, 1680, 1530, 1470, 1290, 1250, 1170, 1040, 1000, 930, 900, 870, 840, 755 and 700 cm -1
proton nuclear magnetic resonance spectrum (300 MHz; CDCl 3 ; chemical shifts in ppm; coupling constants J in H 2 ): 1.41 (s, 9H); 1.8 (s broad, 1H); 4.43 (psq, J=0.9 and 4.4, 1H); 4.78 (s broad, 1H); 5.18 (dt, J=1.2 and 10.5, 1H); 5.24 (s broad, 1H); 5.26 (dt, J=1.2 and 17, 1H); 5.71 (ddd, J=5.5, 10.5 and 17, 1H); 7.24-7.36 (m, 5H)
13 C nuclear magnetic resonance spectrum (CDCl 3 ): 28.23 (CH 3 ); 59.22 (CH); 75.33 (CH); 79.85 (C); 117.06 (CH 2 ); 127.29 (CH); 127.56 (CH); 128.33 (CH); 136.27 (CH); 138.14 (C); 155.61 (C)
elemental analysis:
calculated % C 68.41 H 8.04 N 5.32
measured % C 68.43 H 8.14 N 5.08
EXAMPLE 3
526 mg (2.0 mmol) of 1-phenyl-1-t-butoxycarbonylamino-2-hydroxybut-3-ene, syn form, 20 cm 3 of dry methylene chloride, 1.9 cm 3 (20.0 mmol) of distilled ethyl vinyl ether and 50.2 mg (0.2 mmol) of pyridinium p-toluenesulphonate (PPTS) are introduced successively into a 50 cm 3 single-necked flask placed under an argon atmosphere and equipped with a magnetic stirring system. The resulting homogeneous reaction mixture is left to react for 4.5 hours at a temperature of about 20° C. When the reaction is complete, 1 drop of pyridine is added and the reaction mixture is then diluted in 60 cm 3 of methylene chloride. The organic phase is washed twice with water and twice with a saturated aqueous solution of sodium chloride and then dried over anhydrous sodium sulphate. After filtration, the solvents are driven off under reduced pressure on a rotary evaporator. The residue obtained is purified by passage over a column of silica gel using a hexane/ether mixture (8/2 by volume) as the eluent. 580 mg (1.73 mmol) of 1-phenyl-1-t-butoxycarbonylamino-2-(1-ethoxyethoxy)but-3-ene are obtained with a yield of 87% in the form of two epimers in a ratio of 55/45, said product having the following characteristics:
melting point: 66°-72° C.
infrared spectrum (film): characteristic absorption bands at 3370, 2970, 2925, 2875, 1680, 1520, 1495, 1365, 1285, 1250, 1170, 1080, 1050, 1005, 955, 930, 890, 870, 755 and 705 cm -1
proton nuclear magnetic resonance spectrum (300 MHz; CDCl 3 ; chemical shifts in ppm; coupling constants J in Hz): 0.9 (min) and 1.07 (maj) (2t, J=7, 3H); 1.05 (min) and 1.22 (maj) (2d, J=5.3 (min) and 5.4 (maj), 3H); 1.40 (s, 9H); 2.90-2.98 and 3.05-3.51 (m, 2H); 4.16 and 4.23 (2psdd, J=6.6 and 7, 1H); 4.31 (min) and 4.62 (maj) (2q, J=5.3 (min) and 5.4 (maj), 1H); 4.71 (maj) and 4.73 (min) (2m, 1H); 5.22 and 5.23 (2dt, J=1.2 and 10.5, 1H); 5.25 and 5.30 (2dt, J=1.2 and 17.4, 1H); 5.37 and 5.44 (2m, 1H); 5.77 (min) and 5.91 (maj) (2ddd, J=7, 10.5 and 17.4, 1H); 7.17-7.37 (m, 5H)
elemental analysis:
calculated % C 68.03 H 8.71 N 4.18
measured % C 68.00 H 8.78 N 4.13
EXAMPLE 4
A solution of 251 mg (0.75 mmol) of 1-phenyl-1-t-butoxycarbonylamino-2-(1-ethoxyethoxy)but-3-ene, syn form, in 1.5 cm 3 of acetonitrile is introduced into a 15 cm 3 single-necked flask placed under an argon atmosphere and equipped with a magnetic stirring system. 1.5 cm 3 of carbon tetrachloride, 2.25 cm 3 of distilled water and, with thorough stirring, 409.5 mg (4.875 mmol) of sodium bicarbonate are then added successively. 882 mg (4.125 mmol) of sodium periodate are then added in small portions. The reaction medium is left to react for 5 minutes, with stirring (evolution of gas), and 25.1 mg (10% by weight) of RuCl 3 are then added all at once. The reaction mixture, which has turned black and become highly heterogeneous, is left to react for 48 hours at a temperature of about 20° C., with vigorous stirring.
The reaction mixture is diluted with water to give a total volume of 12 cm 3 . The black basic aqueous phase is extracted 3 times with 20 cm 3 of ether. The basic phase is then cooled to 0° C., after which it is treated dropwise with 3 cm 3 of a 2M aqueous solution of hydrochloric acid, in the presence of 30 cm 3 of methylene chloride, with vigorous stirring. The resulting acidic aqueous phase is extracted 8 times with 35 cm 3 of methyl chloride. The organic phases are combined and washed with 3 times 8 cm 3 of water and 1 times 10 cm 3 of a saturated aqueous solution of sodium chloride. They are dried over a 1/1 (w/w) mixture of sodium sulphate and magnesium sulphate and filtered under reduced pressure on Celite. The solvents are driven off under reduced pressure to a volume of 5 to 8 cm 3 . The residue is dried over a 4 molecular sieve. The organic phase is separated from the molecular sieve and the remaining solvent is then driven off on a rotary evaporator.
205 mg (0.58 mmol) of pure 3-phenyl-3-t-butoxycarbonylamino-2-(1-ethoxyethoxy)propionic acid, syn form, are obtained with a yield of 77% in the form of a pale yellow oil having the following characteristics:
infrared spectrum (film): characteristic absorption bands at 3700-2200, 3060, 2980, 2930, 2850, 1720, 1660, 1602, 1590, 1500, 1450, 1400, 1370, 1280, 1250, 1170, 1080, 1050, 1030, 955, 930, 890 and 700 cm -1
proton nuclear magnetic resonance spectrum (300 MHz; CDCl 3 ; chemical shifts in ppm; coupling constants J in Hz); 0.81 and 1.04 (2t, J=7, 3H); 1.18 and 1.20 (2d, J=5.4, 3H); 1.42 (s, 9H); 2.60-2.88 and 3.15-3.52 (m, 2H); 4.35-4.50 and 4.65-4.80 (m, 2H); 5.29 (s broad, 1H); 5.72 (s broad, 1H); 7.13-7.38 (m, 5H); 8.52 (s broad, 1H).
Although the invention has been described in conjunction with specific embodiments, it is evident that many alternatives and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all of the alternatives and variations that fall within the spirit and scope of the appended claims. The above references are hereby incorporated by reference. | A stereoselective process for preparing phenylisoserine derivatives is disclosed. Benzylamine is reacted with an agent for introducing a phenyl or a t-butoxycarbonyl group. The product undergoes double anionization and then is reacted with acrolein to provide a mixture of alcohol syn and anti diasteroisomers. The syn isomer is isolated by chromatography. Whereupon, the hydroxyl is protected and the product is oxidized to provide the phenylisoserine derivative. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0000]
This application is a Continuation of U.S. application Ser. No. 10/505,136, filed Sep. 16, 2004 (now allowed); which is a 371 of PCT/FI03/00126, filed Feb. 20, 2003; the disclosure of each of which is incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention describes the use of natural cyclodextrins (α-CD, β-CD and γ-CD) in sublingual and buccal formulations in order to improve the dissolution rate and bioavailability of selected cannabinoids, especially classical cannabinoids such as cannabidiol (CBD), cannabinol (CBN) and Δ 9 -tetrahydrocannabinol (THC).
BACKGROUND OF THE INVENTION
[0003] Cannabinoids are a group of compounds which are ligands to cannabinoid receptors (CB 1 , CB 2 ) found in the human body (Pertwee, 1997). Cannabinoids were originally found from Cannabis sativa L., the origin of marijuana and hashish. Over the last few years, marijuana or its components have been reported in the scientific literature to counter the symptoms of a broad range of conditions including multiple sclerosis and other forms of muscular spasm, including uterine and bowel cramps; movement disorders; pain, including migraine headache; glaucoma, asthma, inflammation, insomnia, and high blood pressure. There may also be utility for cannabinoids as an oxytoxic, anxiolytic, anti-convulsive, anti-depressant and anti-psychotic agent (Williamson and Evans, 2000), or anti-cancer agent, as well as an appetite stimulant.
[0004] Nowadays over 60 chemically related compounds, collectively classified as cannabinoids, have been isolated from Cannabis sativa L., including tetrahydrocannabinol (THC), cannabidiol (CBD) and cannabinol (CBN). In addition, various synthetic ligands for cannabinoid receptors have been developed during the last few years. The cannabinoids are usually divided in the groups of classical cannabinoids, non-classical cannabinoids, aminoalkylindol derivatives and eicosanoids (Pertwee, 1997). Classical cannabinoids are isolated from Cannabis sativa L. or they can comprise synthetic analogs of these compounds. Non-classical cannabinoids are bi- or tricyclic analogs of tetrahydrocannabinol (THC) (without the pyran ring); aminoalkylindols form a group which differs structurally substantially from classical and non-classical cannabinoids.
[0005] The pharmacological and toxicological studies of cannabinoids have been focused mainly on THC (commercially available under the name Dronabinol) which in 1985 was approved by the FDA for the treatment of chemotherapy associated nausea and vomiting, and later for AIDS-associated wasting and anorexia. Dronabinol is a synthetic analog of THC which is marketed in USA as Marinol. In Marinol, THC is dissolved in sesame oil and it is administered orally as a capsule containing 5 or 10 mg of THC. The major problem of THC in oral administration is its low bioavailability due to its poor dissolution properties and high first-pass metabolism. The bioavailability of orally ingested THC ranges from only 6% to approximately 20% depending on the drug vehicle employed.
[0006] Cyclodextrins (CDs) are cyclic oligosaccharides consisting of (α-1,4)-linked α-D-glucopyranose units, with a lipophilic central cavity and a hydrophilic outer surface (Fromming and Szejtli, 1994). CDs are able to form inclusion complexes with many drugs by taking up the whole drug, or more commonly, the lipophilic moiety of the molecule, into the cavity. The most abundant natural CDs are α-cyclodextrin (α-CD), β-cyclodextrin (β-CD) and γ-cyclodextrin (γ-CD), containing six, seven, and eight glucopyranose units, respectively. Of these three CDs, β-CD appears to be the most useful pharmaceutical complexing agent because of its cavity size, availability, low cost and other properties. There are also a number of CD derivatives available, such as hydroxypropyl-β-CD and methylated CDs. One of the major differences between natural CDs and the CD derivatives above is that natural CDs have been shown to form low solubility complexes with various drugs, as opposed to water-soluble CDs derivatives. Water-soluble CD derivatives form only water-soluble complexes with lipophilic drugs.
[0007] In drug formulations, CDs have been used mainly to increase the aqueous solubility, stability and bioavailability of various drugs, food additives and cosmetic ingredients (Frömming and Szejtli, 1994). In addition, CDs can also be used to convert liquid compounds into microcrystalline powders, prevent drug-drug or drug-additive interactions, reduce gastro-intestinal or ocular irritation, and reduce or eliminate unpleasant taste and smell.
[0008] Studies dealing with the use of CDs with cannabinoids (classical, non-classical and aminoalkylindol derivatives) are referred to in the following publications. Shoyama et al. (1983) have reported that THC forms an inclusion complex with natural β-CD with increasing chemical stability of THC. Shoyama et al. (1983) prepared the solid THC/β-CD inclusion complex by mixing THC and β-CD in a methanol/water solution and hypothesised that CDs (in general) may also be used to improve the aqueous solubility, membrane permeability and bioavailability of THC. Jarho et al. (1998) have reported that HP-β-CD increases the aqueous solubility of THC and that co-administration of small amounts of a water-soluble polymer, hydroxypropyl methylcellulose (HPMC) enhances the complexation between HP-β-CD and THC. In addition, Song et al. (2000) and Porcella et al. (2001) have recently used HP-β-CD to solubilize the aminoalkylindol derivative WIN-55212 in topical ophthalmic formulations.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a novel use of a complex between a specific group of cyclodextrins and cannabinoids. Specifically, the invention relates to a complex of a cyclodextrin selected from the group consisting of α-CD, β-CD and γ-CD, and a cannabinoid selected from the classical cannabinoid-group consisting of cannabinol, tetrahydrocannabinol and cannabidiol.
Specifically, the present invention is directed to the use of the complex for the preparation of a pharmaceutical composition for sublingual or buccal administration. The invention is also directed to pharmaceutical compositions containing such a complex which are intended for sublingual or buccal administration, for example in the form of a tablet, capsule, chewing gum, lozenge or pill.
BRIEF DESCRIPTION OF THE DRAWINGS
[0000]
Furthermore, the invention is directed to a method for treating an individual, such as a human, for a condition responsive to treatment with a cannabinoid, the method comprising administering sublingually or buccally to said individual a sufficient amount of a complex of a cyclodextrin selected from the group consisting of α-CD, β-CD and γ-CD and a cannabinoid selected from the classical cannabinoid group consisting of cannabinol, tetrahydrocannabinol and cannabidiol.
[0012] In addition, the present invention is also directed to a process for the preparation of a complex of a cyclodextrin selected from the group consisting of α-CD, β-CD and γ-CD, and a cannabinoid selected from the classical cannabinoid-group consisting of cannabinol, tetrahydrocannabinol and cannabidiol, the process comprising combining the selected cyclodextrin with the selected cannabinoid in solution, in a heterogenous state or in the solid state, including using methods such as precipitation, freeze-drying, spray-drying, kneading, grinding, slurry-method, co-precipitation, and neutralization, and optionally separating said complex.
BRIEF DESCRIPTION OF THE INVENTION
[0013] FIG. 1 shows the dissolution profile of CBD from gelatin capsule.
[0014] FIG. 2 shows the dissolution profile of a natural β-CD/CBD complex form a gelatin capsule.
[0015] FIG. 3 shows the dissolution profile of a natural γ-CD/CBD complex from a gelatin capsule.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention describes the use of natural CDs to improve the dissolution rate, absorption rate and bioavailability of classical cannabinoids when administered sublingually or buccally.
[0017] Sublingual and buccal drug administration routes are potential alternatives for cannabinoid therapy due to the circumvention of the first-pass metabolism resulting in increased bioavailability of the cannabinoids. The absorption of the cannabinoids across the oral mucosa may also increase the onset of action compared to absorption of cannabinoids from the GI-tract (traditional oral formulations). One of the major requirements of sublingual/buccal drug administration is a fast dissolution of the drug at the site of absorption (sublingual area in the mouth). This is due to the fact that only the dissolved drug is able to absorb into the systemic circulation and that in sublingual drug administration the patient may swallow (due to increased salvation) the dosage form before the release of the drug.
[0018] The present innovation is based on the finding that insoluble cannabinoid/natural cyclodextrin complexes can be used to significantly increase the dissolution rate of cannabinoids which can be used in sublingual cannabinoid formulations. The increased dissolution rate of the cannabinoids is due to the better solubility/dissolution properties of the solid cannabinoid/natural cyclodextrin inclusion complexes compared to pure cannabinoid, whereas the dissolution rate of pure cannabinoids is too slow for sublingual drug formulations.
[0019] The solid cannabinoid/natural CD complexes can be prepared by simply stirring cannabinoids and natural CDs in an aqueous solution which leads to the precipitation of solid complexes (i.e., the cannabinoid molecules are inside of the CD cavity and form inclusion complexes).
[0020] The complexation of cannabinoids with natural CDs produce low solubility complexes that leads to the precipitation of solid “true” cannabinoid/natural-CD complexes. The “true” cannabinoid/natural-CD complexes significantly improve the dissolution, solubility and bioavailability properties of cannabinoids, and thus improves the pharmaceutical usefulness of CDs in cannabinoid formulations.
[0021] As discussed above, the bioavailability of THC is 6-20% after oral administration. THC is commercially available as a capsule containing 5-10 mg of THC (Marinol).
[0022] In sublingual and buccal formulations a smaller dose of cannabinoids can be administered due to by-pass of the first-pass metabolism. Jarho et al. showed that with a 40% solution of HP-β-CD, a 1 mg/ml solution of THC can be obtained. Thus, it can be calculated that (after freeze-drying) 400 mg of HP-β-CD would be needed to complex 1 mg of THC. The same formulation can be prepared theoretically with 3.6 mg of natural β-CD (assuming 1:1 stochiometry for the complex) which increases the usefulness of CD technology in sublingual and buccal drug formulations.
[0023] The novel inclusion complexes of the invention can be prepared in conventional manner, known to a person skilled in art. Such complexes are typically made by dissolving a selected cannabinoid in a selected CD, and the product, which precipitates, is the cannabinoid/CD-complex. The amounts of cannabinoids and CD are selected to give desired complexation efficiency which also depends on the complexation constant between cannabinoid and CD. The complexation constant (K) between cannabinoids and CDs are usually in a range of 1 M −1 to 100 000 M −1 . Typically cannabinoid and CD are used in a weight ratio (dry weight to dry weight) ranging between 1:3 and 1:1000.
[0024] The formation of inclusion complex can be facilitated by using solvents, such as organic solvents, for example methanol or ethanol. The temperature can vary to some degree, but it is typically for convenience the ambient temperature.
[0025] The cannabinoid/CD-solution can also be freeze-dried or spray-dried, to form a powder to be included in a pharmaceutical preparation.
[0026] The cannabinoid CD inclusion complexes can also be prepared under heterogenous conditions (suspension) and in solid phase. These methods include methods such as kneading, grinding, and the so-called slurry method. In solution, methods such as co-precipitation and neutralization can be used to prepare the solid inclusion complexes.
[0027] The pharmaceutical preparation can be any suitable pharmaceutical preparation for sublingual and buccal administration.
[0028] The pharmaceutical preparation according to the invention contains the said complex in pharmaceutically acceptable amounts together with pharmaceutically acceptable carriers, adjuvants or vehicles known in the art. The pharmaceutical composition may be in a dosage form suitable for sublingual or buccal use, such as tablets, capsules, lozenges, pills, pastilles, chewing gum etc. Suitable vehicles for making such administration forms are for example starch, lactose, sucrose, sorbitol, talc, stearates, and gums etc. All such formulations are made using per se known formulation techniques.
[0029] The therapeutic dose to be given to a patient in need of treatment will vary depending i.a. on the body weight and age of the patient, the particular condition being treated as well as the manner of administration and are easily determined by a person skilled in the art. Generally a concentration of 0.1 mg to 500 mg cannabinoid, typically 0.1 mg to 50 mg per unit dose, to be given for example 1 to 4 times a day, would be suitable for most purposes.
[0030] The following examples illustrate the invention without limiting the same in any way.
Example 1
[0031] In this example the effect of natural β-CD on the dissolution characteristics of CBD have been described.
[0032] A powder containing a CBD/β-CD inclusion complex was prepared by the precipitation method. In this method a methanol solution of CBD was added dropwise to an aqueous β-CD solution and after equilibration the white precipitate (CBD/β-CD inclusion complex) was isolated and dried. The HPLC analysis of the powder showed that 9.1 mg of the powder contained 1.0 mg of CBD. All the following dissolution experiments were made in 2% RM-β-CD dissolution medias (pH 6.6) to ensure the free solubility of CBD.
[0033] FIG. 1 shows the dissolution profile (dissolved CBD as a function of time) of CBD from a gelatine capsule containing 1.0 mg of pure CBD and 99 mg of lactose (Mean±SD, n=6). FIG. 2 shows the same data with a capsule containing 9.1 mg of natural β-CD/CBD-complex (equivalent to 1 mg of THC) and 90.9 mg of lactose (Mean±SD, n=4).
[0034] FIGS. 1 and 2 show that the complexation of CBD with natural β-CD significantly increases the dissolution rate of CBD. With a β-CD/CBD formulation, CBD is fully dissolved in 30 minutes. Without β-CD, the dissolution rate is much slower and CBD is not fully dissolved in 3 hours.
Example 2
[0035] In this example the effect of natural γ-CD on the dissolution characteristics of CBD have been described.
[0036] A powder containing a CBD/γ-CD inclusion complex was prepared by the precipitation method. In this method a methanol solution of CBD was added dropwise to an aqueous γ-CD solution and after equilibration the white precipitate (CBD/γ-CD inclusion complex) was isolated and dried. The HPLC analysis of the powders showed that 7.7 mg of the powder above contained 1.0 mg of CBD. All the following dissolution experiments were made in 2% RM-β-CD dissolution medias (pH 6.6) to ensure the free solubility of CBD.
[0037] FIG. 1 shows the dissolution profile (dissolved CBD as a function of time) of CBD from a gelatine capsule containing 1.0 mg of pure CBD and 99 mg of lactose (Mean±SD, n=6). FIG. 3 shows the same data with a capsule containing 7.7 mg of a natural γ-CD/CBD-complex (equivalent to 1 mg of THC) and 92.3 mg of lactose (Mean±SD, n=4).
[0038] FIGS. 1 and 3 show that the complexation of CBD with natural γ-CD significantly increases the dissolution rate of CBD. With a γ-CD/CBD formulation, CBD is fully dissolved in 30 minutes. Without γ-CD, the dissolution rate is much slower and CBD is not fully dissolved in 3 hours.
REFERENCES
[0000]
Fröomming K-H, Szejtli J: Cyclodextrins in pharmacy. Kluwer Academic Publishers, Dortrecht, 1994.
Higuchi T, Connors K A: Phase-solubility techniques. Adv. Anal. Chem. Instr. 4:117-212, 1965.
Porcella A, Maxia C, Gessa G L, Pani L: The synthetic cannabinoid WIN55212-2 decreases the intraocular pressure in human glaucoma resistant to conventional therapies. Eur. J. Neurosci. 13:409-412, 2001.
Pertwee, R G: Pharmacology of cannabinoid CB1 and CB2 receptors. Pharmacol. Ther. 74: 129-180, 1997.
Shoyama Y, Morimoto S, Nishioka I: Cannabis XV: preparation and stability Δ 9 -tetrahydrocannabinol-β-cyclodextrin inclusion complex. J. Nat. Prod. 46:633-637, 1983.
Song Z-H, Slowey C-A: Involvement of cannabinoid receptors in the intraocular pressure lowering effects of WIN55212-2. J. Pharm. Exp. Ther. 292:136-139, 2000.
Williamson E M, Evans F J: Cannabinoids in clinical practise. Drugs 60:1303-1314, 2000.
Zhang M-Q, Rees D C: A review of recent application of cyclodextrins for drug discovery. Exp. Opin. Ther. Patents. 9:1697-1717, 1999. | The present invention is directed to the novel use of complexes of cyclodextrin. In particular the invention is directed to a complex of a cyclodextrin selected from the group consisting of α-CD, β-CD and γ-CD and a cannabinoid selected from the classical cannabinoid-group consisting of canabinol, tetrahydrocanabinol and canabidiol. | 0 |
This is a continuation of Ser. No. 656,577 filed Feb. 9, 1976, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to positionable cleats and associated conveyors, and more particularly to positionable cleats and conveyors for items such as parts.
Conveyors are used in the movement of items, such as parts, from one processing station to another. For example parts which are ejected from a mold are conveyed to machines which segregate and separate the parts according to type. The conveyor may take the form of an elevator to raise the parts from one level to another, or it may merely move the parts horizontally from one location to another.
In order to assure that the parts will be spaced properly and to assure conveyance in the case of an elevator conveyor, it is customary for the conveyor to have periodically positioned cleats. The nature and spacing of the cleats depends upon the type of part being conveyed.
The typical conveyor has permanently fixed cleats, so that when a change in parts is made, by a change in mold, for example, it is necessary to change the conveyor. While there are conveyors with interlocked parts that permit a change in cleating, the conveyors are complex, the parts are difficult to change and the conveyors are comparatively expensive.
Accordingly, it is an object of the invention to realize a conveyor system which can accommodate a wide variety of items. A related object is to achieve a conveyor system for different kinds of parts.
Another object of the invention is to realize positionable cleats for conveyors which do not require complex components and are easily changed in accordance with the item to be conveyed. A related object is to achieve positionable linkage which are relatively inexpensive to produce, to install and to operate.
A further object of the invention is to realize a conveyor which is able to accommodate positionable cleats without the need for complex linkages and interlocks. A related object is to realize a relatively inexpensive and easily installed and operated conveyor with positionable cleats.
SUMMARY OF THE INVENTION
In accomplishing the foregoing and related objects, the invention provides a conveyor cleat that is configured to be temporarily secured to a conveyor belt. The latter includes periodic recesses for temporarily receiving cleats at various positions along its length.
In accordance with one aspect of the invention the cleat has projections which are received in oppositely positioned recesses of the belt.
In accordance with another aspect of the invention the recesses for the cleats are formed by regularly positioned channels, on one side of the belt, extending in a direction transverse to the usual direction of motion of the belt.
In accordance with yet another aspect of the invention the cleats are removed using a screwdriver-like device to pry the belt away from the cleat at the projections.
In accordance with a further aspect of the invention each cleat includes a longitudinal groove which extends in the direction of the length of the belt to position a tool which bows the belt to facilitate installation of the cleat.
In accordance with still another aspect of the invention the cleat projections have recesses to accommodate side guides which stabilize the conveyor during the traverse of curved paths.
DESCRIPTION OF THE DRAWINGS
Other aspects of the invention will become apparent after considering several illustrative embodiments, taken in conjunction with the drawings, in which:
FIG. 1 is a perspective view of an elevator conveyor with positionable cleats in accordance with the invention;
FIG. 2 is a sectional view of a portion of the conveyor of FIG. 1;
FIG. 3A is an enlarged perspective view of a portion of the conveyor of FIG. 1, illustrating removal of a cleat in accordance with the invention;
FIG. 3B is a cross section of the conveyor fragment shown in FIG. 3A;
FIG. 4A is a perspective view of a cleat in accordance with the invention being used with a special tool to facilitate installation on a belt; and
FIG. 4B is a partial perspective view of the cleat of FIG. 4A being installed on a belt in accordance with the invention.
DETAILED DESCRIPTION
Turning to the drawings, FIG. 1 shows a conveyor 10 in accordance with the invention for use in elevating items, such as molded parts from a first position A to an elevated position B. It will be understood that the conveyor 10 is merely illustrative and that the invention may be used in all types of conveyors, including those that operate horizontally and vertically.
The conveyor 10 of FIG. 1 is formed by a belt 20 with removable and positionable cleats 30. The belt 20 extends around upper and lower pulleys 11 and 12. At the pulley positions guides 13 and 14 are included to contact the cleats 30 and stabilize them as the belt travels around the pulleys. It will be understood that the guides 13 and 14 may be used in other regions of belt travel for additional stability.
As can be seen in FIGS. 1 and 2, the belt 20 has a ribbed inner surface 21 and a smooth outer surface 22. In the particular form of belt depicted in FIG. 2, the inner surface 21 is formed by alternating channels 21c and ridges 21r. Such a belt can be of the type commonly known as a "timing belt", which is used primarily with engines and is readily and widely available.
The cleat 30-1 shown in FIG. 2 is formed by a base member 31 which mounts supports 33-1 and 2 for projections 32-1 and 2 (of which only the supports 33-2 and the projection 32-2 are visible in the cross-sectional view of FIG. 2). The projections 32-1 and 2 engage a channel 21c-1 near opposite edges of the belt 20. The base member 31 also mounts an angular flange 38 that engages the items to be conveyed and extends from a side of the base member 31 that is opposite to that for the supports 33-1 and 2.
Since the belt 20 has periodic channels 21c, the cleat 30 is easily moved to another position, or replaced entirely.
To change the cleat 30-1 its projections are disengaged from the channel 21c-1. This is readily accomplished, as shown in the partial perspective view of FIG. 3A by the use of a screwdriver-like tool 40 with a split blade 41 inserted between the edge 20e of the belt 20 and the inside wall of a mounting 33-1 for the cleat projection 32-1.
As indicated in the cross-sectional view of FIG. 3B, the belt is easily pried from the projection 32-1 and freed from the cleat 30-1. The cleat may then be moved to another position or replaced with a different kind of cleat.
To reposition the cleat 30-1 a special tool 50 is used as shown in FIG. 4A. The tool 50 is a spring clip that fits on one side into a longitudinal groove 36. Consequently, as pictured in FIG. 4B, one edge of the belt 20 is brought against the support 33-2, with the projection 32-2 in a new channel 21c-2, the belt 20 is bowed by virtue of the tool 50 and the other side is easily slipped over the opposite projection 32-1; its upper surface has a taper 33t indicated in FIGS. 3B and 4A.
In addition, as can be seen in FIGS. 3B and 4A, the supports 33-1 and 33-2 have lateral extensions 34-1 and 34-2 which provide a channel 34c between the projections 34 and the base member 31 for the guides 13 and 14 (FIG. 1).
The projections 34-1 and 34-2 have a tapered edge 34t (facing the base member 31) to facilitate travel of the cleats along the guides 13 and 14 along a curved path.
It will be apparent that the tool 50 can be used to expedite the removal of a cleat by inserting it into the groove 36 before the tool 40 is used. It will also be apparent that cleats in accordance with the invention can be made to exceed the width of the belt 20 to any degree desired.
While various aspects of the invention have been set forth by the drawings and the specification, it is to be understood that the foregoing detailed description is for illustration only and that various changes in parts, as well as the substitution of equivalent constituents for thos shown and described may be made without departing from the spirit and scope of the invention as set forth in the appended claims. | Cleats which may be positioned as desired on a conveyor belt. Each cleat has ears which permit its temporary and alterable attachment to a belt with alternating ridges and channels that are transverse to the direction of movement of the belt. | 1 |
CONTINUATION IN PART
[0001] The present invention is a Continuation in Part of the U.S. patent application Ser. No. 13/898,674 titled “Dual Actuated Jackscrew Nut And/Or Bolt Head” filed on May 21, 2013 of the same inventor.
FIELD OF INVENTION
[0002] The present invention relates to jackscrew nuts and bolt heads.
BACKGROUND OF INVENTION
[0003] Jackscrew nuts and bolt heads circumvent the need for high power torque wrenches, especially with larger bolt diameters. Instead of having to tighten one nut or bolt head with high torque and big tool to bring the respective central thread connection to the required load, a number of circular arrayed jackscrews that are screwed in the nut and/or bolt head are sequentially tightened with comparatively low torques requiring only comparatively small tools. The jackscrews thereby lift off and the nut and/or bolt head from their flange position as is well known in the art.
[0004] The single actuation of nut and/or bolt head via jackscrews commonly requires extensive repetitive actuation of the individual jackscrews to induce the overall loading lift off. A substantial portion of that overall loading lift off is commonly needed in comparatively low overall nut and/or bolt load range, which would require relatively low tightening torque on the nut and/or bolt head. This in turn would substantially reduce overall jackscrew actuations. Therefore, there exists a need for a jackscrew nut and/or bolt head that provides for a dual actuation such that low load displacement may be accomplished by tightening the nut and/or bolt head directly and such that the final loading may be provided via the jackscrews. The present invention addresses this need.
[0005] During final tightening of jackscrews, contact pressures between the jackscrew bottom and the opposing washer or flange commonly cause galing between the surfaces. This substantially increases friction in the interface. In addition to load related elastic deformations and due to necessary loose thread connections, the jackscrews are forced out of their natural assembly direction. This causes edge contact of the jackscrew bottom, which increases local peak stresses and galing even more. In the prior art it has been attempted to reduce this issue by making the jackscrew bottom slightly spherical. Nevertheless a spherical surface pressing against a planar surface causes again high peak stresses and galing. Therefore, there exists a need for a nut and/or bolt head jackscrew assembly incorporating a load washer with spherical faces that are held in alignment with spherical jackscrew bottoms. The present invention addresses also this need.
[0006] Jackscrew nuts and/or bolt heads commonly need to be utilized at radially tight locations, while at the same time providing pre tightening and an interlocking between the nut and/or bolt head and a washer. The present invention addresses also this need.
SUMMARY
[0007] A jackscrew nut and/or bolt head assembly includes a circumferentially and radially interlocked load washer. Spherical faces at the washer top are thereby held in alignment with corresponding spherical jackscrew bottoms. The spherical-to-spherical jackscrew-washer interface assures evenly distributed contact pressures during out of angle elastic jackscrew displacement and minimizes galing.
[0008] The circumferential and radial interlocked load washer provides further for a transfer of a primary torque exerted onto the main body of the nut and/or bolt head via an assembly torque access, which may be a standardized outside spline such as well known triple square, twelve spline or the like. The assembly torque access may be incorporated at the top and/or circumference of the nut and/or bolt head. In case it is incorporated at the circumference, the assembly torque access may also be incorporated into the load washer in a fashion such that load washer and nut and/or bolt head may have the primary torque concurrently applied.
[0009] The washer interlock may be provided by a castle shaped top of the load washer that interlocks with corresponding recesses at the bottom of the nut and/or bolt head. In addition, the jackscrews may be reversed thinned with a bottom diameter larger than a central thread diameter, which in turn is larger than a jackscrew top diameter. The top diameter may be provided by a top shaft that is guided in a corresponding top guide hole of the nut and/or bolt head. At the same time a bottom guide shaft of the jackscrew is guided in bottom guide hole within either a washer castle or the nut and/or bolt head. This keeps the jackscrew thread free of tilting forces that may occur during elastic deformation of the nut and/or bolt head during tightening. Also, the larger bottom diameter maximizes area contact and minimizes contact pressures with the load washer. The jackscrew heads may have radial recesses for applying torque to the jackscrew. Circumferential portions of the jackscrew heads may have a continuous diameter such the circular arrayed jackscrew heads may be together accessed by pre tightening tool. An overall outside diameter of the nut and/or bolt head may be kept to a minimum while providing a more centralized tool access to the individual jackscrew heads. This may be of particular advantage in tight applications of the present invention.
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 is a front perspective view of a first embodiment of the invention in a nut configuration.
[0011] FIG. 2 is a partial cut view of FIG. 1 .
[0012] FIG. 3 is a bottom perspective view of a partial assembly of FIG. 1 .
[0013] FIG. 4 is a front perspective view of a second embodiment of the invention in a nut configuration
[0014] FIG. 5 is a front perspective partial cut view of a third embodiment of the invention in a bolt head configuration.
[0015] FIG. 6A is front perspective partial cut view of a fourth embodiment of the invention in nut configuration with a pre tightening tool above .
[0016] FIG. 6B shows a jackscrew of the fourth embodiment.
DETAILED DESCRIPTION
[0017] According to a first embodiment of the invention and referring to FIGS. 1-3 a jackscrew tightening assembly 1000 may feature a central thread 1002 with a thread axis 1005 . In case of the jackscrew tightening assembly 1000 being a nut, the central thread 1002 may be an internal thread. In case of the jackscrew tightening assembly 1000 being a bolt head, the central thread 1002 may be an external thread as shown in FIG. 5 . Parts of the jackscrew tightening assembly 1000 are a main body 1008 , jackscrews 1026 , a load washer 1035 and a washer interlock 1044 . The main body 1008 is extending radial outward with respect to the central thread 1002 as is well known for jackscrew nuts and/or bolts. The main body 1008 has a main top 1011 , a main bottom 1014 that is opposite the main top 1011 in axial direction with respect to the central thread axis 1005 , through holes 1017 with a through hole axis 1020 that is in an offset to the central thread axis 1005 , and a secondary thread 1023 at least along a portion of the through hole 1017 . The jackscrews 1026 are extending through respective through holes 1017 , and engaging via their jackscrew threads 1027 with the respective secondary threads 1023 . The jackscrews 1026 have jackscrew heads 1029 facing away from the main bottom 1014 and spherical bottoms 1032 facing away from the main top 1011 . The jackscrews 1026 are preferably arrayed in a number around the central thread 1002 such that upon even tightening of all jackscrews 1026 the axial sum of all their individually exerted axial loads is transferred onto the central thread 1002 in a balanced fashion via the main body 1008 as may be well appreciated by anyone skilled in the art.
[0018] The load washer 1035 is adjacent the main bottom 1014 and surrounding the central thread 1002 . The load washer 1035 has a washer top 1038 that is facing the main bottom 1014 and a number of spherical faces 1041 that are formed into the washer top 1038 . The spherical faces 1041 are matching their respective spherical bottoms 1032 and are in substantial axial alignment with them and rotationally symmetric with respect to the central thread axis 1005 . The load washer 1035 is at least circumferentially but preferably also radial held with the main body 1008 via a washer interlock 1044 that includes a first interlock feature 1047 provided by the load washer 1035 and a second interlock feature 1050 that is at least circumferentially but preferably also radial mating the first interlock feature 1047 and that is part of the main body 1008 such that the spherical faces 1041 are held in alignment with respective spherical bottoms 1032 . The first interlock feature 1047 may be an internal spline that is axially extending through a central through hole 1039 of the load washer 1035 . The second interlock feature 1050 may be an external spline axially extending from the main bottom 1014 . According to FIGS. 1 , 2 , the second interlock feature 1050 may be a body contour 1062 axially extending from the main bottom 1014 towards the main top 1011 and the first interlock feature may be one or more protrusions axially extending above the washer top 1038 .
[0019] Further part of the jackscrew tightening assembly 1000 may be an assembly torque access 1053 via which a primary torque may be externally applied to the jackscrew tightening assembly 1000 . The assembly torque access may be part of at least one of the main body 1008 and the load washer 1035 such that the primary torque that is applied to at least one of the main body 1008 and the load washer 1035 is also applied via the washer interlock 1044 to one other of the main body 1008 and the load washer 1035 while the spherical bottoms 1032 remain in substantial axial alignment with their respective spherical faces 1041 . The assembly torque access 1053 may be a body outside contour 1063 that at least in part corresponds to a well known twelve spline, triple square standard or the like. The body outside contour may also serve as the second interlock feature 1050 . Part of the assembly torque access 1053 may also be a load washer contour 1065 that is axially substantially collinear with the body outside contour 1063 such that the primary torque may be concurrently applied to both the main body 1008 and the load washer 1035 with the same tool as may well appreciated by anyone skilled in the art.
[0020] According to FIG. 3 , the assembly torque access 1053 may be a body top spline 1068 protruding from the main top 1011 . The body top spline 1068 may have jackscrew access recesses 1071 that are radial recessed into it such that the jackscrew heads 1029 are accessible while the body top spline 1068 radial extends in between the jackscrew heads 1029 .
[0021] Referring to FIG. 5 , the main body 1008 and the load washer 1035 may be circumferentially and radial held together via interlock shafts 1074 of the jackscrews 1026 engaging with receptacles 1077 formed into the load washer 1035 . Receptacle disks 1080 featuring the spherical faces 1041 may be placed inside and preferably at the bottom of the receptacles 1077 . Their small size provides for a cost effective fabrication of them with superior hardness of at least their spherical faces 1041 , which may further reduce risk of galing in the interface as may be well appreciated by anyone skilled in the art. At the same time, the load washer 1035 may be fabricated from a less hard and brittle material making it less susceptible to cracking due to out of balance peak loading from the jackscrews 1026 as may also be well appreciated by anyone skilled in the art.
[0022] The interlock shafts 1074 may be accessed via the axial gap between the main body 1008 and the load washer 1035 by a hook tool 700 having a hook 702 corresponding to the diameter of the interlock shafts 1074 . By use of the hook tool, the primary torque may be applied for initially tightening the main body 1008 .
[0023] The hook tool 700 provides torque transfer with only partial circumferential access to the main body 1008 , which may be advantages in tight locations.
[0024] At least one of the jackscrews 1026 , the load washer 1035 , the main body and the receptacle disks 1080 may be permanently magnetic to assist in keeping the jackscrew tightening assembly 1000 together during its installation and handling. The through hole axes 1020 may be in an angle to the central thread axis 1005 such that the jackscrew heads 1029 are closer to the central thread axis 1005 than the spherical bottoms 1032 . This may advantageously provide for a more centralized access to the jackscrew heads 1029 with a tightening tool, while at the same time keeping the most outward diameter of the main body 1008 to a minimum.
[0025] In case the load washer 1035 is configured as a well known lock washer with one directional serrations on its bottom or other features preventing the load washer 1035 from being rotated in loosening direction of the main body 1008 , the jackscrews 1026 may be loosened to the extent that the jackscrew shafts 1074 disengage from the receptacles 1077 and the main body 1035 rests directly on the washer top 1038 prior to loosening the main body 1008 . That way, the locking load washer 1035 may remain stationary while the main body 1035 slides on the washer top 1038 . To provide still a gap for hook tool 700 access, the main body 1008 may have a central circular rim extending downward from the main bottom 1014 .
[0026] Referring to FIGS. 6A and 6B , in a fourth embodiment of the invention the main body 1008 features top guide holes 1022 that are extending from the main top 1011 concentric with respect to their through hole axes 1020 . The secondary threads 1023 are adjacent and below the top guide holes 1022 and concentric with respect to their respective top guide hole 1022 . Recessed into the main bottom 1014 are a number of castle recesses 1058 and preferably circumferentially evenly arrayed. Bottom guide holes 1024 are extending from the main bottom 1014 and are also concentric with their respective top guide holes 1022 .
[0027] The jackscrews of the fourth embodiment have preferably each a top guide shaft 1072 in addition to the bottom guide shaft 1074 . Each top guide shaft 1072 is adjacent the jackscrew head 1029 and in between the jackscrew head 1029 and the spherical bottom 1032 . The top guide shafts 1072 are guided in respective top guide holes 1022 . The load washer 1035 has a number of castle extensions 1057 that extend above the washer top 1038 . Castle guide holes 1078 are recessed into the castle extensions 1057 and have spherical faces 1041 formed at their bottom preferably horizontally leveled with the spherical faces 1041 that are formed into the washer top 1038 . While the load washer 1035 is in mating contact with the main body 1008 , the castle extensions 1057 are interlocking with the castle recesses 1058 axially with respect to the central thread axis 1005 . The bottom guide shafts 1074 are preferably guided circumferentially alternating in either the bottom guide holes 1024 or the castle guide holes 1078 .
[0028] The bottom guide shaft 1074 has a bottom diameter BD that is preferably larger than the jackscrew thread 1027 diameter THD. The top guide shaft 1072 has a top diameter TD that is smaller than the jackscrew thread 1027 diameter THD. The jackscrew heads 1029 may have circumferentially continuous circle portions that are circumferentially interposed with a radial torque access recess. This provides on one hand torque access to individual jackscrews 1026 with correspondingly shaped nuts as is well known in the art. On the other hand, the jackscrews 1026 may be concurrently accessed with a jackscrew assembly tightening tool 800 that has an array of jackscrew head access holes 802 on its tool bottom 803 . The jackscrew head access holes 802 are preferably circumferentially arrayed and are matching the jackscrew head 1029 pattern on above the main top 1011 . The jackscrew head access holes 802 are close to an outer tool diameter TOD that is preferably smaller than an outer main body diameter BOD. This greatly improves access clearance especially in tight situations, which is made possible due to the even load transfer over a large number of jackscrew heads 1029 and their top guide shafts 1072 that hold the jackscrew heads 1029 rigid against out of axis bending, which may be well appreciated by anyone skilled in the art. A tool access 801 on the tool top 804 may be a square hole for coupling with a hydraulic torque wrench as is well known in the art.
[0029] During tightening of the jackscrews 1029 the main body 1008 may come under load and elastically deflect radially outward at the main bottom 1014 . To keep the castle guide holes 1078 raidally aligned with top guide holes 1022 in that case, a castle spacing between adjacent castle extensions 1057 may have an outer castle spacing CLO that is less than an inner castle spacing CLI. In that way, the castle recesses 1058 are radially opposed by the castle extensions 1057 while the main bottom 1014 may elastically deform in direction away from the central thread axis 1005 .
[0030] In the fourth embodiment, the jackscrews 1029 are screwed in from the main bottom 1014 and from the castle recesses 1058 . The load washer 1035 is than mated with the main body 1008 and the spherical bottoms 1032 brought into contact with spherical faces 1041 . Main body 1008 and load washer 1035 are together screwed on and/or in at their assembly location. Then the pre tightening tool 800 may be coupled with the jackscrew tightening assembly 1000 by mating its jackscrew head access holes 802 with the jackscrew heads 1029 . The pre tightening tool 800 may be coupled to a hydraulic torque wrench via its tool access 801 and a pre tightening torque conveniently applied to the main body 1008 via the jackscrew heads 1029 . The top guide shafts 1072 assist thereby to transfer the pre tightening force onto the main body 1008 . After removing the pre tightening tool 800 , the individual jackscrew heads 1029 may be accessed to bring the jackscrew tightening assembly 1000 up to final loading. Loosening of it may be performed in reverse as may be clear to anyone skilled in the art.
[0031] Accordingly, the scope of the Figures and the Specification above is set forth by the following claims and their legal equivalent: | A jackscrew nut and/or bolt head assembly includes a bottom washer that is interlocked via circumferentially arrayed castle extensions and recesses. Spherical faces at the washer top are thereby held in alignment with corresponding spherical jackscrew bottoms, which assures evenly distributed contact pressures during out of angle elastic jackscrew displacement during jackscrew loading. The bottom washer interlock may provide further for a transfer of a primary pre tightening torque exerted onto the main body of the nut and/or bolt head via a tool that concurrently accesses all jackscrew heads extending above the main body. The assembly may be initially tightened via the primary torque whereby secondary jackscrew actuation and displacement is greatly reduced. The jackscrews are thinned in reverse for maximum contact area at their spherical bottoms. | 5 |
RELATED APPLICATIONS
[0001] This application is related to co-pending applications: Ser. No. ______, filed ______, entitled, “HIGH-VOLTAGE VERTICAL TRANSISTOR WITH A MULTI-LAYERED EXTENDED DRAIN STRUCTURE”, and Ser. No. ______ , filed ______ , entitled, “HIGH-VOLTAGE LATERAL TRANSISTOR WITH A MULTI-LAYERED EXTENDED DRAIN STRUCTURE”, both of which are assigned to the assignee of the present application.
FIELD OF THE INVENTION
[0002] The present invention relates to semiconductor devices fabricated in a silicon substrate. More specifically, the present invention relates to field-effect semiconductor transistor structures capable of withstanding high voltages.
BACKGROUND OF THE INVENTION
[0003] High-voltage, field-effect transistors (HVFETs) are well known in the semiconductor arts. Most often, HVFETs comprise a device structure that includes an extended drain region that supports the applied high-voltage when the device is in the “off” state. HVFETs of this type are commonly used in power conversion applications such as AC/DC converters for offline power supplies, motor controls, and so on. These devices can be switched at high voltages and achieve a high blocking voltage in the off state while minimizing the resistance to current flow in the “on” state. The blocking or breakdown voltage is generally denoted as Vbd. The acronym Rsp refers to the product of the resistance and surface area, and is generally used to describe the on-state performance of the device. An example of a prior art HVFET having an extended drain region with a top layer of a conductivity type opposite that of the extended drain region is found in U.S. Pat. No. 4,811,075.
[0004] In a conventional HVFET the extended drain region is usually lightly doped to support high voltages applied to the drain when the device is off. The length of the extended drain region is also increased to spread the electric field over a larger area so the device can sustain higher voltages. However, when the device is on (i.e., conducting) current flows through the extended drain region. The combined decrease in doping and increase in length of the extended drain region therefore have the deleterious effect on the on-state performance of the device, as both cause an increase in on-state resistance. In other words, conventional high-voltage FET designs are characterized by a trade-off between Vbd and Rsp.
[0005] To provide a quantitative example, a typical prior art vertical HVFET (NMOS-type) may have a Vbd of 600V with a Rsp of about 16 ohm-mm 2 . Increasing the length of the extended drain would affect device performance by increasing Vbd beyond 600V at the expense of a higher Rsp value. Conversely, reducing the length of the extended drain would improve the on-state resistance to a value below 16 ohm-mm 2 , but such a change in the device structure would also cause Vbd to be reduced to less than 600V.
[0006] A device structure for supporting higher Vbd voltages with a low Rsp value is disclosed in U.S. Pat. Nos. 4,754,310, 5,438,215, and also in the article entitled, “ Theory of Semiconductor Superjunction Devices ” by T. Fujihira, Jpn. J. Appl. Phys., Vol. 36, pp. 6254-6262, Oct. 1977. In this device structure the extended drain region comprises alternating layers of semiconductor material having opposite conductivity types, e.g., PNPNP . . . . As high voltage is applied to the layers of one conductivity type, all of the layers are mutually depleted of charge carriers. This permits a high Vbd at much higher conducting layer doping concentrations as compared to single layer devices. The higher doping concentrations, of course, advantageously lower the Rsp of the transistor device. For example, in the article entitled, “ A new generation of high voltage MOSFETs breaks the limit line of silicon ” by G. Deboy et al., IEDM tech. Digest, pp. 683-685,1998, the authors report a vertical NMOS device with a Vbd of 600V and a Rsp of about 4 ohm-mm 2 .
[0007] Another approach to the problem of achieving high-voltage capability is disclosed in the paper, “ Realization of High Breakdown Voltage in Thin SOI Devices ” by S. Merchant et al., Proc. Intl. Symp. on Power Devices and ICs, pp. 31-35,1991. This paper teaches an extended drain region that comprises a thin layer of silicon situated on top of a buried oxide layer disposed on top of a semiconductor substrate. In operation, the underlying silicon substrate depletes charge from the thin silicon layer at high voltages. The authors claim that high values of Vbd are obtained as long as the top silicon layer is sufficiently thin and the buried oxide layer is sufficiently thick. For instance, a lateral NMOS device with Vbd of 600V and Rsp of about 8 ohm-mm 2 is obtained using this approach.
[0008] Other background references of possible interest to those skilled in the art include U.S. Pat. Nos. 6,184,555, 6,191,447, 6,075,259, 5,998,833, 5,637,898, International Application No. PCT/IB98/02060 (International Publication No. WO 99/34449), and the article, “ High Performance 600 V Smart Power Technology Based on Thin Layer Silicon-on-Insulator ” by T. Letavic et al., Proc. ISPSD, pp. 49-52, 1997.
[0009] Although the device structures described above achieve high Vbd with relatively low on-state resistance as compared to earlier designs, there is still an unsatisfied need for a high-voltage transistor structure that can support high voltages while achieving a much lower on-state resistance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention is illustrated by way of example, and not limitation, in the figures of the accompanying drawings, wherein:
[0011] FIG. 1 is a cross-sectional side view of a vertical high-voltage, field-effect transistor (HVFET) device structure in accordance with one embodiment of the present invention.
[0012] FIG. 2 is a cross-sectional side view of one embodiment of a lateral HVFET fabricated in accordance with the present invention.
[0013] FIG. 3A is a top view of lateral HVFET fabricated in accordance with another embodiment of the present invention.
[0014] FIG. 3B is a cross-sectional side view of the lateral HVFET shown in FIG. 3A , taken along cut lines A-A′.
[0015] FIG. 4 is a cross-sectional side view of another embodiment of a vertical HVFET device structure fabricated according to the present invention.
[0016] FIGS. 5A-5K are cross-sectional side views of a vertical HVFET device structure taken at various stages in a fabrication process in accordance with yet another embodiment of the present invention.
[0017] FIG. 6 is a cross-sectional side view of still another embodiment of a vertical HVFET device structure fabricated according to the present invention.
DETAILED DESCRIPTION
[0018] A high-voltage field-effect transistor having an extended drain or drift region and a method for making the same is described. The HVFET has a low specific on-state resistance and supports high voltage in the off-state. In the following description, numerous specific details are set forth, such as material types, doping levels, structural features, processing steps, etc., in order to provide a thorough understanding of the present invention. Practitioners having ordinary skill in the semiconductor arts will understand that the invention may be practiced without many of these details. In other instances, well-known elements, techniques, and processing steps have not been described in detail to avoid obscuring the invention.
[0019] FIG. 1 is a cross-sectional side view of a vertical n-channel (i.e., NMOS) HVFET 20 in accordance with one embodiment of the present invention. It should be understood that the elements in the figures are representational, and are not drawn to scale in the interest of clarity. It is also appreciated that a p-channel transistor may be realized by utilizing the opposite conductivity types for all of the illustrated diffusion/doped regions. Furthermore, although the figure appears to show two separate devices, those of skill will understand that such transistor structures are commonly fabricated in an annular, inter-digitated, or otherwise replicated manner.
[0020] The device structure of FIG. 1 includes an insulated-gate, field-effect transistor (IGFET) having a gate 30 (comprised, for example, of polysilicon), and a gate-insulating layer 29 that insulates gate 30 from the underlying semiconductor regions. Gate-insulating layer 29 may comprise ordinary silicon dioxide or another appropriate dielectric insulating material. The extended drain region of vertical HVFET 20 comprises two or more parallel N-type drift regions 22 situated between p-type body regions 26 and extending down to the N+ substrate 21 . For instance, FIG. 1 shows drift region 22 a extending from beneath gate oxide 29 a between P-body regions 26 a & 26 b down to N+ substrate 21 . Similarly, drift region 22 b extends from gate oxide 29 b between P-body regions 26 c & 26 d down to N+ substrate 21 .
[0021] Source electrode 32 is electrically connected to N+ source regions 27 , which are disposed in respective P-body regions 26 . For example, N+ source region 27 a is disposed in P-body region 26 a ; N+ region 27 b is disposed in P-body region 27 b , and so on. It is appreciated that a variety of alternative source electrode connections are also possible. The area of the P-body regions directly beneath gate 30 (between N+ source regions 27 and drift regions 22 ) comprises the IGFET channel region of the transistor. In this particular embodiment, the gate region is a metal-oxide semiconductor (MOS), and the IGFET is a NMOS transistor. Thus, the channel regions of HVFET 20 are defined at one end by N+ source regions 27 and at the other end by N-type drift regions 22 , which extend vertically from gate oxide 29 down to the N+ substrate 21 . Insulating layers 33 separate gate 30 from source electrode 32 .
[0022] The n-type extended drain or drift regions 22 are separated laterally by insulating regions or dielectric layers 28 . In the embodiment of FIG. 1 , dielectric layers 28 extend vertically from beneath P-body regions 26 down to N+ substrate 21 along the full vertical length of the drift regions 22 . By way of example, dielectric layers 28 may comprise silicon dioxide, but other insulating materials, such as silicon nitride, may also be used. Disposed within each of the dielectric layers 28 , and fully insulated from the semiconductor substrate 21 and drift regions 22 , is a field plate member 24 . Field plate members 24 comprise a conducting layer of material such as heavily doped polysilicon, metal, metal alloys, etc. As shown in the embodiment of FIG. 1 , each of the field plate members 24 is electrically connected to source electrode 32 . Alternatively, the field plate members may be connected to a separate electrode. Gates 30 are also connected to a separate electrode (not shown). Drain electrode 31 provides electrical connection to the bottom of N+ substrate 21 .
[0023] The extended drain region of vertical NMOS high-voltage transistor 20 of FIG. 1 consists of a plurality of laterally interleaved layers of doped semiconductor material (e.g., n-type), insulating material (e.g., silicon dioxide), and conducting material (e.g., heavily-doped polysilicon). In the on state, a sufficient voltage is applied to the gate such that a channel of electrons is formed along the surface of the P-body regions 26 . This provides a path for electron current flow from source electrode 32 , N+ source regions 27 , through the channel regions formed in P-body regions 26 , down through the N-type drift regions 22 , through the N+ substrate 21 , to drain electrode 31 .
[0024] Practitioners in the semiconductor arts will note that in a conventional vertical HVNMOS transistor, the N-type drift region is normally very thick (i.e., long) and lightly doped; both of which contribute to high on state resistance. In the device structure of FIG. 1 , on the other hand, the doping in the N-type drift regions may be considerably higher, such that the on-state resistance is dramatically lowered. Lowering the on-state resistance is achieved in HVFET 20 by the use of multiple, parallel-arranged extended drain or drift regions.
[0025] In the off state, a high voltage (e.g., 200V-1200V) is applied across the respective drain and source electrodes 31 and 32 . As the voltage increases, the presence of field plate regions 24 on opposite sides of drift regions 22 cause the N-type drift regions to become depleted of free carriers. Ideally, the doping profile in the drift regions 22 is tailored such that the resulting electric field is approximately constant along the path from the drain to the source. For example, the doping concentration may be highest near the N+ substrate 21 , lowest the near the P-body regions 26 , and linearly graded in between.
[0026] The thickness of both the N-type drift regions 22 and oxide layers 28 should be designed so as to guard against prevent premature avalanche breakdown. Avalanche breakdown can be avoided by making the drift region relatively narrow, which reduces the ionization path and thereby increases the critical electric field at which avalanche occurs. In the same regard, making oxide layers 28 relatively wide allows the device structure to support a larger voltage for a given electric field.
[0027] By way of example, a device manufactured in accordance with FIG. 1 having a drift region that is about 50 um high and about 0.4-0.8 um wide, with an oxide layer width in the approximate range of 3.0-4.0 um is capable of supporting about 800V. In such a device, the doping in the drift region may be linearly graded from about 5×10 15 cm −3 near the P-body regions to about 1×10 17 cm −3 near the N+ substrate. The on-state resistance of such a device is about 1.0 ohm-mm 2 .
[0028] Practitioners in the art will appreciate that the device performance for HVFET 20 may be improved when manufactured as a smaller total cell pitch (i.e., combined width of field plate, oxide layer and drift regions) because the contribution of each drift region is fairly constant.
[0029] Referring now to FIG. 2 , there is shown a lateral NMOS high-voltage transistor 40 in accordance with another embodiment of the present invention. HVFET 40 of FIG. 2 operates according to the same principles discussed in connection with the transistor structure of FIG. 1 , except that current flows laterally, as opposed to vertically, through the drift regions. Note that in the embodiment of FIG. 2 , field plate members 44 are fully insulated from the semiconductor material by oxide layers 49 .
[0030] In this example, field plate member 44 a is disposed within oxide layer 49 a just below the source and drain electrodes 46 and 45 , respectively. Field plate member 44 b is disposed within oxide layer 49 b below N-type drift region 42 a and above N-type drift region 42 b . The field plate members may be connected to a field plate electrode at a certain location out of the plane of the figure. The N-type drift region, which comprises the extended drain of the transistor, extends laterally from beneath P-body region 48 across to N+ drain region 43 . N+ drain region 43 connects both drift regions 42 a & 42 b with drain electrode 45 .
[0031] An N+ source region 47 , which is electrically connected to source electrode 46 , is disposed adjacent P-body region 48 . The HVFET 40 utilizes a vertical MOS gate structure 12 that comprises a gate electrode 56 that connects to gate 55 . In this embodiment, gate 55 comprises a layer of polysilicon that extends vertically from gate electrode 56 . Gate 55 extends below the P-body region, and may extend down to oxide layer 50 , as shown. Gate 55 is insulated from N+ source region 47 , P-body region 48 , and N-type drift region 42 by gate oxide 53 . An oxide region 58 separates gate electrode 56 from source electrode 46 .
[0032] Oxide layer 50 insulates N+ substrate 41 from gate 55 , N-type drift region 42 , and N+ drain region 43 . As can be seen, oxide layer 50 extends laterally over N+ substrate 41 beneath each of the regions 42 , 43 , and 55 . Substrate electrode 57 provides electrical connection to the bottom of N+ substrate 41 . The substrate may serve as the bottom field plate for drift region 42 b.
[0033] The on-state and off-state operations of HVFET 40 are similar to those described for the embodiment of FIG. 1 . In this case, however, the source and drain electrodes are located on the top surface. This means that electrons flows down through N+ source region 47 , across the channel region formed in P-body region 48 adjacent to gate oxide 53 , laterally across the N-type drift regions 42 , and up through the N+ drain region 43 before reaching the drain electrode.
[0034] Note that even though FIG. 2 shows a trench gate structure, planar gate structures could also be used. Additionally, a trench drain structure could also be used in an alternative implementation. Furthermore, although the embodiment of FIG. 2 shows the extended drain region comprising two laterally-extending, parallel N-type drift regions 42 a and 42 b , other embodiments may utilize more than two parallel drift regions. In other words, the embodiment of FIG. 2 is not limited to just two drift regions, but could include any number of layers of drift, oxide, and field plate regions within manufacturing limits.
[0035] FIGS. 3A & 3B illustrate another embodiment of a lateral HVFET in accordance with the present invention. FIG. 3A is a top view of a lateral HVNMOS transistor 60 , and FIG. 3B is a cross-sectional side view of the same device, taken along cut lines A-A′, which extends through drift region 62 a . (Note that the source electrode 66 , drain electrode 65 , gate 75 , gate oxide 73 and oxide layer 79 are not depicted in FIG. 3A to avoid confusion. These elements are shown in the cross-sectional side view of FIG. 3B .)
[0036] The lateral device structure of FIG. 3 is similar to that shown in FIG. 2 . But rather than orient the drift, oxide, and field plate layered regions on top of one another (vertically), the embodiment of FIG. 3 has these regions oriented side-by-side. Unlike the embodiment of FIG. 2 , each of the N-type drift regions 62 , oxide layers 69 , and field plate members 64 extend from underlying insulating layer 70 toward the upper substrate surface. Each of the N-type drift regions 62 and field plate members 64 are insulated from N+ substrate 61 by insulating layer 70 . In one embodiment, layer 70 comprises silicon dioxide. An additional electrode 77 provides electrical connection to the bottom of N+ substrate 61 .
[0037] The planar gate and drain configurations of HVNMOS transistor 60 are illustrated in the side view of FIG. 3B . Alternatively, a trench drain structure and/or a trench gate structure may be utilized. In this embodiment, a gate member 75 is disposed above P-body region 68 and is insulated from the semiconductor substrate by a gate oxide 73 . Source electrode 66 contacts N+ source region 67 , which is disposed in P-body region 68 . P-body region 68 is itself shown disposed in N-type drift region 62 .
[0038] N+ drain region 63 is disposed at the opposite end of the N-type drift region 62 and is electrically connected to drain electrode 65 .
[0039] The embodiments of FIGS. 2 and 3 show the field plate members being coupled to the lowest chip potential, e.g., ground. The source may be tied to the field plate members (at the lowest chip potential), or, alternatively, the source region may be left floating. In other words, the embodiments of FIGS. 1-3 are not limited to a source follower configuration. Each of the transistor structures of the present invention may be implemented as a four-terminal device, wherein the drain, source, field plate members, and insulated gate members are connected to a separate circuit terminal. In another embodiment, the field plate and insulated gate members may be connected together.
[0040] With reference now to FIG. 4 , there is shown a cross-sectional side view of another embodiment of a vertical HVNMOS transistor 80 constructed according to the present invention. The device structure shown in FIG. 4 is similar to that of FIG. 1 , except that the planar gate has been replaced by a trench gate structure. As in the vertical device structure of FIG. 1 , transistor 80 comprises a plurality of parallel-arranged N-type drift regions 82 that extend vertically from P-body regions 86 down to the N+ substrate 81 . Each of the drift regions 82 is adjoined on both sides by an oxide layer 88 . For example, N-type drift region 82 a is bounded on one side by oxide layer 88 a and on the opposite side by oxide layer 88 b.
[0041] Disposed within each of the oxide layers 88 , and fully insulated from the drift region and substrate semiconductor materials, is a field plate member 84 that may be electrically connected to source electrode 92 . The N-type drift regions 82 , oxide layers 88 , and field plate members 84 collectively comprise a parallel layered structure that extends in a lateral direction, which is perpendicular to the direction of current flow in the on-state. When transistor 80 is in the on-state, current flows vertically from the drain electrode 91 through the parallel N-type drift regions 82 , through the MOS channel formed on the sidewalls of the P-body region, to the source electrode 92 .
[0042] The trench gate structure of vertical HVNMOS transistor 80 comprises gate members 90 disposed between field plate members 84 and P-body regions 86 . In the embodiment of FIG. 4 , a pair of N+ source regions 87 is disposed in each of P-body regions 86 on opposite sides. Each P-body region 86 is located at one end of a corresponding N-type drift region 82 . A thin gate-insulating layer 89 (e.g., oxide) insulates each of gate members 90 (e.g., polysilicon) from the P-body semiconductor material.
[0043] For example, FIG. 4 ′,shows gate members 90 a & 90 b disposed along opposite sides of P-body region 86 a . N+ source regions 87 a & 87 b are disposed in P-body region 86 a at opposite sides adjacent to the gate members; both regions 87 a & 87 b are electrically connected to source electrode 92 . P-body region 86 a adjoins the source electrode at one end and drift region 82 a at the other end. When transistor 80 is in the on-state conducting channel regions are formed along the sides of P-body region 86 a such that current flows from source electrode 92 , through N+ regions 87 , across P-body 86 , down through N-type drift regions 82 and N+ substrate 81 , to drain electrode 91 .
[0044] Practitioners in the art will appreciate that the pair of N+ source regions 87 shown disposed in each P-body region 86 of FIG. 4 may alternatively be replaced by a single N+ region that extends across the full width of region 86 adjacent to source electrode 92 . In this case, the P-body region may be connected to the source electrode at various points (dimensionally into the page of the figure.) In one embodiment, source electrode 92 may protrude through N+ source 87 to contact the underlying P-body region 86 (see FIG. 5K ).
[0045] The trench gate structure of the embodiment of FIG. 4 potentially offers an advantage of a simplified manufacturing process, due to the elimination of the T-shaped semiconductor regions shown in FIG. 1 . Also, the vertical HVNMOS structure of transistor 80 may provide lower on-resistance due to the elimination of the JFET structure formed between the P-body regions.
[0046] FIGS. 5A-5K illustrate the various processing steps that may be employed to fabricate a vertical high-voltage transistor in accordance with the present invention. The described fabrication method may be used not only to form the device of FIG. 5K , but also the vertical device structure shown in FIG. 4 .
[0047] FIG. 5A shows a vertical high-voltage transistor after the initial processing step of forming an epitaxial layer 101 of n-type semiconductor material on an N+ substrate 100 . To support applied voltages in the range of 200V to 1000V the device structure should have an epitaxial layer that is about 15 um to 120 um thick. By way of example, the epitaxial layer of the device shown in FIG. 5 is 40 um thick. The N+ substrate 100 is heavily doped to minimize Its resistance to current flowing through to the drain electrode, which is located on the bottom of the substrate in the completed device. Substrate 100 may be thinned, for example, by grinding or etching, and metal may be deposited on its bottom surface to further reduce the on-resistance of the transistor. Most often, these processing steps would be performed after the topside processing has been completed.
[0048] The thickness and doping of epitaxial layer 101 largely determine the Vbd of the device. The doping may be carried out as the epitaxial layer is being formed. The optimal doping profile is linearly graded from the drain (at the bottom, adjacent to N+ substrate 100 ) to the source (at the top). Tailoring the doping concentration so that it is heavier near the substrate 100 results in a more uniform electric-field distribution. Linear grading may stop at some point below the top surface of the epitaxial layer 101 . By way of example, for the embodiment shown in FIG. 5 the doping concentration is approximately 2×10 15 cm −3 near the P-body region to about 6×10 18 cm −3 near the N+ substrate 100 .
[0049] After the epitaxial layer 101 has been formed, the top surface of layer 101 is appropriately masked and deep trenches are then etched into, or alternatively completely through, the epitaxial layer. FIG. 5B shows a cross-sectional view of the device structure following etching of epitaxial layer 101 and part of substrate 100 . Note that the lateral width of the etched trenches is determined by the combined thickness of the dielectric and conductive refill layers, as described below.
[0050] Spacing between adjacent trenches is determined by the required thickness of the remaining mesa of epitaxial layer material, which, in turn, is governed by the breakdown voltage requirements of the device. It is this mesa of epitaxial material that eventually forms the N-type drift region of the device structure. It should be understood that this mesa of material might extend a considerable lateral distance in an orthogonal direction (into the page). Although the embodiment of FIG. 5 illustrates a device having an extended drain region that comprises a single N-type drift region, it is appreciated that the vertical high-voltage transistor of FIG. 5 may be constructed with a plurality of parallel-arranged N-type drift regions. Ideally, it is desired to make the lateral thickness (i.e., width) of the N-type drift region(s) as narrow as can be reliably manufactured in order to achieve a very high Vbd with a low Rsp. Of course, a larger lateral thickness is easier to manufacture, but the specific on-resistance of the device suffers with a larger lateral thickness since the current is required to flow across a larger silicon area. In one implementation, the thickness is in the approximate range of 0.4 to 1.2 microns. In this example, the thickness of the mesa is about 1 um.
[0051] FIG. 5C shows the device structure of FIG. 5B after partial filling of the etched trenches with a dielectric material, e.g., silicon dioxide. As shown, in the embodiment of FIG. 5 oxide region 102 a covers one side of etched epitaxial region 101 , while oxide region 102 b covers the other side of epitaxial region 101 . Oxide region 102 also covers the top surface of N+ substrate 100 in each of the trenches.
[0052] The dielectric material may be introduced into the trenches using a variety of well-known methods. For instance, regions 102 may be grown thermally, deposited by chemical vapor deposition, and/or spun on in liquid form. For a given lateral thickness of epitaxial layer material 101 , the thickness of the dielectric layer may be set to provide a required breakdown voltage, with thicker dielectric layers providing a higher Vbd. However, thicker dielectric layers increase the cell pitch of the transistor structure and result in higher specific on-resistance. In one implementation, the 600V device structure of FIG. 5 has an oxide layer lateral thickness of 4 um. For devices with other V bd performance, this thickness may be in the range of about 2 um-5 um.
[0053] FIG. 5D illustrates the device structure of FIG. 5C following the steps of filling the remaining portions of the trenches with a conductive material and planarizing the surface to form field plate regions 103 . For example, the conductive material may comprise a heavily doped polysilicon, a metal (or metal alloys), and/or silicide. Conductor regions 103 a and 103 b form the field plate members of the device. In most cases, field plate members 103 a and 103 b should be made as narrow as can be reliably manufactured, since the field plate members occupy silicon area without directly contributing to device conductivity or breakdown voltage characteristics. In one embodiment, the lateral thickness of field plate members 103 is approximately 0.5 um-1.0 um. The planarization of the surface may be performed by conventional techniques such as chemical-mechanical polishing.
[0054] At this point in the process, fabrication of the extended drain region of the device is essentially complete. The remaining processing steps may be adapted to produce a stand-alone, high-voltage, depletion-mode MOSFET device structure (as shown in FIG. 5G and FIG. 6 ) or a high-voltage FET that incorporates a low-voltage MOSFET structure (e.g., FIG. 5K ), or other high-voltage devices.
[0055] FIG. 5E is a cross-sectional side view of the device structure of FIG. 5D after the introduction of an N+ source region 105 at the top surface of epitaxial layer 101 . Source region 105 may be formed using ordinary deposition, diffusion, and/or implantation processing techniques.
[0056] After formation of the N+ source region 105 an interlevel dielectric layer 106 if formed over the device. In the embodiment of FIG. 5 , interlevel dielectric layer 106 comprises ordinary silicon dioxide that may be deposited and patterned by conventional methods. Openings are formed in dielectric layer 106 and a conductive layer of material (e.g., metal, silicide, etc.) is deposited and patterned to produce the structure shown in FIG. 5F . In this cross-sectional view, source electrode 109 provides electrical connection to N+ source region 105 , and electrodes 110 a and 110 b provide electrical connection to field plate members 103 a and 103 b , respectively.
[0057] FIG. 5G shows the device structure of FIG. 5F following formation of a drain electrode 111 on the bottom of N+ substrate 100 . For example, drain electrode 111 may be formed using the conventional technique of metal sputtering. As described earlier, the bottom of the substrate may first be subjected to grinding, implanting, etc., to lower the drain contact resistance.
[0058] The device of FIG. 5G represents a completed high-voltage transistor having a stand-alone drift region; that is, the device of FIG. 5G does not include a low-voltage, series MOSFET structure at the top of the epitaxial layer. Instead, the extended drift region formed by the epitaxial layer, itself, performs the function of the MOSFET without the inclusion of a P-body region. Practitioners in the arts will note that in this device structure current cannot be completely turned-off, since there exists a continuous n-type path for electrons to flow from source electrode 109 to drain electrode 111 . Current flow In the device structure of FIG. 5G , however, does saturate when the mesa-like epitaxial layer 101 is pinched-off at high drain voltages.
[0059] The device structure of FIG. 6 achieves pinch-off of the extended drain region at lower voltages than the device of FIG. 5G . This is achieved by reducing the spacing between the field plate members 103 and epitaxial layer 101 near the top of the N-type drift region, thereby increasing the capacitance to pinch-off the vertical drift region at a relatively low voltage. FIG. 6 shows a multi-tiered field plate structure extending laterally into oxide regions 102 a & 102 b to control the pinch-off voltage and, therefore, the saturation current. Alternatively, the field plate members may comprise a single step, a linearly graded lateral extension, or some other profile shape designed to achieve the same result.
[0060] Those skilled in the arts will appreciated that for certain circuit applications it may be advantageous to utilize the stand-alone transistor structure of FIG. 5G (or FIG. 6 ) in series with an ordinary external, low-voltage switching MOSFET. In such an application the low-voltage (e.g., 40V) MOSFET could be used for switching purposes in order to completely turn off current flow in the high-voltage (e.g., 700V) transistor device.
[0061] Referring now to FIGS. 5H-5K , there is shown an alternative processing sequence that may be used to fabricate a vertical HVNMOS transistor that includes an insulated gate MOS structure.
[0062] Trenches 112 a and 112 b are formed in respective dielectric layers 102 a and 102 b on opposite sides of epitaxial layer 101 to accommodate the formation of the insulated gate structure. The depth of trenches 112 a and 112 b extends from the surface of N+ source region 105 to a depth governed by the intended MOSFET channel length and field plating considerations. In this example, the trench depth is about 1-5 um. By way of example, trenches 112 may be formed by appropriate application of a patterned masking layer to the semiconductor substrate followed by conventional dry or wet etching techniques into oxide layer 102 .
[0063] FIG. 5J shows the device after formation of gate dielectric layers 116 and gate members 113 within trenches 112 . The gate dielectric layers 116 a & 116 b may be formed by growing or depositing oxide on the sidewalls of the stacked N+ source, P-body, and epitaxial regions. The device threshold voltage determines the thickness of layers 116 . In one embodiment, layers 116 comprise silicon dioxide having a thickness on the order of 250-1000 angstroms.
[0064] In the embodiment shown, a portion of dielectric layers 112 isolates field plate members 103 from gate members 113 . Alternatively, trenches 112 may expose the top portion of field plate 103 and the same processing steps used to create layers 116 may also be used to form dielectric layers on the sidewalls of the field plates to isolate the field plates from the gate members.
[0065] Once dielectric layers 116 have been formed on the sidewalls of trenches 112 , a conductive material, such as doped polysilicon, may be deposited to fill the remaining portions of the trenches. In this implementation, the doped polysilicon forms the gate members 113 a and 113 b of the MOS transistor structure. FIG. 5J shows the device after introduction of a P-body region 107 and a N+ source region 105 at the top surface of epitaxial region 101 . In the completed device, application of a sufficient voltage to gate members 113 causes a conductive channel to be formed along the sidewall portions of P-body region 107 between N+ source region 105 and epitaxial region 101 . The channel length is therefore determined by the thickness of P-body region 107 , which, for the particular embodiment shown, may be approximately 0.5 um-3.0 um, with the N+ source region 105 in the range of about 0.1-0.5 um. A shorter channel length results in a lower channel resistance, which likewise reduces the on-resistance of the device. It should be understood, however, that a too short channel would cause punch-through problems.
[0066] FIG. 5K shows the completed HVFET device structure following formation of an interlevel dielectric layer 106 (e.g., silicon dioxide, silicon nitride, etc.). This layer may be deposited and patterned to form contact openings. In the embodiment shown, the etching of layer 106 is followed by etching of the field plates, gate members, N+ and P-body regions. This is followed by deposition and patterning of a conductive layer (e.g., metal, silicide, etc.) to create source electrode 109 , gate electrodes 115 , and field plate electrodes 110 , which provide electrical connection to the respective regions of the device. The optional etching step described above allows the source electrode to contact the P-body region without patterning the N+ source region, thus simplifying the process. A conductive layer may also be applied to the bottom of substrate 100 (after optional treatment by grinding, etching, implanting, etc.) to form the drain electrode 111 .
[0067] Note that while source electrode 109 is shown extending down to P-body 107 in the cross-sectional view of FIG. 5K , in other embodiments electrode may only extend to the upper surface of source region 105 . It should also be appreciated that electrode 109 does not separate region 105 into two separate source regions in the illustration of FIG. 5K . Rather, electrode 109 is fabricated in the form of a plug that is surrounded by N+ material that comprises region 105 . | A method for fabricating a high-voltage transistor with an extended drain region includes forming in a semiconductor substrate of a first conductivity type, first and second trenches that define a mesa having respective first and second sidewalls then partially filling each of the trenches with a dielectric material that covers the first and second sidewalls. The remaining portions of the trenches are then filled with a conductive material to form first and second field plates. Source and body regions are formed in an upper portion of the mesa, with the body region separating the source from a lower portion of the mesa. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b). | 7 |
BACKGROUND OF THE INVENTION
This invention relates generally to the field of extruded moldings, typically composed of aluminum or other material of similar properties, and more particularly relates to extruded molding sets that are utilized for joining vertically oriented panels and doors, such as found for example in shower enclosures.
When joining panels, doors and the like in a side-by-side planar or angled manner, it is known to utilize elongated molding sets, usually produced by extrusion. The molding sets are paired extruded members that connect to each other longitudinally. One elongated extruded member is joined to a panel member and the other extruded member is joined to a second panel or a door. Each of the extruded members is provided with a connection base configured to receive and retain the panel or the door, usually in conjunction with mechanical fasteners. The free sides of the extruded members are configured to mate or interconnect with each other, preferably without the need for mechanical fasteners, bonding or like means, with the interconnection being longitudinally extensive. With the extruded members respectively joined to the panel and door, the panel and door are positioned adjacent to each other and the extruded members are interlocked to combine the two extruded members into a relatively rigid vertical supporting and connecting means for the panel and door.
An example of an extruded molding set as described above is shown in U.S. Pat. No. 7,856,771 to Guidos et al. The extruded molding set shown in this patent comprises a pair of extruded moldings that are provided with two interconnecting means, a pivoting engagement interconnection and a mechanical locking interconnection, whereby the two moldings are first mated at the engagement interconnection, then one molding is pivoted to connect the mechanical interlocking connection, thereby securing the moldings to each other. A problem with this and similar constructions is that once the moldings are interlocked there is no easy way to disconnect the moldings, which would be desirable for example in order to replace a panel or door, which are often composed of glass, or to remove a panel or door to provide a temporary large access opening, for example.
It is an object of this invention to provide an extruded molding set intended and adapted for use with panels or doors, the set being structured to mechanically interlock together without the necessity of additional mechanical fasteners, wherein the set comprises structure which allows the extruded molding set to be easily and readily disconnected if desired.
SUMMARY OF THE INVENTION
The invention is an extruded molding set adapted for use with panels, doors or similar members, referred to hereinafter generally and collectively as panels, whereby the panels can be connected to each other in a side-by-side planar or angled orientation, the molding set comprising a pair of elongated extruded moldings, each molding structured to receive and retain a panel, and the moldings configured so as to longitudinally mate in interlocking manner. The first extruded member comprises a panel connection base adapted to retain a first panel, a first front face, a first rear face, a pivot flange member disposed on the free end of the first front face, a tongue member extending interiorly from the first rear face, and a release flange member extending laterally. The second extruded member comprises a panel connection base to retain a second panel, a second front face, a second rear face, a pivot channel member adapted to receive the pivot flange member, a locking channel member to receive the tongue member, and a recessed portion. With this construction, with the extruded members connected to the panels, the pivot flange member of the first extruded member is mated with the pivot channel member of the second extruded member. The extruded members are then pivoted together such that the tongue member of the first extruded member mates with the locking channel member of the second extruded member, thereby interlocking the extruded member set. The combination of the release flange member of the first extruded member and the recessed portion of the second extruded member defines a release channel sufficiently sized to allow for insertion of a pry tool such that the tongue member of the first extruded member can be removed from the locking channel member of the second extruded member, thereby disconnecting the extruded member set.
Alternatively presented, the invention is an extruded molding set comprising a first extruded molding comprising a first panel connection base, a first front face extending from said first panel connection base, a first rear face extending from said first panel connection base, a pivot flange member disposed on said first front face, and a tongue member and a release flange member disposed on said first rear face; a second extruded member comprising a second panel connection base, a second front face extending from said second panel connection base, a second rear face extending from said second panel connection base, a pivot channel member disposed on said second front face, and an internal flange, a locking channel member and a recessed portion disposed on said second rear face; said pivot flange member received by said pivot channel member in a manner whereby said first and second extruded members are pivotable relative to each other; said tongue member received by said locking channel member in a manner whereby said first and second extruded members are mechanically interlocked together; the combination of said release flange and said recessed portion defining a release channel adapted to receive a pry tool therein, whereby said tongue member may be leveraged from said locking channel member to disconnect said first and second extruded members.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a prior art extruded molding set.
FIG. 2 is a cross-sectional view of another prior art extruded molding set.
FIG. 3 is a cross-sectional view of an embodiment of the extruded molding set shown prior to interlocking.
FIG. 4 is a cross-sectional view of the embodiment of FIG. 3 shown in the interlocked position.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings, the invention will now be described in detail with regard for the best mode and the preferred embodiment(s). The drawings are provided as required for illustrative purposes and not intended to be limiting. The term “panel” as used herein shall be taken to refer to and include panels, doors or similar members, such as for example glass shower enclosure panels and doors.
FIGS. 1 and 2 illustrate prior art embodiments of extruded molding sets adapted for connecting panels to each other in a manner similar to the manner of this invention but without the release structure. Each of the extruded molding sets in the figures show a first extruded molding 101 connected to and retaining a first panel 102 and a second extruded molding 105 connected to and retaining a second panel 106 . The two extruding moldings connect in interlocking manner through the combination of a pivoting engagement assembly 103 and a locking assembly 104 . The extruded members 101 and 105 are joined together by first aligning or mating the pivoting engagement assembly 103 . One of the extruded members 101 or 105 is then rotated such that the locking assembly 104 snaps together. Once interconnected, the extruded members 101 and 104 cannot easily be separated.
A preferred embodiment of the extruded molding set of the invention is shown in FIGS. 3 and 4 . The extruded molding set comprises a first extruded molding 10 and a second extruded molding 20 . The moldings 10 and 20 are preferably composed of aluminum, but may be composed of any material possessing similar properties, such as other metals or rigid plastics. The moldings 10 and 20 are elongated members with the extended dimension defining a longitudinal direction. Each of the moldings 10 and 20 is adapted to receive and retain, or looked at another way, to be mountable onto the edge of a panel member 30 / 31 . The moldings 10 and 20 may be joined to the panel edges in any known manner, such as for example by utilizing mechanical fasteners, mechanical interlocking or bonding compositions. As illustrated, first extruded molding 10 comprises a first panel connection base 11 suitable for connection to a fixed first panel 30 , and second extruded molding 20 comprises a second panel connection base 21 suitable for connection for example to a pivoting second panel member 31 , e.g., a door. The particular configurations of the panel connection bases 11 and 21 are not critical to the invention, and other known configurations, such as those panel connection bases shown in the illustrated prior art sets, may be substituted for the configurations in the illustrations without departing from the functionality of the invention. The sides of the moldings 10 and 20 opposite the panel connection bases 11 and 21 and extending away from panels 30 and 31 are configured as shown to be generally open.
The first extruded member 10 comprises a first front face 12 and a first rear face 13 , both of which extend away from the first panel connection base 11 . A longitudinally elongated pivot flange member 14 is disposed on the free edge of the first front face 12 , i.e., the edge not connected to the first panel connection base 11 . The pivot flange member 14 is preferably generally triangular or rounded in cross-section and extends toward the interior of the first extruded member 10 . A longitudinally elongated tongue or rail member 15 is positioned on the interior of the first rear face 12 and extends inwardly. A longitudinally elongated release flange member 16 is disposed on the free edge of the first rear face 12 at the junction with and extending beyond the tongue member 15 , the release flange 16 extending generally laterally.
The second extruded member 20 comprises a second front face 22 and a second rear face 23 . A longitudinally elongated pivot channel member 25 is disposed on the free edge of the second front face 22 , the pivot channel member 25 facing outwardly. The pivot channel member 25 is configured to receive and retain the pivot flange member 14 of the first extruded member 10 in a stable and relatively secure manner after the extruded members 10 and 20 are interconnected, in a manner which allows the extruded members 10 and 20 to be pivoted relative to each other during the interlocking operation. Thus, the mating sides of the pivot channel member 25 and the pivot flange member 14 will correspond or match, such that for a generally triangular pivot flange member 14 the receiving side of the pivot channel member 25 will be generally triangular, and for a generally curved pivot flange member 14 the receiving side of the pivot channel member 25 will be correspondingly curved. The second extruded member 20 further comprises a longitudinally elongated locking channel member 26 positioned on second rear face 23 , the locking channel member 26 configured to receive and retain the tongue member 15 of the first extruded member 10 . An internal flange 24 on the second rear face 23 extends generally laterally beyond the locking channel member 26 away from the second panel connection base 21 . The second rear face 23 further comprises a recessed shoulder or portion 27 disposed on the opposite side of the locking channel member 26 from the internal flange member 24 .
The extruded members 10 and 20 are interlocked by first aligning and mating the pivot flange member 14 and the pivot channel member 25 , such that the pivot flange member 14 is positioned and received within the concave side of the pivot channel member 25 . At this stage the extruded members 10 and 20 are oriented in a slightly open combination. As one or both of the extruded members 10 and 20 are pivoted together, the tongue member 15 of the first extruded member 10 encounters the internal flange 24 of the second extruded member 20 , as seen in FIG. 3 . Continued pivoting causes the first rear face 13 to be biased outwardly relative to the first panel connection base 11 such that when the tongue member 15 slides along the internal flange 24 and becomes aligned with the locking channel member 26 , the tongue member 15 and first rear face 13 snap forward. The tongue member 15 is now received and retained by the locking channel member 26 and the internal flange 24 abuts the rear of the first rear face 13 . With the tongue member 15 seated in the locking channel member 26 , the pivot flange member 14 of the first extruded member 10 is fully seated within the pivot channel member 25 , as shown in FIG. 4 . The extruded members 10 and 20 and their attached panels 30 and 31 are now connected in a fixed manner.
In the interlocked position, the release flange member 16 of the first extruded member 10 extends past the locking channel member 26 so as to reside adjacent but separated from the recessed portion 27 of the second extruded member 20 . The combination of the release flange member 16 and the recessed portion 27 define a longitudinally elongated release channel 28 . With this structure, the extruded members 10 and 20 can be separated by inserted a pry member or tool, such as the flat blade of a screwdriver for example, into the release channel 28 . The pry member is used to leverage the tongue member 15 out of the locking channel member 26 so that the extruded members 10 and 20 can then be pivoted apart and separated.
It is understood that equivalents and substitutions for certain elements set forth above may be obvious to those of ordinary skill in the art, and therefore the true scope and definition of the invention is to be as set forth in the following claims. | A first extruded molding and a second extruded molding combined to form an extruded molding set, the moldings joined in a mechanical interlocking manner, the first extruding molding having a release flange and the second extruded molding having a recessed portion that together define a release channel, whereby the first and second molding may be disconnected by inserting a pry tool into the release channel to release the mechanical interlock. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to diagnostic measurements and therapeutic treatment of body cavities. More particularly, one form of the invention concerns a method and apparatus for making dynamic biomechanical measurements of a body cavity. More specifically, the method involves the use of pressure and flow of fluid (liquid or gas) in and out of the body cavity to characterize the elastic properties of the cavity wall and to draw conclusions as to the presence or absence of disease in the organ that contains the cavity. Another form of the invention concerns controlled pressurization of the body cavity for therapeutic purposes, which includes both pain/discomfort reduction and motility rehabilitation.
[0003] 2. Discussion of the Prior Art
[0004] In the past pressurized inflation of body organs and body cavities has been used in a variety of fashions. Some of these uses include air inflation of a body cavity for purposes of visualization (colonoscopy, laperoscopy) and others to deliver vital oxygen into the lungs (artificial ventilation), and intrauterine insufflation to check for potency during an ablative procedure. The use of pressure to extrapolate mechanical properties of tissue or body cavities has also been used to a limited extent in pulmonary function testing.
[0005] Other existing technology uses a balloon inserted in the rectum to measure threshold for sensitivity or pain in individuals with Irritable Bowel Syndrome. The machine is called a ‘Barostat’ (Brouin M., Gastroenterology, 10 Jun. 2000: 122(7): 1771-7). The Barostat can also be used to measure stress/strain relationship of the wall of the rectum (Whitehead W E, Dig. Dis. Sci, 01 Feb. 1997: 42(2): 223-41; Disrutti E., Gastroenterology, 01 May 1999: 116(5): 1035-42). The current invention measures biomechanical properties without the use of a balloon. The Barostat is not used for therapeutic applications like the current invention.
[0006] Biologic tissue is known to be viscoelastic in nature, a property that is known to be altered by disease state.
[0007] In Irritable Bowel Syndrome, the colon loses its ability to coordinate movement due to increase, decrease, or alteration in its muscular tone. However, as will become apparent from the description which follows, these spastic or flaccid tendencies are measured and treated by the method of the present invention.
SUMMARY OF THE INVENTION
[0008] The method and apparatus described in the present invention involves the controlled infusion of a fluid (gas or liquid) into a body cavity both for therapeutic purposes as well as for the purpose of ascertaining the dynamic biomechanical properties of the organ in which the cavity is contained. The methods of the invention are diverse and cover many aspects of medicine. In particular, the diagnostic methods of the invention are concerned with two types of biomechanical measurements, namely measurements during pressurization (load) and during depressurization (unload). Loading occurs when the fluid (liquid or gas) is actively infused into the body cavity, and unloading occurs when the fluid (liquid or gas) is passively allowed to be expelled from the cavity by the organ's own biomechanical rebound.
[0009] In one form of the method of the invention, a flexible tube is used to connect the body cavity to the apparatus of the invention and this novel method includes the following features:
(a) a pressurizing system capable of producing fluid (liquid or gas) which is calibrated in a manner that is to accurately measure pressure and/or flow during the load phase; (b) a system that is capable of controllably delivering the fluid (liquid or gas) in a safe manner; (c) a system that includes tubing that permits the efficient delivery and infusion of the fluid (liquid or gas) into the body cavity; (d) a system that includes means for accurately monitoring pressure and/or flow characteristics during the inflow or load phase; (e) a system that includes tubing that enables the fluid (liquid or gas) to be expelled from the body cavity and delivered into a discharge bag; (f) a system that enables monitoring of pressure and/or flow during the outflow or unload phase; (g) a system that enables data collection for purposes of interpretation during both the inflow and outflow phases; and (h) a system that provides interactive features which permit the user to adjust the parameters of pressure and/or flow, based on the nature of the body cavity being investigated, including:
choosing the initiation pressure during the inflow phase; choosing the pressure level at which the loading phase ends and the unloading phase begins; that is, during the inflow/outflow transition; choosing the pressure level at which the unloading phase is terminated; choosing the maximum pressure allowable within the body cavity during the pressurizing phase; choosing the maximum volume allowable for infusion in the body cavity; and a system which allows for automatic cessation of pressurization, along with the opening of a safety valve if the preset maximum pressure is exceeded.
[0024] Once the user of the apparatus initiates a specific study, the study will proceed from inflow to outflow without interruption so long as the pressure within the body cavity remains within predetermined levels. In this regard, the system is designed to permit the user to reset the system and repeat the study under the same or different parameters.
[0025] In the one form of the diagnostic method of the invention, the apparatus allows for data collection and storage capabilities so that the pressure and flow data can later be used for purposes of interpretation as to the dynamic loading/unloading biomechanical properties of the cavity under investigation. Ultimately, the same data can also be used for therapeutic planning.
[0026] The therapeutic features of the invention allow for the following:
a system to pressurize a cavity (colon) in a certain therapeutic fashion to reduce pain or abnormal perceptions/sensations. a system to allow the tissue (musculature of the colon) to exert effort to expel fluid (liquid or gas) at a certain controlled predetermined fashion. a system to tailor the inflation/deflation parameters based on the disease process of the organ in question. a system to manipulate the parameters of therapeutic inflation/deflation based on biomechanical feedback system and on the pain/discomfort reduction effectiveness, or other subjective perceptions of relief expressed by the patient.
[0031] The apparatus of the invention can also be used for motility rehabilitative purposes. More particularly, the apparatus can be used to train body cavities with motility dysfunction to function more normally. This can be achieved with repetitive inflation and deflation of the body cavity. With repeated training of the body cavity using the device, the organ can be rehabilitated in a manner to achieve for long-term, sustainable normal functional motility.
[0032] When used for rehabilitation purposes the apparatus:
(a) can be used to pressurize a selected body cavity in a repetitive fashion as predetermined by the user; (b) can be used to determine the strengths and weaknesses of the body cavity, hence allowing the user to design a treatment plan; (c) can be used to carry out procedures that are customized for the unique biomechanical features of a body cavity; (d) can be used to restrain and restrict or even stimulate the mechanical response of a body cavity to a finite and predetermined range; (e) can be used to cause the body cavity to be rehabilitated and “rewired” neurologically for proper motility and biomechanical functioning; and (f) can be customized for each individual patient using modes and settings of the system. These variables include: flow rate, pressure, pressure rate change, interval between cycles, amplitude of cycle, variations between cycles, resistance of outflow, and number of cycles. Variations can also be made within same treatment mode (intratreatment variation), variation from one treatment to the next (intertreatment variations) and interactive variations (programmed).
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a generally perspective view of one form of the apparatus of the invention for making biomechanical measurements of a body cavity.
[0040] FIG. 2 is a generally diagrammatic view illustrating the various components that make up apparatus of the invention shown in FIG. 1 .
[0041] FIG. 3 is a generally diagrammatic view illustrating the operational interrelationship among the various components of one form of the apparatus of the invention.
[0042] FIG. 4 is a generally diagrammatic view illustrating the sequence of operation of one form of the priming method of the invention.
[0043] FIG. 5 is a generally diagrammatic view further illustrating the sequence of operation of one form of the apparatus of the invention.
[0044] FIG. 6 is a generally diagrammatic view illustrating the automatic termination feature of the invention.
[0045] FIG. 7 is a graphical representation illustrating operational pressures as a function of time during the performance of an alternate, diagnostic form of the method of the invention.
[0046] FIG. 8 is a generally diagrammatic view further illustrating the sequence of operation of an alternative rehabilitation form of the apparatus of the invention.
[0047] FIG. 9 is a graphical representation illustrating pressure as a function of time during the rehabilitation method of the invention.
DESCRIPTION OF THE INVENTION
[0048] Referring to the drawings and particularly to FIGS. 1 and 2 , one form of the apparatus of the invention is there shown and generally designated by the numeral 14 . The apparatus here comprises a hollow housing 16 having a front panel 18 upon which a display button 20 is mounted. Front panel 18 also carries a start button 22 and a reset button 24 . Disposed within the hollow housing 16 —See FIG. 2 —is a conventional air compressor 26 which draws air from atmosphere, compresses it and introduces the compressed air into an air tank 28 via a conduit 27 .
[0049] Interconnected with air tank 28 is an elongated fluid (liquid or gas) flow conduit that comprises a first segment 30 that has a proximal end 32 and a distal end 34 . Proximal end 32 is connected to air tank 28 while distal end 34 communicates with the first portion, or inflow branch 35 a of an interface means, shown here as a disposable external tubing assembly 35 . The second portion, or main trunk 35 b of tubular assembly 35 communicates with the body cavity “B” that is to be pressurized. Disposed intermediate proximal end 32 and distal end 34 of the first segment 30 of the fluid (liquid or gas) flow conduit is a pressure gauge 36 , a pressure regulator 38 , a flow regulator 40 and a safety valve 42 . Pressure gauge 36 is used to verify that there is sufficient pressure in conduit segment 30 to initiate the inflow cycle of one form of the method of the invention. The pressure regulator 38 ensures uniformity of pressure during the conduct of the method of the invention and the flow regulator 40 ensures uniformity of air flow through the segment 30 . The safety valve 42 , which communicates with atmosphere, remains closed during the operational sequences of the method unless the pressure in the system exceeds a predetermined maximum level in which case the safety valve automatically opens to vent the system to atmosphere. Also disposed intermediate the proximal and distal ends of segment 30 is an inflow valve 44 that remains in a closed position while the apparatus is in a standby mode.
[0050] As illustrated in FIG. 2 of the drawings, the third portion, or outflow branch 35 c of the external tubing assembly 35 communicates with a second segment 46 of the fluid (liquid or gas) flow conduit. This second segment has a proximal end 46 a and a distal end 46 b that is interconnected with a disposable discharge bag 48 . Disposed between the proximal and distal ends of second segment 46 are an outflow valve 50 and an outflow regulator 52 for regulating fluid (liquid or gas) flow through segment 46 . Communicating with second segment 46 , proximate its proximal end 46 a , is the important sensor means of the invention, shown here as a pressure sensor 54 . Pressure sensor 54 senses the pressure within second segment 46 , generates an appropriate pressure signal and transmits the pressure signal to the control means, or microprocessor, of the invention which is housed within housing 16 .
[0051] Turning also to FIG. 3 of the drawings, it can be seen that the control means of the present form of the invention comprises the central processing unit, CPU, 58 of a conventional microprocessor 60 that is interconnected with, and controls the operation of, many of the operating components that make up the apparatus of the invention.
[0052] In the conduct of one form of the method of the invention, the user first activates the apparatus by manipulating the main switch 62 ( FIG. 1 ). Upon activation of the device, the control means, or CPU 58 , which has been appropriately programmed in a manner well known to those skilled in the art, will cause the inflow valve 44 to open and will energize the compressor 26 so as to cause—See FIGS. 2 and 3 —the controlled pressurization of air tank 28 and the segment 30 . When the pressure in segment 30 reaches a predetermined level as determined by the pressure gauge 36 , the CPU will receive an appropriate signal from the pressure gauge 36 via the signal pressure indicator 64 . At this point, the CPU will cause the illumination of an illuminable green, ready light 69 , which is mounted on panel 18 of housing 16 , and will also cause an audio signal to be emitted by the audio signaling device 70 carried by housing 16 . Upon receiving these signals the user will set the appropriate operating parameters of the method that is to be conducted. In the present form of the invention this is accomplished through use of the setting 72 , the mode 74 , the up 76 and the down 78 features of the apparatus ( FIG. 3 ). After the appropriate operating parameters have been set, the user pushes the start button 22 causing the CPU to commence the testing cycle by first opening the inflow valve 44 thereby permitting the controlled pressurization of the body cavity “B”. In accordance with this method of the invention, the pressurization of the body cavity will be constantly monitored by the sensor means or pressure sensor 54 . When the pressure reaches a preset level, the CPU will cause the inflow valve 44 to close, the compressor to be deenergized and the outflow valve 50 to open. Opening of the outflow valve 50 signals the commencement of the outflow, or unload, phase of the method of the invention.
[0053] At the commencement of this important outflow phase, the body cavity “B” will recoil in a manner to exert a rebound pressure that will drive the air from the body cavity, through conduit 46 and into the disposable collection bag 48 via the flow regulator 52 . The end of the outflow cycle occurs when the pressure within the system drops below a predetermined level. At this time the outflow valve 50 will be automatically closed by the CPU. It is to be understood that, if during the testing process, the pressure within segment 30 exceeds a predetermined level as determined by the pressure gauge 36 and the sensor 54 , the CPU will automatically deenergize the compressor 26 and will cause the safety valve 42 to automatically open.
[0054] If the user wishes to repeat the test, the reset button 24 ( FIG. 1 ) is pushed. This will cause the opening of the outflow valve 50 for a predetermined, short period of time in order to decompress the external tubing assembly 35 and the body cavity space “B”. The CPU will then close the outflow valve 50 , and close the inflow valve 44 ( FIG. 3 ) and will energize the compressor 26 . As before, when the pressure within segment 30 reaches a predetermined level the green ready light will be illuminated and the testing method can be repeated in the manner previously described.
[0055] Turning next to FIG. 4 of the drawings, the priming method of the invention is there illustrated. This priming step can be accomplished in one of two ways, either by pressing the reset button 24 or by operating the main switch 62 ( FIG. 1 ). In either case, this causes outflow valve 50 to open, the inflow valve 44 to close and the compressor 26 to be energized. The pressure within segment 30 is then determined using pressure gauge 36 , and this pressure is compared with the preset starting threshold pressure. This step is repeated until the pressure within the segment 30 exceeds the desired starting threshold pressure at which point the microprocessor closes the outflow valve 50 , causes the green light 69 to illuminate and causes an audio signal to be generated 70 .
[0056] Referring next to FIG. 5 of the drawings, the method of the present invention is further illustrated there. Following appropriate programming of the microprocessor unit of the invention and after the apparatus has been interconnected with a source of electrical power “S” ( FIG. 1 ), the ready button 66 is pressed to start the testing procedure. As indicated in FIG. 5 , this causes the inflow valve 44 to open. At this point the pressure sensor 34 monitors the pressure P XT in the external tubing assembly 35 and compares this pressure to a preset critical pressure. At such time that the pressure P XT exceeds the predetermined critical pressure P C , the CPU closes the inflow valve 44 , deenergizes the compressor 26 and opens the outflow valve 50 . At this time the apparatus, or Zero, timer 84 , which is set at zero, is started. Once the timer reaches a predetermined elapsed time as, for example, 10 seconds, the P XT is monitored using sensor means until it reaches a level less than a predetermined ending pressure P E . When this pressure is reached, the cycle is finished, the green light 69 is energized and an audio signal is generated 70 .
[0057] Turning to FIG. 6 of the drawings, the automatic termination feature of the method of the invention is there illustrated. This feature of the invention, which is preprogrammed in the microprocessor, is triggered when the pressure P AT in the conduit 30 , as measured by gauge 36 or sensor 54 , exceeds a predetermined pressure P MAX . When this happens, the safety valve is opened, the compressor 26 is automatically deenergized, the outflow valve 50 is automatically opened, a red signal light 85 is illuminated and an audio alarm is sounded 71 .
[0058] FIGS. 7A and B graphically depict pressure changes in the system as a function of time during the conduct of the diagnostic method of the invention. More particularly, FIG. 7A depicts pressure changes in segment 30 of the internal system as measured by pressure gauge 36 . Similarly, FIG. 7B depicts pressure changes in the external system, or disposable assembly 35 during the loading and unloading cycles of the diagnostic method of the invention. As illustrated in FIG. 7A , as the air is introduced into the body cavity “B” at the starting pressure P S , which exceeds the external pressure P E , the pressure first decreases and then progressively increases as a function of time. As shown by segment 91 of FIG. 7A , the initial pressure change is relatively slow. However, as the body cavity exerts resistance to the inward flow of air, the pressure increases more rapidly as illustrated by segment 93 of FIG. 7A . When the pressure reaches a critical level P C , the pressure curve flattens indicating the completion of the inflow study. The various diagnostic parameters that can be extracted from the graphical representation include but are not limited to the initial slope as depicted by segment 91 , the maximum slope ( 93 ), the time to reach maximum slope, etc. Analysis of these parameters, which reveal the elastic properties of the body cavity, can be used to draw conclusions as to the presence or absence of disease in the organ that contains the cavity.
[0059] Referring to FIG. 7B , once the peak pressure P C is reached the compressor is deenergized by the CPU and the outflow valve 50 is opened. This permits the air under pressure to flow from the body cavity “B” toward the discharge bag 48 . As indicated by the curved segment 95 there is initially a steep decline in pressure followed by a slower decline in pressure. The parameters that can be extracted from the graphical representation include the initial slope of the curve, the peak slope P S of the curve and the time to reach a 50% decline in pressure. These parameters can also be used to draw conclusions as to the condition of the organ that contains the cavity.
[0060] It is to be understood that many different types of loading and unloading studies can be performed using the apparatus of the invention to extract a variety of biomechanical parameters and functional motility characteristics of the organ under study. Furthermore, it is to be appreciated that, while the Figure drawings illustrate studies of pressure as a function of time, studies can also be undertaken involving data collection and plotting of fluid (liquid or gas) flow as a function of time, rather than pressure change as a function of time, along with other fluid (liquid or gas) mechanics correlations.
[0061] Turning to FIGS. 8 and 9 of the drawings, the various steps in an alternate form of the method of the invention for purposes of rehabilitation are there illustrated. More particularly, as previously mentioned, the apparatus can be used to train body cavities with motility dysfunction to function more normally. By way of example, this can be achieved by repeatedly inflating and deflating the body cavity. This technique can also be used to determine the strengths and weaknesses of a particular body cavity and can be customized for each individual patient. As indicated in FIG. 8 , when the apparatus is in the “ready” status, the “modes” and “settings” buttons ( 74 , 72 of FIG. 1 ) can be used to place the apparatus in the rehabilitation mode at the appropriate setting. When this is done the cycle counter 99 sets itself to n=0. The first cycle then begins with the microprocessor opening the inflow valve 44 and closing the outflow valve 50 . This will permit controlled pressurization of the body cavity. The pressurization of the body cavity is monitored by the sensor 54 and appropriate pressure signals are transmitted to the CPU. The CPU compares the pressure P XT in the external tubing system 35 with a predetermined peak pressure P P ( FIG. 9 ). At such time as the external pressure exceeds the peak pressure, the CPU automatically closes the inflow valve 44 and opens the outflow valve 50 . This permits fluid (liquid or gas) outflow from the body cavity in a manner to cause a decrease in the pressure. When the pressure decreases below a predetermined pressure P T , the counter 99 records the completed cycle as n=n+1. If the number of cycles is below the planned number of cycles n p , i.e., n<n p , another cycle is automatically commenced. If the number of cycles reaches or exceeds the planned number of cycles, the system will automatically go into the reset mode ( FIG. 8 ).
[0062] It is to be understood that the methods of the invention for rehabilitation can be customized for a particular patient with the pressure levels, the number of cycles to be undertaken and a variety of modes and settings can be specially selected for that particular patient. The settings are extracted from data obtained during the diagnostic phase of the invention when used on that patient undergoing the therapeutic intervention. | A method and apparatus for both the diagnostic measurement and therapeutic treatment of a body cavity. According to one form of the method of the invention, a fluid (liquid or gas) under pressure is introduced into a selected body cavity while monitoring the pressure or flow of the fluid (liquid or gas) into the cavity. Following pressurization of the body cavity, fluid (liquid or gas) inflow and outflow data is collected and analyzed. The data collected is used to draw various conclusions about the biomechanical properties of the body cavity and the organ in which it is present, and also to draw conclusions about presence or absence of disease as well as the character of disease. According to another method of the invention a fluid (liquid or gas) is controllably infused into the body cavity to controllably expand the body cavity for purposes of therapeutic treatment. | 0 |
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,616,198 entitled "Contact Arrangement for a Current Limiting Circuit Breaker" describes the early use of a first and second pair of circuit breaker contacts arranged in series to substantially reduce the amount of current let-through upon the occurrence of an overcurrent condition.
When the contact pairs are arranged upon one movable contact arm such as described within U.S. Pat. No. 4,910,485 entitled "Multiple Circuit Breaker with Double Break Rotary Contact", some means must be provided to insure that the opposing contact pairs exhibit the same contact pressure to reduce contact wear and erosion.
One arrangement for providing uniform contact wear is described within U.S. Pat. No. 4,649,247 entitled "Contact Assembly for Low-voltage Circuit Breakers with a Two-Ann Contact Lever". This arrangement includes an elongate slot formed perpendicular to the contact travel to provide uniform contact closure force on both pairs of contacts.
U.S. Pat. No. 5,030,804 entitled "Contact Arrangement for Electrical Switching Devices" describes providing a pair of cylindrical plates on either side of the contact arms and forming elongated slots within each of the cylindrical plates.
Other examples of circuit breakers employing rotary contacts are found in U.S. Pat. No. 5,281,776 entitled "Multipole Circuit Breaker with Single Pole Units; U.S. Pat. No. 5,310,971 entitled "Molded Case Circuit Breaker with Contact Bridge Slowed Down at the End of Repulsion Travel"; and U.S. Pat. No. 5,357,066 entitled "Operating Mechanism for a Four-Pole Circuit Breaker".
State of the art circuit breakers employing a rotary contact arrangement employ a rotor assembly and pair of powerful expansion springs to maintain contact between the rotor assembly and the rotary contact arm as well as to maintain good electrical connection between the contacts, per se. The added compression forces provided by the powerful expansion springs must be overcome when the contacts become separated by the contact "blow open" forces of magnetic repulsion that occur upon extreme overcurrent conditions within the protected circuit before the circuit breaker operating mechanism has time to respond.
One purpose of the invention is to describe a rotary contact arrangement having expansion springs arranged between the rotary assembly and the rotary contact arm that maintain good electrical connection between the contacts during quiescent operating current conditions while enhancing contact separation upon occurrence of extreme overcurrent conditions.
SUMMARY OF THE INVENTION
A circuit breaker rotary contact assembly employs a common pivot between the rotor assembly and the rotary contact arm. A pair of off-center expansion springs directly engage the rotor at one end and engage the rotary contact arm via a linkage arrangement at an opposite end thereof. Both the rotary contact arm and the rotor assembly are slotted at the points of contact with the extension springs for tolerance compensation between the rotary contact assembly components as well as to reduce contact wear and contact erosion
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view of a circuit breaker employing a rotary contact assembly according to the invention;
FIG. 2 is a top perspective view of the complete contact assembly contained within the circuit breaker of FIG. 1;
FIG. 3 is a an enlarged top perspective view of the rotor in isometric projection with the contact arm assembly of FIG. 2;
FIG. 4 is an enlarged front plan view of the rotary contact arm assembly according to the invention with the contacts in the CLOSED position;
FIG. 5 is an enlarged front plan view of the rotary contact arm assembly according to the invention with the contacts in the OPEN position; and
FIG. 6 is an alternate embodiment of the rotary contact arm assembly according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A multi-pole circuit breaker 10 is shown in FIG. 1 consisting of a case 14 and cover 15 with an operating handle 16 projecting from the cover through an aperture 17. The operating handle interacts with the circuit breaker operating mechanism 18 to control the ON and OFF positions of the central rotary contact arm 30, and central rotary contact arm assembly 32 within the circuit breaker operating mechanism. The contact arm assembly 32 being formed within the central pole 11. A first rotary contact arm 22 and first rotary contact arm assembly 20 within a first pole 12, on one side of the operating mechanism 18 within the central pole 11, and a second rotary contact arm 24 and second rotary contact arm assembly 21 within a second pole 13 on the opposite side of the central pole, move in unison to provide complete multi-pole circuit interruption. An elongated pin 38 interconnects the operating mechanism 18 with the center, first, and second rotary contact arm assemblies 32, 20, 21. As described within the aforementioned U.S. Pat. No. 4,649,247 a rotor 19 interconnects each of the rotary contact arms 22, 24, 30 with the corresponding pairs affixed contacts 27, 27' and, movable contacts 28, 28'.
The rotor 19 in the circuit breaker assembly 9 is depicted FIG. 2 intermediate the line strap 23 and load strap 31 and the associated arc chutes 33, 34. The first rotary contact arm assembly 20 and second rotary contact arm assembly 21 of FIG. 1 are not shown herein but are mirror images of the central rotary contact arm assembly 32 and operate in a similar manner. The arc chutes 33, 34 are similar to that described within U.S. Pat. No. 4,375,021 entitled "Rapid Electric Arc Extinguishing Assembly in Circuit Breaking Devices Such as Electric Circuit Breakers". The central rotary contact arm 30 moves in unison with the rotor 19 that, in turn, connects with the circuit breaker operating mechanism 18 of FIG. 1 by means of the elongated pin 38 to move the movable contacts 28, 28' between the CLOSED position depicted in solid lines in FIG. 4 and the OPEN position. The clevis 35 consisting of the extending sidearms 36, 37 attach the rotor 19 with the circuit breaker operating mechanism 18 and the operating handle 16 of FIG. 1 to allow both automatic as well as manual intervention for opening and closing the circuit breaker contacts 27, 27' and 28, 28'. The rotor 19 is positioned between the line and load straps 23, 31 along with one of the contact pairs 27, 28; 27', 28' to hold the contacts in close abutment to promote electrical transfer between the fixed and moveable contacts during quiescent circuit current conditions. The operating pivot pin 29 of the central rotary contact arm 30 extends through the rotor 19 and responds to the rotational movement of the rotor to effect the contact closing and opening function in the manner described within the Italian Patent Application (75IT100) entitled "Rotary Contact Assembly for High Ampere-Rated Circuit Breakers".
In accordance with the teachings of the invention, a hinged attachment between the slotted rotor surfaces 19A, 19B arranged on opposite sides of the slotted movable contact arm 30 within the rotor assembly 39 as now shown in FIG. 3 provides for automatic tolerance compensation between the slotted rotors and the slotted movable contact arms within all three poles 11-13 of the circuit breaker 10 of FIG. 1. The slotted contact arm 30 includes a slotted pivot aperture 46 for receiving the pivot pin 29 and a pair of top and bottom links 48, 49 attached to the slotted movable contact arm by means of pins 52, 53 and apertures 54, 55 arranged within the V-shaped slots 50, 51. The slotted rotor 19 defines a pair of outer surfaces 19A, 19B each include central apertures, one of which is shown at 60 for receiving the pivot pin 29, along with opposing shallow slots 44A, 44B and opposing deep slots 45A, 45B, as indicated. A first expansion spring 40 is attached to the slotted rotors by means of first pins 42A, 42B. The slotted contact arm 30 is inserted within the slot 63 formed within the slotted rotor intermediate the rotor outer surfaces 19A, 19B. The first pin 42A extends through the shallow slot 44A and the second pin 42B extends through the deep slot 45B. The first pin 42A extends under the surface 61 defined under the movable contact 30A and then through one end of an opposing expansion spring 58 on the rotor outer surface 19B. The second pin 42B extends through the deep slot 45B, through the aperture 56 in the top link 48, and then through the other end of the expansion spring 58 on the rotor outer surface 19B. A second expansion spring 41 is attached to the slotted rotor by means of second pins 43A, 43B. The second pin 43A extends through the deep slot 45A, through the aperture 57 in the bottom link 49, and then through one end of an opposing expansion spring 59 on the rotor outer surface 19B. The second pin 43B extends through the shallow slot 44B, over the surface 62 defined on the movable contact arm 30B and then through the other end of the expansion spring 59 on the rotor outer surface 19B.
The slotted rotor assembly 39 is depicted in FIG. 4 with the movable contacts 28, 28' on the opposite ends of the contact arms 30A, 30B in the CLOSED condition relative to the fixed contacts 27, 27' (shown in FIG. 1). The top and bottom links 48, 49 are arranged on the top and bottom parts of the slotted contact arm 30 within the V-shaped slots 50, 51 and within the associated slots 45A, 45B on the slotted rotor 19 as viewed from the rotor surface 19A. The expansion spring 41 is shown arranged between the pins 43A, 43B and the expansion spring 40 between the pin 42B in the top link 48 and the pin 42A is omitted to show the positional relationship between the line of force F 1 directed through the pins 42B, 52 in the top link 48. This arrangement provides optimum contact pressure between the movable and fixed contacts 28, 27, 28', 27' while allowing for contact wear compensation and tolerance adjustment between the components within the rotor assemblies 39 within the individual poles within the circuit breaker of FIG. 1.
Upon occurrence of a large overcurrent condition within the circuit breaker assembly of FIG. 2 containing the slotted rotor assembly 39 of FIG. 5, the magnetic repulsion forces generated between the movable and fixed contacts 28, 27, 27' (shown in FIG. 1) within the circuit breaker assembly drive the movable contact arms 30A, 30B and the associated movable contacts 28, 28' in the counterclockwise direction about the pivot pin 29 to the OPEN position shown in FIG. 5. The rotation of the upper link 48 moves the link pin 52 to the position indicated in FIG. 5 such that the line of force exerted by the expansion springs 40, 41 (FIG. 3) is now directed through the pins 42B, 52 in the top link 48 as indicated at F 2 , locking the slotted contact arm 30 in the OPEN position to prevent re-closure of associated the movable and fixed contacts 28, 27, 28', 27' until the circuit breaker operating mechanism 18 shown in FIG. 1 has responded to separate the movable and fixed contacts 28, 27, 28', 27' within each of the circuit breaker poles 11-13 . Upon movement of the circuit breaker operating handle 16 to reset the circuit breaker operating mechanism, the slotted contact arm 30 rotates in the clockwise direction about the pivot 29 to return the contact arms 30A, 30B to the CLOSED position shown in FIG. 4. It has been determined that the automatic expansion and contraction of the springs 40, 41,58, 59, the top and bottom links 48, 49 and the provision of the slots 44A, 44B, 45A, 45B of FIG. 3 results in the best tolerance adjustment between the rotor assembly 39 than has ever heretofore been attainable in so-called rotary contact arrangements with self locking contact arm capabilities within circuit breakers.
U.S. Pat. No. 4,616,198 entitled "Contact Arrangement for a Current Limiting Circuit Breaker" describes a circuit interruption arrangement having a single pair of fixed and movable contacts that become separated by rotation of a single contact arm to which the movable contact is attached at one end.
In further accordance with the teachings of the invention, a semi-rotor assembly 64 is depicted in FIG. 6 to include a semi-rotor 65 having a circular forward surface as indicated at 65A and a planar rear surface as indicated at 65B. The movable contact 69 is positioned at one end of the contact arm and the pivot pin 70 attaches the contact arm to the semi-rotor 65 at the opposite end thereof. A contact braid 72 is fixedly attached to the movable contact arm as indicated at 73 at one end, and to the load strap 74 at the opposite end as indicated at 80. In a similar manner as described with respect to FIGS. 3-5, a link 75 connects with the contact arm 68 at one end by means of the pin 77 and is positioned within the slot 65C within the semi-rotor 65 and is retained therein by means of the extended pin 79. A similar expansion spring 81 extends between the pin 79 at one end of the expansion spring as indicated at 78 and the extended pin 82 within the slot 67 at the opposite end of the expansion spring as indicated at 83. An opposing expansion spring (not shown) extends between the pin 79 and the extended pin 82 on the other side of the semi-rotor assembly 64. The link 75 is arranged such that the force line F 3 exhibited by the expansion spring between the semi-rotor and the contact arm is directed along the link pins 77, 79 resulting in the maximum contact pressure exhibited between the movable and fixed contacts 69, 71 when the contacts are in the CLOSED position indicated in solid lines. Upon occurrence of a large overcurrent condition within the circuit breaker assembly of FIG. 2 containing the semi-rotor assembly 64 of FIG. 6, the magnetic repulsion forces generated between the movable and fixed contacts 69, 71 within the circuit breaker assembly drive the movable contact arm 68 and the associated movable contact 69 in the counterclockwise direction about the pivot pin 70 to the OPEN position indicated in dashed lines. The force line F 4 exhibited by the expansion spring between the semi-rotor and the contact arm is now directed along the link pins 77, 79 in such a manner that the movable contact arm 68 is locked in the in the OPEN position to prevent re-closure of associated the movable and fixed contacts 69, 71 until the circuit breaker operating mechanism 18 shown in FIG. 1 has responded to separate the movable and fixed contacts 28, 27 within each of the circuit breaker poles 11-13. Upon movement of the circuit breaker operating handle 16 to reset the circuit breaker operating mechanism, the movable contact arm 68 rotates in the clockwise indicate direction about the pivot 70 to return the contact 69 to the CLOSED position in the manner described earlier.
The provision of a link connection between a rotor assembly and a movable contact arm has been shown herein to improve performance of a circuit breaker during contact separation as well as contact closure. The arrangement of at least one expansion spring between the link and the associated rotor provides optimum contact force by compensating for component tolerance and contact erosion and wear while still maintaining a reliable means for locking the contact arm 30 open in the event of an over current condition. | A circuit breaker rotary contact assembly employs a common pivot between the rotor assembly and the rotary contact arm. A pair of off-center expansion springs directly engage the rotor at one end and engage the rotary contact arm via a linkage arrangement at an opposite end thereof. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/568,856 filed on May 11, 2000, entitled “Corner Connection for Temporary Shoring,” now U.S. Pat. No. 6,416,259.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally directed to a system for temporarily shoring up an excavation site. More particularly the invention is directed to a corner connection used in a reinforcing arrangement that supports sheet piling in an excavation site.
2. Description of the Prior Art
In a typical excavation site, workers are exposed to numerous hazards. The most common hazard is having the walls of the excavation site cave in on the workers, thus causing serious injury. Often due to soil conditions and wetness, the sides of a construction site will simply collapse. Water is a particularly dangerous hazard because it is so heavy and can destroy shoring which has not been properly reinforced. Realizing this problem the government, at both the federal and state level, has set up specific requirements for all excavation sites to avoid the problem of cave-ins. For example the United States Department of Labor and, more specifically, the Occupational Safety and Health Administration (OSHA) requires that excavation sites be prepared with some type of shoring. Additionally many companies are now aware of the problems involved in a typical excavation site and have developed internal policies requiring shoring for any excavations they contract to have completed.
A good example of a typical excavation project would be found in replacing underground storage tanks for a gasoline station. Typically, in such an operation, sheet piling is pounded into the ground in a generally rectangular configuration around the work site. The piling has to be driven extremely deeply into the ground and arranged to provide sufficient support against potential cave-ins. Typically the sheet piling has to be driven so that half its total height remains underground after the excavation has been completed. Use of such large amounts of material is quite expensive. After the sheet piling has been installed, the workmen then remove the dirt and fill material from within the rectangular shoring. During the work of removing the old storage tanks and replacing them with new storage tanks the shoring provides protection to the workmen against potential cave-ins. Once the storage tank replacement operation has been completed the shoring can either be completely removed or simply cut down two a safe distance below ground and then left in place. Such a method of shoring an excavation site is extremely expensive.
Various solutions have been proposed in an attempt to cut down on the costs of shoring an excavation site. For example U.S. Pat. No. 5,154,541 discloses a modular earth support system. Specifically the patent teaches using panels which are adapted to be placed around an excavation site and interlocked with one another to form a generally rectangular shoring configuration. Once the panels are in place, reinforcing beams are placed behind the panels to ensure the weight and force of the dirt behind the panels does not cause the panels to fail. The main drawback of using such a system is that standard I-beams cannot be used. Rather, special beams which are cut exactly to size and additionally have a customized end configuration must be used. Such beams are particularly expensive, especially considering a large number of beams of varying sizes would have to be kept available for differently sized excavation sites.
Another proposed solution to reducing the high cost of shoring excavation sites can be found in U.S. Pat. No. 4,685,837. This patent proposes using panels as shoring members in an excavation site. The panels are reinforced by using laterally extending braces. The braces are connected to one another by a bracket or the braces maybe connected to each other by means of a connection in which one brace has a pair of tabs welded thereto with each tab having an aperture formed therein. The apertures align with a hole in a second brace and a pin is placed though the apertures to complete the connection. In either case there is no provision to adjust the length of the braces and connectors and they must be custom made for each different sized excavation site.
Numerous other proposed solutions are available including using wooden shoring which is a custom made to a particular excavation site. Such shoring is used only at the designated site and then disposed of. As a result this approach is prohibitively expensive. Also wooden shoring is not as durable as its metal counterparts. Often water along with regular wear and tear at the construction site can destroy the shoring during the construction job.
Based on the above, therefore there exists a need in the prior art of excavation shoring to provide a system wherein shoring can be provided at an excavation site in an inexpensive and reusable manner which does not suffer the disadvantages of the prior art discussed above. More specifically there exists in the in the art to provide a connector for interconnecting various beams used to reinforce shoring in a manner which enables the shoring to be adjusted easily or at least matched readily to the size of different excavation sites and additionally be reusable.
SUMMARY OF THE INVENTION
The present invention is directed to a corner connection for temporary shoring in an excavation site. Specifically, the corner connection is used to secure I-beams together at corners within the excavation site. Typically, four I-beams are connected together to form a rectangular frame that is suspended within the excavation for bracing the shoring walls thereof however, any polygonal shape may be used. The corner connection itself comprises mating socket or connecting members which are placed over the ends of I-beams to be fastened together.
One of the connecting members includes an outwardly extended tab while the other includes a pair of outwardly extended tabs. The first outwardly extending tab fits between the two extending tabs of the corresponding connecting member. All of the tabs are provided with apertures which are placed in alignment when the connection is made so that a bolt or pin can be passed through the apertures to secure the two connectors together. The socket members also include a large eyelet for receiving a chain or other elongated supporting member which is typically used to suspend the resulting I-beam frame at a desired height within the shoring wall. Alternative embodiments provide for a secondary bar attached to the connectors to provide additional support. Also numerous beam/connector arrangements may be provided at different heights within a single excavation site. Such an arrangements provide much greater support for the side walls of the excavation site.
Additional objects, features and advantages of the present invention will more readily be apparent from the following description of the preferred embodiment thereof, when taken in connection with the drawings wherein like reference numerals refer to correspond parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prospective view of a corner connection and associated supporting beams for temporary shoring according to a first preferred embodiment of the invention as it would be seen in use in a typical excavation site;
FIG. 2 is a perspective view of a corner connection including two corner connectors shown in their engaged condition connecting two reinforcing beams according to the first preferred embodiment of the invention;
FIG. 3 is a plan view of a corner connection including two corner connectors shown in their engaged condition according to the first preferred embodiment of the invention;
FIG. 4 is a prospective view of a corner connection including two corner connectors shown in their engaged condition according to a second preferred embodiment of the invention;
FIG. 5 is a plan view of a corner connection including two corner connectors shown in their engaged condition according to the second preferred embodiment of the invention; and
FIG. 6 is a prospective view of a set of three corner connections and associated supporting beams for temporary shoring according to the first preferred embodiment of the invention as it would be seen in use in a typical excavation site.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 there is shown a typical excavation site 5 incorporating corner connections 11 - 14 for temporary shoring 18 according to a preferred embodiment of the invention. The temporary shoring 18 actually comprises three major elements: interlocking sheet piling 19 , at least two reinforcing I-beams or wales 20 - 23 and corner connections 11 - 14 , each connection including two connectors for the I-beams 20 - 23 . Interlocking sheet piling 19 is shown placed along the walls of the excavation site 5 . Such interlocking sheet piling 19 , which in the embodiment shown is formed by interconnecting two types of side wall panels and corner panels (not separately labeled), is usually driven into the ground prior to any digging. Typically a driving machine 25 , which is essentially a pile driver, is used to drive each section of piling 19 , which in the embodiment shown is formed by interconnecting two types of side panels and corner panels (not separately labeled), to a desired depth within the ground. As mentioned above, typically such sheet piling 19 was driven two to three times the depth of the excavated hole. In this preferred embodiment however, because of reinforcing structure 26 of the I-beams 20 - 23 and the corner connections 11 - 14 , the sheet piling 19 need only be driven slightly deeper than the desired depth of the excavation hole. In either case the sheet piling 19 is driven into the ground one panel at a time each panel becoming an upstanding wall portion.
The panels of piling 19 have interlocking edges and thus can provide support for each other once they are in place. Also the panels are formed in an undulating pattern for added strength. Typically such panels are made of relatively thick and expensive sheet metal. It is important to note that using large quantities of such a sheet metal is extremely expensive. Furthermore, using prior shoring methods, the sheet metal was often left at the excavation site at the conclusion of the construction job. As will be discussed more fully below, with the subject method, the amount of sheet piling used is not only reduced, but less sheet piling is required initially because the sheet piling only has to extend as deep as the excavation hole.
The reinforcing structure 26 is provided behind the interlocking sheet piling 19 . The reinforcing structure 26 includes the set of I-beams 20 - 23 which interact with the set of corner connections 11 - 14 . Such a structure 26 is needed in order to prevent the sheet piling 19 from buckling under the weight of the earth surrounding the sheet piling 19 . This is particularly true when the earth is wet or particularly loose. The corner connections 11 - 14 are designed to receive the ends of the I-beams 20 - 23 to form a rectangular structure. While a rectangular shape is shown here and is probably the most common configuration used it should be kept in mind that any polygonal configuration of three or more sides could be used and not depart from the spirit of the invention. The reinforcing structure 26 is then placed along the inside perimeter of the interlocking sheet piling 19 . Under normal conditions the reinforcing structure 26 would simply be suspended by a chain or other mechanism (not shown) at a desired height within the excavation site 5 . If however, the sheet piling 19 starts to buckle under the weight of wet earth it will immediately engage with the reinforcing structure 26 . As pressure is placed on the I beams 20 - 23 and corner connections 11 - 14 they will only give a small distance before applying an enormous normal force which will stop the sheet piling 19 from any further buckling.
Turning now to FIGS. 2 and 3 there is illustrated a close-up view of a corner connection 11 including two meeting connectors 29 , 30 and the ends of at least two I-beams or wales 20 , 21 . Each connector 29 , 30 has a similar overall shape. However, one type of connector 29 has a single tab 32 while the other type of connector 30 has a double tab 34 , 36 . A single tab type connector 29 shown in FIG. 2 includes a box-like main body portion 40 having an opening 45 therein for receiving an I-beam 21 . The box-like main body portion 40 comprises five major panels to form the open box shape. Opposing top 50 and bottom 51 panels are connected with opposing side panels 55 , 56 to form the square or rectangular opening 45 designed to receive the I-beam 21 . An end panel 57 also preferably square or rectangular in shape, closes off one end of the box type main body 40 . These five pieces 50 , 51 , 55 , 56 , 57 are all made of heavy steel and are welded together. The end panel 57 and one of the side panels 56 has the single tab 32 welded thereto. The tab 32 is a flat plate like member which extends laterally from the box-like main body portion 40 of the connector 29 and has an aperture 60 formed therein. The tab 32 is made of a similar material as the panels of the box-like main body 40 . The tab 32 is preferably welded to the side 56 and end 57 panels. While other methods may be used to attach the tab 32 , it is important that the tab 32 be able to withstand the tremendous hydraulic pressures which may be transmitted by the sheet piling 19 as it starts to buckle.
Optionally a gusset 62 is formed between the side panel 56 and the tab 32 for added strength. As seen in FIG. 3 , an additional gusset 67 may be formed between the tab 32 and the end panel 57 . Preferably an eyelet 69 is formed on the top panel 50 . The eyelet 69 is designed to receive a chain or other elongated supporting member (not shown) used to support the I-beams 20 - 23 and corner connections 11 - 14 at a desired height with the excavation site 5 . The eyelet 69 is completely optional as the chain could simply be placed around one of the I-beams 20 - 23 to provide support.
A double tab type connector 30 shown in FIG. 2 includes a box-like main body portion 70 having an opening 75 therein for receiving an I-beam 20 . The box-like main body portion 70 comprises five major panels to form the open box shape. Opposing top 80 and bottom 81 panel's are connected with opposing side panels 85 , 86 to form the square or rectangular opening 75 designed to receive the I-beam 20 . An end panel 87 also preferably square or rectangular in shape closes off one end of the box type main body 70 . These five pieces 80 , 81 , 85 , 86 , 87 are all made of heavy steel and are welded together. The end panel 87 and one of the side panels 86 has top and bottom tabs 34 , 36 welded thereto. The tabs 34 , 36 are flat members which extend laterally from the box-like main body portion 70 of the connector 30 and each have an aperture 90 , 91 formed therein. The tabs 34 , 36 are made of a similar material as the panels of the box-like main body 70 . The tabs 34 , 36 are preferably welded to the side 86 and end 87 panels. While other methods may be used to attach the tabs 34 , 36 it is important that the tabs 34 , 36 be able to withstand the tremendous hydraulic pressures which may be transmitted by the sheet piling 19 as it starts to buckle.
Optionally a gusset 92 is formed between the side panel 86 and the top tab 34 for added strength. Webs (not shown) may be formed between the two tabs 34 , 36 in order to further increase their strength. As seen in FIG. 3 an additional gusset 97 may be formed between the top tab 34 and the end panel 87 . Preferably an eyelet 99 is formed on the top panel 80 . The eyelet 99 is designed to receive a chain or other elongated supporting member (not shown) used to support the I-beams 20 - 23 and corner connections 11 - 14 at a desired height with the excavation site 5 . The eyelet 99 is completely optional as the chain could simply be placed around the I-beams 20 - 23 to provide support.
As can clearly be seen in FIG. 2 , connectors 29 , 30 may easily be joined together by placing the tab 32 of the single tab connector 29 within the two tabs 34 , 36 of the double tab connector 30 . Ideally, the single tab aperture 60 aligns with and has substantially the same diameter as the apertures 90 , 91 formed in each of the two tabs 34 , 36 of the double tab connector 30 . A securing bolt or pin 100 is placed through the aligned apertures 60 , 90 , 91 in order to pivotably secure the connectors 29 , 30 together. The bolt or pin 100 will support all the forces transmitted between the two connected I-beams 29 , 30 and therefore must be made of a particularly strong material such as hardened steel. Although shown here as I-beams, beams of different shapes could be used so long as the connector and beam have mating shapes. For example, round, L-shaped and U-shaped beams could be used, as could a beam of almost any cross section.
Turning now to FIGS. 4 and 5 , there is shown a second preferred embodiment of the invention. Specifically, the box like connectors 29 , 30 of the first embodiment illustrated in FIGS. 2 and 3 now are shown with modifications to support an added reinforcing member. Since the connectors 29 ′, 30 ′ shown in FIGS. 4 and 5 are based on the connectors 29 , 30 shown in FIGS. 2 and 3 only a discussion of the modifications will be provided here.
Essentially each box type connector 29 ′, 30 ′ has a box-like main body 40 ′, 70 ′ that has been lengthened along with its corresponding panels 50 ′, 51 ′, 55 ′, 56 ′, 80 ′, 81 ′, 85 ′, 86 ′ to provide room to support a pair of extra tabs 101 , 102 , 103 , 104 each tab has a aperture 106 , 107 , 108 , 109 formed therein. A reinforcing bar 120 having a tab 130 , 131 located at each end is provided to reinforce the two box type connectors 29 ′, 30 ′. The tabs 130 , 131 located at the end of reinforcing bar 120 each have an aperture 140 , 141 located therein which will cooperate and align with the apertures 101 , 102 , 103 , 104 formed in the tabs 130 , 131 of each box type connector 29 ′, 30 ′. A pin 150 , 151 may then be placed in the respective apertures once they are and proper alignment to hold the reinforcing bar 120 in place. Such an arrangement will increase the maximum permissible load that the shoring connection may take before failure.
Alternatively, as shown in FIG. 6 , in order to handle larger loads on the shoring, multiple rectangular I beam/box reinforcing structures 160 , 170 , 180 may be placed in a single excavation site 5 . For example the three sets of I-beam/box connectors 160 , 170 , 180 shown in FIG. 6 can handle a much greater load that a single set is capable of handling. Since the three sets of I-beams and connectors are identical they are relatively cheap to obtain.
In operation, typically the entire shoring assembly would arrive on a truck. Initially the I-beams 20 - 23 would be arranged in a rectangular or other polygonal shape around the perspective excavation site. Next the connectors 29 , 30 such as shown in FIG. 2 are placed on the ends of the I-beams 20 - 23 forming corner connections 11 - 14 . It is important to note that the connectors may simply be slipped onto the ends of the I-beams 20 - 23 and that they do not need to be welded thereto. Essentially the main body portion 40 of the connector 29 is adapted to slidably receive the end of an I beam 21 until it hits an abutment such as the end wall 57 . Of course, any abutment will do so long as it transfers force from the I-beam 21 to the connector 29 . As such, the connections 11 - 14 and I-beams 20 - 23 may be easily assembled on site 5 . Next the apertures in the tabs of each single and double tab connector are aligned and a pin is placed there through. The reinforcing assembly 26 formed of the I-beams 20 - 23 and corner connections 11 - 14 now defines the edge of the excavation site 5 . The sheet piling 19 is driven into the ground around the reinforcing structure 26 . Previously, the sheet piling 19 would have to be driven 2 ft. into the ground for every 1 ft. deep into the ground the excavation site 5 would extend. The cost of using so much sheet piling 19 is extremely expensive. With this new invention the sheet piling 19 need only extend slightly below the bottom of the excavation site 5 .
Once a the sheet piling 19 is in place, the dirt and other material within the excavation site's perimeter is then removed. The reinforcing structure 26 is then lowered to an appropriate height. The reinforcing structure 26 is held at that height by chains which extend to the eyelet on each box connector. It should be noted that the reinforcing structure 25 will not actually be under load until and if the sheet piling 19 starts to buckle under the load of dirt or water located behind a sheet piling 19 . If the sheet piling 19 starts to buckle the corner connections 11 - 14 will take that load and be forced tighter unto their respective I-beams 20 - 23 . Once any tolerance between the I-beams 20 - 23 and corner connections 11 - 14 is taken up the reinforcing structure 26 will then prevent any further movement of the sheet piling 19 and also prevent a cave in. Workers can then move about the excavation site 5 and safely perform whatever task is necessary. For example, the workers could remove old storage tanks (not shown) which may need removing and replace them with a new set of storage tanks (not shown). Additionally, other structures may be formed within the excavation site 5 . For example, a slab of concrete may be poured at the bottom of the excavation site 5 to aid in supporting storage tanks. Additionally, gravel or other fill material may be placed around the tanks as is needed. All the while, the workers will be safe from any potential cave in.
Once the excavation site 5 is ready to be refilled, typically a corner sheet of piling 19 is removed so as to enable the workers to remove the corner connections 11 - 14 . Once one set of corner connectors is removed, the rest of the reinforcing structure 26 can easily be removed the excavation site 5 and used again. One of the great benefits of the instant invention is that the I-beams 20 - 23 can be rented instead of purchased. This was not possible with prior reinforcing methods because the ends of the I-beam had to be cut to size or a special connector had to be welded there to. Since most rental places require their equipment be returned in substantially the same condition as they were rented the prior art methods could not use rented I-beams. To recognize the cost savings of the subject invention, one must remember that excavation sites are often different sizes. It becomes extremely expensive to have numerous different sized I-beams which have been purchased and must remain in inventory in case an odd size may be needed. With the new invention, a contractor may simply rent the appropriate sized I-beams and return them when the job is done.
Although described with respect to preferred embodiments of the invention, it should be understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. Therefore, the specific embodiments disclosed herein are to be considered illustrative and not restrictive. Instead, the invention is only intended to be limited by the scope of the following claims. | A connection arrangement for temporary shoring in an excavation site is used to secure I-beams together at corners within the excavation site. Typically, four I-beams are connected together to form a rectangular frame that is suspended within the excavation for bracing the shoring walls thereof. However, any polygonal shape may be used. The connection arrangement includes mating socket or connecting members which are placed over the ends of I-beams to be fastened together. One of the connecting members includes an outwardly extended tab while the other includes a pair of outwardly extended tabs. The first outwardly extending tab fits between the two extending tabs of the corresponding connecting member. All of the tabs are provided with apertures which are placed in alignment when the connection is made so that a bolt or pin can be passed through the apertures to secure adjacent connecting members together. Each connecting member also includes a large eyelet for receiving a chain or other elongated supporting member which is typically used to suspend the resulting I-beam frame at a desired height within the shoring wall. Alternative embodiments provide for a secondary bar attached to the connectors to provide additional support. Also numerous beam/connector arrangements may be provided at different heights within a single excavation site. Such an arrangements provide much greater support for the side walls of the excavation site. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of commonly assigned U.S. patent application Ser. No. 08/566,819 now abandoned entitled "Out of Ink Sensing System for an Ink Jet Printer", filed on Dec. 4, 1995.
BACKGROUND OF THE INVENTION
The present invention relates to an ink supply for an ink-jet printer and, more particularly, to a replaceable ink supply configured for use with an ink-jet printer having an actuator configured for engaging a pump portion for supplying ink from an ink container to an ink-jet printhead.
Ink-jet printers frequently make use of a print head mounted to a carriage which is moved back and forth over a print media, such as paper. As the print head passes over appropriate locations on the print media, a control system activates the print head to deposit ink drops onto the printing surface to form images and text.
One type of ink jet printing system disclosed in co-pending patent application, Ser. No. 08/566,819 entitled "Out-of-Ink Sensing System for an Ink-Jet Printer" to Barinaga et al, filed on Dec. 4, 1995, assigned to the assignee of the present invention and incorporated herein by reference, discloses the use of a replaceable ink container that is mounted off the scanning carriage. The ink container is in fluid communication with the print head that is mounted on the scanning carriage. The ink container includes a variable volume chamber and a reservoir for providing ink to the variable volume chamber. An actuator, associated with the printing device, engages the variable volume chamber to force ink from the variable volume chamber to the printing device.
An out of ink sensing technique is used to determine the if the reservoir is out of ink based on ink in the variable volume chamber. The out of ink sensing technique makes use of actuator displacement to determine if a low ink condition exists in the variable volume chamber. A sensor is used to determine the displacement of the actuator.
There is an ever present need for ink container that are relatively inexpensive and are capable of reliably providing ink to the print head. These ink containers should be well suited to high volume manufacturing techniques as well as make together with the printer provide a reliable technique for determining an out of ink condition for preventing damage to the print head.
SUMMARY OF THE INVENTION
The present invention is a replaceable ink container for use with a printing apparatus. The printing apparatus of the type having out of ink detection. The replaceable ink container includes a fluid reservoir having an outlet. The outlet is configured for connection to a fluid inlet associated with the printing apparatus. Also included in the replaceable ink container is an actuator engagement device for engaging an actuator associated with the printing apparatus. The actuator is of the type that is movable between a first position wherein an out of ink signal is generated and a second position. The actuator engagement device is disposed and arranged to engage the actuator to prevent movement of the actuator from the second position to the first position thereby preventing the out of ink signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of an ink supply of the present invention that includes a variable volume chamber for providing ink to a printing system.
FIG. 2 is cross sectional view, taken along line 2--2 of FIG. 1, of a portion of the ink supply of FIG. 1.
FIGS. 3A-3E are cross sectional views of a portion of the ink supply and docking bay showing the pump, actuator and out-of-ink detector in various stages of operation.
FIG. 4 is an exploded view of a non-pressurized ink supply of the present invention for use with the printing system having an actuator.
FIG. 5 is cross sectional view, taken along line 4--4 of FIG. 4, of a portion of the ink supply of FIG. 4.
FIGS. 6A-6C are cross sectional views of a portion of the ink supply and docking bay showing the actuator and the actuator engagement device of the present invention for preventing generation of an out-of-ink signal based on actuator displacement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As discussed in co-pending patent application Ser. No. 08/566,819 the ink supply of the type having a variable volume chamber or diaphragm pump is illustrated in FIG. 1 as reference numeral 20. The ink supply 20 includes a chassis 22 which carries an ink reservoir 24 for containing ink, a pump 26 and fluid outlet 28. The chassis 22 is enclosed within a hard protective shell 30 having a cap 32 affixed to its lower end. The cap 32 is provided with an aperture 34 to allow access to the pump 26 and an aperture 36 to allow access to the fluid outlet 28.
As illustrated in FIGS. 1 and 2, the chassis 22 has a main body 44. Extending upward from the top of the chassis body 44 is a frame 46 which helps define and support the ink reservoir 24. In the illustrated embodiment, the frame 46 defines a generally square reservoir 24 having a thickness determined by the thickness of the frame 46 and having open sides. Each side of the frame 46 is provided with a face 48 to which a sheet of plastic 50 is attached to enclose the sides of the reservoir 24. The illustrated plastic sheet is flexible to allow the volume of the reservoir to vary as ink is depleted from the reservoir. This assists in emptying the reservoir by reducing the amount of backpressure created as ink is depleted from the reservoir.
The body 44 of the chassis 22, as seen in FIGS. 1 and 2, is provided with a fill port 52 to allow ink to be introduced into the reservoir. After filling the reservoir, a plug 54 such as a polypropylene ball is inserted into the fill port 52 to prevent the escape of ink through the fill port.
A pump 26 is carried on the body 44 of the chassis 22. The pump 26 serves to pump ink from the reservoir and supply it to the printer via the fluid outlet 28. In the illustrated embodiment, seen in FIGS. 1 and 2, the pump 26 includes a pump chamber 56 that is integrally formed with the chassis 22. The pump chamber is defined by a skirt-like wall 58 which extends downwardly from the body 44 of the chassis 22.
A pump inlet 60 is formed at the top of the chamber 56 to allow fluid communication between the chamber 56 and the ink reservoir 24. A pump outlet 62 through which ink may be expelled from the chamber 56 is also provided. A valve 64 is positioned within the pump inlet 60. The valve 64 allows the flow of ink from the ink reservoir 24 into the chamber 56 but limits the flow of ink from the chamber 56 back into the ink reservoir 24. In this way, when the chamber is depressurized, ink may be drawn from the ink reservoir, through the pump inlet and into the chamber. When the chamber is pressurized, ink within the chamber may be expelled through the pump outlet.
In the illustrated embodiment, the valve 64 is a flapper valve positioned at the bottom of the pump inlet. The flapper valve 64 illustrated in FIGS. 1 and 2, is a rectangular piece of flexible material. The valve 64 is positioned over the bottom of the pump inlet 60 and heat staked to the chassis 22 at the midpoints of its short sides (the heat staked areas are darkened in the Figures). When the pressure within the chamber drops sufficiently below that in the reservoir, the unstaked sides of the valve each flex downward to allow the flow of ink around the valve 64, through the pump inlet 60 and into the chamber 56.
A flexible diaphragm 66 encloses the bottom of the chamber 56. The diaphragm 66 is slightly larger than the opening at the bottom of the chamber 56 and is sealed around the bottom edge of the wall 58. The excess material in the oversized diaphragm allows the diaphragm to flex up and down to vary the volume within the chamber.
A pressure plate 68 and a spring 70 are positioned within the chamber 56. The pressure plate 68 has a smooth lower face 72 with a wall 74 extending upward about its perimeter. The central region 76 of the pressure plate 68 is shaped to receive the lower end of the spring 70 and is provided with a spring retaining spike 78. Four wings 80 extend laterally from an upper portion of the wall 74.
The pressure plate 68 is positioned within the chamber 56 with the lower face 72 adjacent the flexible diaphragm 66. The upper end of the spring 70, which is stainless steel in the illustrated embodiment, is retained on a spike 82 formed in the chassis and the lower end of the spring 70 is retained on the spike 78 on the pressure plate 68. In this manner, the spring biases the pressure plate downward against the diaphragm to increase the volume of the chamber. The wall 74 and wings 80 serve to stabilize the orientation of the pressure plate while allowing for its free, piston-like movement within the chamber 56. The structure of the pressure plate, with the wings extending outward from the smaller face, provides clearance for the heat stake joint between the diaphragm and the wall and allows the diaphragm to flex without being pinched as the pressure plate moves up and down. The wings are also spaced to facilitate fluid flow within the pump.
As illustrated in FIG. 2, a conduit 84 joins the pump outlet 62 to the fluid outlet 28. In the illustrated embodiment, the top wall of the conduit 84 is formed by the lower member of the frame 46, the bottom wall is formed by the body 44 of the chassis, one side is enclosed by a portion of the chassis and the other side is enclosed by a portion of one of the plastic sheets 50.
As illustrated in FIGS. 1 and 2, the fluid outlet 28 is housed within a hollow cylindrical boss 99 that extends downward from the chassis 22. The top of the boss 99 opens into the conduit 84 to allow ink to flow from the conduit into the fluid outlet. A spring 100 and sealing ball 102 are positioned within the boss 99 and are held in place by a compliant septum 104 and a crimp cover 106. The crimp cover 106 fits over the septum 104 and engages an annular projection 108 on the boss 99 to hold the entire assembly in place.
The reservoir 24 is enclosed within a protective shell 30. A protective cap 32 is fitted to the bottom of the shell 30 to maintain the chassis 22 in position. The cap 32 is provided with recesses 128 which receive the stops 120 on the chassis 22. In this manner, the stops are firmly secured between the cap and the shell to maintain the chassis in position. The cap is also provided with an aperture 34 to allow access to the pump 26 and with an aperture 36 to allow access to the fluid outlet 28.
In the illustrated embodiment, the bottom of the shell 30 is provided with two circumferential grooves 122 which engage two circumferential ribs 124 formed on the cap 32 to secure the cap to the shell. Sonic welding or some other mechanism may also be desirable to more securely fix the cap to the shell.
As represented in FIGS. 3A-3E the ink supply 20 is inserted into a docking bay of an ink-jet printer. Upon insertion of the ink supply 20, an actuator 40 within the docking bay is brought into contact with the pump 26 through aperture 34. In addition, a fluid inlet (not shown) within the docking bay is coupled to the fluid outlet 28 to create a fluid path from the ink supply to the printer. Operation of the actuator 40 causes the pump 26 to draw Ink from the reservoir 24 and supply the ink through the fluid outlet 28 and the fluid inlet associated with the printer.
The upper end of the actuator 40 extends upward through a base plate (not shown) in the docking bay. The lower portion of the actuator 40 is positioned below the base plate and is pivotably coupled to one end of a lever 152 which is supported on pivot point 154. The other end of the lever 154 is biased downward by a compression spring 156. In this manner, the force of the compression spring 156 urges the actuator 40 upward. A cam 158 mounted on a rotatable shaft 160 is positioned such that rotation of the shaft to an engaged position causes the cam to overcome the force of the compression spring 156 and move the actuator 40 downward. Movement of the actuator, as explained in more detail below, causes the pump 26 to draw ink from the reservoir 24 and supply it through the fluid outlet 28 and the fluid inlet associated with the printer.
As illustrated in FIGS. 3A-3E, a flag 184 extends downward from the bottom of the actuator 40 where it is received within an optical detector 186. The optical detector 186 is of conventional construction and directs a beam of light from one leg toward a sensor (not shown) positioned on the other leg. The optical detector is positioned such that when the actuator 40 is in its uppermost position, corresponding to the top of the pump stroke, the flag 184 raises above the beam of light allowing it to reach the sensor and activate the detector. In any lower position, the flag blocks the beam of light and prevents it from reaching the sensor and the detector is in a deactivated state. In this manner, the sensor can be used, as explained more fully below, to control the operation of the pump and to detect when an ink supply is empty.
FIG. 3A illustrates the fully charged position of the pump 26. The flexible diaphragm 66 is in its lowermost position, the volume of the chamber 56 is at its maximum, and the flag 184 is blocking the light beam from the sensor. The actuator 40 is pressed against the diaphragm 66 by the compression spring 156 to urge the chamber to a reduced volume and create pressure within the pump chamber 56. As the valve 64 limits the flow of ink from the chamber back into the reservoir, the ink passes from the chamber through the pump outlet 62 and the conduit 84 to the fluid outlet 28.
As ink is depleted from the pump chamber 56, the compression spring 156 continues to press the actuator 40 upward against the diaphragm 66 to maintain a pressure within the pump chamber 56. This causes the diaphragm to move upward to an intermediate position decreasing the volume of the chamber, as illustrated in FIG. 3B. In the intermediate position, the flag 184 continues to block the beam of light from reaching the sensor in the optical detector 186.
As still more ink is depleted from the pump chamber 56, the diaphragm 40 is pressed to its uppermost position, illustrated in FIG. 3C. In the uppermost position, the volume of the chamber 56 is at its minimum operational volume and the flag 184 rises high enough to allow the light beam to reach the sensor and activate the optical detector.
The printer control system (not shown) detects activation of the optical detector 186 and begins a refresh cycle. As illustrated in FIG. 3D, during the refresh cycle the cam 158 is rotated into engagement with the lever 152 to compress the compression spring 156 and move the actuator 40 to its lowermost position. In this position, the actuator 40 does not contact the diaphragm 66.
With the actuator 40 no longer pressing against the diaphragm 66, the pump spring 70 biases the pressure plate 68 and diaphragm 66 outward, expanding the volume and decreasing the pressure within the chamber 56. The decreased pressure within the chamber 56 allows the valve 64 to open and draws ink from the reservoir 24 into the chamber 56 to refresh the pump 26, as illustrated in FIGS. 3D and 3E. The check valve at the print head, the flow resistance within the trailing tube, or both will limit ink from returning to the chamber 56 through the conduit 84. Alternatively, a check valve may be provided at the outlet port, or at some other location, to prevent the return of ink through the outlet port and into the chamber.
After a predetermined amount of time has elapsed, the refresh cycle is concluded by rotating the cam 158 back into its disengaged position and the ink supply typically returns to the configuration illustrated in FIG. 3A.
However, if the ink supply is out of ink, no ink can enter into the pump chamber 56 during a refresh cycle. In this case, the backpressure within the ink reservoir 24 will prevent the chamber 56 from expanding. As a result, when the cam 158 is rotated back into its disengaged position, the actuator 40 returns to its uppermost position, as illustrated in FIG. 3C, and the optical detector 186 is again activated. Activation of the optical detector immediately after a refresh cycle, informs the control system that the ink supply is out of ink (or possibly that some other malfunction is preventing the proper operation of the ink supply). In response, the control system can generate a signal informing the user that the ink supply requires replacement.
Another embodiment of the ink container of the present invention is represented by an ink container 20' shown in FIGS. 4, 5, and 6A-C. The ink container 20' is a non-pressurized ink container that is configured for use with a printing device having an out of ink sensing system based on actuator displacement. Similar numbering will be used to identify structures of ink container 20' which are similar to structures disclosed in ink container 20 previously discussed. Moreover, similar features in ink container 20' of the present invention will not be discussed in detail because similar structures have been described in detail with respect to ink container 20 discussed previously.
Ink container 20' of the present invention is similar to the ink container 20 discussed previously except that the pump 26 has been eliminated and the cap 32 has been modified to engage the actuator 40 for preventing an out of ink signal based on actuator position, as will be discussed in detail later. Instead an out of ink condition can then be determined using other methods such as drop counting or ink usage.
As shown in FIGS. 4 and 5 the ink container 20' of the present invention includes a chassis 22' which carries an ink reservoir 24' for containing ink, and a fluid outlet 28' in fluid communication with the ink reservoir 24'. The chassis 22' is enclosed with a hard protective shell 30' having a cap 32' affixed to its lower end. The cap 32' is configured for engagement with an actuator associated with the printing apparatus.
In the preferred embodiment the reservoir 24' is formed by plastic sheets 50' which are heat staked to the faces 48' of the frame as discussed previously in respect to ink container 20. In addition, the fluid outlet 28' of the ink container of the present invention includes a septum 104' and a sealing ball 102' similar to the ink container 20 discussed previously.
With the ink container 20' of the present invention properly inserted into a docking bay of an ink-jet printer a fluid inlet (not shown) associated with the ink-jet printer engages the fluid outlet 28' associated with the ink container 20' to form a fluid connection between the ink-jet printer and the ink container 20'. Once fluid communication is established between the ink-jet printer and the ink container 20' fluid is drawn from the ink reservoir 24 to the ink-jet printhead by back pressure generated in the ink-jet printhead. Alternatively, the ink reservoir 24 may be pressurized in some manner such as use of a biasing force against the plastic sheets 50' of the ink reservoir 24' to provide a pressurized fluid flow to the ink-jet printhead if higher flow rates are desired. This can be done by positioning a compressed spring (not shown) between each sheet 50' and the hard protective shell 30'. The spring biases the pair of sheets toward each other to pressurize the ink reservoir 24'.
FIGS. 6A-6C are a representation of the ink supply 20' is inserted into the docking bay of an ink-jet printer. Upon insertion of the ink supply 20', the actuator 40 attempts to engage the pump 26 as previously discussed with respect ink container 20. Because the ink container 20' does not require the use of a pump the cap 32' has an engagement portion which engages the actuator 40 to prevent an out of ink signal FIG. 6A illustrates the actuator 40 moving towards the cap engagement portion 32'. The actuator 40 is urged toward the cap engagement portion 32' by the decompression of spring 156. As shown in FIG. 6B the actuator 40 engages the cap engagement portion 32' with the actuator 40 shown in its upper most position. The flag 184 blocks light beam from the sensor thereby preventing an out of ink signal from the ink-jet printer. The actuator 40 remains in the engagement position with cap 32' until the cam 158 is rotated back to its engagement position whereby the actuator 40 is disengaged from the engagement cap 32'. It can be seen that throughout the entire operation of the actuator 40 with the ink container 20' properly inserted into the docking bay the flag 184 prevents the light beam from reaching the sensor and thereby preventing the actuation of the optical sensor which initiates an out of ink signal as discussed previously with respect to ink container 20. In this manner, the ink container 20' of the present invention allows ink to be provided to the ink-jet printer without an out of ink signal being generated based on actuator position.
To prevent printhead damage resulting from an out of ink condition alternative out of ink indicators may be used such as drop counting to determine ink usage or some form of visual out of ink signal may be used such as a visual inspection of the ink container to determine ink level. Drop counting in described in more detail in co-pending U.S. patent application entitled "Ink Usage Management System" Ser. No. 08/706,045 filed on Aug. 30, 1996 which is assigned to the assignee of the present invention and incorporated herein by reference. The ink container 20' of the present invention is an alternative ink container that may be used in applications where these alternative ink level sensing method are adequate as well as for applications where the system does not require a pressurized supply of ink. Alternatively, the ink container 20' can be modified to provide a source of pressurized ink by providing a biasing member to engage the plastic sheets 50' and pressurize ink within the ink container 20'. The present invention allows more than one type of ink container 20 and 20' to be used with printers of the type which make use of actuator position for determining an out of ink condition. | The present invention is a replaceable ink container for use with a printing apparatus. The printing apparatus of the type having out of ink detection. The replaceable ink container includes a fluid reservoir having an outlet. The outlet is configured for connection to a fluid inlet associated with the printing apparatus. Also included in the replaceable ink container is an actuator engagement device for engaging an actuator associated with the printing apparatus. The actuator is of the type that is movable between a first position wherein an out of ink signal is generated and a second position. The actuator engagement device is disposed and arranged to engage the actuator to prevent movement of the actuator from the second position to the first position thereby preventing the out of ink signal. | 1 |
PRIORITY
[0001] This application is a continuation of U.S. application Ser. No. 12/655,228, filed Dec. 26, 2009.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of closure assemblies that are used in the pool industries. The closure assemblies have generally been used for pool maintenance and closing the swimming pool skimmer for winter (winterizing).
[0003] The field of endeavor for this invention is directed towards in-ground pools and above ground pools that have a skimmer attached to the pool and the pump.
BACKGROUND OF THE INVENTION
[0004] U.S. Pat. No. 4,281,422 by Simonelli discloses a winterizing kit that includes a socket plug that fits into a female receptacle of a filtered water inlet. The socket plug includes a check valve and a nipple to impede the flow of water from the swimming pool and also disconnect an air compressor attached to the pool water line. This invention is not anticipated to be used in a skimmer, but specifically placed into the inlet/outlets in the wall of a pool.
[0005] U.S. Pat. No. 4,825,605 by Weir discloses a closure device for pre-formed wall openings in swimming pool side wall panels that includes the insertion of either rectangular or circular-shaped plugs into the wall openings. The plugs are used to close unwanted openings in the wall of the swimming pool. The plugs are attached to the side wall of the pool.
[0006] U.S. Pat. No. 4,903,351 by Dengel et al. discloses a winterizing faceplate kit for the side wall of the swimming pool. The kit includes a cover plate, faceplate, and a pair of gaskets, where the cover plate is adapted to be removable and to be secured to the sidewall, thus facilitating spring season opening and fall season closure of the swimming pool
[0007] U.S. Pat. No. 4,285,358 by Hodak discloses a sealing assembly similar to U.S. Pat. No. 4,903,351 by Dengel and includes a gasket frame, faceplate and a cover panel which are all attachable to the inside surface of a pool wall in order to shut the water flow from the pool to the skimmer.
[0008] What is needed and has never been disclosed or described in the prior art is an apparatus for pools that have been completed and will allow the skimmer to be sealed from the side drain of the pool, but still allow communication between the pool pump and the main drain through the fittings that are attached at the bottom of the skimmer.
SUMMARY OF THE INVENTION
[0009] The present invention discloses a conventional swimming pool skimmer that is known in the art for many years and has been adapted to receive a removable pool skimmer plug. The removable pool skimmer plug has been designed and adapted to be inserted into the bottom portion of the skimmer that has already been installed in a pool. The removable pool skimmer plug is located below the side drain inlet for the pool or throat.
[0010] The removable pool skimmer plug will have at least one O-Ring or gasket that will provide a vacuum seal to allow the pump to more easily draw water from the main drain of the pool. Since the swimming pool skimmer housing has already been installed, and may be several years old, the removable pool skimmer plug has been designed to provide a vacuum seal to eliminate the pump from drawing water from the throat of the skimmer, which is located on the side wall of the pool.
[0011] The removable pool skimmer plug will be inserted near the bottom of the swimming pool housing on a flange of the pool skimmer body, but still provide a gap to allow water from the main drain port to maintain a constant fluid communication with the port to the pump system.
[0012] It is therefore a primary object of the invention to provide a removable pool skimmer plug that can be used in skimmers that have already been installed into pools, or for existing unmodified skimmers to pump water from these pools to assist in extinguishing fires by using the pool water in those states that are prone to wildfires such as in California, and Florida.
[0013] It is therefore an object of the invention to provide a simple device for previously installed pool systems to provide an easily removable pool skimmer plug for the swimming pool skimmer that will allow the main drain to be in direct fluid communication with the pump system.
[0014] A second object of the invention is that the insertion of the plug into the skimmer will prevent the pump from burnout when the water level drops below the skimmer level.
[0015] Another object of the invention is that when there is a freeze, specifically in the midwest and northern states, it will still be possible to drain water from the main drain, even if there is ice covering the skimmer.
[0016] Another object of the invention, is the elimination of the requirement for a sump pump to drain the pool, which also implies that there are no electrical connections near the pool water site.
[0017] Another object of the invention is to assist in winterizing the pool by inserting the plug into the skimmer and draining the pool water.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows a cross section of the pool skimmer attached to an inground pool.
[0019] FIG. 2 shows a detailed view of the cap, plug body and pool skimmer.
[0020] FIG. 3 shows an exploded perspective of the plug assembly.
[0021] FIG. 4 shows an alternative removable pool skimmer plug.
DETAILED DESCRIPTION
[0022] FIG. one ( 1 ) shows an environmental view of an industry standard pool skimmer ( 1 ). The pool skimmer ( 1 ) is common within the industry of swimming pools, and differs in generic shapes between the various manufacturers of pool skimmers, based upon the manufacturer's specific design criteria. The pool skimmer ( 1 ) is shown imbedded in the side of a pool ( 2 ), where the water line ( 4 ) is shown, depicting the water level, which allows the water to flow into the pool skimmer ( 1 ) and hence be drawn into the pump system. The pool skimmer ( 1 ) is comprised of a body ( 6 ), where the body ( 6 ) may be composed of multiple components either solvent welded or glued together. The body ( 6 ) of the pool skimmer has a centrally located hollow portion ( 8 ). The body also has a throat ( 10 ) attached thereon, where the throat ( 10 ) projects outward from the body ( 6 ) and provides a direct conduit from the pool ( 2 ) to the hollow portion ( 8 ) of the pool skimmer ( 1 ). The throat ( 10 ) has a large central through opening or mouth ( 12 ) that allows the water in the pool ( 2 ) and communicates with the hollow portion ( 8 ) of the body ( 6 ).
[0023] The body ( 6 ) has an upper portion ( 40 ). The pool skimmer ( 1 ) is provided with a lock down lid or cap ( 42 ). The cap ( 42 ) is generally lightly press fit, with a light snap to secure the cap ( 42 ) from easily being dislodged from the upper portion ( 40 ) of the pool skimmer ( 1 ). As can be seen in FIG. 1 , the pool skimmer ( 1 ) comprises an upper portion ( 18 ) and a lower portion ( 20 ). The upper portion ( 18 ) comprises the throat ( 10 ). As is common in the pool skimmer industry, the throat ( 10 ) has a front portion ( 36 ), where the front portion ( 36 ) of the throat ( 10 ) has a weir ( 38 ). The weir ( 38 ) is pivotably mounted to a lower portion ( 40 ) and biased towards the front portion ( 36 ) of the throat ( 10 ). The weir ( 38 ) has positive buoyancy, and prevents debris from migrating from the pool skimmer ( 1 ) back into the pool ( 2 ).
[0024] The lower portion ( 20 ) of the pool skimmer ( 1 ), has, co-located at the bottom of the pool skimmer ( 1 ), a pool drain inlet ( 14 ) and a pump outlet ( 16 ). The pool drain inlet ( 14 ) and pump outlet ( 16 ) are internally sized to accept pvc (poly-vinyl chloride) piping, which is common in the pool and garden industry. An additional feature is to externally size the diameter of the pool drain inlet ( 14 ) and pump outlet ( 16 ) for larger piping, such as 3.0″ pvc pipes. The reason for using larger diameter piping is that the newer pumps need a larger diameter pipe to provide increased efficiency, due to the higher pump flows generated. As is commonly done in the pool industry, the pipes that are either internally or externally attached would be fusion welded or glued into place.
[0025] FIGS. 1, 2, and 3 show that the pool skimmer ( 1 ) is provided with a removable pool skimmer plug ( 22 ). The removable pool skimmer plug ( 22 ) comprises a plug cap ( 32 ) and a plug body ( 28 ). As is common in the industry, the plug body ( 28 ) may be tapered, or may be cylindrically shaped. The plug body ( 28 ) has an upper portion ( 24 ), wherein the upper portion ( 24 ) of the plug body ( 28 ) has a continuous outwardly extended flange or ledge ( 26 ). The ledge ( 26 ) rests upon a correspondingly shaped shoulder ( 44 ) placed towards the lower portion ( 20 ) of the pool skimmer ( 1 ). The plug body ( 28 ) has an internally defined through hole ( 30 ), where the through hole ( 30 ) has means to secure a plug cap ( 32 ). Generally the means to secure the plug cap ( 32 ) would be by threadably attaching the plug cap ( 32 ) to the plug body ( 28 ), or by providing a pin and groove system common in many industries, to secure the plug cap ( 32 ) to the plug body ( 28 ).
[0026] The plug cap ( 32 ) has at least one raised boss ( 34 ). The raised boss(s) ( 34 ) provides a grip surface to the plug cap ( 32 ) and allows a user to easily install or remove the plug cap ( 32 ) from the pool removable pool skimmer plug ( 22 ). The plug body ( 28 ) has an outer surface ( 46 ). The outer surface ( 46 ) of the plug body ( 28 ) has a groove ( 48 ) defined therein. The groove ( 48 ) allows an o-ring ( 50 ) to be placed therein. The o-ring ( 50 ) may be adhesively positioned into the groove ( 48 ) preventing dislocation of the o-ring ( 50 ) when the removable pool skimmer plug ( 22 ) is placed into the pool skimmer ( 1 ).
[0027] As depicted in FIG. 2 , the plug assembly may be provided with a gasket ( 52 ), the gasket ( 52 ) being placed between the ledge ( 26 ) of the plug body ( 28 ) and the shoulder ( 44 ) of the pool skimmer ( 1 ). A second gasket ( 54 ) may be provided and be placed between the ledge ( 26 ) of the plug body ( 28 ) and the cap ( 26 ).
[0028] As shown in FIG. 3 , the cap ( 26 ) may be adapted to receive at least one poppet valve ( 56 ). The poppet valve will be used to alleviate any vacuum developed during the plug assemblies ( 22 ) use.
[0029] The external construction of the pool skimmer ( 1 ) is generally defined by the specific company fabricating the pool skimmer ( 1 ). They attempt to provide improved fixity to the gunnite or concrete by creating some form of ribbing that aids in adhesion. This invention does not revise the external ribbing of the original pool skimmer ( 1 ).
[0030] FIG. 4 shows an alternative construction of the removable pool skimmer plug ( 60 ). The removable pool skimmer plug ( 60 ) has an upper cap portion ( 62 ) where the cap portion ( 62 ) may have an external ledge ( 64 ). The external ledge ( 64 ) would rest upon the shoulder ( 44 ) placed towards the lower portion ( 20 ) of the pool skimmer ( 1 ). The upper cap portion ( 62 ) has a downward protruding boss ( 66 ), where the downward protruding boss ( 66 ) extends into the lower portion ( 20 ) of the pool skimmer ( 1 ) and may have a light friction fit to provide an air tight seal when under vacuum. The downward protruding boss ( 66 ) may have a groove ( 68 ) defined therein, the groove ( 68 ) being adapted to seat an o-ring ( 70 ) between the downward protruding boss ( 66 ) and the lower portion ( 20 ) of the pool skimmer ( 1 ). The downward protruding boss ( 66 ) can be designed with a centrally positioned hollow portion ( 72 ). The upper cap portion ( 62 ) has a grip means ( 74 ), where the grip means ( 74 ) can have a variety of shapes to suit the manufacturer. Such shapes may be cruciform, a singular straight bar, a metallic handle or stirrup to be gripped by a users hand, etc.
[0031] This removable pool skimmer plug ( 60 ) operates as follows. The user places the downward protruding boss ( 64 ) into the lower portion ( 20 ) of the pool skimmer ( 1 ). The downward protruding boss ( 64 ) is sized to provide a light friction fit to the pool skimmer ( 1 ), while the upper cap portion ( 62 ) will rest upon the shoulder ( 44 ) of the pool skimmer ( 1 ). Vacuum from the pool pump will draw the removable pool skimmer plug ( 60 ) so that an air tight seal will be formed providing the pump with the maximum available suction to draw water from the main drain of the pool ( 2 ).
[0032] If no external ledge ( 64 ) is used in the design, upper cap portion ( 62 ) of the removable pool skimmer plug ( 60 ) would have a tapered downward protruding boss ( 66 ) and frictionally fit in the pool skimmer ( 1 ). When the pool pump is in operation, vacuum will draw the removable pool skimmer plug ( 60 ) tighter in the pool skimmer ( 1 ) making a tight seal. At least one o-ring ( 70 ) is used in the removable pool skimmer plug ( 60 ) design. If necessary the downward protruding boss ( 66 ) may have a groove ( 68 ) defined therein for each o-ring ( 70 ). As defined previously, the downward protruding boss ( 66 ) can be designed with a centrally positioned hollow portion ( 72 ). The upper cap portion ( 62 ) has a grip means ( 74 ), where the grip means ( 74 ) can have a variety of shapes to suit the manufacturer. Such shapes may be cruciform, a singular straight bar, a metallic handle or stirrup to be gripped by a users hand, etc.
[0033] Although the foregoing includes a description of the best mode contemplated for carrying out the invention, various modifications are contemplated.
[0034] As various modifications could be made in the constructions herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. | This application describes a device to convert an existing pool skimmer assembly into a pressurizable pool skimmer assembly, which allows the existing pool skimmer assembly to act with this existing pool pump in emergency situations, such as assisting firefighters with pool water for extinguishing local wildfires or house fires. This method utilizes a removable plug cap and o-rings to allow the pool pump to draw the pool water from the pool main drain using the existing pool skimmer. This device can also be used to drain the pool for cleaning the pool or for winterizing the pool, with out the need for an electrical sump pump. | 4 |
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