description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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This is a continuation of application Ser. No. 06/116,354, filed Jan. 28, 1980, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to improvements in devices used by masons to locate a guideline for a course of bricks or the like. More specifically, it relates to improvements in free-standing devices of the type indicated, called story poles.
In the prior art various types of devices for assisting the mason in properly locating his guideline for laying sequential courses of bricks have been proposed. The most common expedient in use is to build up the corners of the work and stretch a line between them. The line may be secured at either end by nails temporarily placed in the mortar or by weights such as bricks placed on either end of the line. In many cases this is entirely satisfactory, but in a significant number of instances these homely expedients are not satisfactory. Using a string as a guide one may laboriously set up by hand a precisely measured guide line for each succeeding course of bricks, but this is time consuming. Time especially in today's labor market is an expense of considerable magnitude.
More sophisticated devices called story poles have been proposed and these were some improvement. However, all of the prior art expedients were useful only for locating lines from the ground up. Many of them required complicated means for anchoring the poles to the masonry wall and none of them were adapted to aligning a row of bricks parallel to the ceiling instead of the floor, which is more desirable when the floor and the ceiling are not parallel and where, due to the sitting of the structure relative the ceiling, the eye of the observer is more likely to line up the work with the ceiling than with the floor.
An additional problem in the case of a non-parallel ceiling and floor, is the difficulty of obtaining a firm purchase on both ceiling and floor.
Particularly, in the art of building fireplaces there is a need for straight course of uniform width. This is of paramount importance because the fireplace in a home is generally the focal point of attention in the room. As the focal point of attention it is subject to critical inspection. Uneven widths of plaster in the seam between the courses which might be tolerated in a wall that is going to be covered up can not be tolerated in a fireplace. It must, or at least should be, uniform throughout its construction.
Therefore, there has existed a long felt need for an instrument or device which would permit precise, but nevertheless rapid, set up and adjustment of the line guide for succeeding courses of bricks.
BRIEF SUMMARY OF THE INVENTION
With the object of overcoming the problems in the prior art, I have invented an improved mason's guide which has an elongate body that carries indicia means, conveniently ruled, disposed along its length; indicia locator means adapted to longitudinal movement along said body; line attachment means carried by the locator and adapted to secure the mason's line thereto; and telescoping extensions of the body carried at both ends of the body.
Having been provided with telescoping extensions at both ends of the body, in the case of a non-parallel ceiling and floor, the device can readily be adapted to maintain the line parallel to the floor or parallel to the ceiling by adjusting the upper extensions or lower extensions as required.
Preferably, the extensions are provided with floor and ceiling engaging means which may have a gripping surface such as rubber or plastic to grip the ceiling and floor. The upper extension may be provided with an articulated joint in order to accommodate uneven surfaces occasioned by irregularities or non-parallel ceiling and floor. It has been found experimentally that the floor engaging means should be a foot that is not articulated, but rigidly connected to the extension. The foot may also be provided with means for anchoring it to the floor.
Preferably, the indicia means is moveable longitudinally on the body; and the indicia locator means is in the form of a collar slidably disposed on the body and having a sight opening with a line indicator 29 (disposed at the same height as string channel 48) defined therein to indicate the position of the string relative the ruled indicia. The indicia locator means may also carry additional means for taking up the slack in and tightening the mason's line.
My improved mason's guide ordinarily would be used in a system using pairs with the guideline stretched between the pairs. Of course, more than two may be used, as for example, in a freestanding fireplace it might be desirable to use a set of four so that a course of bricks could be laid around the entire perimeter of the fireplace after each adjustment of the indicia locator means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings in which a presently preferred embodiment of my invention is depicted:
FIG. 1 is a perspective view of the device of this invention;
FIG. 2 is a view of one of the guides shown in FIG. 1, in section, taken along the lines 2--2;
FIG. 3 is a view of the pole of FIG. 2 taken along the lines 3--3;
FIG. 4 is a sectional view of the device of FIG. 2 taken along the lines 4--4;
FIG. 5 is an enlarged view of a fragment of one of the poles of FIG. 1 partially in section; and
FIG. 6 is taken from the view of FIG. 5 along the lines 6--6.
As seen in FIG. 1 the improved mason's guide has a body 2 which in this preferred form has aluminum wear strips 3 on the corners and aluminum bands 4 which confine the ends of the body components.
As best seen in FIG. 4 a longitudinal bore 6 is formed in the body 2. Disposed for sliding engagement in the bore 6 are upper extension 8 and lower extension 9.
To support and anchor the body 2 the lower extension 9 is fixed to a pedestal 11 broached to provide a seat 12 for the lower extension's end 14 which is secured by means of countersunk screw 16. Set screws 18 are provided as means for anchoring the pedestal.
Upper extension 8 is provided with a capital 19 which is pivotally attached to the upper extension by means of a clevis arrangement (as best seen in FIG. 5) wherein a fork 21 is provided and a pivot pin 22 carried by the fork pivotally engages tongue 24. The tongue in turn is attached to capital 19 by means of countersunk screw 26.
Set screws 39 pierce capital 19 and provide the means for anchoring the capital and making fine adjustments to compensate for any irregularity in the surface thereof.
The body 2 carries wear strips 3 which run longitudinally along the length of the body until they approach a point at the ends at which they jog inwardly. Thus, an aluminum retaining band disposed at each end may encompass the body and the wear strip, but remain substantially flush with the greater surface length of the wear strips.
As better seen in FIG. 2, the wear strips 3 project slightly away from the outer surface 31 of the body 2. The purpose of this clearance is to prevent the line box whose function and construction will be explained presently, from rubbing against the central portion 35 of the body 2. The central portion 35 is made of aluminum, as are the pedestal and capital and extensions in this preferred embodiment. It is to be understood, of course, that other suitable materials such as other metals and plastics can be substituted for wood and aluminum.
The wear strips 3 are attached to the central portion 35 of the body by means of countersunk screws 36 placed at intervals placed along the length of the wear strips. Set screws 37, 38 pierce the aluminum retaining band 4 and central portion 35 of the body to fix (when tightened) upper and lower extensions 8, 9 respectively in any selected positions.
Inset into one face of the body is a channel 40 in which travels a steel measuring tape 41. The tape is closely confined in the channel, but may be adjusted longitudinally. As best seen in FIG. 5, it may be moved past the end of the body in either direction to accommodate the requirements of a particular job. To that end the aluminum retaining band 4 is also provided with an extension 42 of the channel 40.
Referring now to FIGS. 2 and 3, the line box 34 which may be made of any suitable material (made here of aluminum) forms a longitudinally slidable collar around the body 2. The collar 44 is provided with a sight opening 45 on the side that would otherwise cover the tape 41.
A string set 46 is carried on the second side of the line box. On a third side, which is opposite the side in which the sight opening 45 is carried, a string channel 48 is provided. It has a projection 50, the function of which is to give the string or line 51 a precise departure point. The string set 46 is made by Homecraft as an off-the-shelf item which can be purchased in hardware and department stores.
In use, at least a pair of guides 1 are used with a line 51 set between them.
Operation
In a typical utilization of a set of mason's guides for the construction of a fireplace in an existing building, the pedestals of the pair of guides will be set beyond the ends of a proposed fireplace wall, and the upper and lower extensions will be extended sufficiently to brace the pedestal and capital between floor and ceiling.
When the proper extension is made, set screws 37, 38 will be tightened on upper and lower extensions respectively. The pedestal will be anchored by tightening set screws 18 and the capital will be adjusted by tightening set screws 39.
Inasmuch as ceiling and floor may not be parallel, a decision usually will be made to align the wall parallel with the ceiling because the eye of the viewer tends to make the comparison between the lines of the wall and the ceiling rather than the lines of the wall and the floor. This may require some adjustment of the measuring tape 41 on one of the guides. When this has been done the line-box carried by each body will be set on the same numerical indicia on the tape. A course of brick is laid and the line-boxes are adjusted upward to new identical settings, again on the same indicia of measurement on each tape.
Once the adjustment for tape on one of the line-boxes is made, it will not thereafter be necessary to adjust the tape further for that particular operation. Inasmuch as it is possible to adjust both tapes upwardly or downwardly, it is seldom necessary to adjust either tape more than an inch or so to achieve the proper compensation for skewed ceiling and floor lines.
Using the apparatus of this invention one can be assured that each course is straight and that each joint is of the same width, and the need for making up a course with wider or thinner joints is avoided.
The remarkable savings in time that may be accomplished by using the device of this invention can be appreciated from the following examples:
EXAMPLE I
In the construction of the home fireplace six feet long and eight feet high, slightly over three hours was required to put in a brick face that normally would take seven hours using conventional apparatus. The approximate savings was $115 for labor.
EXAMPLE II
In the construction of a fireplace fourteen feet wide and eight feet high with a twelve foot hearth, approximately five hours was required to build a fireplace structure that would normally require ten hours. The savings in labor was approximately $200.
While the principles of the invention have now been made clear in a presently preferred illustrative embodiment, it will occur to those skilled in the art that modifications of structure arrangement, proportions and materials of construction may be made with the assistance of the teachings of this specification for a specific environment in operating requirements without departing from those principles or the spirit of the invention. | A mason's guide system which has at least a pair of elongate bodies that have telescoping extensions of the bodies are provided to engage a floor and ceiling. The bodies are provided with longitudinally adjustable measuring tapes and a moveable marker for precisely locating a line at the same indicia marks on the tapes. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates, in general, to medical lines, and to containers for medicinal substances, for example, chemotherapy and the like.
STATE OF THE ART
[0002] In such applications, it is necessary to be able to securely close the line or container so as to prevent accidental openings and leakage of substances that, if toxic, could lead to serious risks of contamination.
[0003] The currently known closing systems are not free from risks of accidental disengagement, which can also be due to incorrect operation by the operators.
SUMMARY OF THE INVENTION
[0004] The object of the present invention is to provide a safe and effective solution to this problem, whilst at the same time being practical and functional.
[0005] According to the invention, this object is achieved thanks to a safety cap for medical fluid lines and the like, whose unique characteristic lies in the fact that it comprises a hollow body within which a connector is coaxially housed, accessible at one end of the body and configured so as to obstruct the passage through the body in an inviolable manner. Unidirectional coupling means are provided to lock the connector in rotation with respect to the body, in the direction corresponding to the screwing of the connector and a complementary connector to be coupled therewith, and to allow the free rotation of said connector in the opposite direction.
[0006] Thanks to this solution idea, the invention provides a closing cap having a very high degree of safety against risks of undesired or accidental openings, or due to incorrect operation.
[0007] The cap according to the invention may further comprise locking means designed to be positively operated to lock the connector in rotation with respect to the body in the opposite direction of rotation, i.e. in the direction of unscrewing.
[0008] In a first embodiment of the invention, the connector of the cap is a male connector of the luer lock type or the like, having an internally threaded outer hollow element of a known manner, and an inner hollow element. The latter has a transverse partition for closing the flow through the fitting.
[0009] In a second embodiment of the invention, the connector of the cap is a female connector of the luer lock or the like, having an externally threaded hollow element, which has a transverse partition for closing the flow through the fitting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will now be described in detail with reference to the accompanying drawings, provided purely by way of non-limiting example, in which:
[0011] FIG. 1 is a schematic elevational side view of a safety cap according to a first embodiment of the invention,
[0012] FIG. 2 is an axial section view according to the line C-C of FIG. 1 ,
[0013] FIG. 3 is a cross sectional view according to the line B-B of FIG. 1 ,
[0014] FIG. 4 is a cross sectional view according to the line A-A of FIG. 1 ,
[0015] FIG. 5 is a cross sectional view according to the line D-D of FIG. 2 ,
[0016] FIG. 6 is a cross sectional view according to the line E-E of FIG. 2 ,
[0017] FIG. 7 is an elevational side view of a second embodiment of the cap according to the invention,
[0018] FIG. 8 is an axial section view according to the line C-C of FIG. 7 ,
[0019] FIG. 9 is a cross sectional view along line B-B of FIG. 7 ,
[0020] FIG. 10 is a cross sectional view along line A-A of FIG. 7 ,
[0021] FIG. 11 is a cross sectional view along line D-D of FIG. 8 ,
[0022] FIG. 12 is a cross sectional view along line E-E of FIG. 8 ,
[0023] FIG. 13 is an elevational side view of a third embodiment of the cap according to the invention,
[0024] FIG. 14 is an axial section view according to the line C-C of FIG. 13 ,
[0025] FIG. 15 is a cross sectional view along line B-B of FIG. 14 ,
[0026] FIG. 16 is a cross sectional view along line A-A of FIG. 13 ,
[0027] FIG. 17 is a cross sectional view along line D-D of FIG. 14 ,
[0028] FIG. 18 is a cross sectional view along line E-E of FIG. 14 ,
[0029] FIG. 19 is an elevational side view of a fourth embodiment of the cap according to the invention,
[0030] FIG. 20 is an axial section view according to the line C-C of FIG. 19 ,
[0031] FIG. 21 is a cross sectional view along line B-B of FIG. 19 ,
[0032] FIG. 22 is a cross sectional view along line A-A of FIG. 19 ,
[0033] FIG. 23 is a cross sectional view along line D-D of FIG. 20 , and
[0034] FIG. 24 is a cross sectional view along line E-E of FIG. 20 .
DETAILED DESCRIPTION OF THE INVENTION
[0035] Referring initially to FIGS. 1 to 6 , the safety cap according to a first embodiment of the invention is indicated with I and comprises an outer hollow body 1 of a generally cylindrical shape, within which a male connector 2 of the luer lock type and analogues is coaxially housed.
[0036] The male connector 2 is rotatably mounted relative to the body 1 , with the limitations which will be discussed, and has a partly conventional structure. In detail, the male connector 2 comprises an inner tubular element 4 with a conical outer surface protruding from one end of the body 1 , and an internally threaded outer hollow element 5 , which extends towards the inside of the body 1 with a integral hollow sleeve-shaped appendage 6 , locked axially within the body 1 , which is conveniently formed from two half-shells joined together in an interlocking manner.
[0037] During use, the male connector 2 is intended to be coupled to a complementary female connector of the luer lock type or the like and, according to a first aspect of the invention, the inner tubular element 4 is closed at its free end by a transverse wall 7 . Consequently, the flow passage through the cap I is permanently obstructed in an inviolable manner.
[0038] According to another aspect of the invention, the composite formed by the male connector 2 and the sleeve 6 is coupled in rotation in one direction with the body 1 , and is freely rotatable in the opposite direction. However, as will become evident, the rotation in the opposite direction may also possibly be locked, but only following a positive command imparted manually.
[0039] In detail, and referring now to FIG. 6 , the hollow body 1 is internally formed, on the side of the male connector 2 , of a crown of elastically yielding ratchet teeth 12 , cooperating by unidirectional coupling with corresponding projecting teeth 13 formed on the outside of the hollow element 5 of the male connector 2 . The arrangement is such so that the hollow element 5 , and therefore the entire male connector 2 , is coupled in rotation with the hollow body 1 in the direction indicated by the arrow F in FIG. 6 , due to the effect of the engagement between the teeth 12 and 13 . The direction of rotation F corresponds to the screwing of the male connector 2 and a complementary female connector, assuming the hollow body 1 is kept stationary, and then the complementary female connector is rotated to screw it into the male connector 2 . In the opposite direction of rotation, or rather, the unscrewing direction, the male connector 2 is freely rotatable with respect to the hollow body 1 , due to the bounce of the yielding teeth 12 on the teeth 13 , so that the complementary female connector cannot unscrew itself.
[0040] Obviously, in the case in which the hollow body 1 rotates and the complementary female connector is kept stationary, the situation is reversed, i.e. the direction of screwing is opposite to that of the arrow F, and the unscrewing direction is that of the arrow F.
[0041] In this way, during use, an accidental disengagement or due to incorrect operation, between the male connector 2 and the complementary female connector is prevented.
[0042] The variant of the safety cap represented in FIGS. 7 to 12 , indicated by II, is analogous to the embodiment shown previously, and only the differences will now be described in detail, using the same numerical references for identical or similar parts.
[0043] This variant is configured to allow rotation of the male connector 2 corresponding to the unscrewing direction with respect to the complementary female connector but, as mentioned, only following a positive, or rather, voluntary operation. To this effect, the wall of the hollow body 1 is formed with a pair of elastically yielding locking segments 14 , whose free ends 15 are suitable for engaging, as a result of a thrust applied to the segments 14 , respective peripheral teeth formations 16 of the hollow appendage 6 ( FIG. 10 ), so as to lock the rotation of the male connector 2 with respect to the body 1 .
[0044] The variants of the cap according to the invention illustrated in FIGS. 13-18 and in FIGS. 19-24 , and indicated with III and IV, respectively, correspond to the embodiments previously described with reference to FIGS. 1-6 and 7-12 , respectively, with the only difference that the connector consists of a female connector 3 , also of the luer-lock type and the like, instead of the male connector 2 .
[0045] The female connector 3 is formed, in the usual manner, by an externally threaded tubular element with a conical inner surface, protruding from one end of the body 1 and, during use, is intended to be coupled to a complementary male connector of the luer-lock type or the like.
[0046] The female connector 3 is internally closed by a transverse wall 7 , so that the flow passage through the cap III is, in this case as well, permanently obstructed in an inviolable manner. Moreover, the female connector 3 is integrally formed with a sleeve 9 , analogous to the sleeve 6 of the preceding embodiments, locked axially in the body 1 .
[0047] In a completely analogous manner to the embodiment already described, the composite formed by the female connector 2 and the sleeve 9 is coupled in rotation in one direction with the body 1 and is freely rotatable in the opposite direction. However, as will become evident, the rotation in the opposite direction may also possibly be locked, but only following a positive command imparted manually.
[0048] In detail, and with reference to FIG. 17 , the female connector 3 is coupled in rotation with the hollow body 1 in the direction indicated by the arrow F, corresponding to the screwing of this female connector 3 with a complementary male connector, rotating the hollow body 1 , while it is normally freely rotatable in the opposite direction, or rather, in the unscrewing direction. To this effect, the hollow body 1 , as for the embodiments previously described, is formed with a series of elastically yielding ratchet teeth 12 , cooperating by unidirectional coupling with corresponding projecting teeth 13 formed outside the female connector 3 .
[0049] The variant illustrated in FIGS. 19 to 24 is configured, in a manner corresponding to the embodiment of FIGS. 7 to 12 , for possibly locking in rotation the female connector 3 , with respect to the hollow body 1 , in the direction opposite to that indicated by the arrow F, in this case as well, by a positive command imparted manually. To this effect, the hollow body 1 of the cap IV is therefore formed with one or two pairs of elastically yielding locking segments 19 , analogous to the yielding locking sectors 14 , the free ends 20 of which are suitable for engaging respective peripheral teeth formations 21 of the sleeve 9 ( FIGS. 21 and 22 ).
[0050] Of course, the details of construction and the embodiments may be widely varied with respect to those described and illustrated, without departing from the scope of the present invention as defined in the following claims. | A cap for medical fluid lines and the like includes a hollow body within which a male or female connector accessible at one end of the body is coaxially housed. The connector is configured to inviolably obstruct the passage through the body. A unidirectional coupling locks in rotation the connector with respect to the body in the direction corresponding to the screwing of the connector, and a complementary connector, and to enable free rotation of the connector in the opposite direction. The connector can be possibly locked in rotation with respect to the body in the unscrewing direction, only following a positive command. | 0 |
BACKGROUND
This invention relates to traffic safety control systems, and in particular to devices and methods for securing such systems.
As is well recognized, traffic control systems, making use of traffic markers such as traffic cones, are routinely used today to direct motorists away from dangerous areas. Traffic cones are usually brightly colored, hollow, light weight markers made of an elastomeric material so as to minimize damage to persons or vehicles which may collide with them. The wide spread use of these relatively standard traffic cones insures their being made available at reasonable cost.
In addition to delineating area of concern to motorists, traffic markers, including traffic cones, are routinely employed to support warning lights, information signs, and warning flags as further traffic aids. Ropes, chains, and barricade tapes are also affixed to these traffic cones to perimiterize a given area of concern.
For example, in U.S. Pat. No. 5,269,251 devices and methods are disclosed for utilizing standard traffic cones to support standard information signs, standard flags and staffs, standard barricade rope and standard barricade tape, standard chemical light sticks, and battery operated warning lamps. A unique polyvinylchloride adapter (28-FIG. 3) is described, having one end that fits over the top of a typical traffic cone, with the other end of the adapter conformed to execute a variety of tasks, including connecting signs, flags, chemical light sticks, and barricade rope or tape to these standard traffic cones. Provisions are also described for the direct connection of a battery operated warning lamp to a standard traffic cone.
While the above described devices and methods denote important and useful traffic control systems, they do not provide solutions to the problems associated with traffic safety control security systems addressed by the instant invention. By the very nature of traffic cones, they are necessarily placed in positions where they are frequently struck by an oncoming vehicle. Signs, flags, or lighting devices attached to the top of a cone can be thrown free of the cone under these circumstances, and actually become a dangerous projectile for passing motorists or individuals who happen to be in the immediate vicinity of the traffic cone. A similar result is often obtained when these traffic control systems are subject to high winds during extreme weather conditions. And these traffic control devices can themselves constitute a traffic hazard when they become scattered onto a roadway. In addition to vehicular accidents with traffic cones, unauthorized removal of cones and their related accessories (or outright theft of these devices) provide additional cause for concern regarding securing these systems.
It is therefore a primary object of the invention to keep intact any traffic cone accessories and the traffic cone itself all as one unit in the event of collision of the cone with a vehicle, or in the event of high winds during extreme weather conditions.
A further object of the invention is to prevent the unauthorized removal of traffic cone accessories or the traffic cones themselves from traffic safety control areas.
An additional object of the invention is to provide a traffic safety control security system capable of easy set up and knockdown by the end user of the system.
Another object is to permit the stacking of traffic cones either with or without the traffic safety control security system of the invention attached.
Still another object of the invention is to provide a simple and economical method for securely attaching warning lights, informations signs, and warning flags to standard traffic cones.
SUMMARY
These and other objects are obtained with the traffic safety control security system of the invention.
Traffic cones are available in a variety of sizes, those being approximately 28" to 36" in height have been found generally well suited for most traffic control problems. Most traffic cones are hollow with an opening at the top of the narrow portion of the cone. They are usually fabricated in rubber or an elastomeric plastic material so as to limit damage to vehicles or persons during accidental contact. As has been mentioned above, devices and methods are now readily available for connecting standard signs, standard flags with staff, and illuminating lamps to standard traffic cones. In U.S. Pat. No. 5,269,251 noted above these standard traffic control accessories are connected to standard traffic cones by means of an adapter. This adapter is made out of a relatively soft plastic, such as polyvinylchloride, being hollow so as to allow the passage therethrough of a cable or a rope, with a base portion and a top portion. The base is conformed to fit over the narrow top end of standard traffic cones, while the top portion of the adapter is made so as to conveniently accept information signs, warning flags and their staffs, and various types of area illuminating devices. In this invention when the term "Cone Adapter" is used it is referring to traffic accessory cone connectors of this type.
While traffic control systems making use of cone adapters are relatively safe in the case of impact with a moving vehicle in that the traffic cone is usually made of rubber, the cone adapter is usually made of a light weight plastic, and signs and flags can be made of light weight materials, it is still highly desirable to keep the accessories and cone together as a unit if they are involved in a collision. And, of course, securing the accessories and cone together greatly facilitates theft prevention.
It has been found that securing traffic control accessories and traffic cones together can be accomplished economically, and with significant convenience for the end user. In a first embodiment of the invention without making use of cone adapters, a steel cable connects the accessory directly to the traffic cone by means of an attachment on the accessory, and a removable security disc and lock positioned within the traffic cone. For example, a strobe light, information sign, or flag staff can have a flat plate connected at a base portion of the accessory, said plate being larger in diameter than the top surface of a traffic cone, and having a plastic or metal hook affixed at the center of the underside of the plate. An interior, removable security disc is positioned within the traffic cone, near the base or widest portion of the cone. The security disc can be fabricated in a rigid plastic material such as polyethylene, and can have a center hole large enough to permit a looped end of the cable to pass through the disc. To secure the accessory to the traffic cone, one end of the cable is passed through the opening in the hook on the bottom of the plate affixed to the accessory, the looped end of the cable being secured by a crimp sleeve. A second cable loop is formed at the other end of the cable, the looped cable end again being secured by a crimp sleeve. This second cable loop is passed through the center opening in the security disc, and a locking device, such as a padlock, is affixed to this second cable loop. In this configuration if the traffic cone is struck by a moving vehicle the accessories, such as strobe lights, informations signs, and flags, will remain together with the cone, and cannot become dangerous projectiles as was the case in the past. Further, connecting the lock secured cable loop by means of a chain to other similarly secured traffic cones in the traffic control area effectively prevents unauthorized removal or theft of the cones and accessories.
In a second embodiment of the invention the aforementioned cone adapter is employed as the means for connecting accessories including warning lights, signs, and flags. Typically the cone adapter is hollow, with a frusto-conical base portion that fits over the top of standard traffic cones, and an upstanding, circular top portion of smaller diameter, having a hollow center confluent with the hollow center of the base portion, and having suitable slots formed into the upstanding side walls of the circular shaped top portion so as to accommodate accessories such as signs, etc. The use of these multipurpose cone adapters facilitates connecting a variety of traffic control accessories quickly and with added security.
For example, a strobe light can be firmly secured to a standard cone by first adhesively securing the base of the strobe light to a special adapter as will be more fully explained. This special adapter is secured to one end of the security system cable. With the cone adapter in place on a traffic cone, the looped free end of the cable is now passed through the cone adapter and through the opening in the security disc within the traffic cone, and a lock is affixed to this looped free end of the cable. The special adapter fits into the circular top opening in the cone adapter, resulting in a firmly secured strobe light and traffic cone assembly.
In another example, an information sign can be secured with safety to a cone adapter- traffic cone assembly. An opening adjacent the middle of the sign and near the base of the sign provides the means for connecting the sign and cable together. One end of the cable is passed through the opening in the sign, this end of the cable forming a loop which is secured by a crimp sleeve. The looped free end of the cable is then passed through the cone adapter, and then passed through the opening in the security disc, and a lock is affixed to this looped free end of the cable. The sign itself is now secured within slots previously formed into the side of the circular top portion of the cone adapter, or by other suitable modifications to this top portion of the cone adapter.
In still another example of the utility and convenience of this cone adapter-traffic cone security system, a flag and staff are connected to a standard cone. A plastic or metal hook is simply connected to the base of the flag staff, the cable then connects to this hook through the cone adapter, and to the lock within the traffic cone in the same manner as described above for the information sign connection. The base of the flag staff is now secured within the circular opening in the top portion of the cone adapter.
Thus a traffic safety control security system is disclosed to substantially reduce possible injury caused by the traffic control devices becoming projectiles during collision with moving vehicles. Standard traffic cones are quickly and economically converted to supports for slightly modified standard warning lights, information signs, and flags and staffs so as to create a fully secured traffic safety control system. At the same time the security system of the invention greatly facilitates preventing theft of traffic cones and/or related traffic control accessories.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially sectional, perspective view of one version of the traffic safety control security system of the invention, showing a strobe light secured to a standard traffic cone.
FIGS. 2A and 2B are schematic representations of one version of possible devices for securing an information sign or a warning flag to a standard traffic cone.
FIG. 3 is one version of a cone adapter to facilitate the connection of various traffic safety control accessories to the top of standard traffic cones.
FIG. 4 is an exploded, perspective view of one version of the traffic safety control security system of the invention, showing a strobe light and cone adapter combination being secured to the top of a standard traffic cone.
FIG. 5 is a partially sectional, perspective view of one version of the invention, showing an information sign and cone adapter combination in place on top of a standard traffic cone.
FIG. 6 is a partially sectional, perspective view of one version of the invention, showing a warning flag and flag staff and cone adapter in place on top of a standard traffic cone.
FIG. 7 is a partially sectional, perspective view of one version of the invention, showing a strobe light and cone adapter combination in place on top of a standard traffic cone, with a chain passing through a loop in the cable securing the traffic cone and strobe light together, the chain providing the means for preventing theft of the strobe light and/or traffic cone.
DETAILED DESCRIPTION
Referring now to the drawings in which similar structures having the same function are denoted by the same numerals in the various views, in FIG. 1 a first embodiment of the invention 10 illustrating a battery operated strobe light 22 as being connected and secured to a standard traffic cone 12 is depicted. The strobe light 22 has an on/off switch 24, and a top portion consisting of a light emitting bulb 21, and a base portion 26. A support base plate 28, which can be round or other convenient shapes, is affixed to the base portion 26 of the strobe light with any convenient means such as adhesively securing the base plate 28 and the base portion 26 together. On the underside of the support base plate 28 (the side facing away from the strobe light) a metal or plastic closed hook 31, i.e. an open hook 30 as depicted in FIGS. 2A and 2B being closed after assembly within a traffic cone, is attached at the approximate center of the plate. The gist of the invention follows in the description of the means for attaching traffic safety control accessories, such as a strobe light, to the tops of standard traffic cones, while at the same time securing the accessories and traffic cones together so as to prevent their flying away when struck by a vehicle or subjected to high winds. A rope, or wire, or, in a preferred embodiment of the invention, a 1/16" diameter vinyl coated stainless steel aircraft cable is connected by means of a first loop 32 at one end of the cable being secured within the hook 30. This first loop is made at the end of the cable by a crimp sleeve 34 secured to the end of the cable and a portion of the cable a spaced distance below this end. A second loop 36 is made in identical fashion at the other end of the cable. To secure the strobe light 22 and traffic cone together the support base plate 28 affixed to the base portion 26 of the strobe light is placed on the top section 13 of the traffic cone, with the hook 30 on the support base plate 28 now projecting downward through the opening 66 at the top of the cone 12. With the first loop 32 of the cable secured to the hook 30, the traffic cone can be placed on its side so as to expose the large opening 68 at the base portion 15 of the traffic cone. The hook 30 is now crimped so as to form a closed hook 31. A security disc 16 (which can be a rectangularly shaped disc having rounded corners, with a hole 40 at its center, the disc normally being free floating within the traffic cone, but having a sufficient length so as to form a wedge fit with the internal wall 17 of the traffic cone if the disc is moved upwards within the cone) is now placed within the base portion 15 of the cone, the second loop 36 of the cable 14 is grasped and pushed through the hole 40 at the center of the security disc, a padlock 18 or other locking device is secured over this second loop 36. Thus a standard traffic cone and slightly modified standard strobe light are secured together in a fast, economical, and practical manner.
FIGS. 2A and 2B schematically illustrate the same method for direct connection and securing of slightly modified standard traffic control accessories to standard traffic cones as shown and described for FIG. 1. In FIG. 2A an information sign 42, such as a CAUTION sign, is shown having a support base plate 28, with hook 30, affixed to the base of the sign 42. The method for securing the sign to the traffic cone is the same cable 14, security disc 16 and padlock 18 as previously described for connecting and securing a strobe light. And, again in FIG. 2B the same support base plate 28 and hook 30 assembly is affixed to the base of a flag staff 46 with attached flag 44, the flag staff being connected and secured to the traffic cone utilizing the same cable 14, security disc 16, and padlock 18 as described above for the strobe light 22 and information sign 42.
In a second embodiment of the invention, a convenient cone adapter 48 is employed in conjunction with modified traffic safety control accessories, including warning lights, informations signs, and warning flags, and the aforementioned cable 14, security disc 16, and padlock 18. FIG. 3 illustrates one version of a typical cone adapter 48. Cone adapters are usually fabricated in a relatively soft plastic material, such as polyvinylchloride, and can be molded as a single piece, or two or more sections can be cemented or heat sealed together. The adapter 48 consists essentially of a frusto-conical, hollow base section 50, a flat shelf area 62 at the top of this base section, and a generally circular, hollow top section 52 extending a spaced distance upwards from the shelf area 62 of the adapter base portion. The base portion 50 of the adapter can have slots 64 cut into it to facilitate connecting traffic control accessories such as ropes or barricade tapes (not shown). The top section 52 of the adapter 48 can have vertical slots 54 extending from the open end of the top section to the shelf area 62 of the base of the adapter in order to facilitate the connection of an information sign to the adapter. The adapter can be provided with other vertical slots confluent with holes 56 in the sides of the adapter top section to accommodate other accessories, such as a rope (not shown). The shelf area 62 of the adapter has a center opening sufficiently large enough so as to permit the passage therethrough of objects such as the previously described hook 30. In operation the base portion of the adapter simply slip fits over the conical end 13 of a standard traffic cone, and the various traffic control accessories can then be conveniently connected directly to the top section 52 of the adapter 48.
In FIG. 4 an exploded view of one version of the invention making use of a cone adapter to facilitate the connection and securing of a strobe light 22 to a cone 12 is illustrated. A special adapter 70, which can be machined out of aluminum or molded in a suitable plastic material, is employed as the method for securing a strobe light 22 to a cable 14. The special adapter has a flat top surface 72 confluent with a first side wall 73, with a narrower diameter second side wall 74 extending a spaced distance below the first side wall. A hole is counterbored through the special adapter from the center of the top surface 72 to the center of the base portion of the special adapter 70. The counterbored hole 76 has a larger opening 80 adjacent the top surface of the special adapter, narrowing towards a smaller opening 82 at the base of the special adapter. This special adapter slip fits over one end of a cable 14 similar to the cable described in FIGS. 1, 2A, and 2B, except the first loop 32 previously described is replaced by a swedge coupling 78, so that this end of the cable is larger in diameter than the smaller opening 82 at the base of the special adapter 70, and therefore this special adapter cannot fall loose from the cable. The cable itself then runs through the opening 58 in the top of the cone adapter, through the cone adapter via the base opening 60 in the cone adapter, and into the traffic cone, with a second cable loop 36 as previously described in FIGS. 1, 2A, and 2B being secured with a padlock 18 beneath a security disc 16. To complete the assembly of the strobe light 22, cone adapter 48, and traffic cone 12, the base 26 of the strobe light is adhesively secured to the top surface 72 of the special adapter 70, the narrower outer side wall 74 of the special adapter then being slip fitted into the hollow center opening 58 in the top section 52 of the cone adapter.
Again, the utility of a cone adapter in facilitating the connection of traffic control accessories is illustrated in FIGS. 5 and 6. In FIG. 5 an information sign 84, such as a CAUTION sign, is shown as connected by means of slots 54 in the top section 52 of a cone adapter, said cone adapter being in place atop a standard traffic cone. The connection of the sign 84, cone adapter, and traffic cone is secured by means of a cable 14 having a first loop 32 at one end of the cable passing through an opening 86 centrally located near the base of the sign, this first loop being secured by means of a crimp sleeve 34, with the cable having a second loop 36 at its other end secured by a padlock beneath a security disc, as previously described in FIGS. 1, 2A, and 2B.
In a manner similar to FIG. 5, in FIG. 6 a flag staff 88 and attached flag 90 is shown connected to a cone adapter, the cone adapter being in place atop a traffic cone. The flag connects to the cone adapter by simply having the flag staff inserted into the hollow opening 58 in the top section of the cone adapter 48. The flag staff and flag, cone adapter, and traffic cone are secured together by means of attaching a first loop 32 at one end of a cable 14 to a hook 92 (shown in closed position as, for example, hook 30 in FIGS. 2A and 2B as being shown a closed hook 31 in FIG. 1) connected at the base of the flag staff 88, with a second loop 36 at the other end of the cable being secured by a padlock 18 beneath a security disc 16, as previously described in FIGS. 1, 2A, and 2B.
Another important advantage inherent in the instant invention is illustrated in FIG. 7. A strobe light 22 is shown secured to a standard traffic cone according to the invention as part of a traffic safety control system. A chain 94 is shown passing under the feet 20 of a traffic cone, into the base opening 68 in the cone, through the second loop 36 securing the cable 14 within the cone, and then continuing on for connection to other traffic cones in the system, or for connection to a non-movable object in the vicinity of the traffic control area to which the chain can be finally secured. In this manner unauthorized movement, or outright theft of the traffic cones and/or accessories is prevented.
The aforementioned crimp seals, and swedge couplings are conventional, and well known to the art. While the locking device described above for securing the cable is denoted as a padlock, other locking devices, including combination locks and electronically activated locks, can also be employed.
Thus new devices and methods are provided by the instant invention in both preventing injury from traffic safety control systems, and theft of the systems themselves. Information delivery accessories, including warning lights, signs, and warning flags are now quickly and economically installed and secured on standard traffic cones in a manner consistent with the customary placement of these traffic safety control systems.
While versions of the present invention have been shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present invention is to be limited only by the following claims. | A traffic safety control security system is described. Warning lights, signs, and warning flags are connected and secured to the tops of standard traffic cones either with or without the use of cone adapters. One end of a stainless steel aircraft cable connects directly to the traffic control accessories, while the other end of the cable is secured by a removable security disc and padlock within the traffic cone. Interconnecting the accessory and traffic cone together prevents injury to vehicles or individuals nearby if a traffic cone is accidentally struck by a vehicle, or encounters violent weather, causing the accessory to fly loose as a projectile. In addition a chain can now interconnect traffic cones in the system together, preventing theft of the traffic cones and/or accessories. Set up and knock down of the system is consistent with customary traffic safety control procedures. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present Application claims priority from Italian Application No. RM2006A000085 filed on May 17, 2006, which is hereby incorporated by reference in its entirety into the present Application.
FIELD OF THE INVENTION
The present invention relates to a hydraulic system with electronic control for moving automatic closing apparatuses, such as gates or doors, barriers for the passage of vehicles and/or pedestrians, that is simple, reliable, safe, inexpensive, and easy to install.
BACKGROUND OF THE INVENTION
In the following of the description, explicit reference will be mainly made to the case where the automatic closing apparatuses are swing-gates or swing-doors. However, it should be understood that the present invention is not limited to such type of closing apparatuses, being capable to be applied also to other automatic closing apparatuses for delimiting rooms and spaces, such as traffic bollards and underground rotating actuators for gates (for which in the following some embodiments of the system according to the invention will be illustrated), as well as sliding barriers, gates or doors, sectional doors for garages, still remaining within the scope of the present invention.
Presently, systems for moving automatic closing apparatuses comprise hydraulic actuators with high voltage ( 220 V) electric motors.
Such systems suffer from some drawbacks.
First of all, use of high voltage motors entails a more complex implementation of the systems in order to allow high safety for users and operators during installation and maintenance phases.
Moreover, the force applied to the gate is adjustable only at mechanical level through pressure calibration valves mounted on the distributor or directional valve after a pump moving a movable member of the actuator.
Still, gate movement speed is only adjustable through the use of pumps having different capacity, the characteristics of which have to be already defined at the production phase, therefore making such systems not much versatile.
Furthermore, sensitivity of such systems in case of impact of the gate on an object crossing the passage during its movement is absolutely not controllable unless sophisticated external devices, such as wings sensorised through sensitive edges or obstacle detectors, are used, which are complex and expensive also with regard to their installation.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a system for moving automatic closing apparatuses, such as gates, doors, or barriers, that is simple, reliable, safe, inexpensive, and easy to install.
It is specific subject matter of this invention a hydraulic system for moving automatic closing apparatuses, comprising hydraulic actuating means capable to move at least one movable member coupled to at least one closing apparatus, characterised in that said hydraulic actuating means is operated by at least one low voltage dc motor.
Always according to the invention, said at least one low voltage dc motor may operate at 12 V or 24 V.
Still according to the invention, the system may further comprise detecting, preferably electronic and/or magnetic, means for detecting the position of said at least one movable member.
Furthermore according to the invention, said hydraulic actuating means may be capable to linearly move said at least one movable member, making it translate.
Always according to the invention, said detecting means may comprise one or more electronic switches each one of which is capable to detect a corresponding linear position of said at least one movable member.
Still according to the invention, said at least one movable member may be a piston.
Furthermore according to the invention, said one or more electronic switches may be capable to interact with a cursor member of a rod integrally coupled to the piston.
Always according to the invention, said hydraulic actuating means may be capable to angularly move said at least one movable member, making it rotate.
Still according to the invention, said detecting means may be capable to detect the angular position of said at least one movable member.
Furthermore according to the invention, said at least one movable member may be a rotating shaft.
Always according to the invention, said detecting means may comprise a magnetic encoder, provided with a rotating disc, coupled to the shaft of said at least one motor, and with a detection unit.
Still according to the invention, the system may further comprise an electronic unit controlling said at least one motor.
Furthermore according to the invention, the electronic unit may control said at least one motor on the basis of one or more signals which it receives from said detecting means.
Always according to the invention, the electronic unit may be connected to an input/output interface unit.
Still according to the invention, the interface unit may be connected to at least one button, the electronic unit learning one or more movement parameters of said at least one closing apparatus on the basis of at least one signal received from said at least one button.
Furthermore according to the invention, said hydraulic actuating means may comprise a pump capable to move, through a distributor or directional valve for switching an oil flow, said at least one movable member.
Always according to the invention, the system may further comprise means for recognizing, preferably amperometrically, an obstacle.
Still according to the invention, the system may further comprise battery and/or solar panel power supply means.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be now described, by way of illustration and not by way of limitation, according to its preferred embodiments, by particularly referring to the Figures of the enclosed drawings, in which:
FIG. 1 shows a schematic perspective view of a portion of a first embodiment of the system according to the invention;
FIG. 2 shows a top view of the system of FIG. 1 ;
FIG. 3 shows a perspective view of a particular of the system of FIG. 1 ;
FIG. 4 shows a schematic block diagram of the system of FIG. 1 ;
FIG. 5 shows a schematic perspective view of a portion of a second embodiment of the system according to the invention; and
FIG. 6 shows a schematic perspective view of a portion of a third embodiment of the system according to the invention.
In the following of the description same reference numbers will be used for indicating alike elements in the Figures.
DETAILED DESCRIPTION
With reference to FIGS. 1 and 2 , it may be observed that a first embodiment of the system according to the invention comprises a linear hydraulic actuator applied to a swing-gate (not shown), to which it is conventionally coupled through two plates 1 and 2 . In particular, the plate 1 is coupled to the fixed frame of the gate (or to the fixed structure, such as a wall, in which the gate is inserted), whereas the plate 2 is coupled to the wing.
The actuator comprises a low voltage (preferably 12 V or 24 V) dc motor 3 controlling a pump 4 . The pump 4 , through a distributor or directional valve 5 for switching the oil flow, linearly moves a piston 6 , the distal end of which (that is external to a cylinder 9 wherein the other end of the piston 6 slides) is integrally coupled, through the plate 2 , to the gate wing. A rod 7 is integrally coupled to the distal end of the piston 6 , whereby it is linearly moved with respect to the pump 4 by the movement of the same piston 6 .
The motor 3 , the pump 4 , the distributor 5 and the cylinder 9 for sliding the piston 6 are integrally coupled to each other and hinged on the first plate 1 , whereby the linear movement of the piston 6 , coupled to the second plate 2 , causes the wing to which the latter is attached to open or close.
The proximal end (that is the one closest to the pump 4 ) of the rod 7 , the position of which with respect to the pump 4 depends on the movement of the piston 6 , is provided with a cursor 8 capable to interact with a first switch 10 , when the position of the cursor 8 corresponds to the complete opening of the gate wing, and with a second switch 11 , when the position of the cursor 8 corresponds to the complete closing of the gate wing. In particular, when the cursor 8 interacts with one out of the two switches 10 and 11 , a corresponding signal is forwarded through cables 12 to a control electronic unit (not shown in FIGS. 1 and 2 ) that stops the motor 3 and, consequently, the pump 4 .
With reference to FIG. 3 , it may be observed that the system of FIGS. 1 and 2 is further provided with a detector for detecting the position of piston 6 (and, consequently, of rod 7 and cursor 8 ) which detector is made through a magnetic encoder comprising a rotating disc 13 of ferrous material, integral with the shaft of the motor 3 , and a detection unit 14 , measuring the variation of a flow generated by a permanent magnet and sending to the control electronic unit a corresponding signal depending on the detected variations of magnetic field, i.e. on the angular position of the motor and, consequently, the position of the piston 6 .
With reference to FIG. 4 , it may be observed that the electronic architecture of the system of FIGS. 1 and 2 comprises the control electronic unit 16 , that controls the motor 3 of the system hydraulic actuator, and that receives the signals coming from a unit 15 for detecting the position of the piston 6 (depending on the rotation of the motor 3 ). Such detection unit 15 comprises the switches 10 and 11 and the magnetic encoder 13 - 14 .
Unit 16 is further connected to an input/output interface unit 16 , through which system operation data may be read, thus detecting for instance possible malfunctions, and through which system operation parameters may be updated.
In particular, through a button 18 , operatable by an installer, that is connected to such interface unit 17 , it is possible to carry out in an automatic manner stroke and time learning through the control unit 16 , as it already usually occurs in low voltage electromechanical actuators. In fact, the magnetic encoder (or, alternatively, a plurality of limit switches, of the same type as switches 10 and 11 , distributed along the path of the cursor 8 ) allows the control unit 16 to know the position of the gate wing during its movement, and in particular when the latter reaches a final beat (either when opening or closing), thus favouring a substantially automatic learning of operation times.
FIG. 5 shows a second embodiment of the system according to the invention, applied to an underground rotating actuator, wherein the low voltage (preferably 12 V or 24 V) dc motor 3 is still visible, which motor controls the pump 4 that, through the distributor 5 , causes a rotating shaft 19 to rotate, which shaft is connected to the closing apparatus (not shown), e.g. a gate, of which the system controls the movement. The system of FIG. 5 is provided with a detector for detecting the angular position of the shaft 19 that is implemented through a magnetic encoder, comprising a rotating disc 13 and a detection unit 14 , that measures the angular position of the motor 3 .
FIG. 6 shows a third embodiment of the system according to the invention, applied to a traffic bollard or a barrier, wherein a low voltage (preferably 12 V or 24 V) dc motor 3 is still visible, which motor controls a pump 4 that linearly moves, through a distributor 5 connected through two ducts 20 and 21 to a cylinder 9 within which a piston 6 slides, the same piston 6 , to which the traffic bollard (not shown), of which the system controls the movement, is integrally applied. The system of FIG. 6 is provided with both the switches 10 and 11 , capable to interact, similarly to the system of FIGS. 1 and 2 , with the cursor 8 of a rod 7 integral to the piston 6 for detecting its two limit positions, and a detector for detecting the angular position of the piston 6 implemented through a magnetic encoder, comprising a rotating disc 13 and a detection unit 14 , which measures the angular position of the motor 3 .
Other embodiments of the system according to the invention may further comprise a conventional device for amperometrically recognizing an obstacle, that possibly causes an impact during closing, which device is controlled by the electronic unit 16 .
Still, thanks to the low voltage power supply, further embodiments of the system according to the invention may comprise emergency batteries and/or solar panels for ensuring system operation even in case of lack of energy.
The advantages offered by the system according to the invention are evident.
First of all, besides the fact that it operates at low voltage, the system has no calibration valves on the distributor, and all the parameters of speed, force, decelerations and sensitivity are adjustable at electronic level. In particular, adjustments of speed and sensitivity, nowadays impossible on presently commercialized traditional hydraulic automations, are instead possible in the system according to the invention. This entails a great simplification of the system installation, that does not necessarily require intervention of specialized installers, consequently reducing the related costs.
Also, the system according to the invention more easily allows to meet safety regulations in force without using expensive and complex external devices.
Still, use of electronic and/or magnetic detectors for detecting the position of the automatic closing apparatus, or even only the complete opening and the complete closing thereof, allows, on the one hand, to avoid the use of mechanical beats on the ground, forbidden in some countries such as the US for safety reasons, thus also simplifying system installation, and, on the other hand, to eliminate the classical problem of the hydraulic actuator that prosecutes for some seconds its pushing movement even after having arrived at stop, causing a greater wear and a more frequent maintenance thereof.
The present invention has been described, by way of illustration and not by way of limitation, according to preferred embodiments thereof, but it should be understood that those skilled in the art can make variations and/or changes, without so departing from the related scope of protection, as defined by the enclosed claims. | The invention concerns a hydraulic system for moving automatic closing apparatuses, comprising hydraulic actuating means capable to move at least one movable member coupled to at least one closing apparatus, wherein said hydraulic actuating means is operated by at least one low voltage dc motor. Preferably, the electronic unit controls, through an encoder and microswitches, the position of a piston or a rotating shaft that operates the automatic closing apparatus during closing and opening phase, favouring an automatic learning of operation times. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This is a continuation of my patent application serial No. 483,458 filed June 26, 1974, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the construction of and the method of making scissors. The great majority of scissors commercially available today are the hot forged type. These scissors are generally rather expensive for the following reasons:
1. Forging dies are expensive to make and have a relatively short life. The high temperatures and pressures wear them out quickly. They can be dressed up a few times but then must be discarded. Only highly skilled (and highly paid) die makers can make new ones.
2. Forging equipment is expensive. Because of the high pressures required, the presses must be very large. Several hits are necessary to make a forging and then it must be trimmed. All this requires a number of machines and associated handling equipment.
3. Forging labor is high. For most products such as scissors, the process is still manual or at best, semi-automatic. There often are intermediate steps such as shearing bars to length, heating bars prior to hitting, annealing, and the like. Because of the difficult working conditions and skill required, the workmen usually are highly paid.
4. Grinding is extensive. Forging leaves a coating of scale and a very rough finish. For the most part, this has to be ground off as do other surfaces and edges. Since the shape of scissors is irregular, grinding does not lend itself to automation. The many sides, edges, curves, etc. generally have to be done manually in a number of separate steps.
5. This extensive grinding requires a high cost of grinding material and equipment.
6. Much polishing also is required. In order to prepare the scissors for plating, all ground and unground surfaces have to be carefully polished. Polishihg is very time-consuming, especially around the handle area. As with grinding, there is a substantial cost of material and equipment. It also is a manual operation.
7. Utilities cost is substantial. Heating the bar stock and the electricity required to run the large presses plus many grinders, polishers, etc. involves a significant utility cost per unit. Another important cost is the high percent of steel waste. Probably less than fifty percent of the bar stock actually is used for the final scissors because of its shape. The waste has a very low value compared to original steel cost.
For the foregoing reasons, most of the forged scissors are manufactured in low labor cost countries foreign to the United States.
Other methods presently used for scissor manufacturing generally produce the final shape of the scissors first and then follow up with the steps of grinding, polishing, plating and assembly. One such method is that of casting. However, the casting procedure is much inferior in quality to the forged scissors. Its granular micro-structure is a poor one for a cutting edge. The edges wear relatively quickly because of the granular, less dense material. Being cast, the scissors cannot flex during cutting action as do forged or some other type scissors. This results in a stiff, hard to close tool. Althought less expensive than forging, casting does require much labor and, therefore, is done primarily in low labor cost countries. Cast scissors generally are heavy because more weight is necessary to offset the low strength.
Other than hot forging, the most popular method is cold forging and stamping. Cold forging is very similar to plain stamping except that the upper surface from point to pivot is coined or smashed to give the traditional forged appearance. Otherwise, cold forging and stamping are the same in that both involve punching the shape out of a thin, flat length of sheet metal. The process can be an automatic one and thus the labor is low. A disadvantage, however, is that the handle usually is the same thickness as the blade since it is all punched out of the same sheet. This makes for an uncomfortable pressure on the fingers during cutting. The main disadvantage is that, like forgings and castings, these types of scissors cannot be ground and polished automatically. For this reason, producers of these scissors generally do not grind any more than absolutely necessary and do very little polishing at all. The percentage of waste material is not as high as in forging but, because of the shape of the scissors is a poor one for nesting in the blank, the waste probably runs as high as forty percent. Another bad feature is the fact that these scissors usually are of lower carbon than the level required for good cutlery type edges. High carbon steel is very difficult to cold forge. It also is very difficult to punch a shape such as scissors out of high carbon steel. Producers usually use lower carbon grades in order to extend tooling and equipment life.
SUMMARY OF THE INVENTION
It is the general object of the invention to provide a new and improved scissors construction and a method of making the same.
The scissors in accordance with the invention provides an alternative to the forged scissors that offers both low cost and good quality and appearance. The scissors in accordance with the invention combines the ultimate in material and manufacturing efficiency along with a design that provides comfort features exceeding those of forged or any other type of scissors in use today. The scissors construction comprises a handle portion that conforms with the natural finger position and angle during a scissors cutting action. Moreover, the symmetry of the shape lends itself to highly automatic manufacturing along with an extremely low percentage of waste product. Also, the original blank configuration allows the use of low cost grinding, polishing and other operations necessary to produce a high quality cutting tool. The characteristics of low cost and high quality of the scissors in accordance with the invention combine to produce an improved scissors.
Briefly stated, the scissors in accordance with the invention is made by the steps of stamping from a flat sheet of metal a flat blank having a generally straight cutting portion and a curved handle forming portion, forming the cutting edge on the blade portion of the flat blank, and then forming the handle portion by bending and twisting the blank to form a hollow cylindrical portion adapted to receive a finger in the natural position and angle for the application of a cutting force to the scissors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a blank which is used to form each half of the scissors in accordance with the invention;
FIGS. 2 and 3 are views of a blank in intermediate stages of manufacture;
FIG. 4 is a section taken on line 4-4 of FIG. 3;
FIG. 5 is a top plan view of a scissors in accordance with the invention;
FIG. 6 is a right side view of the scissors shown in FIG. 5;
FIG. 7 is a bottom end view of the scissors shown in FIG. 5; and
FIGS. 8, 9, 10 and 11 are views illustrating the analysis used in developing the configuration of the blank used in forming the scissors in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
It is to be understood that the invention is not to be limited to the scope of the specific form thereof herein shown and described and that various embodiments thereof may be employed within the scope of the claims set forth hereinafter.
Each half of the scissors in accordance with the invention is made out of a flat blank such as the one shown in FIG. 1 and indicated generally at 10 therein. The blank 10 has a straight portion 11 extending from the end 12 thereof to a location indicated by the line 14. In the middle of the straight portion of blank 10 there is punched out a hole 16 which is adapted to receive the pivot means of the scissors as will be described hereafter. The blank 10 is provided with a tail portion 20 between line 14 at the end of the straight portion and the other end 18 of the blank 10. The tail portion 20 has a sinusoidal configuration defined by the curve expressed by the formula Z = .3524 sin(90° × d/.660) wherein Z is the coordinate of the curve along the ordinate and d is the coordinate of the curve along the abscissa. The manner in which this curve is determined will be described more fully hereafter.
The portion 22 of the blank 10 between the end 12 and the pivot hole 16 forms the blade of the scissors. The portion 24 of the blank 10 between the pivot hole 16 and the end 14 of the straight portion may be termed an intermediate portion. The sinusoidal tail portion 20 forms the handle of the scissors as will be described hereafter.
The blade portion 22 has a cutting edge 26 formed along one edge thereof and a back edge 28 formed along the opposite edge thereof. The cutting edge 26 and the back edge 28 converge together at the end 12 of the blank 10.
In the making of a scissors in accordance with the invention the first step is to stamp out a plurality of blanks 10 as shown in FIG. 1 from a sheet of high carbon metal. In the stamping operation the blanks 10 nest next to one another whereby the only waste is the pivot hole 16 and the area between the edges 26 and 28 of adjacent stamped blanks 10, such as is shown by the cross hatched area 29 in FIG. 1. This operation is performed on a high speed, automatic punch press. Each scissors is made of a pair of almost identical blanks 10 which form the two halves of the scissors, identical except that one scissor is more pointed than the other.
The next step in the method is for formation of the cutting edge 26 of the blank 10. This step comprises the heat treating of the cutting edge 26 and part of the body by passing the same under an oxygen-acethylene flame or by other suitable heat treating methods. The cutting edge 26 is then ground to a predetermined angle, typically 30° to the edge of the blank 10. In FIG. 2, the blade portion 22 is shown with the cutting edge 26 formed thereon. The other longitudinal edges of the blank 10 are ground to a rounded or beveled condition. The grinding steps are preferably achieved by placing the blank 10 on special moving fixtures passing grinding belts.
The next step is to grind and polish the flat sides of the blank 10, which step is achieved by placing the blank on a small moving conveyor which passes under a series of grinding belts and polishing wheels.
The next step in the manufacturing of the scissors is to form the handle portion of the scissors such that it conforms with the natural finger position and angle for applying a cutting force. The first stage of this step is to bend the handle-forming tail portion 20 into a loop having a hollow cylindrical configuration. This involves bending the portion 20 in a cylindrical shape with the end edge 18 being aligned with the line 14 to provide a shape as is shown in FIGS. 3 and 4. It will be apparent that the edges of the formed handle are defined by the intersection of spaced parallel planes which extend obliquely to the axis 30 of the hollow cylinder thus formed. The end edge 18 is then welded to the blank 10 along the line 14 to secure the handle in place.
The second stage of the handle forming step comprises twisting the intermediate portion 24 of the blank 10 a quarter turn to provide a configuration best shown in FIGS. 5 and 6. The axis 30 of the hollow cylinder now extends at an oblique angle relative to the plane of the flat blade portion 22. This is best illustrated in FIG. 6. In the assembled condition of the scissors the handle provides a substantial surface area for contact with the fingers and receives the fingers in their natural position and angle for producing an effective cutting action.
During the formation of the handle, the blade portion 22 is also bowed slightly for better contact during a cutting action.
The entire scissor half is then chrome or nickel plated. This step may be eliminated in the event that a stainless steel material is used.
The above-described method is followed to make both the scissor halves. Of course, during any mass production operation, a large number of these identical scissor halves are made prior to assembly.
The next step in the making of the scissors is to assemble two identical halves of the type described above. The two scissor halves are assembled by means of a rivet 40 which is inserted through the rivet holes 16 of a pair of scissor halves which are positioned together with their cutting edges arranged to perform a cutting action. A conical spring washer 42 is placed between the rivet head and an adjacent cutting blade and the rivet 40 is spun closed with the spring washer 42 in a compressed condition. Thus, the spring washer 42 serves to bias the cutting blades together to produce a tightening tension on the scissor halves which improves the cutting action.
The final step in the manufacture is to coat the handles with plastic. In this step the handles are dipped into a plastisol material and are then baked dry.
Referring to FIGS. 5, 6 and 7, the two scissor halves are designated with the same reference numerals with primes added to one of them. Referring to FIG. 6 it will be seen that the axes 30 and 30' of the two scissor halves extend at an oblique angle to the plane of the blade portions 22 and 22'. Moreover, these axes 30 and 30' extend in a crossed relationship. Thus, the hollow cylindrical portions provide finger receiving regions which conform to the natural finger position and angle for producing an effective cutting action. For example, if the thumb is inserted in the handle portion 20 it will extend upwardly along the axis 30. Also, another finger, such as the index finger, will be inserted downwardly in the handle portion 20' along the axis 30' to thus provide a grip whereby the fingers are in a crossed relationship extending on an oblique angle to the planes of the cutting blades 22 and 22', which position is ideal for achieving an effective cutting action and applying a cutting force to the scissors. Moreover, the handle portions provide a substantial area for receiving the applying load of the fingers, which area helps distribute the load and provides a comfortable feeling to the fingers.
Referring to FIG. 4, it will be noted that the edges of the hollow cylindrical portions provided by the bent tail portions 20 and 20' are defined by the intersection of spaced parallel planes with the enclosed hollow cylinder, which planes extend obliquely to the axis of the cylinder. Moreover, such edges are in the shape of an ellipse.
The derivation of the mathematical formula used to determine the shape of the handle forming tail portion 20 of the blank 10 will be described with reference to FIGS. 8, 9, 10 and 11. It was first determined that the diameter of the cylinder defined by the handle portion should be 0.840 inches and that the axis of this cylinder should be at an angle of 40° relative to a perpendicular axis, namely angle 0 shown in FIG. 9. It was determined that the major axis of the ellipse to be formed by the edges of the handle was 1.100 inches from the formula the cosine of 40° is equal to 0.840 divided by the major axis. This is apparent from the showing in FIG. 8 wherein the various elements are indicated.
The shape of the edge is that of an ellipse and the various points on the ellipse are governed by the elliptical equation.
The three dimensional showing of FIG. 9 is utilized to go from the ellipse shape to the three dimensional handle configuration desired. This figure demonstrates physically the formulas shown in FIG. 10 which are used to determine the curvature of the handle portion in its originally stamped state. This produced the formula for the shape of the curve which is illustrated in FIG. 11, the formula being Z = .3524 sin (90° × d/.660 wherein Z is the ordinate and d is the abscissa. This formula defines the shape of the tail portion 20 of blank 10 shown in FIG. 1 wherein the tail portion 20 has a sinusoidal shape. | A scissors comprising a pair of halves pivotally mounted together at a medial portion, each of the halves consisting of a one-piece strip of metal having a blade portion extending in one direction from the medial portion and a handle portion extending in the other direction from the medial portion. Each scissor half is formed by stamping a blank from a flat sheet of metal, the blank having a generally sinuous portion at one end thereof for use in forming a hollow cylindrical handle portion adapted to receive a finger in the natural position and angle for applying a cutting force to the scissors. In making the scissors the cutting edge is formed on the blade portion while the blank is in the flat condition and prior to the bending and twisting operation to form the handle portion. | 1 |
CONTRACTUAL ORIGIN OF THE INVENTION
The United States Government has rights in this invention pursuant to Contract No. W-31-109-ENG-38 between the U.S. Department of Energy and Argonne National Laboratory.
This is a division of application Ser. No. 196,710, filed Oct. 14, 1980 now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to a ternary intermetallic-compound capable of reversibly sorbing hydrogen. More specifically, this invention relates to a ternary intermetallic-compound capable of gettering hydrogen at low pressures and at temperatures from about room to about 200° C. and which can be regenerated at low pressures and at temperatures from about 300°-500° C. The temperature and pressure ranges at which gettering and regeneration can occur can be controlled by varying the composition of the compound.
It is generally recognized that impurities in the plasma of magnetic confinement fusion devices such as Tokamaks can seriously limit the performance of such devices by lowering the plasma temperature and quenching the fusion reaction. These impurities are introduced into the plasma by a variety of sputtering and erosion processes occuring at the walls of the devices by hydrogen isotope recycling. These impurities may consist of oxygen, carbon and hydrogen, including the isotopes deuterium and tritium Some metal ions may also be included which have been sputtered from the wall of the device during operation.
Some solutions to the problem of impurity control include modifying the recycling processes, minimizing the erosion rates at the surfaces facing the plasma and removing the offending impurities from the plasma. It has been shown that the trapping and subsequent re-admission of hydrogen isotopes from walls affects plasma profiles, especially at the edge, substantially modifying impurity influxes. In deuterium-tritium burning devices, wall recycling will strongly influence tritium inventory, which must be held to within well-defined limits. Therefore, tritium retention is an important factor in the design of a suitable fusion device.
There is need for a material which can getter hydrogen and hydrogen isotopes under the low pressure, high temperature conditions present in operating magnetic containment fusion devices. Furthermore, the material must be capable of being regenerated for recycling under reasonable condition of pressure and temperature. Such a material can be placed in the fusion device either as a coating on the walls of the device or as a coating on sheets of substrate which can be placed within the device. Preferably the material is reasonably selective for hydrogen, must be able to function as a hydrogen and hydrogen isotope getter at pressures down to at least 10 -6 torr, in the presence of power fluxes up to about 50 w/cm 2 and at temperatures from about room temperature up to about 200° C. Furthermore, the material should have a high hydrogen capacity in order to reduce the frequency of regeneration, it should be able to be regenerated with respect to absorbed hydrogen at a relatively low temperature, preferably no higher than 500° C., and it must be able to function as a hydrogen getter in the presence of other contaminant gases, such as CO, O 2 and N 2 .
One such material which has been used successfully is sublimed titanium. However, titanium is not easily regenerated and fresh layers of titanium must be sublimed for each gettering cycle that is required, which is expensive and time consuming. Another material which fulfills many of the requirements is ST101®. This material is a proprietary Zr-Al based alloy available from SAES Getters of Milan, Italy. However, hydrogen capacity of the alloy is somewhat limited and regeneration of the alloy within a reasonable length of time requires that it be heated to temperatures of at least 750° C.
SUMMARY OF THE INVENTION
It has been found that the substitution of chromium for some of the vanadium in a zirconium-vanadium alloy will form a ternary intermetallic-compound, which is useful as a hydrogen getter under the vacuum and temperature environment found within most magnetic fusion devices. Furthermore, the alloy can be regenerated under vacuum conditions at temperatures as low as about 300° C. The ternary intermetallic compound has the formula Zr(V 1-x Cr x ) 2 where x is in the range of 0.01 to 0.90. By varying the amount of chromium present in the alloy, it is possible to control the pressure and temperature conditions under which the compound will getter hydrogen and most important the conditions under which the getter can be regenerated. This allows the chemical properties of the compound of the invention to be tailored to fit the operating and regeneration requirements in terms of pressure and temperature of different fusion devices.
It is therefore one object of the invention to provide a material which is suitable for use as a hydrogen getter in a fusion plasma type reactor.
It is another object of the invention to provide a ternary intermetallic compound which is capable of gettering hydrogen at temperatures varying from about room temperature to about 200° C. and at pressures down to about 10 -6 torr.
It is still another object of the invention to provide a ternary intermetallic compound which is capable of gettering hydrogen at temperatures varying from about room temperature to about 200° C., at pressures down to about 10 -6 torr, and which can be regenerated at temperatures from about 300° and 500° C.
Finally, it is the object of the invention to provide a ternary intermetallic compound in which the gettering conditions and the regenerating conditions can be controlled.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 contains several curves showing hydrogen absorption isotherms for the compound Zr(V 0 .4 Cr 0 .6) 2 at several different temperatures.
FIG. 2 contains several curves showing pressure composition absorption isotherms at 450° C. for the compound Zr(V 1-x Co x ) 2 where x=0.4, 0.5 and 0.6.
FIG. 3 contains several curves showing the relationship between gettering pressure and temperature.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The ternary intermetallic compound of the invention has the formula Zr(V 1-x Cr x ) 2 where x=0.01 to 0.90. The compound is prepared by melting together appropriate quantities of high-purity powder of zirconium, vanadium and chromium, in a furnace under an inert atmosphere, to form the compound. Preferably, each powdered mixture is melted together several times in order to ensure complete homogeniety of the alloy.
The homogenized intermetallic compound must be activated before it can be successfully used as a hydrogen getter. This is accomplished by contacting the compound with hydrogen gas at a pressure at least above the decomposition pressure of the compound, generally at least one to two atmospheres, for a period of time sufficient to hydride the compounds, generally from 1/2 to 2 hours. It may be preferred to granulate the material to 1/4 to 1/2 inch particles to ensure complete activation.
The amount of chromium in the alloy may vary from about 0.01 to about 0.9 mols. An increase of chromium in the alloy will lower the temperature at which gettering will take place at a given pressure and will also lower the hydrogen capacity of the alloy. Thus, the exact amount of chromium desired in an alloy will depend upon the pressure and temperature conditions under which hydrogen gettering is to take place and perhaps more importantly, on the pressure and temperature conditions which are available to regenerate the getter.
X-ray diffraction patterns taken of the compound of the invention by the Debye-Scherrer method with filtered Cu radiation, have shown that the crystal structure is of the cubic MgCu 2 -type. Lattice expansion on hydriding was found to be about 20% for the compound Zr(V 0 .4 Cr 0 .6) 2 .
EXAMPLE I
An intermetallic compound having the formula Zr(V 0 .4 Cr 0 .6) 2 was prepared by placing a charge containing the appropriate quantities of 99.9% purity powdered materials into water-cooled copper crucible. The charge was melted three times at 100 amps with a tungsten electrode under an argon atmosphere.
1.0104 gm of the sample was then placed in a quartz tube and connected to an all metal vacuum line. The sample was activated at room temperature with a hydrogen pressure of 27 psia. After the initial hydrogen absorption, the hydrogen was then removed by pumping on the sample at 700° C. An adsorption isotherm for the sample at 450° C. was prepared by heating the sample to that temperature, adding about 10 Torr-liters of H 2 to the alloy and waiting 10 to 60 minutes for the pressure to equilibrate. After equilibration, the pressure was noted and another aliquot of about 10 Torr-liters of hydrogen gas was added to the tube and the pressure equilibrated again. This procedure was repeated until a maximum composition of 60-80 Torr-liters of H 2 absorbed/gm alloy was reached. In a like manner, hydrogen isotherms for material of the same composition at 400° C. and 350° C. were also determined. The results are shown in FIG. 1.
EXAMPLE II
Additional samples of the ternary intermetallic compound having the formula Zr(V 0 .5 Cr 0 .5) 2 and Zr(V 0 .6 Cr 0 .4) 2 were prepared and activated as described in Example I. A hydrogen absorption isotherm for the samples at 450° C. was then prepared. The results are shown in FIG. 2. For comparison, the isotherm for Zr(V 0 .4 Cr 0 .6) 2 at 450° C. taken from FIG. 1 is also shown.
EXAMPLE III
As a test of the gettering capability of the material, a 0.2558 gm sample of a hydrided alloy of the composition Zr(V 0 .6 Cr 0 .4) 2 H x was weighted into one chamber of a quartz tube having two chambers. The tube was connected to a high vacuum system. The sample was heated to about 500° C. and degassed at a pressure of 8×10 -7 Torr. The getter was then cooled and maintained at a temperature of about 200° C. The vessel containing the getter was valved off and a pressure of 2.6×10 -2 Torr of hydrogen gas was admitted to the main chamber of the quartz tube. The getter was then exposed to the hydrogen gas. Within 1 minute the system pressure dropped to about 3×10 -5 Torr, confirming the capability of the material to getter hydrogen at low pressures and temperatures of 200° C.
EXAMPLE IV
The hydrided alloy of Example III was regenerated by heating to about 500° C. and pumping to a pressure of about 7×10 -7 Torr which removed most of the hydrogen gas absorbed in the previous example. The getter was cooled to about 200° C. and isolated from the main chamber. Hydrogen gas was again added to the main chamber, which had a volume of about 1 liter, at a pressure of 3.3×10 -2 Torr. When the valve to the getter chamber was opened, the system pressure dropped to 3×10 -5 Torr within one minute. It was determined that the getter absorbed about 0.03 Torr-liters of hydrogen gas.
EXAMPLE V
FIG. 3 which contains several curves showing the relationship between gettering pressure and temperature for several compounds of the invention was derived from FIGS. 1 and 2 in the following manner. For the alloy Zr(V 0 .4 Cr 0 .6) 2 , the pressures at three temperatures (450°, 400° and 350° C.) were taken from FIG. 1 at a hydrogen composition of 20 Torr-liters H 2 absorbed/gm alloy and plotted on FIG. 3. To obtain these lines for Zr(V 0 .5 Cr 0 .5) 2 and Zr(V 0 .6 Cr 0 .4) 2 , the presures at 450° C. at the hydrogen composition of 20 Torr-liters H 2 absorbed/gm alloy were taken from FIG. 2 After assuming the thermodynamic entropies to be equal for all three compounds, the lines shown in FIG. 3 were drawn.
From given operating temperature it is possible using FIG. 3 to determine the minimum hydrogen partial pressure which can be gettered for each compound. Thus for an operating temperature of about 200° C. the compound Zr(V 0 .6 Cr 0 .4) 2 has a minimum hydrogen partial pressure which can be gettered of about 5×10 -6 Torr (about 6.2×10 -9 atm), while Zr(V 0 .5 Cr 0 .5) 2 has a pressure of about 5×10 -8 atm. It may further be seen from FIG. 3 that the minimum hydrogen partial pressure which can be gettered increases as the proportion of chromium in the gettering compound increases. In addition, it may be seen that as the proportion of chromium in the gettering compound increases the gettering temperature decreases. It is clear from the diagram that a gettering compound can be specifically formulated for the temperature and pressure requirements of a particular gettering environment by preselecting the proportions of vanadium and chromium in the compound.
The regeneration temperature is a complex function of the system pumping speed, the regeneration time allowed, and the extent of regeneration required, i.e. how much hydrogen must be removed. For Zr(V 0 .6 Cr 0 .4) 2 any temperature over 200° C. will cause some amount of regeneration, that is to say decomposition of the hydride to alloy hydrogen gas. In general, while any temperature above the operating temperature may be used as a regeneration temperature, the highest permissible regeneration temperature should be used to effect the most complete and most rapid regeneration.
From the preceeding discussion and Examples, it can be seen that the ternary metallic compound of the invention is capable of gettering hydrogen at pressures down to 10 -7 Torr at temperatures varying from about room up to about 200° C. and furthermore that the compound can be regenerated for recycle at temperatures varying from 300° to 500° C. | A ternary intermetallic compound having the formula Zr(V 1-x Cr x ) 2 where x is in the range of 0.01 to 0.90 is capable of reversibly sorbing hydrogen at temperatures ranging from room temperature to 200° C., at pressures down to 10 -6 Torr. The compound is suitable for use as a hydrogen getter in low pressure, high temperature applications such as magnetic confinement fusion devices. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to analog signal processing circuits. More specifically, this invention relates to analog circuits supporting optical location tracking devices to execute filtering, multiplication, division, and automatic gain control functions. New optical location tracking devices are also disclosed in this invention.
Recently, optical location tracking devices have been developed to detect three dimensional location of a light source. One example of such devices is described in U.S. Pat. No. 5,393,970. The reliability and manufacturability of the optical devices have been improved rapidly; they are ready for mass production. In the mean time, the development in the supporting analog signal processing circuits for those optical devices is progressing at a much slower rate. Analog signal processing circuits of current art are too expensive, too slow, and too complex to allow practical applications of optical location systems. The location tracking devices determine the location of a light pointer from the ratio of photo currents detected by their sensors. Although these optical devices have been designed to simplify the calculation equations, there are still many practical difficulties in translating the detected photo current into location using electrical circuits. One major problem is that the amplitude of photo current varies by many orders of magnitudes. It is not easy to design an analog circuit that is accurate for such wide ranges of input levels. It is therefore necessary to normalize the input signals by automatic gain control (AGC) circuits before the input signals are processed. Existing AGC circuits often require averaging and feedback mechanisms. Such AGC circuits are too slow, and they are not compatible with optical location tracking devices. Another major problem is the analog divide operations required for signal processing of these optical devices. Existing analog dividers are typically implemented by an analog multiplier having a feedback mechanism. Such analog divider is very slow, and its accuracy is not adequate for our applications. In addition, we also need to avoid the effect of background noise caused by ambient light. Filtering is often necessary. Due to these practical considerations, a typical support system includes pre-amplifiers, AGC circuits, filters, reference current generators, analog dividers, adders, and multipliers. Such systems are often too slow and their accuracy is poor. To make them function correctly requires careful calibrations, that makes them too expensive for practical applications. Supporting circuits have become the stumbling blocks for realistic applications of optical location tracking systems.
The analog signal processing circuits of the present invention was originally developed to solve the above problems for optical location tracking devices. However, those problems are not unique for optical devices; many other applications also encounter similar problems. Analog signal processing of optical location tracking devices are used as examples to illustrates the structures and operation principles of the present invention in the following sections, but the applications of this invention are certainly not limited in a particular area.
SUMMARY OF THE INVENTION
Accordingly, a primary objective of the present invention is to provide cost-efficient and reliable analog signal analysis circuits. Another objective of this invention is to provide analog circuits capable of executing filtering, automatic gain control, analog signal processing, and amplification by simple single-stage circuits. Another objective of this invention is to provide an analog signal processing circuit operating at a wide range of frequency from DC to GHZ. It is also an objective of this invention to provide an analog circuit that is capable of detecting the ratio of input signal within a wide range of input signal levels. A further objective of this invention is to provide automatic gain control circuit and analog divider function without using slow feedback circuits such as operation amplifiers. Another objective of this invention is to provide a planar optical location tracking device ready for mass production.
The present invention uses a single-stage circuit that is capable of performing all the required analog signal processing for analog systems such as optical location tracking systems. Complex analog analysis and AGC functions can be defined by a systematic procedure using current balance conditions of voltage controlled current sources. This approach improves speed and accuracy of the location tracking systems, while reducing their cost dramatically. The present invention provides flexibility to support many types of optical and electronic devices. We also developed new optical location tracking devices that work better with this invention than prior art devices.
Although this invention was originally developed to support optical location tracking devices, it also provides the flexibility to support many other applications. It can be structured in regular layout similar to application specific integrated circuit (ASIC). It also can be programmed electrically in order to provide ultimate flexibility to support a wide variety of applications.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in details with reference to the preferred embodiments illustrated in the accompanying drawings in which:
FIG. 1 illustrates the operation principles of a prior art optical location tracking device;
FIG. 2 shows an analog signal processing system of the prior art used to analyze the output signals of the device in FIG. 1;
FIG. 3a illustrates the operation principles of a center wall optical location tracking device;
FIG. 3b is the side view of the geometry in FIG. 3a;
FIGS. 4(a,b) provide the side views and top views of a dual wall location tracking device;
FIG. 5 illustrates the method to determine three dimensional location of a light source using dual wall location tracking devices;
FIGS. 6(a-h) illustrate symbols and circuit embodiments of electrical components used by the present invention;
FIG. 7 is a general symbolic block diagram of the present invention;
FIG. 8a is a symbolic circuit diagram of an analog signal processing circuit supporting the location tracking device in FIG. 1;
FIG. 8b is a schematic circuit diagram of a realistic circuit embodiment of the circuit in FIG. 8a;
FIG. 9a is a symbolic circuit diagram of another analog signal processing circuit supporting the location tracking device in FIG. 1;
FIG. 9b is a schematic circuit diagram of a realistic circuit embodiment of the circuit in FIG. 9a;
FIG. 10a is a symbolic circuit diagram of an analog signal processing circuit supporting the location tracking device in FIG. 4a;
FIG. 10b is a schematic circuit diagram of a realistic circuit embodiment of the circuit in FIG. 9a;
FIG. 11 is a symbolic circuit diagram of an analog signal analyzer supporting three dimensional location tracking of dual wall devices.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before the invention itself is explained, a prior art location tracking device and several improved location tracking devices are first explained to facilitate the understanding of the invention.
FIG. 1 illustrates the operation principle of a prior art optical location tracking device supported by the present invention. This location tracking device contains a light detector 102 having three planar light sensors 104x, 104y, 104z. The surfaces of those planar light sensors are oriented vertically to one another. A Cartesian coordinate is defined with its x, y, and z axes perpendicular to the surfaces of the planar light sensors. A light source 100 is placed at a location (X,Y,Z) away from the light detector 102 as shown in FIG. 4A. The output signals of the optical sensor are related to the location (X,Y,Z) of the light source as
I.sub.x :I.sub.y :I.sub.z =X:Y:Z (1)
where I x , I y , and I z represent the photo currents detected by planar light sensors 104x, 104y, and 104z.
Light sensors follow the above behavior has been disclosed in details in U.S. Pat No. 5,393,970.
For a two-dimensional application where the vertical dimension Z is a constant, we can determine the (X.Y) locations by rearranging Eq. (1) as
X=(I.sub.x /I.sub.z)Z (2)
Y=(I.sub.y /I.sub.z)Z (3)
If the vertical dimension Z is a constant, Eqs. (2-3) indicate that two-dimensional location of a light source can be determined using one light detector 102 by measuring the ratio of sensor currents (I x /I z ) and (I y /I z ). Although Eqs. (2-3) appear very simple mathematically, there are many practical difficulties in measuring the ratio of the optical signals as discussed in previous section. FIG. 2A is an example of a current art electronic system needed to translate photo currents into location. An optical signal generator 210 provides electrical signals to a light-emitting-diode (LED) to generate optical signals. The optical signal generator 210 contains an oscillator 214 that determines the frequency of the light signal, and an amplitude-modulating (AM) encoder that modulates the light signals. The light emitted from the LED 200 is detected by a light detector 102 described in FIG. 1. The output signals of the light detector 102 are analyzed by an analog signal analyzer 230. The optical currents are filtered by band-pass filters 232 to reduce the effect of background noise. The filtered signals are amplified by pre-amplifiers 234. Automatic-gain-control (AGC) circuit 235 normalizes the amplitude of input signals before the ratio of the signals is determined by precision analog dividers 236. The outputs of the precision analog dividers 236, which is proportional to (X/Z, Y/Z), are driven by the output amplifier 238.
The analog signal analyzer 230 described in FIG. 2 comprises 3 bandpass filters, 3 pre-amplifiers, 3 voltage control amplifiers configured as AGC, 2 analog multipliers with feedback circuitry to behave as analog dividers, and 2 output amplifiers; this system has 13 discreet circuit components plus many other supporting circuit elements. It is a complex system that requires detailed calibration and careful layout The system is very expensive. It is also very slow because of the feedback mechanisms needed in the AGC and divider circuits. It is by far too expensive for practical applications of the optical location tracking devices.
One troublesome manufacture problem for the light sensing device in FIG. 1 is that it requires non-planar light sensing surfaces. Two types of planar sensors were developed to reduce manufacture cost using planar light sensing surfaces. The optical location tracking device illustrated in FIGS. 3a contains 3 planar light sensors 300x, 300y, 300z, and two walls 310, 312. The directions vertical to the walls form a Cartesian coordinate as shown in FIG. 3a. A distance light source 100 is placed at coordinate (X,Y,Z). The light emitted the light source 100 is partially blocked by those walls, and a shadow 302 is cast on sensors opposite to the light source 300x, 300y. When the distance from the light source to those three light sensors is much larger than the size of light sensors, we can assume the light density is uniform. Under this condition, the photo current detected by those light sensors are proportional to the sensor area exposed to the light beams emitted from the light source 100. FIG. 3b is the side view of the geometry in FIG. 3a along X-Z cross section. From the geometry in FIG. 3b, we know that S:H=X:Z where S is the length of the shadow along x direction, and H is the height of the wall 310. We also know that Ix:Iz=(D-S): D, where D is the dimension of the sensor, Ix is the photo current detected by the sensor opposite to the light source 300x, and I z is the photo current detected by the sensor near the light source 300z. From the geometry shown in FIG. 3b, we have
X= (Iz-Ix)/Iz!*(D/H)*Z (4).
We also have similar relationship along the y axis as
Y= (Iz-Iy)/Iz!*(D/H)*Z (5)
where Iy is the photo current detected by the light sensor 300y at the opposite side of the wall 312 vertical to y axis. The above location tracking device is called "center wall" device in the following sections. Eqs. (4,5) provides a simple relationship to determine two-dimensional coordinates from center wall devices. Those equations are true when the light source 100 stay within the first quadrant where both X and Y are positive. When the light source is out of the first quadrant, we need to redefine the equations. To remove such constraint, another location tracking device is developed.
FIG. 4a shows the side view and the top view of a location tracking device that contains two triangular planar light sensors 402, 404, and two walls 410, 412. The distance between those two walls is D, and the height of the wall is H. The distance from the edge of the wall 410 to the light source 100 along horizontal direction is defined as X. The vertical distance from top of the wall 410 to the light source 100 is defined as Z. The sizes D and H of the device are exaggerated in FIGS. 4(a,b). In reality, D is much smaller than X, and h is much smaller than Z. From the geometry shown in FIG. 4a, we have
X= (Iax-Ibx)/(Iax+Ibx)!*(D/H)*Z=Rx*(D/H)*Z (7)
where Iax is the photo current detected by the top sensor 402, Ibx is the current detected by the bottom sensor 404, and Rx=(Iax-Ibx)/(Iax+Ibx). In the following sections, the location tracking device in FIG. 4a is called "dual wall" device. When the light source is moved to the other side of the wall 412 as illustrated by FIG. 4b, the dual wall device still follows Eq. (7), and the sign of Rx represents the sign of X dimension correctly. The viewing angle of dual wall device is therefore twice wider than that of center wall device. Valid viewing angle of the device is limited by the ratio (H/D).
FIG. 5 shows a method to determine three-dimensional location of a light source using three dual wall devices. The walls of two dual wall devices 500, 502 are separated by a distance L with their walls facing x direction, and the third dual wall device 504 has its walls facing the y axis as shown in FIG. 5. Define the distance to the light source 100 along the x axis as X for the first device 500, and the distance is X' for the second device 502. From Eq. (7) we have ##EQU1## where Iax and Ibx are photo currents measured by triangular sensors in the first device 500, Iax' and Ibx' are photo currents measured by triangular sensors in the second device 502, Rx=(Iax-Ibx)/Iax+Ibx). and Rx'=(Iax'-Ibx')/Iax'+Ibx'). From Eq. (8) we have
Z=L*H/D/(Rx-Rx') (9)
X=Rx*(D/H)*Z= Rx/(Rx-Rx')!*L (10)
The dimension Y can be determined by the third device 504 as
Y=Ry*(D/H)*Z= Ry/(Rx-Rx')!*L (11)
where Ry=(Iay-Iby)/Iay+Iby) while Iay and Iby are photo currents detected by the photo sensors in the third device 504.
The above discussion shows that data analysis of the dual wall device can be done by the same simple mathematical equation, Eqs. (9-11), in all four quadrants of the coordinate.
The dual wall devices provide wider viewing angle. It simplifies the data analysis procedure significantly, it is reliable and ready for mass production. However, it still encounters the same problem that its supporting signal processing system is too slow and too expensive. It still needs analog diver, AGC, and filters to translate photo currents into locations from Eqs. (9-11). Novel analog signal processing circuits of this invention are therefore developed to support the above location tracking devices as set forth in the following sections.
The major building blocks for the circuits of this invention are voltage controlled current amplifiers (VCCA) and current mirrors. To simplify discussions in the following sections, those building blocks are symbolized as shown in FIGS. 6(a-h). FIG. 6a shows the symbol for a VCCA. The output current of a VCCA is A(v)*Ii where Ii is the input current. A(v) is the amplification factor that is a function of the input voltage v. FIG. 6b. shows an example of an embodiment of a VCCA using bipolar transistors. Transistors Q1 and Q3 are matched transistors, and they have identical base voltage. Using the well known relationship of bipolar transistors, we have ##EQU2## where K is a constant independent of the input current, Vb is the base voltage of Q1 and Q3, Vr is the emitter voltage of Q1, Ve is the emitter voltage of Q3, Ii is the input current, and lo is the output current Transistor Q2 in FIG. 6b is used to reduce the effect of base currents as well known to the art While specific embodiments of the invention have been illustrated and described herein, it is realized that other modifications and changes will occur to those skilled in the art. For example, the amplification factor A(v) does not need to follow Eq. (12). The amplification factor can be any function of the input voltage while the present invention will still function correctly. It should be obvious to those skilled in the art that the VCCA also can be realized using MOS devices instead of bipolar devices. We also can replace the voltage controlled current amplifier with a voltage controlled gain amplifier so that the inputs are voltages instead of currents.
FIG. 6c shows the symbol of a p-channel current mirror. FIG. 6d shows and example of an embodiment of the current mirror implemented by p-channel MOS transistors. Transistors MP1, MP2, MP3 are matched transistors, and they have the same gate to source voltage. Therefore, the output currents Ioa and Iob are identical to the input current Ii. FIG. 6e shows the symbol of an n-channel current mirror. FIG. 6f shows and example of an embodiment of the current mirror implemented by n-channel MOS transistors. Transistors MN1 and MN2 are matched transistors, and they have the same gate to source voltage. Therefore, the output currents Ioa is identical to the input current Ii. Current mirrors are well known to the art of circuit design. The embodiment shown in FIGS. 6(d,f) can be replaced by hundreds of other types of current mirrors. There is no need to provide further details about current mirrors.
FIG. 6g shows the symbol of a VCCA and a current mirror sharing the same input, and FIG. 6h shows one example of its embodiment. Transistors Q1, Q3, and Q4 in FIG. 6h are matched transistors. Q1 and Q4 have the same base to emitter voltage, so that the output current is equal to the input current Ii. Q1 and Q3 forms an VCCA as discussed in previous sections. This device is called VCCAM in the following sections.
Using the building blocks shown in FIGS. 6(a-h), we are ready to construct analog signal processing circuits of the present invention. FIG. 7 shows a general symbolic diagram of the analog signal analyzer of this invention. The signal analyzer comprises a plurality of voltage controlled current amplifiers 701, 702, . . . , 70n as shown in FIG. 7. The voltage inputs Vr, Ve of those VCCA's are all connected together so that they have identical amplification factor A(v). The input voltage Vr is connected to a bias circuit, that is shown as a voltage source 740 in FIG. 7. In reality, the bias circuit 740 does not need to be a voltage source. A current source 730 generates a reference current Ior using reference current Ir. The output of the current source is connected to Ve. The input currents I1, I2, . . . , In, and the output currents Io1, Io2, . . . , Ion of those VCCA's are processed by a group of p-channel current mirrors 710. The outputs of those p-channel current mirrors 710 are sent to a group of n-channel current mirrors 720 to generate a bias current Icn. Icn is a function of input currents . The outputs of those n-channel current mirrors 720 are connected to Ve. The summation of all output currents Io1, Io2, . . . , Ion must be equal to Ior+Icn, so that ##EQU3## Eq. (13) shows that the amplification factor A(v) can be adjusted by bias currents Ior and Icn. This relationship provides a powerful and flexible way to execute analog signal processing as demonstrated by examples in the following sections.
FIG. 8a is a symbolic circuit diagram of a signal analyzer to support the location tracking device in FIG. 1. The input of a VCCAM 800 is connected to the output of the x sensor 104x in FIG. 1. The photo current detected by the x sensor 104x is Ix. The input of another VCCAM 802 is connected to the output of the y sensor 104y in FIG. 1 (photo current Iy). The outputs of the current mirrors in those two VCCAM's 800, 802 are connected to the output of the z sensor 104z in FIG. 1. The output of the z sensor 104z is also connected to the input of a VCCA 804. We have Izi=(Iz-Ix-Iy) where Iz is the photo current detected by the z sensor 104z, and Izi is the input current to the VCCA 804. The outputs of the VCCA and two VCCAM's are connected together as node Ve, then connected to a reference current source 810. The output current Ior of the current source 810 is equal to the reference current Ir. The other control voltage Vr is connected to a bias circuit 820. For simplicity, we will not show the bias circuit in the following circuit diagrams. FIG. 8b is the schematic circuit diagram of a realistic circuit implementation of the symbolic circuit in FIG. 8a. Since Iox+Ioy+Ioz=Ir=A(v)*(Ix+Iy+Izi), we have
A(v)=Ir/ Ix+Iy+Izi!=Ir/Iz (14)
Iox=A(v)*Ix=(Ix/Iz)*Ir (15)
Ioy=A(v)*Iy=(Iy/Iz)*Ir (16).
Using Eqs. (2,3,15,16), the two dimensional location X,Y! of the light source 100 is represented by the output currents Iox, Ioy of the circuit in FIG. 8 as
X,Y= (Iox/Ir)*Z, (Ioy/Ir)*Z! (17).
The circuit in FIGS. 8(a,b) requires that Iz>(Ix+Iy). Otherwise the circuit will not function correctly. A modified design shown in FIGS. 9(a,b) removes the limitation. The photo currents Ix, Iy, Iz are sent to the inputs of three VCCA's 900x, 900y, 900z. The output currents Iox and Ioy are duplicated by p-channel current mirrors 902x, 902y and n-channel current mirrors 904x, 904y. The node Ve of all VCCA's are connected together. Ve is also connected to the outputs of the n-channel current mirrors 904x, 904y, and the output of a reference current source 910. FIG. 9b shows the schematic diagram of a realistic implementation of symbolic circuit in FIG. 9a. The node Vr of all VCCA's are also connected together to a bias circuit (not shown). Using the relation that the total currents flowing into node Ve must be zero, we have
A(v)=Ioz/Iz=Ir/Iz (18)
Iox=A(v)Ix=(Ix/Iz)*Ir (19)
Ioy=A(v)Iy=(Iy/Iz)*Ir (20).
Eqs. (19,20) are identical to Eqs. (15,16). It should be obvious that we also can determine the location X,Y! of the light source 100 by Eq. (17) from the output currents of the circuit in FIG. 9a. The major advantage of the circuit in FIG. 9a is that it is no longer limited by the condition Iz>Ix+Iy. However, this circuit can be slightly slower than the circuit in FIG. 8a.
The single stage circuits in FIGS. (8,9) fulfills all the functions supported by the complex instrument in FIG. 2. Using single stage circuits, we are able to execute two analog divisions of input currents (Ix/Iz) and (Iy/Iz) simultaneously. The function of pre-amplifiers and Automatic Gain Control (AGC) amplifiers are served by the fact that the full scale current is always equal to Ir for all the output currents Iox, Ioy. The amplitudes of input currents Ix, Iy, Iz can change by orders of magnitudes while the outputs are only dependent on current ratios instead of their amplitude. The circuit also can serve the function of filters by modulating the reference current Ir with the frequency of the light emitted from the light source. On the other word, the present invention in FIGS. (8,9) is able to replace all the expensive instruments in FIG. 2. This circuit is very fast, our results show that it can operate at GHZ bandwidth. Its accuracy is by far better than the complex system in FIG. 2.
The analog signal analyzers of the present invention have been developed to support optical location tracking devices, but they certainly can support many other applications. For example, the above circuits can execute analog division or analog multiplication of a plurality of inputs simultaneously. The high speed AGC and the filtering function also can be applied to a wide variety of applications. The present invention is also extremely flexible. By properly define the relationship between A(v) and inputs, the present invention is capable of executing complex analog calculation that used to require an analog computer of prior art The circuits in FIGS. (8,9) are simple examples that of this invention. The following examples demonstrate the flexibility of the present invention to support more complex calculations.
FIG. 10a is the symbolic circuit diagram of an analog signal analyzer for the dual wall location tracking devices in FIG. 4. FIG. 10b is the schematic diagram of a realistic embodiment of the circuit in FIG. 10a. The photo currents Ia, Ib of the triangle sensors 402, 404 are inputs to two VCCA's 112,114. The Vr nodes of VCCA's are connected to a bias circuit (not shown). The Ve nodes are connected to the output of the reference current source 124. The output currents Ioa, Iob of those two VCCA's are duplicated by p-channel current mirrors 116 118, and n-channel current mirrors 120, 122. The output of the n-channel current mirror on the left 120 is connected to one output of the p-channel current mirror on the right 118. The output of the n-channel current mirror on the right 122 is connected to one output of the p-channel current mirror on the left 116. In this configuration, A(v)=Ir/(Ia+Ib). When Ia>Ib, the output currents Ipx is
Ipx=Ioa-Iob=A(v)*(Ia-Ib)= (Ia-Ib)/(Ia+Ib)!*Ir (21)
while the other output current Inx is zero. When Ia<Ib, the output current Inx is
Inx=Iob-Ioa= (Ib-Ia)/(Ib+Ia)!*Ir (22)
while the other output current Ipx is zero. From Eqs. (7,21,22) we have
X=(Ipx-Inx)/Ir*(D/H)*Z (23)
Rx=(Ipx-Inx)/Ir (24)
where Rx=(Iax-Ibx)/(Iax+Ibx). Eq. (23) shows that the location X, including the sign of X, can be calculated from the output currents of the circuit in FIG. 10. Similar equations also can be used for Y and X'.
Now we are ready to determine the three dimensional location of the light source X,Y,Z! using dual wall devices shown in FIG. 5. FIG. 11 is the symbolic circuit diagram of an analog signal analyzer to support the location tracking device in FIG. 5. The photo currents Iax, Ibx detected by the light sensors of the first dual wall device 500 in FIG. 5 are sent to a first stage analyzer 150x shown in FIG. 10. The photo currents Iax', Ibx' detected by the light sensors of the second dual wall device 502 are sent to another first stage analyzer 150x'. The photo currents Iay, Iby detected by the light sensors of the third dual wall device 504 are sent to another first stage analyzer 150y. The output currents Ipx, Inx, Ipx', Inx', Ipy, Iny of those three first stage analyzers are sent to 6 VCCA's 151-156 as shown in FIG. 11. The reference current used by those three first stage analyzer is also sent to a VCCA 157. The Vr nodes of all 7 VCCA's are connected to a bias voltage generator (not shown). The Ve nodes of all 7 VCCA's are connected together. The output currents of those VCCA's Ipxo, Inxo, Ipx'o, Inx'o, Ipyo, Inyo, Iuo are sent to a group of p-channel current mirrors 160. Those p-channel current mirrors 160 generate a current Imout=2*Inxo+2*Ipx'0+Ipyo+Inyo+Iuo. An n-channel current mirror 162 duplicates Imout, and sinks the current from Ve node. Ve node is also connected to a reference current source 170. Balancing the total current at node Ve, we have ##EQU4## From Eqs. (9,10,11,23,24,25) we have
A(v)=Iuo/Ir=1/(Rx-Rx') (26)
Z=(Iuo/Ir)*L*H/D (27)
X= (Ipxo-Inxo)/Ir!*L (28)
Y= (Ipyo-Inyo)/Ir!*L (29)
where L, H, D are parameters defined in FIG. 5. Eqs. (27-29) show that signed three dimensional location X,Y,Z! of a light source can be calculated by the two-stage circuit shown in FIG. 11.
As apparent from the foregoing examples, the present invention is extremely flexible in supporting analog signal processing of different calculations. Using single stage circuits, the present invention can execute analog calculation such as ##EQU5## where Ioj is one of the output current, I 1 ,I 2 , . . . ,I j , are input currents of VCCA's, A 1 ,A 2 , . . . ,A j are weighing parameters for the multiplication factor Mul, and B 1 ,B 2 , . . . ,B j are weighing parameters for the denominator DEN of the calculation. Those weighing parameters can be positive or negative numbers, and they do not need to be integers.
The procedures to configure the present invention for the above general calculation are:
(1) Connect input signals I 1 ,I 2 , . . . ,I j to VCCA's. The input signals may need to be modified as shown in the example in FIGS. 8(a,b). Although the foregoing examples use photo currents as input signals, other types of input signals such as voltage (replace VCCA with voltage controlled transconductance amplifier VCTA), currents . . . are also supported.
(2) Connect the nodes, Ve and Vr, that define the gains of those VCCA's (or VCTA's ) so that all VCCA's have the same amplification factor A(v). Provide a bias circuit to the node Vr.
(3) Define the denominator DEN of the desired "divide" operation by controlling the amplification factor A(v). It should be obvious from previous examples in FIGS. (9-11) that the denominator can be defined by providing proper bias currents to node Ve of VCCA's. For the example in FIG. 11, we wanted to substrate Ipx' from the denominator, so we use current mirrors to sink a current 2*Iopx' from node Ve. For the example in FIG. 9a, we wanted to have a denominator independent of an input current Iy, so we use current mirrors to sink a current Ioy from node Ve. For the example in FIG. 10a we wanted to add Ia to the denominator, that is done by simply not sinking any current related to Ia from node Ve.
In general, if we want to subtract a factor k*Ij to the denominator of the desired divide operation, we should sink a current (k+1)*Ioj from node Ve, where Ij is any one of the input currents to VCCA's, Ioj is the output current of the VCCA that has input current Ij, and k is defined by the ratio of current mirrors, which can be any value.
(4) Connect Ve node to a reference current source so that all the output currents are normalized to the reference current. This normalization procedure provides the automatic gain control function because all the outputs are automatically controlled to have their full scale value equal to the reference current. The reference current also serves as the "unit current" for next stage of calculations.
(5) Use current mirrors to define the multiplication factor MUL. This procedure is well known in the current art. There is no need for further discussion.
The above procedures allow a user to execute analog calculations with the general format in Eq. (30) using single stage circuits. Many such calculations can be executed simultaneously as shown by the examples in previous sections. The present invention therefore provides an unprecedented calculation power for analog signal analyzing circuits.
The above procedures show a strong regularity that is ideal for computer automatic design. The electrical components used by this invention also shows a strong regularity that is ideal for systematic integrated circuit design. It is therefore very convenient to design analog signal processing hardware using the concept of application specific integrated circuits (ASIC) or programmable logic that is currently only applicable to logic circuits. Repeating units of VCCA's and current mirrors are manufactured in a general integrated circuit without metal connections. For each specific application, the users input the needed analog calculations for a software to define the metal connections between those components using the above analytical procedures. The final function of the programmable analog circuit is defined by the bias currents that determines the amplification factor A(v). The cost in designing new analog signal analyzer is reduced significantly because we only need to change the metal layers of the IC for each new product. Similarly, the connections can be defined by programmable multiplexers. It is therefore very convenient to design programmable analog signal processing integrated circuits using the present invention.
As apparent from the foregoing, following advantages may be obtained according to this invention.
(1) The present invention uses a few transistors to replace complete prior art systems including pre-amplifiers, filters, AGC, analog dividers, . . . etc.
(2) This invention accepts input signals having a wide range of amplitudes.
(3) As demonstrated by the examples in previous sections, this invention can support a wide variety of applications by simple modifications in its configuration. For those skilled in the art, it is possible to perform very complex calculations with a few stages of circuits. This invention is so flexible that its applications are only limited by the imagination of the users.
(4) The present invention easily achieved GHZ bandwidth using existing manufacture technology.
(5) This invention is able to execute multiple calculations simultaneously. Combining this parallel processing capability with high bandwidth operation, we are able to achieve unprecedented performance for analog signal processing systems.
(6) This invention is ready to be manufactured by existing IC technology. The circuit components used by this invention is ideal for IC design because of their regularity. It is possible to use the concept of Application Specific Integrated Circuits (ASIC) to layout repeating circuit elements of the present invention, then "program" the connections of those circuit elements to support different applications. On the other word, it is possible to build "analog ASIC" or "programmable analog signal processor" of this invention.
(7) This invention does not use any operational amplifier or any other complex feedback mechanism. The circuit is stable and reliable.
The present invention has been described with reference to particular examples to support optical location tracking devices. It is to be understood that variations and modifications can be made within the spirit and scope of the invention by those skilled in the. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims. | An analog signal processing circuit is disclosed in this invention. The analog signal processes performed by the circuit of this invention involve mathematical operations of summation, subtraction, multiplication, division, automatic control and different types of filtering operations. Furthermore, a plurality of single-stage circuits may be interconnected to carry out combination of analog signal processing functions according to the methods and circuit configuration provided in this invention. The analog signal processing processes are performed by the analog signal processing circuit through the balance of currents by combining the basic circuit elements of current mirrors, voltage control signal amplifiers, and current sources and sinks. The circuits developed for carrying out these analog signal-processing steps can also be implemented for optical location tracking systems. Complex analog analysis and AGC functions can be defined by a systematic procedure using current balance conditions of voltage controlled current sources by combining single stage circuits according to the method and circuit configuration of this invention. This approach improves speed and accuracy of the optical location tracking systems, while reducing their cost dramatically. The present invention provides flexibility to support many types of optical and electronic devices. Applying the analog processing circuits disclosed in this invention, new and improved optical location tracking devices are developed. | 6 |
CROSS REFERENCE TO RELATED APPLICATION(S)
This instant application claims priority to U.S. Provisional Patent Application Ser. No. 61/864,720, filed on Aug. 12, 2013.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a unique retrofit LED solar and wind powered rechargeable roadway/street light with solar panels disposed about a roadway/street light pole in a polygonal configuration. This polygonal configuration completely houses the controlling and management system electrical modules therein and being affixed to the interior of the solar panels in a compact manner as a unit that controls and manages the streetlight and a traffic light operation.
In addition, the unique LED solar and wind powered rechargeable roadway/street light has an improved heat dissipation feature for enhancing and extending the life cycle hours for the LED light source while simultaneously reducing the amount of power energy consumption used.
2. Description of the Related Art
At the present time, there are many different types of traditional (non-renewable) and solar and wind powered (renewable) lighting systems for general lighting needs to many users, such as public, private, residential, commercial and government use. Many of the non-renewable and renewable public and private lighting systems commonly utilize commercial power to supply energy for illuminating roadways/streets, property, parking lots, athletic fields, and the like. It is well known that non-renewable and renewable with retrofitted lighting such as those used in roadways/streets or security lights can amount to sizable costs over time, including substantial initial acquisition and installations costs of the equipment, and also the ongoing costs to pay for powering such non-renewable and renewable lighting. Note that the lighting source for illuminating roadways/streets, property, parking lots, athletic fields, and the like as indicated above, could be one from the group consisting of high-pressure mercury (HPM) arc lamps, metal halide lamps, high intensity discharge (HID) lamps, high pressure sodium (HPS) lamps, incandescent lamps, fluorescent lamps and light emitting diode (LED) lamps to name just a few.
These high cost non-renewable and renewable lighting systems are known to experience long commercial and utility power outage delays, where an affected geographical area is left completely in the dark. This is not unusual for a roadway/street, town or city, commercial or government facilities, homes, businesses to be left completely in the dark due to the loss of commercial and utility power.
Also, there is a need to enhance and prolong the life cycle hours of the lighting source, which is shorten by the excessive heat generated over time with no effective way of dissipating the heat in the above mentioned high cost non-renewable and renewable lighting systems. This causes a user to spend a lot of money replacing bulbs or lamps often. Also, it is noted many of these non-renewable and renewable light systems provide very dim lighting.
Therefore, there is a tremendous need for an improved lighting device that avoids all of the aforementioned drawbacks and limitations of the non-renewable and renewable public and private lighting systems.
The prior art patents recited below discloses wind and/or solar-powered light apparatuses for self-generation of power with information and management systems and having solar panels arranged about a pole having different configurations with at least one patent showing the solar panels being arranged in different polygonal configurations.
Note that these wind and/or solar-powered light apparatuses take on many different designs and structures, which are disclosed and described in U.S. Pat. Nos. 4,200,904 A, 7,731,383 B2, 7,976,180 B1, 8,007,124 B2, 8,029,154 B2, 8,350,482 B2, 8,588,830 B2, 2009/0237918 A1, 2009/0268441 A1, 2009/0273922 A1, 2010/0220467 A1, 2012/0020060 A1, 2013/0240024 A1, 2013/0322063 A1 and 2014/0111098 A1, to name just a few of interest. However, they do not singly or in any combination teach the claimed invention.
SUMMARY OF THE INVENTION
The present invention discloses an improved solar and wind powered LED retrofit lighting system with plural solar panels arranged in a polygonal configuration about lighting pole for illumination, power generation and/or for operation of traffic light systems. The polygonal solar configuration includes all of the electrical modules for operating the improved solar and wind powered LED retrofit lighting system, which are affixed thereto and completely housed and sealed therein. This polygonal arrangement provides the capability of being scalable in small foot print of a 250 watts solar panel space that will produce from 600 to over 1200 watts from the solar panels. Such is a great benefit for limited land space. It is to be noted that the improved solar and wind powered LED retrofit lighting system with the polygonal solar panel arrangement is known as the “Revolutionary Energy Savings Technology”, hereinafter referred to as REST.
This arrangement allows the improved solar and wind powered retrofit lighting system to produce power for 5 to 8 hours to charge battery banks that is used to power an inverter and power LED street light lamps for 12 hours at night. Also, this polygonal configuration will help to greatly reduce the amount of fuel used by a power or utility company to generate electricity and grid power. Also, this polygonal arrangement can be installed on utility poles or in a solar farm.
A further aspect of the present invention provides a polygonal frame for securing the required number of solar panels thereto. The frame includes top and bottom plates for closing and completely sealing the polygonal frame. These plates are split in half with semi-circular grooves to fit and mate around a utility pole as a unit. A plurality of securing holes and screws are placed about the peripheral edges of the split plates to be affixed to the peripheral edges of the top and bottom of the polygonal frame through securing holes therein.
A further aspect of the present invention provides a pair of C-shaped clamps with outward extending flanges there from is attached to the top of the pair of half plates at the semi-circular grooves thereof. Note that the C-shaped clamps include a semi-circular groove to be disposed at and above the semi-circular grooves of the half plates. Each of the semi-circular grooves of the C-shaped clamps includes a sealing gasket disposed and sandwiched therein to seal around the utility pole to prevent any water from seeping around the pole and damaging the electronic components that are affixed to the solar panels. Also, each of the C-shaped outward extending flanges include a screw opening therein for receiving a screw member there through to squeeze and seal the gasket about the utility pole when the screws are tightened. A tightening nut can be disposed on the screws to tighten the flanges and gasket about the utility pole for always maintaining a tight and effective seal thereabout.
Another aspect of the present invention provides at least a pair of ¼ inch mounting plates disposed between at least a pair of mating frame members adjacent to the top and bottom portions thereof. These mounting plates are welded between and along the sidewalls thereof and the frame engaged interior wall surfaces. Each of the at least a pair of ¼ inch mounting plates includes a semi-circular groove with a first C-shaped clamp with outward extending flanges with a securing opening for receiving a screw member. Note that the first C-shaped clamps are welded within the mounting plates' semi-circular grooves. If desired, the center of the first C-shaped clamps of the mounting plates could receive screw member to further secure them therein.
Also, a seam weld is disposed along corner edges of the frame walls to secure them together. At least a backing member is attached to the frame walls by a plurality of peripheral edge screw members.
Note that the first C-shaped clamps of the mounting plates are disposed about a utility pole to mate and cooperate with the second C-shaped clamps disposed on an opposite side of the utility pole. At least a first sealing gasket is inserted between the first C-shaped clamps of the mounting plates and the utility pole to further prevent any water from seeping around the pole and damaging the electronic modules that is affixed to the solar panels. Also, the second C-shaped clamps includes a center screw hole for receiving a center screw member to be screwed into the utility pole for always maintaining the second C-shaped clamps tightly secured about the utility pole and the first at all times, as well with the first C-shaped clamps of the mounting plates.
Further, in according to the present invention, a new and innovative heat dissipation design is hereby provided to enable longer operating hours for LED chips.
This new and innovative heat dissipation design includes a polished aluminum basin with an upper outer rim (flange) at the very top thereof with four corners. The four corners having four right angle aluminum support brackets attached thereto and mounted inside of the polish aluminum basin just below the upper outer rim. In addition, the polished aluminum basin is secured to an upper interior wall section of the outer die cast shell with a preferred 5×6 inch aluminum plate being sandwiched there between by a screw through an upper middle wall area or section of the polished aluminum basin through an opening in the preferred 5×6 inch aluminum plate via a molded securing nut and into the upper interior wall section of the outer die cast shell to achieve additional heat dissipation. The aluminum plate has a larger intermediate section with two smaller outward extending ends connected by a pair of incline portions there between.
The new and innovative heat dissipation design further includes a heat sink plate with at least a pair of screw holes at each corner of the heat sink plate to receive the screws. This allows the heat sink plate to seat on top of the four right angle aluminum support brackets to create a large space or inner chamber below the heat sink plate to allow a large volume of ambient air to constantly circulate under the LED chips and vent or transfer heat from the heat sink plate rapidly there from to the large space or chamber above the heat sink plate of the polished aluminum basin.
Also, the LED chips are mounted on top of the aluminum heat sink plate secured by a plurality of screws using heat sink compound to help with the heat transfer process from the base of the LED chips. At the bottom of the aluminum heat sink plate a plurality of spaced fins extend downwardly there from into an upper portion of the polished aluminum basin near the bottom rim and secured by screws horizontally and using heat compound to increase the heat transfer from the heat sink plate to the spaced aluminum fins in the middle close to each LED chip. These fins are used to remove heat with ambient air flow in the inner chamber of the polish aluminum basin.
The polished aluminum basin has an open space in the rear thereof and vent holes in the front, rear and sides to enable ambient air to constantly circulate ambient air flow from the large space or inner chamber and exit to the outside of the basin and allowing ambient air to flow to the outside through a plurality of vent holes of the outer die cast shell and via a plurality of vent holes in a rear cover. A continuous flow passage formed between the outer die cast shell and the aluminum polished basin to constantly circulate ambient air about the aluminum polished basin to preserve the life cycle of the LED chips.
Additional aspects, objectives, features and advantages of the present invention will become better understood with regard to the following description and the appended claims of the preferred embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood, along with its numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
FIG. 1 illustrates a perspective view of the solar and wind powered street/roadway lighting apparatus with solar panels configured in a polygonal configuration according to the present invention.
FIG. 2 illustrates a rear view of the solar and wind powered street/roadway lighting apparatus with solar panels configured in a polygonal configuration according to the present invention.
FIG. 3 illustrates an isometric view of the polygonal solar panel frame with upper and lower C-shaped securing clamps about a utility pole according to the present invention.
FIG. 4 illustrates a rear view of the solar and wind powered street/roadway lighting apparatus with solar panels configured in a polygonal configuration with back solar panel being removed according to the present invention.
FIG. 4A illustrates a rear view of one of the sides of the polygonal solar panels with electrical components affixed thereto according to the present invention.
FIG. 4B illustrates a rear view of the back solar panel with electrical components affixed thereto according to the present invention.
FIG. 5 illustrates an exploded isometric view of the polygonal frame with cooperating sealing gaskets and solar panels according to the present invention.
FIG. 6 illustrates an exploded view of the polished aluminum basin and heat sink plate with the LED chips disposed thereon according to the present invention.
FIG. 6A illustrates a bottom view of the heat sink plate with heat transfer fins disposed thereon according to the present invention.
FIG. 6B illustrates a perspective view of the right angle support bracket for the heat sink plate according to the present invention.
FIG. 6C illustrates a perspective view of the polished aluminum basin and heat sink plate with the LED chips secured together as a unit according to the present invention.
FIG. 7 illustrates a perspective bottom view of the lighting unit with electrical components and camera device according to the present invention.
FIG. 8 illustrates a perspective bottom view of the lighting unit with hinge cover, electrical components, heat dissipation elements and camera device according to the present invention.
FIG. 9 illustrates a component flow diagram of the solar and wind powered street/roadway lighting apparatus according to the present invention.
FIG. 10 illustrates a driving circuit for the solar and wind powered street/roadway lighting apparatus according to the present invention.
DETAILED DESCRIPTION
FIG. 1 illustrates a perspective view of the solar and wind powered street/roadway lighting apparatus 10 with solar panels 12 configured in a polygonal configuration according to the present invention. The polygonal configuration can be selected from the group consisting of any one of a triangle, quadrilateral, pentagon, hexagon, heptagon, octagon, enneagon, decagon, squares, rectangles, parallelograms and rhombuses. The preferred polygonal shape of the present invention is an isosceles triangle.
The solar and wind powered street/roadway lighting apparatus 10 is disposed about a utility or street light pole 11 . As shown in FIG. 1 , a plurality of solar panels 12 with solar cells 13 affixed thereto. These solar panels 12 with solar cells 13 secured to a polygonal support frame 14 C as illustrated in FIGS. 3 and 5 . A top plate with two-part halves 15 a and 15 b are secured to the top of the polygonal support frame 14 C by screw members 16 .
Note that the solar panels 12 with the solar cells 13 can comprise a plurality of photovoltaic cells such as a thin-film photovoltaic material attached thereto.
FIG. 1 further shows a mounting bracket unit 20 that supports a lighting unit 70 and a wind turbine 31 . The bracket unit 20 has a U-shaped brace member 36 disposed about the pole 11 and attached thereto by screw members 25 through a flange member 24 . The U-shaped brace member 36 includes a utility pole support mounting pipe with a lower end portion 38 and an upper end 39 that extends and is secured to the lighting unit 70 . The wind turbine 31 includes a mating U-shaped clamp 27 with a top support surface 30 that secures the wind turbine 31 thereto. The U-shaped clamp 27 is mounted to the top of U-shaped clamp 36 . The top support surface includes semi-circular groove 21 for fitting around the utility/street light pole 11 .
A side wall portion 22 extending downward into a flange member 23 that abuts flange member 24 of the U-shaped brace member 36 to secure them together with screw members 25 . This will bolt the wind turbine 31 and the U-shaped brace member 36 together as a unit. The support surface 30 has a pair of sides 28 and a front end face 29 . The side wall portion 22 decreases in thickness from the flange 24 to the front end 26 .
The utility pole mounting pipe 39 is secured into the space that is closed by the lighting unit 70 by cover member 73 at the rear end thereof. A forward portion of the lighting unit 70 has side wall portions 71 , lens 72 , and the camera 78 a with the camera eye 78 b . Further details of the lighting unit 70 will be discussed later in FIGS. 7 and 8 .
Referring to FIG. 2 , this illustrates the back solar panel 12 with solar cells mounted to the polygonal frame 14 c by the plurality of screws 14 . The top two-part plate halves 15 a and 15 b are secured to polygonal frame 14 c . Also, the two-part plate halves 15 a and 15 b include a pair of C-shaped brackets 17 a and 17 b at the top thereof and being secured thereto by a weld means. Elements 17 c and 17 d receive screw 18 for securing the C-shaped brackets 17 a and 17 b about the opening 17 .
FIG. 3 shows the polygonal frame includes two side members 14 c with sides 14 f and 14 g , which are welded to the side members 14 c by weld 15 c . Also, the weld 15 c is disposed between the edges of side members 14 c at the apex where the apex ends are angle to mate with one another. The two side members 14 c includes a semi-circular groove 14 c that receives first C-shaped clamps with outward extending flanges 41 that receives screws 43 through screw openings 41 a .and held therein by a weld 15 c . The top first C-shaped clamp has a sealing gasket disposed within the semi-circular groove to seal about the utility/street light pole to prevent any water from leaking along the utility/street light pole and into the polygonal frame housing and causing damage to the electronic components affixed to the solar panels.
Note that screw openings 14 b receives screw members 14 to secure the top and bottom plate halves 15 a and 15 b and the back frame plate 14 c thereto.
Second C-shaped clamps with outward extending flanges 41 are disposed about the utility/street roadway pole 11 that receives screws 43 through screw openings 41 and held into abutting engagement with the first. C-shaped clamp flanges 41 . Also, the second C-shaped clamps include semi-circular grooves therein for receiving the utility/street roadway pole 11 , with the top second C-shaped clamp having a second sealing disposed therein to prevent any water from leaking along the utility/street light pole and into the polygonal frame housing and causing damage to the electronic modules affixed to the solar panels. Each of the second C-shaped clamps has a center screw member 43 that is screwed into the center of the utility/street roadway pole 11 to enhance the securing of the second C-shaped clamps about the utility/street roadway pole 11 .
FIG. 4 illustrates a rear view of the solar and wind powered street/roadway lighting apparatus 10 with solar panels 12 configured in a polygonal configuration with a back solar panel 12 being removed. It also shows the first and second C-shaped clamps 40 secured about the utility/street roadway pole 11 . Also, it shows the top and bottom two-part half plates 15 a and 15 b closing the top and bottom of the polygonal frame 14 c.
FIG. 4A shows a side solar panel 12 with cut-outs 43 - 46 . Cut-out 43 receives Charge Controller No. 1 therein, which is represented by element 43 a with clamping means 43 b for retaining it within the cut-out 43 . Cut-out 44 receives Charge Controller No. 2 therein with clamping means 44 b for retaining it within the cut-out 44 . Cut-out 45 receives Battery No. 1 therein, which is represented by element 45 a with clamping means 45 b for retaining it within the cut-out 45 . Cut-out 46 receives a Battery No. 2 therein, which is represented by element 46 a with clamping means 46 b for retaining it within the cut-out 46 .
FIG. 4B shows a plurality of electrical components disposed on an interior wall of the solar panel 12 . Each of these elements will be described below.
1. Element 47 represents a Wind Charger; 2. Element 48 represents a Solar Charger Controller; 3. Element 49 represents Battery No. 3 ; 4. Element 50 represents a Connector Unit for Power from other Solar Panels and Battery; 5. Element 51 represents a Power Sharing and Isolating Unit; 6. Element 52 represents a Grid Power Unit; 7. Element 53 represents a Day Light Sensor; 8. Element 54 represents a Grid Power Supply Unit; 9. Element 55 represents a Battery and LED Control; 10. Element 56 represents a Battery, Camera/WIFI and RF Unit;; 11. Element 57 represents a LED Control Circuit Unit; 12. Element 58 represents a Battery and Traffic Grid; 13. Element 59 represents an Occupancy Sensor; 14. Element 60 represents a Traffic Light Inverter Unit; 15. Element 61 represents a Power Supply for Camera/WIFI; 16. Element 62 represents a Grid Inverter Unit; 17. Element 63 represents a WIFI and RF Unit; 18. Element 64 represents a LED Cluster Control; and 19. Element 65 represents a Connector Panel for outside components, such as internet, WIFI antenna, power to grid, traffic light, remote Ethernet connection for camera/video system, remote control capability and USB for cellular phone charging station.
FIG. 5 illustrates an exploded isometric view of the polygonal frame with cooperating sealing gaskets and solar panels spaced there from. This FIG. shows the top plate with a pair of C-shaped securing clamps 17 a , 17 b with outward extending flanges 19 and disposed at the top of the two-part half plates, which is welded thereto about the utility/street or roadway pole opening 17 . Each of the C-shaped securing clamps 17 a , 17 b include a sealing gasket 17 c that is received in semi-circular grooves of the C-shaped securing clamps 17 a , 17 b . A screw member 18 extends through flanges 19 to tighten the C-shaped securing clamps 17 a , 17 b and squeeze the sealing gasket 17 c in a tight sealing relationship with the utility/street or roadway pole 11 (not shown). This sealing engagement will prevent any water from leaking past and along the pole and against any damage of the electrical components 43 - 65 affixed to the solar panels 12 . Screw holes 16 receives screw member not shown for affixing the two-part plate halves to the top of the polygonal frame 14 c.
Also, FIG. 5 shows an additional sealing gasket 12 b disposed between the frame 14 c and the solar panel 12 for sealing the sealing components of the solar modules 43 - 65 . Screw elements 14 are inserted through screw holes 14 a to secure the solar panels and the sealing gaskets to the polygonal frame 14 c.
FIG. 6 shows an exploded view of the new and innovative heat dissipation design that includes a heat sink plate 103 with at least a pair of screw holes 109 at each corner of the heat sink plate 103 to receive screws (not shown). This allows the heat sink plate 103 to seat on four right angle aluminum support brackets 94 having an L-shape configuration, which is disposed and secured at each corner of the polished aluminum basin 90 a just above a lower annular rim portion 93 thereof to create a large space or chamber 95 above the heat sink plate 103 to allow a large volume of ambient air to constantly circulate above the LED chips 106 and vent or transfer heat from the heat sink plate 103 rapidly there from to the large space or chamber 95 above the heat sink plate 103 of the polished aluminum basin 90 a . As shown in FIG. 6 , the polished aluminum basin 90 a includes a pair of outer sides 92 and a front and rear sides 91 .
A screw hole 96 is disposed near the bottom of the polished aluminum basin 90 a to receive screw 97 to secure it to the outer die cast shell 71 through screw opening 112 of a heat transfer and dissipation plate 110 as shown in FIGS. 7 and 8 , which will be discussed in greater details later. Elements 105 represent the LED chip circuit board. Note that copper track (land) is disposed on the circuit board 105 and covered with high temperature white paint for insulation and used also as a reflector. The white paint on the surface of the heat sink plate 103 guards the circuit board 105 against exposure to water and /or moisture.
Also, the LED chips 106 are mounted on top of the aluminum heat sink plate 103 secured by a plurality of screws 107 , which uses heat sink compound to help with the heat transfer process from the base of the LED chips 106 .
In FIG. 6A , the bottom of the aluminum heat sink plate 103 having a plurality of spaced fins 110 secured by screws horizontally and using heat compound to increase the heat transfer from the heat sink plate 103 to the spaced aluminum fins 110 in the middle close to each LED chip 106 . These fins are used to remove heat with ambient air flow in the inner chamber 95 of the polished aluminum basin 90 a.
FIG. 6B shows the right angle anchor support brackets 94 with right angle legs 98 with a screw opening 99 in at least one of the legs 98 .
Also, the LED chips 106 are mounted on top the aluminum heat sink plate 103 secured by a plurality of screws 107 , which uses heat sink compound to help with the heat transfer process from the base of the LED chips 106 .
FIG. 6C is the same as FIG. 6 , except that is secured together as unit. Since the elements are the same, it would be redundant to recite the same elements as indicated in FIG. 6 above. The bottom portion of the polished aluminum basin 90 a shows the rim portion 93 of the heat sink plate 103 being fixed just above the rim portion 93 , since the right angle support brackets 94 are disposed and secured right above the rim portion 93 to established the aforementioned large space or chamber 95 . This aforementioned large space or chamber 95 helps to protect the LED chips from damage and preserving their life cycle.
In FIG. 7 , the REST LED retrofit lighting system unit 70 , is further being branded as the “NIGHT STAR™” , which is a pending trademark, includes an outer die cast shell 71 with a front portion 74 , a side wall portion 75 , and a top wall ledge portion 77 with vent openings 76 in a rear lower middle wall portion 78 . The rear lower middle wall portion 78 includes a plurality of vent openings 76 on opposite sides thereof, with a camera device 78 b positioned there between. The camera device 78 b can be represented by a camera eye or lens. A LED lens cover 72 is disposed between the front portion 74 and the rear lower wall portion 78 . The cover 72 is pivotally disposed over the aluminum polished basin 90 a to completely close and seal it (See FIG. 7 ).
Also, the “NIGHT STAR™” LED retrofit lighting unit 70 has an outer wall portion 79 and an inner wall portion 79 a at a rear section of the outer die cast shell 71 , which extends and is connected between the rear lower middle wall portion 78 to a rear wall portion 79 b . An upper top closed ceiling portion 83 has electronic components affixed thereto. Element 84 represents WIFI RF Transmitter with securing screws 86 and element 85 represents the Camera Power Supply with securing screws 86 . Also, element 86 represents the Day Light Sensor Socket and element 87 represents Barrier Strips for interconnecting crimp wire connectors. The element 39 , which is the utility pole mounting pipe with wiring 39 a connected to utility power at one end and the other end is connected to the barrier strip 87 . The C-clamps 88 having securing flanges with securing means 89 a for securing the utility pole mounting pipe 39 within the space defined by the upper top ceiling portion 83 . The utility pole mounting pipe 39 is inserted through a rear opening 79 c of the rear wall portion 79 b and into the upper top closed ceiling portion 83 and secured therein by the aforementioned C-clamps 88 and securing means 89 a.
In a middle portion behind the rear lower wall portion 78 is a flange portion 82 with a locking screw opening 82 a for locking a bottom cover 73 thereto (See FIG. 8 ). The cover 73 is pivotally hinged at 79 d at a bottom end of the rear wall portion 79 of a rear section of the outer die cast shell 71 that extends between the rear lower middle wall portion 78 and the rear wall portion 79 to close and completely seal the electronic components affixed to the upper top closed ceiling portion 83 therein to protect against damage and moisture. Above the flange portion 82 is an open ambient air space or area 78 c (see the exploded cut-out section of FIG. 8 ) for circulation of ambient air to the aluminum polished basin 90 a through an annular space or channel 80 between the exterior of the polished aluminum basin 90 a and the interior of the outer die cast shell 71 and an ambient air opening or passage in the rear side wall portion 91 of the polished aluminum basin 90 a.
A spring type locking latch 145 for latching the lens cover 72 between open and closed positions. Other types of latches could be utilized, if desired.
In regards to FIG. 8 , many of the elements will not be repeated, since it would be redundant. Only those elements will be discussed that are not shown in FIG. 7 . Note that the polished aluminum basin 90 a includes the large space or chamber 95 , the annular space or channel 80 between the polished aluminum basin 90 a and an interior wall (not shown) of the outer die cast shell 71 below the top wall ledge portion 77 to circulate ambient air through vent openings 76 in the rear lower middle wall portion 78 and into the large chamber 95 of the polished aluminum basin 90 a under the LED chips and around the polished aluminum basin 90 a through channel 80 . The ambient air is first entered into a plurality of vent holes 76 disposed in a bottom wall surface portion 73 c of the cover 73 and into the open ambient air space 78 c (see the exploded cut-out section of FIG. 8 ) above the flange portion 82 and the rear lower middle wall portion 78 , which continues to circulate flow into the annular channel 80 and through the plurality of vent openings 76 in the outer front side wall portion 91 and the outer rear side wall portion 91 and through inner front and rear side wall portions 91 a and through outer side wall portions 92 and inner side wall portions 92 a into the large chamber 95 to constantly dissipate heat to enhance the life cycle of the LED chips 106 .
Note that the open space 78 c 9 as shown in the exploded cut-out section of FIG. 8 will also allow ambient air to constantly flow into the annular space or channel 80 and through an ambient air passage 81 disposed in the outer and inner rear wall portions 91 , 91 a and into the large space or chamber 95 . This ambient air flow will flow through and above the rear lower wall portion 78 and the plurality of vent holes disposed therein and through the plurality of vent holes 76 in the front and side wall portions 91 , 91 a and 92 , 92 a to enable ambient air to constantly circulate and exit there from to dissipate heated ambient air flow from the large space or chamber 95 to the outside of the basin 90 a through the annular space or channel 80 and through the plurality of vent holes 76 in the bottom wall surface portion 73 c of the cover 73 and the plurality of vent holes 76 in the rear lower middle wall portion 78 via open space 78 c to the exterior of the outer die cast shell 71 to protect the LED chips from damage, while simultaneously enhancing their life cycle. It is noted that the open space 78 c is also defined by the bottom wall surface portion 73 c of the cover 73 and the upper top closed ceiling portion 83 of the outer die cast shell 71 rear section defined by elements 79 , 79 a , 79 b and 79 c when the cover 73 is closed.
Since the outer rim (flange) of the heat sink plate 103 is mounted on the right angle aluminum brackets 94 ( FIG. 6 ) mounted inside of the polish aluminum basin 90 a to allow an increase of rapid transfer heat from heat sink plate 103 to the large polish aluminum basin chamber 95 . In addition, the polish aluminum basin has a preferred 5×6 inch aluminum plate 110 , which can be of different dimensions, if desired, and sandwiched between the aluminum basin 90 a along a top outer surface thereof and into abutting engagement with a top inner side wall surface of the outer die cast shell 71 for additional heat transfer and dissipation to further enhance the life cycle of the LED chips 106 .
The preferred aluminum plate 110 has a larger intermediate section 113 a with two smaller outward extending ends 111 connected by a pair of incline portions 114 there between and is secured from the inside of the aluminum basin 90 a at an upper wall section thereof to the outer die cast shell 71 at an upper wall section thereof and through screw opening 112 disposed in the intermediate section 113 a of the aluminum plate 110 and into engagement with the outer die cast shell 71 by the screw 97 that is first inserted through screw opening 96 of the aluminum basin 90 a.
Further in FIG. 8 , the cover 73 will now be described. The cover 73 has an outer wall portion 73 a , an inner wall portion 73 b and upper ceiling wall 73 c . The ceiling wall has a plurality of vent openings 76 , a Power Supply Module 73 g with securing screws 73 h , a Power Transformer 73 e with a securing screw flange 73 f and a Barrier Strip 87 (See FIG. 7 above for details). Element 73 d is a locking screw hole for receiving the locking screw 73 i to engage the flange locking screw hole 82 a for locking the cover closed to the lighting unit 70 .
Referring now to the block diagram of FIG. 9 , the solar cells 13 are configured by the Solar panel Power Source 116 to provide DC Voltage to the Solar Charge Controller 119 that regulates the charge cycle and connected to the LED Control (CTL) Circuit Unit 127 , this scene occurs when it is (dusk) and turn power to the LED Street Light Cluster Unit 130 with the arrival of (dawn) Day Light, the control unit will turn off power to the LED Street Light Cluster Unit 130 in the Cobra Head Light Unit.
The LED Control (CTL) Circuit Unit 127 receives Power from the Battery Pack LED Light Unit 126 , which also send Power to the Timer Unit 128 . Power goes from the Timer Unit 128 to the Occupancy Sensor 129 , when activated the Occupancy Sensor 129 will send a trigger pulse high or low to activate the Timer Unit 128 . The Timer Unit 128 will then send a high or low voltage control signal to activate the Power Management Circuit to lower the current draw from the LED Street Light Cluster Unit 130 . Also the Grid Power Supply Unit 125 will also supply power to the LED Street Light Cluster Unit 130 , which will enable the LED Street Light Cluster Unit to operate with or without grid power.
The Triangle Mount Solar Panels all have Charge Controller 119 . Two Panels have individual charge controller with battery 122 and one have only charge controller connected to the Power Isolator and Power Share Unit 123 .
The Wind Turbine Power Source 117 connected to the charge controller 120 then to the Power Isolator and Power Share Unit 123 .
The Utility Power Source 118 is connected to the Day Light Sensor 121 from Day Light Sensor 121 to the Power Supply Unit 125 to the Grid Charge Controller 124 .
Then the Utility Power Source 118 is connected to the Day Light Sensor 121 from the Day Light Sensor 121 to the Power Supply Unit 125 to Grid Charge Controller 124 and to the Power Isolator and Power Share Unit 123 . This unit uses high speed Blocking Diodes to prevent the reversal of DC Voltage to other in coming DC Voltage from other power sources. The Power Sharing Circuit 123 directs the DC Voltage to charge individual Battery Packs.
The unit has three (3) Battery Packs. Of these three Battery Packs, Battery Pack 126 is used to power the LED Circuit Unit 127 , Timer Unit 128 , Occupancy Sensor 129 and the LED Street Light Cluster Unit 130 for the Cobra Head Light Unit.
The second Battery Pack 131 is used to supply power to the Power Supply Unit 132 , which regulate and send power to the WIFI, RF Transmitter/Receiver 133 , Video Camera 134 and USB Ports 135 .
The Third Battery Pack is used to send power to the Inverter 136 to power the traffic and control system. The Grid Tie Inverter 138 shares power from the same battery pack to send power back to the Utility GRID. This unit is scalable with the solar panel, battery and LED Light Cluster 130 for the Cobra Head and Shoe Box Lighting.
Note that that all in/out connections including antennas are made at the Connection Panel 135
With reference to FIG. 10 , the Day Light Sensor Circuit 141 is connected between the utility grid (120/200 VAC) and the primary winding of (T 1 ), that is transformer 1 is designed with an auto current and voltage protection that will disconnect the primary winding of (T 1 ) transformer 1 due to higher voltage, such that the primary winding is designed to operate at the MOV. This can also protect against high transient voltage or lightening, which will trigger the resettable fuse to open and reset with normal voltage operation.
The second feature is the current sensor that is designed trigger the resettable fuse due to short or high current draw on the secondary winding of (T 1 ).
The LED CTL AUTO SW CIRCUIT 142 , also have high voltage and high current sensing circuit protection with the DC Voltage and current, the auto resettable fuse will disconnect, if there is a short in the secondary. The Camera Power Unit also has the same protection.
While the foregoing written description of the invention enables one of ordinary skill in the art to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiments, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed. | The present invention discloses an improved renewable energy and rechargeable LED lighting unit having a roadway/street light pole with a polygonal frame member configuration disposed there about. A plurality of solar panels affixed to the polygonal configuration. The solar panels include a plurality of electrical modules that are affixed directly to an interior wall of at least one of the solar panels without interfering with the polygonal frame member when attached. A two-part closure plate arrangement are attached directly to the polygonal frame member and completely enclose and seal the plurality of electrical modules between the frame member and the at least one of the solar panels. | 8 |
This application claims the benefit of Korean Patent Application No. P2003-92697 filed in Korea on Dec. 17, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a liquid crystal display, and more particularly to a liquid crystal display device and a driving method thereof that are adaptive for reducing the number of data lines as well as the number of data drive integrated circuits corresponding thereto.
2. Description of the Related Art
Generally, a liquid crystal display (LCD) controls the light transmittance of a liquid crystal using an electric field, thereby displaying a picture. To achieve this, the LCD includes a liquid crystal display panel having a pixel matrix and a driving circuit for driving the liquid crystal display panel. The driving circuit drives the pixel matrix such that picture information can be displayed on the display panel.
FIG. 1 illustrates a conventional liquid crystal display device.
Referring to FIG. 1 , the conventional LCD includes a liquid crystal display panel 2 , a data driver 4 for driving data lines DL 1 to DLm of the liquid crystal display panel 2 , and a gate driver 6 for driving gate lines GL 1 to GLn of the liquid crystal display panel 2 .
The liquid crystal display panel 2 has thin film transistors TFT each of which is provided at each crossing of the gate lines GL 1 to GLn and the data lines DL 1 to DLm and liquid crystal cells connected to the thin film transistors TFT and arranged in a matrix type.
The gate driver 6 sequentially applies a gate signal to each gate line GL 1 to GLn in response to a control signal from a timing controller (not shown). The data driver 4 converts data R, G and B from the timing controller into analog video signals to thereby apply video signals for one horizontal line to the data lines DL 1 to DLm every one horizontal period when a gate signal is applied to each gate line GL 1 to GLn.
The thin film transistor TFT applies a signal from the data lines DL 1 to DLm to the liquid crystal cell in response to a control signal from the gate lines GL 1 to GLn. The liquid crystal cell can be equivalently expressed as a liquid crystal capacitor Clc because it has a common electrode opposed to a pixel electronde connected to the thin film transistor TFT with a liquid crystal therebetween. Such a liquid crystal cell includes a storage capacitor (not shown) connected to a pre-stage gate line in order to keep the data voltage charged in the liquid crystal capacitor Clc until the next data voltage is charged therein.
The liquid crystal cells of such a related art conventional LCD has a number of vertical lines equal to the number (i.e., m) of the data lines DL 1 to DLm because they are provided at crossings of the gate lines DL 1 to DLn and the data lines DL 1 to DLm. In other words, the liquid crystal cells are arranged in a matrix type in such a manner to make m vertical lines and n horizontal lines.
The related art LCD requires m data lines DL 1 to DLm so as to drive the liquid crystal cells having m vertical lines. Therefore, the related art LCD has a drawback in that a number of data lines DL 1 to DLm should be provided to drive the liquid crystal display panel 2 and hence process time and a manufacturing cost are wasted. Furthermore, the related art LCD has a problem in that because a large number of data drive integrated circuits (IC's) are included in the data driver 4 so as to drive the m data lines DL 1 to DLm, the manufacture cost is high.
SUMMARY OF THE INVENTION
Accordingly, it is an advantage of the present invention to provide a liquid crystal display device and a driving method thereof that are adaptive for reducing the number of data lines as well as the number of data drive integrated circuits corresponding thereto.
In order to achieve these and other advantages of the invention, a liquid crystal display device according to one aspect of the present invention includes a plurality of data lines; a plurality of gate lines provided in a direction crossing the data lines; first and second control lines provided in a direction being parallel to the gate lines; first liquid crystal cells provided at one side of the data lines; second liquid crystal cells provided at the other side of the data lines; a first switching part provided for each first liquid crystal cell to apply video signals supplied from the data lines to the first liquid crystal cells under control of the first control line and the gate line; and a second switching part provided for each second liquid crystal cell to apply video signals supplied from the data lines to the second liquid crystal cells under control of the second control line and the gate line.
The liquid crystal display device further includes a gate driver for sequentially applying a gate signal to the gate lines during an ½ frame interval; a data driver for applying said video signals to the data lines when said gate signal is applied to the gate lines; and a control signal supplier for supplying control signals alternated for each ½ frame unit to the first and second control lines.
In the liquid crystal display device, the first switching part includes a first thin film transistor connected to the gate line to be turned on when said gate signal is applied, thereby receiving said video signal; and a second thin film transistor turned on when said control signal is applied to the first control line to apply said video signal to the first liquid crystal cell.
In the liquid crystal display device, the second switching part includes a third thin film transistor connected to the gate line to be turned on when said gate signal is applied, thereby receiving said video signal; and a fourth thin film transistor turned on when said control signal is applied to the second control line to apply said video signal to the second liquid crystal cell.
The first and second liquid crystal cells receive said video signals alternately for each ½ frame unit in response to said control signals applied alternately for each ½ frame unit.
In the liquid crystal display device, the first liquid crystal cells and the first switching part are provided at odd-numbered vertical lines while the second liquid crystal cells and the second switching part are provided at even-numbered vertical lines.
Alternatively, the first liquid crystal cells and the first switching part are provided at even-numbered vertical lines while the second liquid crystal cells and the second switching part are provided at odd-numbered vertical lines.
A method of driving a liquid crystal display device according to another aspect of the present invention includes applying video signals corresponding to data to first liquid crystal cells positioned at the ith vertical line (wherein i is an even number or an odd number) during a first-half ½ frame interval of one frame interval; and applying said video signals corresponding to said data to second liquid crystal cells positioned at the (i+1)th vertical line during a second-half ½ frame interval of said one frame interval.
In the method, said step of applying said video signals to the first liquid crystal cells includes applying a first control signal to turn on a first thin film transistor included in a first switching part connected to each of the first liquid crystal cells; sequentially applying a gate signal to all the gate lines to sequentially turn on each second thin film transistor included in the first switching part; and applying said video signals to the data lines when said gate signal is applied.
In the method, said step of applying said video signals to the second liquid crystal cells includes applying a second control signal to thereby turn on a third thin film transistor included in a second switching part connected to each of the second liquid crystal cells; sequentially applying said gate signal to all the gate lines to sequentially turn on each fourth thin film transistor included in the second switching part; and applying said video signals to the data lines when said gate signal is applied.
Said first and second control signals are applied in such a manner as to alternate with each other for each ½ frame interval.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the invention will be apparent from the following detailed description of the embodiments of the present invention with reference to the accompanying drawings, in which:
FIG. 1 is a block circuit diagram illustrating a configuration of a conventional liquid crystal display;
FIG. 2 is a block circuit diagram illustrating a configuration of a liquid crystal display according to a first embodiment of the present invention;
FIG. 3 is a waveform diagram of control signals applied to the control lines and gate signals applied to the gate lines shown in FIG. 2 ;
FIG. 4 is a block circuit diagram illustrating a configuration of a liquid crystal display according to a second embodiment of the present invention;
FIG. 5A and FIG. 5B depict the liquid crystal cells driven in response to the control signals shown in FIG. 3 ;
FIG. 6 is a block circuit diagram illustrating a configuration of a liquid crystal display according to a third embodiment of the present invention; and
FIG. 7 is a block circuit diagram illustrating a configuration of a liquid crystal display according to a fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
Hereinafter, embodiments of the present invention will be described in detail with reference to FIGS. 2 to 7 .
FIG. 2 schematically shows a liquid crystal display (LCD) according to a first exemplary embodiment of the present invention.
Referring to FIG. 2 , the LCD according to the first embodiment of the present invention includes a liquid crystal display panel 20 , a data driver 22 for driving data lines DL 1 to DLm/ 2 of the liquid crystal display panel 20 , a gate driver 24 for driving gate lines GL 1 to GLn of the liquid crystal display panel 20 , and a control signal supplier 23 for supplying control signals to first and second control lines C 1 and C 2 provided in parallel to the gate lines GL 1 to GLn.
The liquid crystal display panel 20 is comprised of first and second liquid crystal cells 10 and 12 provided alternately at crossings of the gate lines GL 1 to GLn and the data lines DL 1 to DLm/ 2 , a first switching part 14 for driving the first liquid crystal cell 10 , and a second switching part 16 for driving the second liquid crystal cell 12 .
The first and second liquid crystal cells 10 and 12 can be equivalently expressed as a liquid crystal capacitor Clc because they comprise a common electrode opposed to a pixel electrode connected to each of the first and second switching parts 14 and 16 and having a liquid crystal therebetween. Herein, each of the first and second liquid crystal cells 10 and 12 includes a storage capacitor (not shown) connected to a pre-stage gate line (or common electrode) or the control lines C 1 and C 2 in order to keep a voltage of a video signal charged in the liquid crystal capacitor C 1 c until the next video signal is applied.
The first liquid crystal cell 10 and the first switching part 14 are provided at, for example, the right side of the data line DL, that is, at even-numbered vertical lines. The second liquid crystal cell 12 and the second switching part 16 are provided at the left side of the data line DL, that is, at odd-numbered vertical lines. In other words, the first and second liquid crystal cells 10 and 12 are provided an opposite sides of a single data line DL running between them. In this case, the first and second liquid crystal cells 10 and 12 receive video signals from the data lines DL positioned adjacently to each other. Accordingly, the LCD according to the first embodiment of the present invention allows the number of data lines DL to be reduced to a half of that in the conventional LCD shown in FIG. 1 .
Alternatively, in the present embodiment, a position of the first and second liquid crystal cells 10 and 12 may be reversed as shown in FIG. 4 . In other words, as shown in FIG. 4 , the first liquid crystal cell 10 and the first switching part 14 may be provided at the left side of the data line DL while the second liquid crystal cell 12 and the second switching part 16 may be provided at the right side of the data line. In other words, the first liquid crystal cell 10 and the first switching part 14 may be provided at the odd-numbered vertical lines while the second liquid crystal cell 12 and the second switching part 16 may be provided at the even-numbered vertical lines.
The first and second control lines C 1 and C 2 are provided in parallel to the gate line GL (e.g., at the upper/lower sides of the gate line GL) and connected to any one of the first and second switching parts 14 and 16 . Herein, the first control line C 1 is connected to the second switching part 16 while the second control line C 2 is connected to the first switching part 14 .
The first switching part 14 for driving the first liquid crystal cell 10 includes first and second thin film transistors TFT 1 and TFT 2 . The first thin film transistor TFT 1 is connected to the data line DL and the gate line GL to be turned on when a gate signal is applied to the gate line GL. The second thin film transistor TFT 2 is connected between the first thin film transistor TFT 1 and the first liquid crystal cell 10 to be turned on when a second control signal is applied to the second control line C 2 .
The second switching part 16 for driving the second liquid crystal cell 12 includes third and fourth thin film transistors TFT 3 and TFT 4 . The third thin film transistor TFT 3 is connected to the data line DL and the gate line GL to be turned on when a gate signal is applied to the gate line GL. The fourth thin film transistor TFT 4 is connected between the third thin film transistor TFT 3 and the second liquid crystal cell 12 to be turned on when a first control signal is applied to the first control line C 1 .
The gate driver 24 sequentially applies a gate signal SP to the gate lines GL 1 to GLn for each ½ frame unit as shown in FIG. 3 in response to the control signal supplied from a timing controller (not shown). In other words, the gate driver 24 in the first embodiment of the present invention drives the gate lines GL 1 to GLn for each ½ frame unit.
The data driver 22 converts data R, G and B signals from the timing controller into analog video signals to apply them to the data lines DL 1 to DLm/ 2 . The data driver 22 alternately applies a video signal to be supplied to the first liquid crystal cell 10 and a video signal to be supplied to the second liquid crystal cell 12 for each ½ frame unit. In this case, the LCD according to the first embodiment of the present invention allows the number of data lines DL 1 to DLm/ 2 to be reduced to a half of that in the conventional LCD shown in FIG. 1 , so that the number of data drive IC's included in the data driver 22 also is reduced by half.
The control signal supplier 23 alternately supplies first and second control signals CS 1 and CS 2 to the first and second control lines C 1 and C 2 for each ½ frame unit as shown in FIG. 3 . For instance, the control signal supplier 23 can supply the first control signal CS 1 to the first control line C 1 during the first-half ½ frame interval while supplying the second control signal CS 2 to the second control line C 2 during the second-half ½ frame interval. Further, the control signal supplier 23 can supply the second control signal CS 2 to the second control line C 2 during the first-half ½ frame interval while supplying the first control signal CS 1 to the first control signal C 1 . Alternatively, the LCD according to the present invention can supply the first and second control signals CS 1 and CS 2 from the timing controller without having the control signal supplier 23 separately as shown in FIG. 2 .
A procedure for supplying video signals to the liquid crystal cells 10 and 12 will be described in detail.
Firstly, the first control signal CS 1 to the first control line C 1 during the first-half ½ frame interval. Then, the fourth thin film transistors TFT 4 connected to the first control line C 1 are turned on. At this time, the second thin film transistors TFT 2 keep a turn-off state.
During the first-half ½ frame interval, the gate signal SP is sequentially applied to the gate lines GL 1 to GLn. At this time, the third thin film transistor TFT 3 connected to the gate line GL is turned on for each horizontal line. Video signals to be supplied to the second liquid crystal cell 12 are applied to the data lines DL 1 to DLm/ 2 . Then, the video signals supplied to the data lines DL 1 to DLm/ 2 are applied, via the third and fourth thin film transistors TFT 3 and TFT 4 , respectively, to the second liquid crystal cell 12 . Thus, during the first-half ½ frame interval, the second liquid crystal cells 12 positioned at the odd-numbered vertical lines as shown in FIG. 5A are driven. Meanwhile, the first thin film transistors TFT 1 also are sequentially turned on by the gate signals SP, but video signals are not applied to the first liquid crystal cell 10 because the second thin film transistors TFT 2 are turned off.
Thereafter, during the second-half ½ frame interval, the second control signal CS 2 is applied to the second control line C 2 . Then, the second thin film transistors TFT 2 connected to the second control line C 2 are turned on. At this time, the fourth thin film transistors TFT 4 remain off.
During the second-half ½ frame interval, the gate signal SP is sequentially applied to the gate lines GL 1 to GLn. At this time, the first thin film transistor TFT 1 connected to the gate line GL is turned on for each horizontal line. Video signals to be supplied to the first liquid crystal cell 10 are applied to the data lines DL 1 to DLm/2. Then, the video signals supplied to the data lines DL 1 to DLm/2 are applied, via the first and second thin film transistors TFT 1 and TFT 2 , to the first liquid crystal cell 10 . Thus, during the second-half ½ frame interval, the first liquid crystal cells 10 positioned at the even-numbered vertical lines as shown in FIG. 5B are driven. Meanwhile, the third thin film transistors TFT 3 also are sequentially turned on by the gate signals SP, but video signals are not applied to the second liquid crystal cell 12 because the fourth thin film transistors TFT 4 are turned off.
In other words, the LCD according to the first embodiment of the present invention applies the control signals CS 1 and CS 2 alternately for each ½ frame unit to the first and second control lines C 1 and C 2 to thereby alternately turn on the second thin film transistors TFT 2 or the fourth thin film transistors TFT 4 , so that it can alternately drive the first and second liquid crystal cells 10 and 12 for each ½ frame unit. Furthermore, the LCD according to the first embodiment of the present invention supplies desired video signals to the first and second liquid crystal cells 10 and 12 positioned at the left/right sides using a single of data line DL, so that it can reduce the number of data lines DL and the number of data drive IC's to a half of the prior art, thereby reducing a manufacturing cost thereof.
Alternatively, in the present invention, the second control signal CS 2 may be applied during the first-half ½ frame interval while the first control signal CS 1 may be applied during the second-half ½ frame interval. Then, the first liquid crystal cells 10 positioned at the even-numbered horizontal lines as shown in FIG. 5B are driven while the second liquid crystal cells 12 positioned at the odd-numbered horizontal lines as shown in FIG. 5A are driven. In other words, the LCD according to the present invention can control the sequence in which the first and second control signals CS 1 and CS 2 are applied to thereby control a driving sequence of the first and second liquid crystal cells 10 and 12 .
Alternatively, in the present invention, a shape of the liquid crystal display panel 20 can be established variously. For instance, the first and second liquid crystal cells 10 and 12 may be arranged in such a manner to be located at the upper side of the gate lines GL as shown in FIG. 6 and FIG. 7 . In other words, in another embodiment of the present invention, first and second liquid crystal cells 10 and 12 positioned at the left/right sides on a basis of the data line DL can be arranged in such a manner to be located at the same horizontal line as shown in FIG. 6 and FIG. 7 . In this case, the first liquid crystal cell 10 and the first switching part 14 are arranged at the even-numbered (or odd-numbered) vertical lines while the second liquid crystal cell 12 and the second switching part 16 are arranged at the odd-numbered (or even-numbered) vertical lines. A procedure for applying video signals to the liquid crystal cells 10 and 12 in another embodiment of the present invention is identical to that in the embodiment of the present invention as shown in FIG. 2 and FIG. 3 .
Meanwhile, the LCD according to any one of the embodiments of the present invention is applicable to various liquid crystal panels. For instance, the LCD according to any one of the embodiments of the present invention is applicable to a TN-mode liquid crystal or an IPS-mode liquid crystal, etc.
As described above, according to the present invention, the liquid crystal cells positioned at the odd-numbered vertical lines and the liquid crystal cells positioned at the even-numbered vertical lines are alternately driven for each ½ frame unit. A single data line drives the liquid crystal cells positioned adjacently with each other at the left/right sides, so the number of data lines can be reduced to about half. Accordingly, the number of data drivers for supplying driving signals to the data lines also can be reduced to about half, thereby reducing a manufacturing cost.
Although the present invention has been explained by the embodiments shown in the drawings described above, it should be understood to the ordinary skilled person in the art that the invention is not limited to the embodiments, but rather that various changes or modifications thereof are possible without departing from the spirit of the invention. Accordingly, the scope of the invention shall be determined only by the appended claims and their equivalents. | A liquid crystal display device and a driving method thereof for reducing the number of data lines and the number of data drive integrated circuits corresponding thereto are disclosed. In the device, a plurality of gate lines is provided in a direction crossing a plurality of data lines. First and second control lines are provided in a direction being parallel to the gate lines. First liquid crystal cells are provided at one side on a basis of the data lines. Second liquid crystal cells are provided at other side on a basis of the data lines. A first switching part is provided for each first liquid crystal cell to apply video signals supplied from the data lines to the first liquid crystal cells under control of the first control line and the gate line. A second switching part is provided for each second liquid crystal cell to apply video signals supplied from the data lines to the second liquid crystal cells under control of the second control line and the gate line. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention involves a control method for starting an air conditioner compressor which can perform either a cooling operation or a heating operation.
2. Description of the Prior Art
In an air conditioner, the heat load varies depending on the indoor and outdoor temperatures. Consequently, the load applied to a compressor also varies in proportion to the heat load, thereby causing variations in the level of oil which is an important factor in the reliability of the compressor. The oil in the compressor serves to reduce or prevent friction between the components therein. When the oil does not reach a sufficient level to prevent the friction due to the abrupt variations in the discharge gas pressure of the compressor, the wall surfaces or vanes of the compressor become worn away. Accordingly, there is a problem in that the life time of the compressor is shortened.
In an air conditioner capable of performing either a cooling operation or a heating operation, it is well known that the discharge gas pressure of the compressor during the heating operation is about three to five times greater than during the cooling operation. Accordingly, it is necessary to control the starting patterns of the compressor during the heating operation mode differently from that during the cooling operation mode.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for controlling a compressor to start by different patterns according to the heat load in an air conditioner capable of performing either a cooling operation or a heating operation, thereby stabilizing the oil level therein.
It is another object of the present invention to provide a method for controlling a compressor to start by different patterns according to the outdoor temperature in an air conditioner capable of performing either a cooling operation or a heating operation, thereby lengthening the life time thereof.
It is still another object of the present invention to provide a method for controlling a compressor to start by different patterns according to the target operation frequency in an air conditioner capable of performing either a cooling operation or a heating operation, thereby increasing the reliability of the air conditioner.
In order to achieve the objects described above, there is a novel control method for starting a compressor of an air conditioner comprising the steps of: determining whether the cooling operation mode or the heating operation mode is selected; receiving the outdoor temperature (To); comparing the outdoor temperature (To) to a reference temperature in the selected operation mode; setting the corresponding rate of increase for the starting frequency of the compressor according to the comparison results; and, starting the compressor at the rate of increase and then operating the frequency at a target operation frequency (F T ).
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and advantages may be more fully understood by reading the description of the preferred embodiment with reference to the accompanying drawings wherein:
FIG. 1 is a schematic diagram of an air conditioner to which a method of the present invention is applied;
FIG. 2 is a wave-form diagram showing the starting pattern of a compressor in the cooling operation mode according to this invention;
FIGS. 3 to 5 are three wave-form diagrams showing different starting patterns predetermined by high, medium, and low values, respectively, of a target operation frequency in the heating operation mode; and,
FIGS. 6A and 6B are respective portions of a flow chart showing the control method for starting a compressor according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings. FIG. 1 is a schematic diagram of an air conditioner to which the method of the present invention is applied. As shown in FIG. 1, an air conditioner may be divided into roughly two units - an indoor unit A and an outdoor unit B. The outdoor unit B comprises a microprocessor 2 for controlling the entire operation of the outdoor unit B, a transmitting/receiving section 1 for interfacing the indoor unit A (more specifically, the indoor microprocessor; not shown) with the microprocessor 2, an outdoor fan 3 for forcibly liquefying (in the cooling operation mode) or evaporating (in the heating operation mode) the refrigerant in the outdoor heat exchanger, a compressor 5, a compressor driving section 4 for operating compressor 5 according to the control signal from the microprocessor 2, and a temperature sensing section 6 for sensing: (i) the outdoor temperature (To), (ii) an outdoor tube temperature, (iii) a surface temperature of compressor 5 and (iv) a discharge gas temperature of compressor 5. Reference numeral 7 denotes a power supply section. FIG. 2 is a wave-form diagram showing the starting pattern of a compressor in the cooling operation mode. FIGS. 3 to 5 are wave-form diagrams showing different starting patterns predetermined by the value of a target operation frequency in the heating operation mode. FIGS. 6A and 6B show a flow chart showing a compressor starting control method.
When a user turns the operation switch (not shown) for the air conditioner "ON" and selects several operation instructions such as the desired operation mode, e.g., the amount of the air, the direction of the air, the desired room temperature, etc., the microprocessor (not shown) of the indoor unit A transmits the selected instructions to microprocessor 2 in the outdoor unit B via the transmitting/receiving section 1. The microprocessor in the indoor unit A also calculates a target operation frequency (F T ) based on the instructions and temperature signals and transmits the target operation frequency (F T ) to the microprocessor 2. The microprocessor 2 then generates a control signal for operating compressor 5 according to the target operation frequency (F T ). In operating compressor 5 in the manner described above, microprocessor 2 determines at stage 101 (see FIG. 6A) whether the selected mode is a cooling operation mode. When the selected mode is the cooling operation mode, the control process goes to stage 102 of the cooling operation sequence 107, where microprocessor 2 receives the outdoor temperature (To) from temperature sensing section 6. At stage 103, it is determined whether or not the outdoor temperature (To) is higher than a first reference temperature, for example 18° C. When the outdoor temperature (To) is below 18° C., the rate of increase (Tspeed) of the starting frequency of compressor 5 is set to a value of A (stage 104). To the contrary, when the outdoor temperature (To) is above 18° C., the rate of increase (Tspeed) of the starting frequency of compressor 5 is set to a value of B (stage 105), where B is greater than A. That rate of increase (Tspeed) is controlled to be different with each other is aimed not to immoderately operate the compressor 5. For example, let A=1, B=2. When the outdoor temperature (To) is below 18° C., compressor 5 is started at the slow increasing rate of 1 Hz per 1 second. On the other hand, when the outdoor temperature (To) is above 18° C., compressor 5 is started at the fast increasing rate of 2 Hz per 1 second.
In FIG. 2, after the operation frequency reaches a predetermined value, for example 52 Hz, compressor 5 is operated at 52 Hz for a predetermined time and then the operation frequency is converted into the target frequency (F T ).
The control method for starting the compressor in the heating operation mode will be now described. Generally, the discharge gas pressure in the heating operation mode is relatively greater than that in the cooling operation mode. Accordingly, it is necessary to control compressor 5, considering the effect that the rate of increase has on the oil level. At stage 108, it is determined whether the selected mode is in the heating operation mode. When the selected mode is in the heating operation mode, the heating operation sequence 121 is initiated wherein microprocessor 2 receives the outdoor temperature (To) from temperature sensing section 6 at stage 110. At stage 111, it is determined whether the outdoor temperature (To) is higher than a second reference temperature, for example 0° C. When the outdoor temperature (To) is below 0° C., the increasing rate (Tspeed) of the starting frequency of compressor 5 is set to a value of C (stage 112). To the contrary, when the outdoor temperature (To) is above 0° C., the rate of (Tspeed) of the starting frequency of compressor 5 is set to a value of D, where D (stage 113) is greater than C. That rate of increase (Tspeed) is controlled to be different from each other and is aimed not to immoderately drive the compressor 5.
Microprocessor 2 reads the target operation frequency (F T ) at stage 114, and then controls the operation of compressor 5 according to various pre-set patterns determined by the value of the target operation frequency (F T ) at stages 115 to 120. That is, when the target operation frequency (F T ) is in the "HIGH" frequency range, for example above 74 Hz, compressor 5 is started in a pattern I comprised of a sequence of steps represented in FIG. 3: (1) increasing the frequency from zero to 52 Hz and then maintaining 52 Hz, (2) increasing the frequency to 85 Hz at time t 1 and then maintaining 85 Hz, (3) decreasing the frequency to 64 Hz at time t 2 and then maintaining 64 Hz, (4) increasing the frequency to 85 Hz at time t 3 and then maintaining 85 Hz, and (5) increasing the frequency to 102 Hz at time t 4 and then maintaining 102 Hz as shown in FIG. 3. Then, at time t 5 , the compressor 5 is operated at the target operation frequency (F T ).
When the target operation frequency (F T ) is in the "MIDDLE" frequency range, for example a frequency range of 52 Hz to 74 Hz, compressor 5 is started in a pattern II somewhat similar to the pattern I of the "HIGH" frequency range. However, the values to which the operation frequency is increased and then maintained or decreased and then maintained are different from those in the "HIGH" frequency range. In FIG. 4, compressor 5 is started in a sequence of steps: (1) increasing the frequency from zero to 38 Hz and then maintaining 38 Hz, (2) increasing the frequency to 64 Hz at time t 1 and then maintaining 64 Hz, (3) decreasing the frequency to 52 Hz at time t 2 and then maintaining 52 Hz, (4) increasing the frequency to 64 Hz at time t 3 and then maintaining 64 Hz, and (5) increasing the frequency to 71 Hz at time t 4 and then maintaining 71 Hz. Then, at time t 5 , the compressor is operated at the target operation frequency (F T ).
Finally, when the target operation frequency (F T ) is in the "LOW" frequency range, for example below 38 Hz, compressor 5 is started in a pattern III similar to the cooling operation mode.
In FIG. 5, compressor 5 is started by increasing the frequency from zero to 38 Hz and then maintaining 38 Hz and then is operated at the target operation frequency (F T ). | A method of starting a compressor of an air conditioner involves raising the operation frequency of the compressor from zero to a target operation frequency in different patterns (stages), depending upon (1) whether the air conditioner is being operated in a heating mode or a cooling mode, and (2) whether, during a heating mode, the target operation frequency is in a high range, a medium range, or a low range. During a heating mode at either of the high and medium target frequency ranges, the compressor frequency is increased and decreased on its way to reaching the target operation frequency. | 5 |
CONTINUITY
This application is a continuation-in-part of our co-pending U.S. patent application Ser. No. 07/545,174 filed Jun. 28, 1990, abandoned.
FIELD
The field of the invention is automatic guidance of trackless vehicles, particularly vehicles that navigate by dead reckoning and without a driver on board.
SUMMARY
The invention is an inexpensive flexible way of providing benchmarks of improved accuracy for updating the position of a vehicle that is navigated primarily by dead reckoning. The distance traveled is measured by rotation of wheels on the vehicle and the direction by gyroscopic navigation methods, which are susceptible to error and drift. Accumulated errors in position and direction are corrected by having the vehicle detect the relative location of each successive magnetic marker over which it passes on the floor.
One object of the invention is to provide apparatus for measuring, with improved accuracy, the position of a vehicle relative to a known marker at the floor to ascertain the vehicle's position relative to a factory reference system.
Another object is to utilize a generally transverse array of sensors on the vehicle to sense the marker and to process the sensed data regarding marker position in a particular way to determine the relative position of the vehicle with improved accuracy.
Another object is to determine marker-vehicle relative position by taking readings with a plurality of sensors, including the sensor having the greatest reading, the two sensors immediately on one side of it, and the two sensors immediately on the other side of it, and correlating and interpolating the readings with a stored spatial pattern of magnetic field strength whereby a measurement of improved accuracy is realized.
Another object is to ascertain the longitudinal position of the vehicle by means of the marker by sensing the occurrence of maximum readings of the sensors as the vehicle passes over the marker.
Another object is to utilize the generally transverse array of sensors to concurrently sense two closely positioned markers having predetermined relative and factory reference locations and, thereby, provide concurrent measurements for ascertaining the attitude of the array of sensors, associated bearing of the vehicle in addition to determination of lateral and longitudinal vehicle position.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 depicts a guided vehicle system that utilizes the invention.
FIG. 2 shows an update marker magnet in the floor.
FIG. 3 shows an array of Hall magnetic sensors on the vehicle.
FIG. 4 is a curve of analog voltage output from one of the Hall sensors as a function of distance of the sensor from a floor magnet.
FIG. 5 is a block diagram of some electronic equipment on the vehicle for processing magnet sensor signals.
FIGS. 6, 6A, 6B, 6C, and 6D are, in combination, a schematic diagram of the same electronic equipment.
FIG. 7 is a simplified flow chart of an algorithm for processing sensor data to measure the lateral position of the vehicle relative to a magnet and to detect when a row of Hall sensors crosses the magnet.
FIG. 8 is a simplified flow chart similar to FIG. 7 including sensor null measurement and related calibration during the WAIT LOOP.
FIGS. 9, 9A, and 9B comprise a simplified flow chart of an algorithm for processing sensor data to concurrently measure the lateral position of the vehicle relative to two magnets and to detect when the row of Hall sensors crosses each magnet.
FIG. 10 is similar to FIG. 3, showing an array of Hall magnetic sensors on the vehicle, and including indicia exemplary of the presence of two magnets.
FIG. 11 is similar to FIG. 1, depicting a guided vehicle system that utilizes the invention and showing the presence of two magnets on the path ahead of the vehicle.
DESCRIPTION OF PREFERRED EMBODIMENT
Vehicle
FIG. 1 is a stylized top view of a guided vehicle 2 driving in the direction of the arrow 4 toward a magnet 6 that is mounted in the floor. The vehicle 2 has drive wheels 8, 10 on the left and right sides respectively, which are powered individually by motors that are not shown. Caster 12, 14, 16 and 18 support the vehicle at its left-front, left-rear, right-front and right-rear corners respectively. The terms left, right, front and back are used here for convenience of description; the vehicle operates symmetrically in either direction.
Touch-sensitive feelers or bumpers 20, 22 are located at the front and back of the vehicle respectively to detect obstacles in the path and to activate switches to stop the vehicle. A transversely arranged linear array of magnetic sensors 24 is mounted on the vehicle as shown in FIG. 1.
Floor magnet
In FIG. 2 a floor magnet 6 is shown in place in a hole 32 in the floor. The magnet in this embodiment is cylindrical, placed with its axis vertical, and has its south-polarized face 34 facing upward and its north-polarized face 36 at the bottom of the hole. The diameter of the magnet in this embodiment is 1 inch and its axial height is 3/4 inch.
Magnetic-Field Sensors
The array 24 of magnetic-field sensors in shown in plan view in FIG. 3. In this embodiment it comprises twenty-four Hall-effect sensors spaced for example 0.8 inch apart in a straight line perpendicular to the longitudinal centerline of the vehicle and laterally centered on the centerline of the vehicle. The first sensor is labeled 37; the twelfth sensor is 48; the thirteenth sensor is 49 and the twenty-fourth sensor is 60.
The sensors are commercially available devices whose analog output voltage varies as a function of the magnetic field it detects. Each sensor has a null voltage, which is its output when no magnetic field is present. When a magnetic field is present the voltage consistently increases or decreases relative to the center of flux of the magnet and to the null voltage, depending upon whether the magnet crosses a south or north pole. In the described embodiment of the invention the sensors always detect a south pole field 34, so their output voltage always increases as a result of being near a magnet.
A representative graph 64 of the analog output voltage versus distance of a sensor from the center of the magnet 6 is shown in FIG. 4. Voltage output from the Hall sensor (such as sensor 45, for example) is shown on the ordinate 62, in volts. The distance from the center of the magnet to the sensor is shown on the abscissa 61 in inches. For the measurement shown, the graph has a depressed zero and the output voltage in the absence of any magnetic field is the null voltage 66 of about 6.44 volts.
In this measurement, when the sensor 45 is directly over the center of the magnet the analog output voltage is approximately 7.1 volts. When the sensor 45 is approximately one inch away from the center of the magnet 6 the analog output voltage 64 produced by the sensor is approximately 6.65 volts. Thus, two magnets which are more than four inches apart, but sufficiently close to be simultaneously sensed, produce detectable signals which are essentially independent.
Circuits for Processing Sensor Signals
Signals from the twenty-four Hall sensors of array 24 are input at terminals 68, 69 to a pair of ganged multiplexers 70, 71, as shown in FIG. 5. The multiplexers 70, 71 receive analog signals continuously from the twenty-four sensors 37-60, and select one at a time sequentially for output at line 72. The two output signals from the multiplexers are connected to a signal-conditioning circuit 74 whose functions are explained in more detail below. Its output at line 76 is connected to an analog-to-digital converter (A/D) 78 whose output comprises eight digital lines 80 that conduct digital signals to a microcontroller 82.
Output data from the microcontroller 82 are in serial form differential output at a line 84, which conducts the data through a communication chip 85 and differential output lines 87, therefrom, to a communication board, not shown. A control bus 86 enables the microcontroller 82 to control multiplexers 70, 71 and the A/D converter 78 as described more fully below.
Circuit Details
More details of the electronic circuits on the vehicle are shown in FIGS. 6 and 6A-D. In combination, FIGS. 6A-D comprise a single circuit layout, numbered in clockwise rotation and divided as seen in FIG. 6. Interconnections among FIGS. 6A-D comprise twenty-four lines between FIGS. 6A and 6B, six lines between FIGS. 6B and 6C, and four lines between 6C and 6d. The lines between 6A and 6B comprise twenty four sensor inputs 68,69. Interconnections between 6B and 6C comprise five lines, generally designated 114, and line 16. Lines 84, 84', 114' and 631' connect components of FIGS. 6C and 6D.
The twenty-four sensor inputs 68, 69 are connected to two sequentially addressed multiplexers which may be Model AD7506 multiplexers. Outputs 72, 73 are each connected through a series resistor 91 to an inverting input 93 of amplifier 95. Output of amplifier 95 is conducted through a series resistor 90 to an inverting input 92 of a difference amplifier 94. A non-inverting input 96 of the difference amplifier 94 is provided with a fixed reference voltage from a regulated DC voltage source 98 and an inverting amplifier 100, which are conventional circuits.
The output 104 of the difference amplifier 94 is connected to the analog input terminal of an analog-to-digital converter 78. The circuits involving subcircuits 94, 95, 98, and 100 are represented by the signal-conditioning circuit block 74 of FIG. 5.
The A/D converter 78 is a commercially available semiconductor device and may be model No. AD678 marketed by Analog Devices company of Norwood, Mass. It converts the analog signals that it receives on line 76 to 8-bit digital data at its eight output lines 80. Those lines 80 conduct the digital signal to input terminals of the microcontroller 82.
The microcontroller 82 may be of the type Intel 8051, 8751, etc. The one used in this embodiment is a Model DS5000, which is available from Dallas Semiconductor company of Dallas, Tex., and which is the same as Intel 8751 except with more internal RAM. A crystal 110 and two capacitors 112 are connected to a terminal of microprocessor 82 to determine the clock frequency of the microprocessor. Five lines generally indicated as 114 are connected from outputs of the microcontroller 82 to inputs of multiplexers 70, 71 to enable the microcontroller to step multiplexers 70, 71, through the twenty-four sensor inputs sequentially by addressing them one at a time. Output lines 84 from the microprocessor lead to a communications chip 85 and therefrom to a communication board related to a main microcontroller. Communications chip 85 may be a Motorola-manufactured and marketed MC3487.
The following table is a list of component types and values, as used in the circuit of FIGS. 6A-D.
______________________________________Reference Type Device number/value______________________________________C1 Capacitor 1.0 microfaradsC2 Capacitor 1.0 microfaradsC3 Capacitor 1.0 microfaradsC8 Capacitor 0.1 microfaradsC9 Capacitor 33 picofaradsC10 Capacitor 33 picofaradsC11 Capacitor 0.1 microfaradsC12 Capacitor 1.96 microfaradsC13 Capacitor 0.1 microfaradsC14 Capacitor 0.1 microfaradsCR1 Diode 1N914CR2 Diode HLMP6500Q1 Transistor 2N2222R1, R2 Resistor 100K OhmsR3 Resistor 150K OhmsR4 Resistor 100K OhmsR5 Resistor 1.69K OhmsR6 Resistor 2.21K OhmsR7 Resistor 4.7K OhmsR8, 9 Resistor .2K OhmsR10 Resistor 100K OhmsR11, 12 Resistor 18K OhmsR13, 14 Resistor 2.2K OhmsR15, 16, 17 Resistor 100K OhmsR18 Resistor 150K OhmsR19 Resistor 4.3K OhmsR20 Resistor 450 OhmsE1-24 Hall Sensor 91S312U1, U9 Multiplexer AD7506U2 Difference Amplifier LF347U3 Communications Chip MC3486U4 Microcontroller D5500032U5 A/D Converter AD670KNU6 Logic Circuit 74LS132U7 Communications Chip MC3487U8 DC Regulator LM317LZY1 Crystal 12MHZ______________________________________
Data Processing
A simplified algorithm is shown in the flow chart of FIG. 7 to explain how the microprocessor 82 determines the lateral and longitudinal positions of floor-mounted magnet 6 as the array of Hall sensors 24 passes generally over the magnet 6. Programming techniques for accomplishing the specified steps, seen in FIG. 7 and also in FIGS. 8 and 9, are known in the computer art.
Initializing and Updating of the Null Voltages
When the update marker system is activated the null voltage of each sensor 37-60 is measured by multiplexing the outputs of the sensors one at a time. The respective null signals of each of the sensors are measured several times, added together and divided to obtain an average value. Averaging is necessary to reduce the effects of errors in measurements of the null voltages. Each sensor has a different average null voltage; an average is computed for each sensor alone.
Because the sensor outputs vary with temperature the null voltage is remeasured (updated) for all of the sensors after each time that a magnet is traversed. This reduces errors that otherwise might result from differences in temperature along a vehicle's path.
A simplified description of the program of FIG. 7 starts at a flow line 120. In block 122 the null voltages of the sensors 37-60 are measured. To do this the microprocessor 82 of FIGS. 6 A-D address the first sensor by way of multiplexers 70, 71. The signal from the first sensor passes across line 72 to the difference amplifier 94 and the A/D converter 78, thence to the microprocessor 82, FIGS. 6 A-D, where it is temporarily stored.
Returning to FIG. 7, in block 122 the multiplexers 70, 71 then measure the null voltage of the second sensor, etc. until all sensors have been measured. The entire sequence is then repeated several times in block 122, starting again with the first sensor. In block 124 all of the null readings of the first sensor are averaged and in block 126 the average value of null readings of the first sensor is stored. This averaging and storing process is performed for all twenty-four of the sensors.
Detection of a Magnet
After the null voltages have been stored the program goes into a wait loop 128. In the wait loop the microprocessor 82 continuously polls each sensor 37-60 to determine whether or not a signal level in excess of a predetermined threshold level exists, which would indicate the presence of a magnet nearby.
Details of the wait-loop are as follows. Block 130 shows the polling of sensor signals. In Block 132 the previously stored null voltage corresponding to each sensor is subtracted from the signal output of that sensor to obtain a difference signal, representing the strength of a magnetic field. In the block 134 the difference signal is tested to ascertain whether or not it exceeds a predetermined threshold level, which is set so as to differentiate between noise and true magnetic marker signals. If the difference signal is below the threshold level the wait-loop routine is repeated.
In another preferred embodiment, the program flow of which is seen in FIG. 8, the averaging and storing process is continued through a wait loop 128'. In this embodiment, a running average of each null voltage is calculated in block 150 by the following equation:
N.sub.j (t)=(K.sub.1 *N.sub.j (t-1)+r.sub.j (t))/(K.sub.1 +1)
where:
j represents the figure number of a selected sensor (i.e. j=37 thru 60).
t is the time of the current sample.
t-1 is the time of the previous sample.
N j (t) is the average measurement of each null voltage at time t for sensor j.
K 1 is an integer multiplier which determines the time or sample by sample weighting of past and present measurements on the current running average voltage calculation. (K 1 may be on the order of 100.)
N j (t-1) is the average measurement of each null voltage at the previous sample or time t-1 for sensor j.
r j (t) is the raw voltage measurement of the voltage at time t for sensor j.
When a difference signal is found to exceed the predetermined threshold level, the null voltage calculation is terminated. All other program functions in wait-loop 128' are the same as those of wait-loop 128.
Selection of a Group of Sensors
If the difference signal is large enough, block 136 stores the difference signal. It then finds the sensor having the greatest such difference signal and the sensor having the second greatest. The program of microprocessor 82 identifies the two closest sensors on the left side of the sensor that has the greatest difference signal, and the two closest sensors on the right side of the sensor that have the greatest difference signal, in block 138. Thus a group of five sensors is defined. The program then refers in block 140 to a lookup table that is stored in its memory to determine the distance to the magnet from each sensor, based on the magnitude of the signal received from the sensor.
Two tables, as shown by example below, relate the voltage measured by each sensor (37-60) to the absolute distance to the center of magnet 6. Table 1 is a lookup table comprising voltages measured at incremental distances by a sensor (37-60) from a magnet 6. Table 2 is a table providing the actual distances from the sensor to the center of the magnetic field as derived from currently used sensors (37-60) and magnet field strength.
______________________________________Relative Table 1 Table 2Memory Location (Measured Voltage) (Radial Distance)______________________________________ 0 142 raw ADC units 0.0 inches 1 139 0.0941 2 133 0.1882 3 124 0.2823 4 112 0.3764 5 99 0.4705 6 85 0.5646 7 71 0.6587 8 58 raw ADC units 0.7528 inches 9 46 0.846910 37 0.941011 29 1.035112 23 1.129213 17 1.223314 13 1.317415 9 1.411516 7 1.505617 4 1.599718 3 1.693819 2 1.7879______________________________________
The step of looking up the distance from the sensor to the magnet is performed by the microprocessor 82, and is represented by the block 140 of FIGS. 7 and 8. The five selected sensors are denoted by S i (where i=-2 to 2) and the center sensor or sensor having the greatest measured voltage is S 0 . Before a search is made to correlate each measured voltage with the related distance to the center of magnetic flux, the stored null voltage, N j , is subtracted from the currently derived raw signal from each sensor (37-60) to provide a search variable, E i , devoid of the null offset error as shown in the following equation:
E.sub.i =S.sub.0 -N.sub.j
A sequential search through Table 1 is performed for each search variable E i each time the group of five sensors is sampled. To determine the distance from each selected sensor (S -2 ,-1,0,1,2) to the center of magnetic flux, the table is searched until the difference between the value in Table 1 and the search variable changes sign. When the sign change occurs, the search variable is determined to be between the last and next-to-last Table 1 value used. An interpolation variable, I, is next calculated as follows:
I=(E.sub.i -T.sub.k)/(T.sub.k-1 -T.sub.k)
where the previously undefined variables are:
k is the relative memory position of the last Table 1 value used.
T k represents the Table 1 value at relative memory position k.
T k-1 represents the Table 1 value at relative memory position k-1.
also:
R represents a radial distance measurement of Table 2.
R k represents the Table 2 value at relative memory position k.
R k-1 represents the Table 2 value at relative memory position at k-1.
The radial distance, D i , from each sensor to the center of flux of magnet 6 is then calculated as:
D.sub.i =I*(R.sub.k-1 -R.sub.k)+R.sub.k-1.
To calculate the position of the center of flux of magnet 6 from a common fixed point, such as array end 160, on the array 24, each D i is treated as a lateral vector, the sign of which is determined by its position relative to sensors having the greatest and second greatest difference signals as herebefore related. The position of the center of flux of magnet 6 from the common fixed point 160 is then calculated by adding or subtracting each D i depending upon the sign of the vector to or from linear distance L i of each sensor from array end 160 as shown in the following equation:
P.sub.i =L.sub.i +/-D.sub.i.
A further correction may be made to relate the center of flux of magnet 6 to the centerline 164 of vehicle 2 by adding a constant which represents the distance from fixed point 160 on array 24 to centerline 164 of vehicle 2. See FIG. 3.
Average Lateral Position
In block 144 an average is taken of the five estimates of the location 145 of the magnet with respect to the centerline 59 of the vehicle. One estimate is available from each of the five sensors of the group (having asterisks in FIG. 3) whose middle one is the sensor of strongest signal.
In this example, sensor 45 is S 0 , sensor 43 is S 2 , sensor 44 is S 1 , sensor 46 is S 1 , and sensor 47 is S 2 .
After each of the five sensors have been sampled, an average estimate of the position, X 1 , of the center of flux of magnet 6 is calculated as shown below:
X.sub.1 =(P.sub.-2 +P.sub.-1 +P.sub.0 +P.sub.1 +P.sub.2)/5+C
where
C is the distance 162 from the distance from fixed point 160 on array 24 to the centerline 164 of vehicle 2.
The accuracy of measurement is further ameliorated by a running average of the successively measured values of X 1 . Though other equations may be used to calculate the running average, the following equation is employed in the currently preferred embodiment:
X(t)=(K.sub.2 *X(t-1)+X(t))/(K.sub.2 +1)
where
X(t) is the running average of the measurement of the center of flux of magnet 6 for the series of five sensors measured at time t and related to the centerline 164 of vehicle 2.
X(t-1) is the previous running average of the measurement of the center of flux of magnet 6 for the series of five sensors measured at time t-1 and related to the centerline 164 of vehicle 2.
K 2 is the filter or decay constant for the running average. K 2 is on the order of three in the currently preferred embodiment.
As one familiar with computer addressing would know, the values of measured voltages for Table 1 need not be derived from incremental distances, but only from measurements taken at known, regularly increasing or decreasing distances which are then stored in the related memory location in Table 2. New and useful Tables 1 and 2 may be generated for combinations of sensors and magnets which yield different voltage versus distance values by measuring the voltage as a function of distance for the new combination. As seen in Table 2, in the above example, the radial distances stored in incremental memory locations are even multiples of 0.0941 inches.
Time of Peak Sensor Signals
The next program function, performed in block 142, is to determine whether or not the peak of sensor voltage has been passed. The peak values of output voltage from the Hall sensors of array 24 occur when the array 24 is directly over the floormounted magnet 6. When the reading of the sensors start to decline the array of sensors has passed over the center of flux of magnet 6. This condition is detected by block 142 by conventional programming.
Improved Accuracy of the Measurement
The combination of precalibrating each sensor prior to measurement to take out the offsetting null voltage and averaging and calculating a running average until the peak voltage is reached provides a measurement of significantly improved accuracy. The accuracy of the lateral position measurement 145 is 0.02 inch.
Output
The process of selecting a group of sensors, looking up distances and averaging them is a form of cross-correlation of received signals with a store field pattern. This result is transmitted, block 146, from the microprocessor 82 to a main microprocessor, not shown. It is transmitted promptly when the peak readings are detected, so the time of transmission of the data serves as an indication of the time at which the sensor array 24 crosses the marker magnet 6. In this way both lateral and longitudinal position information are obtained from one passage of the array 24 over magnet 6.
Data from block 146 is transmitted to the main microprocessor board. The program, at point 148, then returns to the starting program flow line 120 of FIGS. 7 and 8.
Another embodiment having two arrays of sensors such as array 24 is also feasible.
Reference is now made to FIGS. 9-11, wherein a second preferred embodiment is seen. In the second embodiment, two magnets 6, 6' are placed in sufficiently close proximity that magnetic flux from each of magnets 6, 6' is sensed by a plurality of sensors 37-60 concurrently, yet separation 163 of magnets 6, 6' is sufficient to permit independent processing of signals derived from each magnet 6 or 6'.
As seen in FIG. 10, exemplary path 157 of the center of flux of one magnet 6 is the same as the path described in FIG. 3. A second path 257 is seen for second magnet 6'. The table below summarizes the results of signals derived from two concurrently measured magnetic paths 157, 257, showing the assumed greatest signal level sensed for each magnet, next highest level and sensors active for the measurement of position of each magnet (indicated by a single asterisk (*) for magnet 6 and a double asterisk (**) for magnet 6'):
______________________________________Relative sensor First magnet (6) Second Magnet (6')Position Number Number______________________________________S-2 43 51S-1 44 52*S0 45 53S1 46* 54S2 47 55______________________________________ *indicates the sensor adjacent to the sensor having the greatest signal magnitude and having the second greatest signal magnitude thereby providing an indication the center of magnetic flux lies therebetween.
FIGS. 9 and 9A-B show a simplified flow chart of the logical and calculational steps for determining the position of the vehicle relative to each magnet 6, 6'. FIG. 9 shows the orientation of FIG. 9A relative to FIG. 9B. Program flow line 120 connects the output of block 252 in FIG. 9B to START in FIG. 9A. Program flow line 220 connects the "yes" output of block 260 in FIG. 9B to CONTINUE in FIG. 9A. Program flow line 222 connects the "yes" output of block 254 and the "no" output of block 142 of FIG. 9A to START 2 in FIG. 9B.
As before described, the null offsets are calculated during a known null period as specified in blocks 122, 124, and 126. As earlier described, in FIG. 8, a WAIT LOOP 128' provides an updating of the null calibration for each of the sensors until an over threshold measurement indicates detection of magnetic flux of a first magnet 6 or 6'. Upon such detection as part of block 236 activity, the sensor values are stored and the sensor having the strongest signal is selected as eariler described for block 136 in FIG. 7. In addition in block 236, a first sensor group active flag is set to signal a first magnet position measurement is active.
As earlier described, the activities of blocks 138, 140, and 144 select the group of sensors used in the calculation of what is now the first sensor group, interpolate the distance from each sensor of the first group to the center of magnetic flux of the first detected magnet and average, then calculate a running average of the position of the vehicle relative to the magnet. Decision block 142 branches to a block 146' when the peak value of the first sensed signal is detected or to a second path headed by START 2 before the peak is discovered.
At START 2, input program flow line 222 leads to decision block 224 wherein a decision is made whether or not a second group active flag is set indicating a signal has previously been detected from a second magnet. If the second group flag is not set, a single pass through blocks 230, 232, and 234 is made. Blocks 230, 232, and 234 comprise programming functions which are similar to those described for blocks 130, 132, and 134, except blocks 230, 232, and 234 only process information related to sensors of array 24 not involved with the first group. If no threshold is detected in block 234, an updated null calibration is calculated for each sensor which is not part of the first group and a branch is made TO CONTINUE to merge with program flow line 220. If a signal above threshold is detected, a branch is made to block 336 wherein the appropriate signal values are stored and processed as in block 136 for a second group of sensors and the second group active flag is set.
The program proceeds directly from block 336 to block 238. If the second group active flag is set upon entry at program flow line 222, a branch is made directly to block 238 therefrom.
Sequentially, blocks 238, 240, and 244 perform the same functions upon data received from sensors of the second group as blocks 138, 140, and 144 perform upon data received from sensors of the first group. Decision block 242 determines whether or not a signal peak, as before described, has been reached. If not, the process continues to decision block 260. If so, measured position values, as derived from both magnets 6 and 6', are transmitted to the main processor for use in navigation and guidance updating, the first and second group active flags are reset as shown in block 252. From block 252, the logic path proceeds to START at program flow line 120 to repeat the function preliminary to the search for one or more additional magnets along the vehicle's path.
From decision block 260, a branch is made to block 238 if the first group active flag is reset indicating a peak has been detected for the first measured magnetic field. If the first group active flag is set, the program proceeds to program flow line 220 whereat block 138 is entered to subsequently process the output of the first group of sensors dedicated to making a measurement of the position of the first detected magnetic field.
If within block 142 a peak voltage is detected, the programs proceeds to block 146' wherein the measured position determined by first group measurements are stored for later recovery and transmission to the main processor and the first group active flag is reset. From block 16', decision block 254 is entered, wherein a branch is made to proceed TO START 2 through program flow line 222 if the second group active flag is set or to proceed to block 256 if the second group active flag is reset. At block 256, only the first group measured position is reported based upon only one magnetic field having been detected and no concurrent measurement having been made.
Although the invention has been illustrated by describing only one particular preferred embodiment, its scope is not limited to that embodiment, but rather is determined by the claims. | An improved accuracy position and direction updating system for use with an automatic guided vehicle that navigates by dead reckoning. Permanent magnets providing detectable position indicators are mounted in the floor and may be at widely spaced locations such as fifty feet apart along the route of the vehicle. A row of Hall sensors is transversely mounted on the vehicle. The sensors detect the lateral location of each floor magnet relative to the vehicle as the vehicle passes over the magnet. Sensors are precalibrated, correcting for errors in sensor null voltage readings due to changes in sensor characteristics due to causes comprising aging and temperature. Data from five sensors that are closest to the magnet are correlated with a stored pattern of magnetic field and their position data are averaged to determined a first estimate of the lateral or first dimensional position of the vehicle. A running average is calculated from sequentially acquired estimates to improve the results. Such precalibration and averaging provides an improved accuracy of the lateral or first dimensional position measurement between the array of Hall sensors and the magnet. A high frequency measurement of the time at which the signals from the row of sensors reaches a peak value, which is the time that the row of sensors arrives at the magnet, provides an improved second dimensional position measurement. More than one magnet is read concurrently to provide position and bearing information during one processing cycle. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to a computer system. More specifically, the present invention relates to a tracking system for air waybills.
BACKGROUND OF THE INVENTION
[0002] Air waybills (AWBs) are legal documents describing a contract between an air line and a shipper (or IATA agent). Conventionally, the air waybill forms are printed on forms with pre-printed air waybill numbers. In order to electronically track shipments, shippers enter the air waybill number from the pre-printed form into a computer system. Thus, each time an air waybill form is issued (printed), a user manually enters the air waybill number pre-printed on the air waybill form into a computer system. Manually entering the air waybill numbers is a time consuming process, which reduces the efficiency and productivity of the carrier's staff.
BRIEF SUMMARY OF THE INVENTION
[0003] According to one embodiment, a method includes receiving information to create an air waybill (AWB). The method also includes assigning an AWB number and a fiscal number to the AWB. The method further includes sending the AWB to an authorization server. The method also includes receiving an authorization response from the authorization server before issuing the AWB.
[0004] According to another embodiment, a computer program product includes a computer-readable medium having code to receive information to create an air waybill (AWB). The medium also includes code to assign an AWB number and a fiscal number to the AWB. The medium further includes code to send the AWB to an authorization server. The medium also includes code to receive an authorization response from the authorization server before issuing the AWB.
[0005] According to a further embodiment, an apparatus includes a processor and a memory coupled to the processor. The processor is configured to receive information to create an air waybill (AWB). The processor is further configured to assign an AWB number and a fiscal number to the AWB. The processor is also configured to send the AWB to an authorization server. The processor is further configured to receive an authorization response from the authorization server before issuing the AWB.
[0006] 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 of the disclosure. 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 disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the technology of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings.
[0008] FIG. 1 illustrates one embodiment of a system for generating and/or storing air waybills.
[0009] FIG. 2 illustrates one embodiment of a data management system configured to process air waybills.
[0010] FIG. 3 is a schematic block diagram illustrating one embodiment of an exemplary computer system that may be used in accordance with certain embodiments of the system for processing air waybills.
[0011] FIG. 4 is a flow chart illustrating a method for issuing an air waybill according to one embodiment.
[0012] FIG. 5 is a form illustrating assigning fiscal numbers according to one embodiment.
[0013] FIG. 6 is a form illustrating editing air waybills according to one embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Improvements in efficiency and productivity when tracking air waybills may be accomplished by electronically generating air waybill numbers for air waybills and fiscal numbers for the air waybills. The electronically-generated air waybill number and fiscal number for an air waybill may be transmitted to an authorization server, which authorizes and records the air waybill number and the fiscal number. Upon receipt of an approval from the authorization server an air waybill may be issued (printed) and may be stored in an electronic application. According to one embodiment, the authorization server may be a government server for tracking air waybills for tax collection. For example, Brazil has recently established an electronic system for recording and approving air waybills.
[0015] FIG. 1 illustrates one embodiment of a system 100 for generating and/or storing air waybills. The system 100 may include a server 102 , a data storage device 106 , a network 108 , and a user interface device 110 . In a further embodiment, the system 100 may include a storage controller 104 , or storage server configured to manage data communications between the data storage device 106 , and the server 102 or other components in communication with the network 108 . In an alternative embodiment, the storage controller 104 may be coupled to the network 108 .
[0016] In one embodiment, the user interface device 110 is referred to broadly and is intended to encompass a suitable processor-based device such as a desktop computer, a laptop computer, a personal digital assistant (PDA), a mobile communication device or organizer device having access to the network 108 . In a further embodiment, the user interface device 110 may access the Internet to access a web application or web service hosted by the server 102 and provide a user interface for enabling a user to enter or receive information. For example, the user may enter information for an air waybill into the system 100 .
[0017] The network 108 may facilitate communications of data between the server 102 and the user interface device 110 . The network 108 may include any type of communications network including, but not limited to, a direct PC-to-PC connection, a local area network (LAN), a wide area network (WAN), a modem-to-modem connection, the Internet, a combination of the above, or any other communications network now known or later developed within the networking arts which permits two or more computers to communicate, one with another.
[0018] In one embodiment, the server 102 is configured to store air waybills and request authorization for air waybills from a government authorization server. Additionally, the server may access data stored in the data storage device 106 via a Storage Area Network (SAN) connection, a LAN, a data bus, or the like.
[0019] The data storage device 106 may include a hard disk, including hard disks arranged in an Redundant Array of Independent Disks (RAID) array, a tape storage drive comprising a magnetic tape data storage device, an optical storage device, or the like. In one embodiment, the data storage device 106 may store air waybills. The data may be arranged in a database and accessible through Structured Query Language (SQL) queries, or other data base query languages or operations.
[0020] FIG. 2 illustrates one embodiment of a data management system 200 configured to process air waybills. In one embodiment, the data management system 200 may include a server 102 . The server 102 may be coupled to a data-bus 202 . In one embodiment, the data management system 200 may also include a first data storage device 204 , a second data storage device 206 , and/or a third data storage device 208 . In further embodiments, the data management system 200 may include additional data storage devices (not shown). In such an embodiment, each data storage device 204 , 206 , 208 may each host a separate database that may, in conjunction with the other databases, contain redundant data. Alternatively, the storage devices 204 , 206 , 208 may be arranged in a RAID configuration for storing a database or databases through may contain redundant data.
[0021] In one embodiment, the server 102 may submit a query to selected data storage devices 204 , 206 to collect stored air waybill numbers. The server 102 may store the consolidated data set in a consolidated data storage device 210 . In such an embodiment, the server 102 may refer back to the consolidated data storage device 210 to obtain a set of data elements associated with a specified air waybill. Alternatively, the server 102 may query each of the data storage devices 204 , 206 , 208 independently or in a distributed query to obtain the set of data elements associated with an air waybill. In another alternative embodiment, multiple databases may be stored on a single consolidated data storage device 210 .
[0022] The data management system 200 may also include files for administering and generating air waybills. In various embodiments, the server 102 may communicate with the data storage devices 204 , 206 , 208 over the data-bus 202 . The data-bus 202 may comprise a SAN, a LAN, or the like. The communication infrastructure may include Ethernet, Fibre-Chanel Arbitrated Loop (FC-AL), Small Computer System Interface (SCSI), Serial Advanced Technology Attachment (SATA), Advanced Technology Attachment (ATA), and/or other similar data communication schemes associated with data storage and communication. For example, the server 102 may communicate indirectly with the data storage devices 204 , 206 , 208 , 210 ; the server 102 first communicating with a storage server or the storage controller 104 .
[0023] The server 102 may host a software application configured for generating, storing, and/or obtaining authorization for an air waybill. The software application may further include modules for interfacing with the data storage devices 204 , 206 , 208 , 210 , interfacing a network 108 , interfacing with a user through the user interface device 110 , and the like. In a further embodiment, the server 102 may host an engine, application plug-in, or application programming interface (API).
[0024] FIG. 3 illustrates a computer system 300 adapted according to certain embodiments of the server 102 and/or the user interface device 110 . The central processing unit (CPU) 302 is coupled to the system bus 304 . The CPU 302 may be a general purpose CPU or microprocessor. The present embodiments are not restricted by the architecture of the CPU 302 , so long as the CPU 302 supports the modules and operations as described herein. The CPU 302 may execute the various logical instructions according to the present embodiments.
[0025] The computer system 300 also may include random access memory (RAM) 308 , which may be SRAM, DRAM, SDRAM, or the like. The computer system 300 may utilize RAM 308 to store the various data structures used by a software application having code to electronically generate air waybills. The computer system 300 may also include read only memory (ROM) 306 which may be PROM, EPROM, EEPROM, optical storage, or the like. The ROM may store configuration information for booting the computer system 300 . The RAM 308 and the ROM 306 hold user and system data.
[0026] The computer system 300 may also include an input/output (I/O) adapter 310 , a communications adapter 314 , a user interface adapter 316 , and a display adapter 322 . The I/O adapter 310 and/or the user interface adapter 316 may, in certain embodiments, enable a user to interact with the computer system 300 in order to input information for an air waybill. In a further embodiment, the display adapter 322 may display a graphical user interface associated with a software or web-based application for generating, storing, and/or authorizing air waybills.
[0027] The I/O adapter 310 may connect one or more storage devices 312 , such as one or more of a hard drive, a compact disk (CD) drive, a floppy disk drive, a tape drive, to the computer system 300 . The communications adapter 314 may be adapted to couple the computer system 300 to the network 108 , which may be one or more of a LAN, WAN, and/or the Internet. The user interface adapter 316 couples user input devices, such as a keyboard 320 and a pointing device 318 , to the computer system 300 . The display adapter 322 may be driven by the CPU 302 to control the display on the display device 324 .
[0028] The present embodiments are not limited to the architecture of computer system 300 . Rather the computer system 300 is provided as an example of one type of computing device that may be adapted to perform the functions of a server 102 and/or the user interface device 110 . For example, any suitable processor-based device may be utilized including without limitation, including personal data assistants (PDAs), computer game consoles, and multi-processor servers. Moreover, the present embodiments may be implemented on application specific integrated circuits (ASIC), very large scale integrated (VLSI) circuits, or other circuitry. In fact, persons of ordinary skill in the art may utilize any number of suitable structures capable of executing logical operations according to the described embodiments.
[0029] FIG. 4 is a flow chart illustrating a method for issuing an air waybill according to one embodiment. At block 402 information is received for completing an air waybill. The information may include, for example, shipper, contents of the shipment, destination of the shipment, and origin of the shipment. At block 404 an air waybill number and a fiscal identifier are assigned to the air waybill. The air waybill number may be selected from a stock of air waybill numbers available to the user. At block 406 the air waybill is transmitted to an authorization server. The air waybill may be transmitted as an extensible markup language (XML) file. The authorization server may be, for example, a government server for approving air waybills. According to one embodiment, the air waybill may be generated and sent through one or more internal authorization servers before transmission to an external authorization server such as the government authorization server. At block 408 an authorization response is received from the authorization server. At block 410 the response is determined to be an accepted air waybill or a rejected air waybill. If the air waybill is accepted, the method proceeds to block 416 to print the air waybill. If the air waybill is not accepted, the method proceeds to block 414 to display an error. According to one embodiment, additional information may be received for the air waybill and the method continues to block 406 to re-transmit the air waybill to the authorization server with the additional information.
[0030] The fiscal number assigned to an air waybill may be 12 characters in length having three digits indicating a series number and nine digits indicating a counter identification (ID). Thus, the fiscal number may range from 000000000001 to 99999999999. The fiscal range may be unique to a geographical area such that identical fiscal numbers may be used in different geographical areas to represent different air waybills. For example, fiscal numbers in Sao Paulo state of Brazil may be are unique to fiscal numbers in the Rio de Janeiro state of Brazil.
[0031] When air waybill numbers are assigned electronically a computer system may be used to assign and track air waybill numbers. For example, the air waybill numbers may be tracked as inventory at an assigned location. Thus, when a user generates a new air waybill, an air waybill number may be assigned to the air waybill based on a previous assignment of air waybill numbers to the user's location or the shipment's location. Air waybill number assignments may be displayed, entered, and/or updated through a form.
[0032] FIG. 5 is a form illustrating assigning air waybill numbers according to one embodiment. A form 500 may obtain input from a user for assigning air waybill numbers. The form 500 includes a menu control 502 , and sections 504 , 506 , 508 . The section 504 allows retrieval of air waybill number assignments based on at least one of stock range, station, office, and IATA account number. A user may enter information into one or more of the input boxes 532 , 534 , 536 , 538 of the section 504 and press the retrieve button 540 to retrieve assigned air waybill numbers meeting the entered criteria. Alternatively, a user may view all of the assigned air waybill number information by leaving the boxes 532 , 534 , 536 , 538 blank when pressing the button 540 .
[0033] Assigned air waybill information is displayed in the section 506 . The section 506 may include a table having columns displaying information about the assigned air waybills. According to one embodiment, the table includes a range indicator column 510 , an airline code number (ACN) column 512 , a start air waybill (AWB) number column 514 , an end AWB number column 516 , a next available AWB column 518 , a station column 520 , an office column 522 , an IATA account number column 524 , and a pre-fill indicator column 526 . Each line in the table of section 506 provides information for an air waybill stock range. The start AWB number column 514 indicates the starting AWB number in the air waybill stock range, and the end AWB number column 516 indicates the ending AWB number of the air waybill stock range. The next available AWB number column 518 indicates the next air waybill number that is available for use in the air waybill stock range. For example, if a new AWB is generated and printed from the air waybill stock range, the next available AWB displayed in the column 518 may be assigned to the AWB.
[0034] The range indicator column 510 may indicate if the air waybill stock range is an air waybill range reserved for system use, domestic system use, manual use, or if the air waybill stock range is blacklisted. The pre-fill indicator column 526 may indicate whether a default participant is pre-filled for AWBs generated in the AWB stock range. For example, no participant may be prefilled, an agent participant may be prefilled, a shipper participant may be prefilled, both the shipper and participant information may be prefilled, or the subcontractor may be prefilled for the displayed AWB stock range. The IATA account number column 524 displays the IATA cargo agent code. According to one embodiment, an IATA account number may indicate the IATA account number associated with a station displayed in the station column 520 .
[0035] According to one embodiment, warning levels may be configured to trigger a warning message to a user or a system administrator. For example, when the number of AWB numbers remaining in an AWB stock range reaches a threshold number, a warning message may be displayed with the form 500 or placed in a system queue for delivery to a system administrator.
[0036] The section 508 allows input for creation, updating, or deleting an AWB stock range depending on the selection of radio buttons 550 . The user may enter information corresponding to range indicator, ACN, start AWB number, end AWB number, next available AWB number, station, office, IATA account number, and pre-fill indicator in boxes 552 , 554 , 556 , 558 , 560 , 562 , 564 , 566 , 568 , respectively. After entering data and selecting a radio button 550 the user presses a process button 570 to perform the action selected by the radio button 550 . The new or updated information may be displayed in the section 506 .
[0037] Air waybills may be created, updated, deleted, and/or printed through a form on a computer system. According to one embodiment, the air waybill form may be reached by clicking on Air Waybill in the menu control 502 . FIG. 6 is a form illustrating editing air waybills according to one embodiment. A form 600 may include a menu control 602 and sections 604 , 606 , 608 . The section 604 may allow a user to retrieve a specific air waybill by entering an identifying number in an input box 610 and selecting a identifier type in radio buttons 612 , 614 . An air waybill number may include an airline code number (ACN) and a shipment reference number. According to one embodiment, a user may search for air waybills by the fiscal identifier or the air waybill number. When a user presses a retrieve button 616 , information corresponding to the entered identifier in the input box 610 is displayed in section 606 .
[0038] The section 606 may display information such as origin, destination, delivery date, remarks, fiscal series, fiscal number, and electronic submission in boxes 620 , 622 , 624 , 626 , 628 , 630 , and 632 , respectively. The fiscal series, fiscal number, and electronic submission boxes 628 , 630 , 632 may be display-only fields and not accept user input. The electronic submission box 632 indicates whether the displayed air waybill was generated electronically through an authorization server. According to one embodiment, a user may enter changes to the information for the retrieved air waybill in the section 606 . According to another embodiment, the user may enter information for a new waybill into the section 606 . After entering and/or editing data in the section 606 , the user may select from actions available for the air waybill in the section 608 . For example, a user may select from a create button 640 , a print button 642 , a reset button 644 , a lock button 646 , an assign button 648 , and a discard button 650 .
[0039] If the lock button 646 is pressed the air waybill is locked and all future changes may be recorded in an air waybill history. If the assign button 648 is pressed the air waybill number is assigned to a reference booking, and a pop-up window may be displayed to allow entry of an air waybill number. If the lock button 646 is pressed the information for the air waybill may be locked from future changes by users. If the print button 642 is pressed the air waybill may be printed. If the create button 640 is pressed the information entered in boxes 620 , 62 , 624 , 626 may be added to an air waybill. Then the air waybill may be processed as described above in FIG. 4 to authorize the air waybill with an authorization server. When the fiscal identifier is assigned the boxes 628 , 630 , 632 may change to indicate the assigned fiscal identifier. According to one embodiment, the air waybill may include additional information such as manifest information and invoice information.
[0040] If the discard button 650 is pressed the air waybill may be deleted. According to one embodiment, the discard button 650 is available only if the air waybill has not been authorized by an authorization server. If the air waybill was previously authorized additional processes may be performed to inform the authorization server of the deletion. For example, a simple object access protocol (SOAP) request may be submitted to the government server with the air waybill number and instruction to delete the air waybill. Next, a second SOAP request may be sent to the government server requesting the status of the deletion request. If no status update is available from the government server, additional SOAP requests may be submitted until the deletion request status has been received. A pop-up window in the form 600 may be displayed to the user with the status of the deletion request.
[0041] 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. | Air waybills may be used by governments to aid in tax collection efforts. Conventionally, air waybills are printed on forms with pre-printed air waybill numbers and the number from the form entered into electronic storage. The air waybills may be used by some governments to assess taxes. New government rules allow the submission of electronic air waybills to government servers for tax enforcement. Electronic air waybills may be implemented by a computer system to increase the efficiency and productivity when accounting for shipments through a county. For example, air waybill numbers and fiscal identifier numbers may be assigned to an air waybill electronically. The air waybill is then transmitted to the government server for approval. Upon acceptance by the government of the air waybill the computer system may print the issued waybill. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to guiding a railway track positioning device installed on a track renewal machine with respect to a reference base rigid with the machine.
Generally, in railway track renewal or maintenance works such as ballast cleaning operations, the new track or the track subsequent to the maintenance operations must be either laid in the position it had before the works or shifted if necessary in relation to the former position of the track in order to take proper account of track creep at certain locations with respect to the initial track laying as a consequence, for example, of a certain falling away of the ground or similar reason.
When lifting the track for example previously to a ballast-clearing or screening operation during the ballast cleaning works, the rails are subjected to forces tending to produce a certain geometrical deformation in the track. For properly lining the track the ballast must be efficiently packed, levelled and scraped. These steps are performed by several specially equipped machines. However, since lining operations cannot under all circumstances be carried out immediately after the ballast cleaning operation due to speed differences between the track renewal machines and to railway traffic requirements, especially when reconditioning a single-track line, the track must be relaid after cleaning the ballast to a desired position which is either the original position or a position slightly shifted in relation thereto.
The device for meeting these requirements must be incorporated in the track renewal or maintenance machine without exceeding the gage limits.
THE PRIOR ART
The methods usually implemented for lining a railway track utilize a reference base consisting of three different points, with two points located on the already lined track and one point located on the track to be lined, as disclosed in the French Patent FR No. 1,429,056. In this specific method the height of the point located on the arc of the lined track section measured in relation to the chord is determined by the two points remotest from each other and the value of the height of a second point located on the track section to be lined is determined, whereafter the track is shifted at this second point until the value of the height measured at this point assumes the desired predetermined magnitude.
The devices for carrying out the method disclosed in the above-mentioned patent FR No. 1,429,056 utilize the geometry theorem known as the "power of a point with respect to a circle". In fact, the power of a point in relation to a circle is equal to the product of segments formed by this point and the points of intersection with the circle of any secant passing through this point. The point may lie either inside or outside the circle. The point concerned is materialized by a fulcrum through which two straight lines bearing on two reference points are caused to pass. The materialization of these straight lines is obtained in a first form of embodiment by two scissor-forming rods, the fulcrum lying on the inner side of the arc, the length of the two rods being so calculated that their four ends bear on the track arc and the arc is properly lined. One rod bears on the still non-lined arc end and on an intermediate, already lined point, while the second rod bears on the other end of the already lined arc, the other end denoting the proper position of a fourth point of said arc which is brought to this position by shifting.
Another device also disclosed in the French Patent FR No. 1,429,056 is similar to the above-described device and utilizes two straight segments intersecting each other outside the arc at a fulcrum point, one segment bearing on the lined end portion of the arc and passing through a second, already lined point while the other segment bears on the non-lined arc end and an intermediate point of this straight line shows the position where the point to be lined should lie.
The other forms of embodiment proposed in the French Patent FR No. 1,429,056 are similar to those briefly set forth hereinabove, the straight lines being materialized by cords, cables or rods, the arcs being either the track center line or rails, or a virtual arc located at a predetermined distance from the track.
The chief drawback characterizing the method described in this French Patent FR No. 1,429,056 is that one of the points constituting the reference base lies on the track section to be lined, so that its position is inaccurate, and therefore the measure of the height of the third reference point and the positioning of the lined point are inaccurate.
Another inconvenience characterizing this prior art method is that the reference base extends on either side of the point to be positioned, so that its use on a railroad track relaying machine operating on the site, such as a ballast clearing and screening machine, is rather complicated.
SUMMARY OF THE INVENTION
With the present invention it is possible to avoid these various inconveniences by copying the existing track before relaying or maintaining same, which on the one hand is sufficient for a provisional lining and on the other hand permits of accelerating the final lining procedure, particularly when the existing track laying does not require any correction.
It is also possible to shift one portion of the track with respect to its former position when the shifting in one or the other direction with respect to the initial position took place accidentally.
The apparatus of the present invention is characterized notably in that since the reference base is dependent on the old track exclusively, there is a certainty that the track will not depart from its former position unless a shifting is desired in relation to this former position for compensating a shifting from the initial laying which might have occured accidentally, this shifting being obtained by introducing a factor into the function giving the direction of the straight line passing through the rear end of the chord rigid with the machine. For the same reason, carrying out the present invention is facilitated since the reference base and the positioning device lie at different locations and there are no problems to be solved as far as their lay-out on the track relaying or maintenance machine is concerned.
The point positioning after the track relaying or maintenance operations may take place in two ways, i.e. either by recording the curvature of the old track section and one point of this section is positioned after the relaying or maintenance of the section by utilizing the recorded value, so that the point lies in its former position, or alternatively, when measuring the curvature of a section of the old track this value is utilized for positioning a point located on the relayed or maintained track section comprising the point and the old track section has a constant curvature or, if said track section has a variable curvature, when a value depending on the measured curvature and on a factor taking due account of the curvature variation is used. It is this second form of embodiment that will be discussed presently.
In order to afford a clearer understanding of the invention, reference will now be made to the accompanying drawings.
THE DRAWINGS
FIG. 1 is a diagram illustrating the basic principle of this invention;
FIG. 2 is a side elevational view of a ballast clearing and screening machine in accordance with this invention;
FIG. 3 is a plan view from above of the machine of FIG. 2, and
FIG. 4 is a schematic cross section on the line 4--4 in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, AFBC denotes a circular arc showing the center line of the track, or a rail, or an equivalent arc lying at a constant and predetermined distance from the track. A and B are two points of this arc lying on, or corresponding to, the old track section. Point P is the point where the track is treated and where the track undergoes a geometric deformation. The arc PC is shown on purpose with an exaggerated deformation and illustrates the actual track position after the treatment (maintenance or relaying), while arc PC in dash lines is the desired track position. The arc points located beyond point C are already positioned.
The distance AB=a is constant and predetermined, F is the middle point of arc AB but could also be another intermediate point. The distance between points B and C is equal to b which is a constant and predetermined value. According to this invention, by measuring the height of the arc from the chord AB at point F it is possible to measure the angle β between the two virtual chords AB and BC so that the point C lies likewise on the same circle as points A and B. After materializing the calculated position of point C, the track is shifted laterally to the calculated position.
The angle β is determined through the following calculations in which certain mathematical terms have been simplified on the basis of the following remarks:
The radius of a track arc is usually of the order of a few hundred meters and its chordal length AB and BC is of the order of 10 to 20 meters, with maximum height of the midpoint of the arc from the chord for such values of about a few centimeters. Thus, the following simplified terms are obtained for the height f and the calculation of angle β: ##EQU1## is the value of the length of segment GE of a line perpendicular to the chord AB at its midpoint, E being the point of intersection of chord BC with the line GE and r being the radius of the track arc. In fact, rather than calculating the angle β it is sufficient to calculate the position of point E so as to determine the position of chord EBC. The position of point E is calculated from the value of the length of segment GE=y=(2(a+b)/a)f (IV). The machine for carrying out the method described hereinabove takes due account of this last remark. If the curvature of arc ABC is not constant, a factor taking due account of the curvature variation must be introduced, this also applying when it is desired to shift the track with respect to its former position.
Now a clearing-screening machine for cleaning the ballast will be described which is designed for carrying out the present invention.
The ballast clearing and screening machine comprises a self-powered tractor vehicle 1 rolling on the track 2 to be cleaned and a second vehicle 3 rolling on the renewed track. The tractor vehicle 1 is provided with conveyors 4, 5 for discharging the rubbish and a screener 6 for cleaning the ballast fed by other conveyors 7, 8 and excavated by the clearing device 9. Other conveyors 10 and 11 transfer the clean ballast to a point behind the clearing device 9 where it is tamped by a tamper 12, and also behind the tamper for making up the missing ballast. Means (not shown) are provided ahead of the clearing device 9 for lifting the track and thus facilitating the clearing operation. Behind the clean ballast conveying and distributing means 11 a shifting device 14 is provided for positioning the track on the clean ballast.
The above-mentioned devices and means are well known to those conversant with the art and lend themselves to various changes without departing from the basic principles of the present invention which relates only to guiding a device for positioning the railroad track and also to a railroad track renewal or maintenance machine equipped.
A rectangular frame 16 is suspended by means of four hydraulic cylinders 17 from the chassis 18 of the self-propelled tractor vehicle 1. This frame is composed of four U-section members rigidly assembled at right angles with one another by means of squares 43 fastened to the four corners of the frame. Two track feelers 19 and 20 are secured to the two cross members 21 and 22 of frame 16 by means of two pairs of lugs 23, 24 and 25, 26, respectively. The position of these two feelers 19, 20 is fixed in relation to the frame 16 and their purpose is to materialize the reference points A and B. More particularly, the reference base consists in fact of the middle points A' and B' of their axis of rotation, which lie permanently on the virtual axis or center line 27 of track 2. A third track feeler 28 is mounted on a cross member 29 of frame 16 by means of a pair of lugs 30 and 31. The middle point F' of the axis of rotation of this third feeler 28 is coincident with the middle point of arc A', B'. Furthermore, this third feeler 28 is movable in a direction across the frame 16 so as to constantly follow the track center line. Finally, point C' is the middle point of the track at the point of operation of the shifting device 14. The distances between points A', B' and B', C' have constant and predetermined values. The measure of the height of the arc at point F' with respect to chord A', B' is the distance from point F' to the straight line A', B' when the track feelers 19, 20, 28 contact the running rails of track 2. A spring 32 or 33 constantly urges the third feeler 28 for engagement with a pair of running rails. A mechanical multiplying device for automatically showing the position of point E' or the equivalent thereof is composed of an arm 13 pivoted to feeler 28 and cross member 29, and also to a rod 36 parallel to cross member 29 through their middle pivot points F', 34 and 35, respectively. The ends of rod 36 are pivotally connected to one end of a pair of arms 37, 38, respectively, which are pivotally connected in turn to two pivot points 39 and 40 of a pair of squares 41, 42 for positioning said arms 37, 38 to cross member 29. Pivot pins 34, 39 and 40 are stationary and the other pivot pins are movable. The positions of the fixed pivot pins 34, 39 and 40 with respect to arms 13, 37 and 38, respectively, are such that a movement f' of point F' is attended by a movement Y' of the free ends 44 and 45 of arms 37 and 38, in conformity with the above-mentioned relationship (IV). Since in this case the chord EBC is materialized by a light beam from an emitter 46 located at point E or the equivalent thereof and received by a receiver 47 at point C or the equivalent thereof, these two devices should preferably be so disposed that the light beam cannot be interrupted by an obstacle.
Under these conditions, the emitter 46 and receiver 47 are disposed at a location spaced laterally and vertically from arc A', B', C' or, in other words, it is assumed that there is an arc A", B", C" equivalent to arc A', B', C' and obtained for example by a similarity and a translation. Point A" is not materialized since it is useless; point B" is materialized by a small vertical slit formed on a screen 52 disposed across the light beam emitted by the emitter 46 at point E", thus permitting the passage of only a thin light beam 48 corresponding to chord B", C". The emitter 46 lies at any time, inasmuch as the feelers 19, 20 and 28 engage the track running rails, in position E" spaced by a distance y" from chord A", B". The emitter 46 is supported by a vertical rod 49 (FIG. 4) fulcrumed to a horizontal arm 50 pivotally mounted on a pivot pin 51 at the end 45 of arm 38. This pivot pin 51 is guided at its upper end by a slide block 53 movable along a slideway 54 fastened to cross member 29. The pivotal mounting of rod 49 and arm 50 permits retracting the emitter within the limits of the maximum moving dimensions as determined by the frame 16. The perforated screen 52 is secured in a similar manner to the frame 16 so as to lie in a vertical plane passing through the axis of feeler 20. The receiver 47 is composed of several photosensitive elements and divided into three vertical areas. If the light beam 48 passing through the screen 52 is intercepted by elements of the central area, the track point corresponding to point C" is at the desired position; if on the other hand the beam is intercepted by elements belonging to other areas, the track must be shifted until the beam is intercepted by the central area. The receiver 47 is secured to the shifting device 14. When the light beam is intercepted by the elements of anyone of the external areas of receiver 47, a signal is fed to a device showing the direction and the amount of shift to be impressed to the track for laying the track in the proper position.
The above-described device can also be used for checking the track alignment along straight track sections, in which case points E", B" and C" should be aligned and parallel to the track. The emitter 46, receiver 47 and screen 52 may be installed on one or the other side of the machine. If desired, these component elements may be disposed on both sides (E"', B"', C"',) since they also provide a useful information as to whether they do not protrude beyond the limits of the maximum moving dimensions or detect the presence of a foreign body; in fact, if an obstacle happens to intercept the light beam between the emitter and receiver, a sound signal is produced and the machine operation is stopped.
The mechanical multiplying device described hereinabove may if desired be replaced by a hydraulic, pneumatic or electrical device.
By modifying the length y, for example, it is possible to shift the track with respect to its former position.
When the machine is running light, the frame 16 is retracted underneath the frame 18 of the tractor vehicle 1. By way of example, in a typical form of embodiment of the invention the distances between points A', B', C' may be as follows:
A'B'=11.5 meters
A'F'=5.25 meters
B'C'=19 meters
It is possible to integrate a microprocessor for recording the lay-out of the former track and calculating the position of the emitter in order to either repeat the same lay-out after the renewal or maintenance works, or shift the lay-out in relation to the former position.
Though preferred forms of embodiment of the present invention have been described and illustrated herein, it will readily occur to those conversant with the art that various changes and modifications may be brought thereto without departing from the essential principles of the present invention. | A guidance system permits of guiding the railroad track positioning device of a track renewal and maintenance machine as the machine moves in the track working direction. To this end the curvature of a track section to be worked upon comprised in a chord of predetermined length is measured and as a function of this curvature the direction of a second chord is measured, one end of this second chord being coincident with the rear end of the section whereas its predetermined and constant length is so selected that its other end lies on the already renewed or maintained track section and shows the position of a point of this section before the renewal or maintenance works. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of applicants co-pending application Ser. No. 07/784,772, as filed on Oct. 30, 1991 now abandoned. The disclosure of the parent application is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of fabricating a scale model of an object too small to be evaluated by conventional measurement techniques. More specifically, the present invention relates to a method for constructing a high-fidelity, disassembleable corporeal model of a minuscule object where said model provides significant accuracy of the differentiated characteristics of the object with respect to shape, materials structure and materials composition.
2. Description of the Prior Art
It is often necessary or desirable to create a scaled model of a given object for purposes of analysis, testing and education. A common example is seen in the testing of aerodynamic configurations for both land and air vehicles. In order to evaluate the aerodynamics of a wing or lifting body, for example, a small scaled model is constructed in the laboratory and then subjected to wind tunnel and other similar testing. To construct such a model, the engineering specifications for the full sized object are downsized and the model fabricated via conventional processes.
In cases where a model is constructed of an object for which there exists no construction or design specifications, such as a bone or a tooth, a model is sometimes made by forming a cast or negative impression of the object. The negative impression is then used to form a model. Disadvantages with this technique reside in its exclusive application to replicate the external physical details of an object, thereby rendering it useless to construct a model in which external and internal characteristics such as material structure, composition or function may be observed and disassembled for study or analysis.
In instances where it is necessary to construct a three-dimensional model of an internal biological structure without physical invasion of the body, e.g., a prosthesis, an image of the rough external and internal details of the object may first be obtained by use of X-rays. X-ray radiographs can then be used in conjunction with information of the structure previously known to construct the model. Such a technique is disclosed, for example, in U.S. Pat. No. 4,436,684, as issued to White. Such techniques, while oftentimes sufficiently accurate to form a prosthesis, do not generally enable the generation of a model which discloses differentiated shapes, compositions, material structure and/or functionality. This limitation is due to the nature of the X-ray medium which is limited to providing an image of materials which differ in their absorption coefficient to X-rays. Accordingly, only materials of varied density may be viewed and thus reproduced by such a method. Moreover, X-rays are generally useless to define details in objects which prevent the passage of X-rays, e.g., shielded or metallic objects.
Techniques heretofore used to construct a conceptual model of microscopic and especially submicroscopic objects such as molecules, living cells, minute electronic structures and the like, have relied upon crude approximations of their external shape. As a consequence, such models provide no more than a general representation of the characteristics of a given object and are therefore useless for purposes of quantitative evaluation.
SUMMARY OF THE INVENTION
The present invention addresses the above and other disadvantages of prior modeling techniques by providing a method to construct a scaled model of an object too small to be susceptible to conventional evaluation techniques, where such model accurately portrays the external and internal characteristics of the object.
The present invention generally involves a series of sequential steps including: (1) characterizing the object to differentiate external and internal shapes, elemental compositions, material structures and individual component functionality; (2) evaluating the object to determine the frequency of reoccurring differentiated characteristics; (3) establishing a reference appropriate for quantitative measurement of both internal and external characteristics of the object; (4) cross-sectioning the object at the desired frequency; (5) recording the results of the dissection via photographic or other imaging techniques; (6) obtaining quantitative measurements of the internal and external characteristics of the object; and (7) constructing the model.
The chief advantage offered by the method of the present invention is realized in the ability to construct an accurate model of microscopic or even submicroscopic objects which possess unknown internal or external characteristics.
Another advantage of the present invention is the ability to portray the differentiated characteristics of the object as to shape, materials structure, composition and/or function. Yet another advantage is realized in the ability to form a model which may be disassembled for closer empirical evaluation of one or more of its characteristics.
Other advantages of the invention will become apparent from the following detailed description made in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates the steps of a preferred embodiment of the method of the present invention.
FIG. 2 is a diagrammatical representation of an MOS transistor for which a model is made in accordance with the process of the present invention.
FIG. 3 diagrammatically represents a preliminary analysis of the transistor of FIG. 2 which was conducted to differentiate the characteristics of interest.
FIG. 4 diagrammatically represents a reference axis which has been chosen to evaluate the transistor.
FIG. 5 diagrammatically represents the manner in which the transistor is cross-sectioned in order to obtain the measurements necessary to construct the model.
FIG. 6 diagrammatically represents the steps by which the information revealed in the cross-sectioning step is recorded.
FIG. 7 diagrammatically represents the quantification of the various characteristics of the object.
FIG. 8 diagrammatically represents the completed model which is disassembleable in accordance with variations in material structure and function.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is directed to a process comprised of a series of steps whereby a microscopic or submicroscopic object may be faithfully reproduced in a disassembleable model which distinguishes between the individual internal and external characteristics of the object. As used herein, the term "characteristics" refers to the physical shape of the object and its subcomponents; the elemental composition of the object; the various molecular structures of the object; and the functionality of the object. Accordingly, the process of the present invention enables the construction of a model which differentiates each or some of these characteristics.
The fundamental steps necessary to practice the process of the present invention are represented in FIG. 1 as comprising: (1) characterizing the original object; (2) determining the frequency of physical dissection necessary to accurately evaluate the desired characteristic(s) of the object; (3) selecting a reference plane based on the position of the differentiated characteristic(s) of interest; (4) dissecting the object at the selected frequency; (5) recording the results of the dissection procedure; (6) obtaining measurements from the dissection procedure; and (7) constructing the model.
Each of the individual steps set forth in FIG. 1 may not be uniformly utilized or progress in necessarily the same order in every case. Variables which may effect the utilization and order of these steps include the knowledge already available about the specific characteristics of the object to be replicated. Generally speaking, however, FIG. 1 represents a preferred embodiment of the various steps comprising the present invention.
By reference to FIG. 1, the first step of the present invention involves "characterizing" the object. Characterizing as used herein refers to the analysis of the individual characteristics of the object, which, as identified above, includes the object's shape, composition, materials structure and function. Characterizing the object itself includes a number of substeps which may or may not be necessary in a given case depending on the characteristics to be emphasized in the final model. In this connection, it is anticipated that it will not always be necessary or desired in the final model to include each of the four characteristics defined above.
The first substep involves an analysis of the general external geometry of the object, i.e., spherical, tetrahedral, plasmatic, fibrous, etc. This may be accomplished, for example, by visualizing the object through an optical or electron microscope. In most cases, however, this substep will be unnecessary since the object will already have a known external shape.
The second substep involved in characterizing the object includes a determination of the degree of reproduction, accuracy and detail required in the final model. In some instances, it may be desirable to construct a model which is physically accurate as to both internal and external detail, but does not differentiate on the basis of chemical composition, material structure or function. In instances where a model of a living cell is desired, it may alternately be desirable to construct a model which chemically differentiates between each of the individual subcomponents. In the case of a micro-electronic component, it may be desirable to differentiate between the individual crystal structures and their associated functions. Though the emphasis in each case may vary, it is contemplated that it will be desirable in each case to construct a disassembleable model.
The last substep in characterizing the object involves an analysis of the object to determine the preferred technique to obtain quantitative and qualitative information necessary to construct the model. Again, the method of this analysis will vary depending on both the object of study and the objective of the final model. For example, if the object comprises an integrated circuit and a model is desired which differentiates between the crystalline and polycrystalline structures, it may be desirable to cross-section the object and then employ an etching solution which will reveal the differentiated structures under an electron microscope. If the object comprises a biological structure, e.g., a pollen grain, and it is desired to construct a model faithful to both internal and external shapes, it may be desirable to cross-section the object in a variety of planes and then review the cross-sections under an optical or scanning microscope. If the object is known to be comprised of a series of concentric shells of material varying in chemical composition, it may be desirable to chemically strip away these individual shells to reveal the next concentric structure. As may be apparent, one or more of the above and other processes may be used in a given occasion dependent upon the objectives of the model.
The next step generally entails a physical analysis of the results of the characterizing steps identified above in order to determine the frequency of reoccurring undifferentiated characteristics in the object. This is necessary to correctly evaluate the position of the reference as will be discussed below, as well as the frequency of the individual cross-sections. If the objective of the model is to merely reproduce the internal and external shape of the object and the object is possessed of only three layers of material which are evenly distributed in a linear fashion, the frequency of the cross-sections will be greatly reduced. If, however, such a model were to be produced of a microscopic organism, e.g., a paramecium, the frequency of the cross-sections would be considerably larger due to the greater number of differentiated, non-repetitive structures.
To further elaborate on this step, the frequency of the individual cross sections will be determined as both a function of the accuracy required of the completed model and the objective of the modeling study. In an example where the subject of interest involves a three layered submicroscopic object where the second or middle layer is deposited in a series of rings about an axis, and a disassembleable model is desired which accurately details the physical structure and interrelationship of the layers, it will be desirable to cross section the object in a plane perpendicular to the rings at a frequency enabling a determination of the thickness and width of each ring. This may entail a series of cross sections oriented parallel to the x and y axes. Ideally, it would be desirable to perform a minimum number of cross sections which would be necessary to locate and plot the axis defined by the rings. When the axis is found, a single cross section parallel to both the x and y axes will enable the physical structure of the rings to be determined, assuming that the individual rings possess uniform thickness and width. If, however, the rings are irregular in shape, width or thickness, it will be necessary to increase the frequency of the cross sections through each of the rings to establish their physical configuration. This is a function of the extent of change in the slope of the external surfaces of each ring. In general, the greater the change in the slope of the external or internal surfaces, the greater the frequency of cross sections which will be required in each case. If, for example, each ring possesses a stepped external surface, it will be necessary to establish a cross section both before and after each "step" in order to determine the relative position of the step as well as the amplitude of the step along the z axis. If, however, the ring describes an irregular yet gradually modulating shape, it will be necessary to cross section only as often as necessary to determine the slope or gradient of the external surfaces of each ring. This may be determined by moving along the x or y axis until a quantifiable variation along the z axis is discovered. If this variation describes a generally linear pattern, the amplitude revealed as a result of each cross section may be recorded and a line therebetween may be plotted. To facilitate the aforedescribed cross sectioning process, it may be desirable to use a supplemental stripping or etching technique to remove either the first or third layer so as to enable the shape and relative orientation of the rings to be ascertained.
Aside from the method described above, the frequency of cross-section can also be determined by the change or variation of molecular stucture, composition or functionality to be reproduced in the object of study.
Once the object has been "characterized" as identified above, and the frequency of the cross-sections has been determined, a reference axis or plane must then be established from which quantitative and qualitative measurements of the various shapes and structures may be obtained. This step necessarily follows the first two steps described above in which a general knowledge of the external and internal characteristics of the object was gathered.
In most instances, this reference will comprise a plane situated at or proximate to a natural differentiation in the shape, structure, or composition of the object. In the example involving the integrated circuit, the reference plane may be situated at the interface of the crystalline and amorphous regions. In the example involving the pollen grain, a reference axis may be chosen along the long axis of the pollen grain or, in the event of a spherical grain, the geometric center of the grain may be used as the intersection of the x, y and z axes in a Cartesian coordinate system. Depending on the object of study, it may be desirable to use one or more references in a given case.
As noted, the selection of the appropriate reference will vary depending on the characteristic(s) to be emphasized in the model. It is preferred, however, that the reference, e.g., the reference plane, be also positioned in a way to facilitate the construction of the model itself.
The method of the present invention usually requires physical dissection of the object to be replicated. Physical dissection is generally necessary to enable the precise measurement and relative location of the internal and external characteristics of the object, e.g., shape, composition, materials structure and function. In some cases, however, other noninvasive techniques, e.g., radiographs can also be used to obtain the physical information necessary to build the model. Once the frequency and nature of the dissection or other procedure has been ascertained as discussed above, the object is dissected along or in accordance with a Cartesian or polar coordinate system based on the position of the reference point, axis or plane. In most cases, the object will be cross-sectioned. This may be accomplished in accordance with conventional techniques such as cleaving, mechanical polishing, Focussed Ion Beam cross-section (FIB) or microtomy. Depending on the nature of the object and the focus of the model, these cross-sections may be performed in a variety of intersecting planes. In a Cartesian system, it is expected that these cross-sections will be made along the x, y and z axes.
Once a series of cross-sections have been obtained in accordance with the desired frequency as described above, the images of the cross-sections are magnified and subjected to further analysis so as to allow for relative measurement of internal and external characteristics. The extent of this magnification and analysis is a function of both the focus of the model, as well as the accuracy and scale desired in the final product. The magnified images are captured via conventional photographic techniques, or are the product of more exotic techniques such as X-ray Energy Dispersive (XED), Auger Electron Spectroscopy (AES), Secondary Ion Mass Spectroscopy (SIMS), Resistivity or Spreading Resistance Dot Map (SRP), Atomic Force Microscopy (AFM), and Scanning Tunneling Microscopy (STM).
The next successive step involves obtaining measurement from the images obtained as a result of the above techniques. These measurements may be obtained manually from the images noted above. In a preferred embodiment, however, the images obtained above are fed directly into a computer and the internal and external surfaces digitized whereby automatic measurements may be obtained.
From these dimensions, a model may be constructed by any of a number of techniques, including conventional methods using templates and scaled mockups, or more sophisticated techniques such as computer controlled machining or stereolithography.
EXAMPLE 1
A model was constructed of an MOS transistor in accordance with the process of the present invention as described above. It was an object of the modeling process to reproduce the relative positioning of the nine layers comprising the transistor including: (1) a P substrate; (2) a N + a N - arsenic and phosphorus doped layer; (3) SiO 2 gate; (4) a phosphorus-doped polysilicon gate; (5) SiO 2 spacers; (6) an intermediate dielectric phosphorus-doped SiO 2 layer; (7) a boron phosphorus-doped SiO 2 layer; (8) a contact layer comprised of three sublayers of Ti/Al/Ti; and (9) a top protection layer.
The transistor was known to possess a generally rectangular geometry having external dimensions of approximately 5.5 microns by 3.5 microns in the x and y planes. It was desired to construct a model scaled to 1:80,000. It was further desired to produce a model that faithfully reproduced the relative size, shape and composition of the different components of the transistor as identified above.
It therefore was necessary to characterize the transistor based on the various material structures and composition, e.g., crystalline, polycrystalline silicon doped and undoped regions and insulating and conductive layers, comprising the transistor. In order to accomplish this, the transistor was first subjected to a selective and sequential stripping process in order to remove each layer. This stripping process was accomplished by both dry and wet etching. The material analysis was performed at the appropriate location utilizing a combination of techniques: X-Ray Energy Dispersive (XED), Auger Electron Spectroscopy (AES), Secondary Ion Mass Spectroscopy (SIMS), Spreading Resistance (SRP) and Transmission Electron Microscopy (TEM).
Based on the results of the sequential stripping, it was determined that the modeling process would require three or four cross-sections cut in intersecting directions. For sake of simplicity, a reference plane was chosen to run along the boundary of the P substrate doped regions and all upwardly progressive layers. This plane was desirable since the silicon-silicon dioxide interface represented the flattest and largest subcomponent of the object and would furthermore represent a convenient baseline for the modeling process. This reference plane was adapted to Cartesian coordinates, and was defined by the intersection of the x and y axes. The transistor was then cross-sectioned in accordance with the frequency noted above in the x and y planes. These cross-sections were prepared by physical polishing of the transistor to a desired location.
These cross-sections were again analyzed by XED and AES to better locate the position and the chemical composition of some
These cross-sections were again analyzed by XED and AES to better locate the position and the chemical composition of some of the layers. The cross-sections were again selectively etched to reveal the location of the different materials e.g., crystalline and polycrystalline layers.
Once these cross-sections had been prepared and analyzed in this fashion, the cross-sections were photographed via a high resolution scanning electron microscope which was provided with a measurement scale. This scale allowed the individual layers to be manually measured and relatively positioned with respect to each other.
From these measurements, a two dimensional scaled drawing was made from the photographic images of each of the cross sections, which in this case included cross sections in the x and y planes. A series of templates were constructed of each component of interest from each of the cross sections as earlier described. These templates accurately replicated the dimensions of the different components of the transistor at the planes defined by the cross sections.
These templates were assembled at the frequency of the cross sections to form a skeleton which was filled in with a clay or plastic solution to form a solid body or mockup of the transistor and its individual components. From this mockup a negative mold was formed of the individual components of interest in the modeling study. From this negative mold a rough cast of the each component was formed. This cast was subsequently subjected to both coarse and fine finishing steps to improve the accuracy of each the external structure of each component as well as to improve the fit between each component structure in the disassembleable model.
While certain specific and preferred embodiments of the present invention have been illustrated herein, it will be understood that still further variations and modifications can be made therein without departing from the spirit and scope of the invention as claimed below. | A method to construct an accurate scaled model from an original too small to allow for physical measurement is disclosed, said method generally comprising the steps of determining the initial geometry of the original, analyzing the original to determine its internal structure, establishing a reference useful for quantitative measurement of the object, physically dissecting the original, recording the results of the physical dissection, and constructing the model at a desired scale based on quantitative measurements obtained from the dissection of the original. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application claims the priority of Korean Patent Application Number 10-2011-0080323 filed Aug. 11, 2011, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF INVENTION
1. Field of Invention
The present invention relates to an operating shift apparatus for a transmission. More particularly, the present invention relates to an operating shift apparatus for a transmission which may improve shift feeling using variable rotational inertia according to rotation.
2. Description of Related Art
Generally a transmission is disposed between a clutch of a vehicle and a drive shaft for receiving rotational speed of an engine and shifting the rotational speed. Particularly, an operating shift apparatus is mounted to a manual transmission for a driver to manipulate the transmission according to running state of a vehicle.
The operating shift apparatus is connected to a shift lever through a control cable and allows manipulating operation of a transmission. The operating shift apparatus includes a select lever selecting shift gears and a shift lever engaging the selected shift gear a control shaft operated by the select lever and the shift lever.
A weight is integrally formed to the shift lever. And thus, mass of the weight may increase rotational inertia when the shift lever rotates, so that shift feeling may be improved.
However, the shift lever and the weight are integrally formed, and thus constant rotational inertia may be realized relationless shift stages. That is, when weight and position of the weight is determined, constant rotational inertia is determined. And thus, shift characteristic, according to shift stages or kind of a vehicle, may not be reflected according. Also, alteration of position of the weight may be limited and thus rotational inertia is proportional to weight of the weight.
The information disclosed in this Background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
SUMMARY OF INVENTION
Various aspects of the present invention provide for an operating shift apparatus which may vary rotational inertia of a shift lever.
Also, the present invention has been made in an effort to provide an operating shift apparatus which may reduce total weight of the apparatus.
An operating shift apparatus for a transmission of which a control shaft is disposed to a transmission case, the operating shaft apparatus according to various aspects of the present invention may include a select lever which is connected to the control shaft and selects a shift gear, a shift lever which is connected to the control shaft and engages the selected shift gear and a weight disposed to the shift lever for enhancing rotational inertia of the shift lever, wherein the shift lever and the weight are independently formed.
The shift lever may rotate on the control shaft integral with the control shaft.
The weight may rotate dependently according to rotation of the shift lever.
The weight and the shift lever may rotate on different rotation axis and each may have different angle of rotation.
The rotation axis of the weight may be formed to a predetermined position of the transmission case.
Ratio of the angles of rotation of the shift lever and the weight may be variable according to the rotation axis of the weight.
The operating shaft apparatus may further include an extended portion protruded from the shift lever and a guide hole formed to the extended portion.
A connecting protrusion, inserted into the guide hole, may be formed to the weight.
The connecting protrusion may be slidably movable within the guide hole for the weight easily to rotate dependently according to rotation of the shift lever.
Ratio of the angles of rotation of the shift lever and the weight may be variable according to shape of the extended portion and position of the guide hole.
The operating shaft apparatus may further include an extended portion protruded from the shift lever and a connecting protrusion formed to the extended portion.
A guide hole may be formed to the weight for the connecting protrusion to be inserted therein.
The connecting protrusion may be slidably movable within the guide hole for the weight easily to rotate dependently according to rotation of the shift lever.
Ratio of the angles of rotation of the shift lever and the weight may be variable according to shape of the extended portion and position of the connecting protrusion.
Relative rotation angle of the weight may be gradually reduced during the shift lever rotates for realizing shift.
The rotational inertia of the shift lever may be gradually reduced during the relative rotation angle of the weight is gradually reduced.
According to various aspects of the present invention, in rotation of a shift lever, relatively small weight may realize relatively large rotational inertia using lever ration of the shift lever and weight. And thus, total weight of the apparatus may be reduced.
The lever ratio may be variable according to rotation of the shift lever and weight. And thus the rotational inertia of the shift lever may be changed during shift stage. And thus, driver' shift feeling may be improved.
The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an operating shift apparatus for an exemplary transmission according to the present invention.
FIG. 2 is a top plan view of an operating shift apparatus for an exemplary transmission according to the present invention.
FIG. 3 is a drawing showing each stage of rotation operation of an operating shift apparatus for an exemplary transmission according to the present invention.
DETAILED DESCRIPTION
Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
FIG. 1 is a perspective view of an operating shift apparatus for a transmission according to various embodiments of the present invention.
As shown in FIG. 1 , an operating shift apparatus 10 for a transmission according to various embodiments of the present invention includes a control shaft 50 , a transmission case 60 , a select lever 40 , a shift lever 20 and a weight 30 .
The control shaft 50 is mounted to the transmission case 60 and connected with the select lever 40 and the shift lever 20 . That is, the control shaft 50 is connected with the select lever 40 and the shift lever 20 within the transmission case 60 and realizes selecting shift gears and engages the shift gears.
The select lever 40 is connected with the control shaft 50 and selects shift gears and the shift lever 20 is connected with the control shaft 50 and engages the shift gears. The select lever 40 and the shift lever 20 are connected with a manual lever, of which a driver manipulates, through a control cable.
A select lever rotating shaft 42 may be vertical to the control shaft 50 . And thus, when the select lever 40 rotates, the control shaft 50 or parts of the control shaft 50 moves along length direction of the control shaft 50 . A shift lever rotating shaft 22 may rotate on the control shaft 50 . And thus, the shift lever 20 may rotate integrally with the control shaft 50 around the control shaft 50 . Relationship and construction of the select lever 40 , the shift lever 20 and the control shaft 50 are obvious to a person skilled in the art, and thus detailed description will be omitted.
The shift lever 20 includes the shift lever rotating shaft 22 , a cable protrusion 23 , an extended portion 24 and a guide hole 26 .
The shift lever rotating shaft 22 is connected to the control shaft 50 . That is, the shift lever rotating shaft 22 is coincide with shaft center of the control shaft 50 or connected with the control shaft 50 to rotate the control shaft 50 .
The cable protrusion 23 is formed to a predetermined position of the shift lever 20 for connecting the shift lever 20 with a manual lever, of which a driver manipulate, through a control cable. The cable protrusion 23 is protruded from the shift lever 20 for connecting the cable.
The extended portion 24 may be integral to, and or monolitically formed with the shift lever 20 or may be formed for rotating with the shift lever 20 integrally. The extended portion 24 may be protruded parallel to rotating direction of the shift lever 20 . In FIG. 1 , the extended portion 24 is formed as a plate, but it's shape is not limited as shown.
The guide hole 26 is formed to the extended portion 24 for connecting the shift lever 20 with the weight 30 .
The weight 30 includes a weight rotating shaft 32 and a connecting protrusion 36 .
The weight rotating shaft 32 is formed to the weight 30 and connected to a predetermined position of the transmission case 60 or the weight rotating shaft 32 is formed to a predetermined position of the transmission case 60 and is connected to the weight 30 . That is, rotation center of the weight 30 is different of that of the shift lever 20 .
The connecting protrusion 36 is formed to the weight 30 and is inserted into the guide hole 26 . That is, the shift lever 20 the weight 30 are connected by the connecting protrusion 36 and the guide hole 26 . The weight 30 rotates dependently to rotation of the shift lever 20 . The connecting protrusion 36 is slidably movable within the guide hole 26 for the weight 30 easily to rotate dependently according to rotation of the shift lever 20 . That is, the guide hole 26 is formed to allow the connecting protrusion 36 moving within the guide hole 26 in predetermined distance.
While the guide hole 26 is formed to the extended portion 24 and the connecting protrusion 36 is formed to the weight 30 in FIG. 1 , however the connecting protrusion 36 may be formed to the extended portion 24 and the guide hole 26 may be formed to the weight 30 .
FIG. 2 is a top plan view of an operating shift apparatus for a transmission according to various embodiments of the present invention.
As shown in FIG. 2 , the shift lever 20 and the weight 30 rotate simultaneously with each different rotation angle.
The cable protrusion 23 rotates on the shift lever rotating shaft 22 and the connecting protrusion 36 rotates on the weight rotating shaft 32 . The cable protrusion 23 and the connecting protrusion 36 are separated each other in predetermined distance.
Rotation centers of the shift lever 20 and the weight 30 are not equal, and the cable protrusion 23 and the connecting protrusion 36 are separated, and thus ratio of the angles of rotation of the shift lever 20 and the weight 30 are variable. The ratio of the angles of rotation of the shift lever 20 and the weight 30 may be lever ratio of the shift lever 20 and the weight 30 and the rotational inertia of the shift lever 20 may be variable according to the lever ratio.
The lever ratio may be variable according to distance between the cable protrusion 23 and the connecting protrusion 36 and distance between the shift lever rotating shaft 22 and the weight rotating shaft 32 . That is, the lever ratio may be changed according to shape of the extended portion 24 and position of the guide hole 26 , and position of the weight rotating shaft 32 .
In FIG. 2 , L 1 and L 1 ′ denote lines connecting the shift lever rotating shaft 22 and the connecting protrusion 36 before and after moving and A 1 denotes angle between the L 1 and L 1 ′. That is, the A 1 denotes rotation angle of the shift lever 20 . L 2 and L 2 ′ denote lines connecting the weight rotating shaft 32 and the connecting protrusion 36 before and after moving and A 2 denotes angle between the L 2 and L 2 ′. That is, the A 2 denotes rotation angle of the weight 30 . In this case, the lever ratio between the shift lever 20 and the weight 30 is shift lever rotation angle A 1 : weight rotation angle A 2 .
In FIG. 2 , for easy comprehension of the lever ratio of “shift lever rotation angle A 1 : weight rotation angle A”, L 1 ′ and L 2 ′ are identically drawn when the shift lever rotating shaft 22 , the weight rotating shaft 32 and the connecting protrusion 36 are on the same line.
FIG. 3 is a drawing showing each stage of rotation operation of an operating shift apparatus for a transmission according to various embodiments of the present invention.
As shown in FIG. 3 , the connecting protrusion 36 may be movable within the guide hole 26 according to rotation of the shift lever 20 and the guide hole 26 is formed for allowing weight 30 to dependently rotate according to rotation of the shift lever 20 .
In FIG. 3 , while exact rotation angle and the rotation ratio are not expressed, however the lever ratio between operation of the operating shift apparatus 10 from (a) to (b) of FIG. 3 and from (b) to (c) of FIG. 3 may be different. In detail, when the shift lever 20 rotates anticlockwise direction of the drawing, the lever ratio gradually reduced. That is, the lever ratio is gradually reduced at last phase of the shift operation. The rotational inertia at last stage of the shift operation is reduced comparing the early of the of the shift operation. In the FIG. 3 , while operation of the operating shift apparatus 10 are expressed as 3 stages for easy comprehension, it is not limited thereto.
As described above, according to various embodiments of the present invention, in rotation of a shift lever, relatively small weight may realize relatively large rotational inertia using lever ration of the shift lever and weight. And thus, total weight of the apparatus may be reduced. The lever ratio may be variable according to rotation of the shift lever 20 . The rotational inertia at last stage of the shift operation is reduced comparing the early of the of the shift operation. And thus, impact and noise at last stage of the shift operation may be reduced by gradually reducing rotational inertia.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | An operating shift apparatus for a transmission may improve shift feeling using variable rotational inertia according to rotation. The operating shift apparatus for a transmission may include a control shaft is disposed on a transmission case, a select lever which is connected to the control shaft and selects a shift gear, a shift lever which is connected to the control shaft and engages the selected shift gear and a weight disposed to the shift lever for enhancing rotational inertia of the shift lever, wherein the shift lever and the weight are independently formed. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a floor cover and the lining of the floor area pertaining to the foot space in a motor vehicle, and more particularly the invention relates to a part and component of the kind referred to above for direct installation in a motor vehicle and being comprised of a preformed, polyurethane foam part basically of areal extension.
Linings and covers of the kind to which the invention pertains are generally known. Aside from just being a lining of floor space, they have also to an increasing extent the function of noise abatement and attenuation. The known constructions, however, are disadvantaged by the fact that even though they can be manufactured accurately as far as dimensions are concerned, the location of installation in the vehicle such as the floor is concerned often has tolerance variations to such an extent that the accuracy of manufacturing these lining parts does not avoid that there is lack of sealing and abutment near the edge zone or around perforations and openings or the like. As stated, such parts are supposed to materially contribute to the attenuation of sound and noise, such a formation of gaps is quite undesirable; the sound attenuation and absorption is drastically attenuated by such gaps.
DESCRIPTION OF THE INVENTION
It is an object of the present invention to provide for a novel improved lining and cover for the foot area and floor space in automobiles and being of the kind referred to above which, however, avoids the formation of gaps and, therefore, will not deteriorate any sound attenuation properties they themselves possess.
In accordance with the preferred embodiment of the present invention, it is suggested to provide along any edge of such a foot lining cover or the like as referred to in the object statement, with projecting preferably integrally configured sealing lips made of the same material and which in addition is reinforced by an insert that extends into the form part as well as into the sealing lips and is embedded by the form part materials that form the sealing lips.
These lips made in accordance with the invention project beyond the tolerance variations and will snugly abut along the vehicle floor edges whereever such abutment is necessary, without forming any undesirable gap. It is important that the sealing lip is basically made of the same material such as polyurethane foam as the principal part so as to provide by and in itself certain sound attenuating properties; even though the sealing lips may be thinner than the remainder of the form parts which feature was found not to have any detrimental effect on noise abatement. On the other hand it has to be avoided that the sealing lips, owing to their thinness, can tear. For this reason the insert is provided. On one hand it does not impede the function of the various parts involved but strengthens the lip particularly as far as tearing is concerned. In furtherance of the invention it is suggested to provide the insert as a glass fiber mesh or thermoplastic or jute fiber mesh or webbing. Glass fiber material is preferred but thermoplastic material is close second. One could provide blends of various materials or mixtures of fibers. The insert itself can be a regular mesh, a web, be braided, woven or the like. The insert may be a single layer or single ply element but for strength reasons, when in some cases a strong wear is expected a multilayer configuration may be preferred. The insert extends preferably throughout the form part, in order to avoid problems in terms of undue boundary zones or the like.
The lips are preferably bent either up or down, i.e. away from the general planar configuration of adjacent forms and parts. Such a curved configuration makes possible a better matching of the lining part to the contour of the vehicle's bottom. A curved lip contour is particularly advantageous for ensuring abutment along a curved laterally extending floor and internal wall surfaces in the vehicle. The free end of the sealing lips should of course project beyond the abutment surface generally of the particular lining. Owing to this projecting version of the lips as the cover part abuts the floor of the vehicle, the lip is elastically deformed e.g. back into the plane of the abutment form part surface itself or away whatever the circumstances. This elastic yielding is of course very beneficial for sealing purposes.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention, it is believed that the invention, the objects and features of the invention and further objects, features and advantages thereof will be better understood from the following description taken in connection with the accompanying drawings in which:
FIG. 1 illustrates a cross section through a first preferred embodiment of the present invention for practicing the best mode thereof; and
FIG. 2 is similarly a preferred embodiment of a differently configured form part improved in accordance with the best mode of practicing the invention.
Proceeding now to the detailed description of the drawings, FIG. 1 illustrates generally a foot cover, foot mat or floor lining 1 of general areal configuration and being basically comprised of a preshaped polyurethane foam part 1. This foam part 1 is provided along the edges, which may be outer edges as well as edges around internal openings or perforations, with outwardly extending sealing lips 2. These lips of course are made of the same material as and are thus integral with the form part 1 itself i.e. of foam polyurethane. The foam part 1 with sealing lips are made in one and the same working steps so that there are no weak interfaces through manufacturing techniques.
The sealing lips as well as the lower part of the part 1 are reinforced through an insert 3 which has a lateral extension that is larger than the areal lateral extension of the form part 1 itself, owing to the portion of insert 3 that extends to the sealing lips 2. The insert 3 is preferably made of a fibrous material such as glass fiber, thermoplastic fibers or jute fibers; the fibers can be separated and just put next to each other or can be interwoven and formed into a mesh, a braided pattern, a weave or the like. The sealing lips including the insert are curved meaning that they extend at a curvature away from the plane of extension of the form part itself.
In the case of FIG. 1 specifically the sealing lips are bent down which means that as the form part is placed onto a floor then owing to the springness and elasticity of the lips themselves they are bent back so that the edge 2a of the lips firmly abuts and matches in contours snug relation to whatever floor part it is situated on.
The particular form part 11 of FIG. 2 is a different part; it is simply a bar with sealing lip 12 with insert 13, both being curved, in this case, in a different direction as far as the overall extension of the form part 11 is concerned and as compared with the form part 1. As the part is situated on a support surface the sealing lip will be bent up more and will resist thus resiliently though resilient reaction which means that the bar 11 with the sealing lip 12 is more easily adaptable to an upward curved support against which it is sealed.
The invention is not limited to the embodiments described above but all changes and modifications thereof, not constituting departures from the spirit and scope of the invention, are intended to be included. | Foot cover for placement on the floor space of motor vehicles includes a polyurethane form part being provided with a sealing lip extending from edges and edge portions of the form part and is integral therewith; a reinforcing insert extends into and is embedded by the sealing lip. | 8 |
BACKGROUND OF THE INVENTION
In many instances, when several fluids usually not more than three, have to flow from a given static system into a rotating system in a separate and independent way, a conventional apparatus called rotary joint is used. This mechanism permits the passage of fluids at high speed rotation and normally a rotary joint transports the fluid at relative high pressure. The most common joint is for only one single fluid.
When the speed of rotation is not high, other devices called swivel joints are used.
All of them fail in transporting fluids in several independent and separated lines from a given static system to a rotating system.
In very special applications, some times it is necessary to transport solid powder in a carrier gas from a static system into a rotating one.
A conventional well made rotary joint will not be able to sustain such a condition with solid fines suspended in a high pressure gas, said solid fines transportation in a certain condition requires high pressure and pressure drop in a fluid line with gas fines phase is high.
This condition is detrimental for the seal mechanisms in a conventional rotary joint as the fine powder will stick within interfaces between sealing elements and rotating elements.
A more special and specific case of stringent requirements for transporting fluids from static to rotating system is when separated gases from several independent lines or/and also parallel solid suspended fines lines must go from the static system into a rotating system. Thus, the complete scheme of requirements of the rotating system for introducing the fluids and fines becomes more complex.
For instance, in the case of a furnace converter for making steel, when oxygen, other gases like propane and solid fines i.e. lime, must go simultaneously into a converter that is tilted several times during the process, very stringent conditions for separated transport of fluids and solids into the rotating converter system result.
For these cases within the context of the iron and steel making industry and particularly when transporting gases and solids into a converter for injections in the liquid bath i.e. the case of Q÷BOP type process, rotary joints and combinations of special and commercial rotary joints have been developed for specific fluids transport and specific conditions.
In the case of the present invention a principle for a multi-fluid and solids transport is presented with improvement in simplicity of design and construction. Easy maintenance is inherent due to the assembly design and simplicity of parts.
SUMMARY OF THE INVENTION
The apparatus of the present invention has been conceived for its application in the introduction of oxygen and other gases or liquids and solids with transporting gas into a converter furnace for the treatment of liquid metal, particularly in the refining of pig iron and smelting of iron bearing solids.
These fluids and gas transporting solids are injected into the liquid metal, through tuyeres located in the bottoms of such converters.
More specifically, the systems for which the mechanism of this invention is devoted comprise a furnace converter with basic lining material that contains during the process, liquid iron bearing metal to which different gases and solids are injected, for instance oxygen, nitrogen, propane, air, carbon dioxide and possibly some other gases serving as phneumatic transport for solids in form of fines. The injection of fluids and solids into the liquid bath has a great metallurgical advantage, for example the possibility of injecting lime fines resulting in a much better slag forming evolution compared to the classical way of introducing lump lime through the mouth of the converter when refining pig iron for making steel in a Basic Oxygen Furnace process.
In this bottom injection system it is also possible for instance to inject in the same way, fines of carbon in less than 0.3 mm size through tuyeres located in the bottom of the furnace. This injection of carbon for instance, provides external energy to the system and makes it more flexible in terms of heat input requirements, for example for increasing the capacity of melting iron bearing solids by the combustion of the extra carbon input through the bottom tuyeres into the bath.
This is important because it creates flexibility in the thermal balance of the process which in practical terms results in the possibility of controlling the hot metal to cold metal charge ratio into the converter.
The injection of several fluids and/or fluids with solid fines into the converter in a simultaneous and continuous way must be accomplished, in order to allow the continuous injection into the converter, even when the converter is rotating. For instance, a complete cycle of the process of refining the hot metal and melting the cold iron bearing solids charged in the converter, includes steps of charging, sampling, tapping, and deslagging. This in turns implies the tilting of the converter with the necessity of a simultaneous and continuous introduction of fluids into the converter.
This condition results in the necessity of a mechanism for permitting the introduction of several different fluids for injection when the converter is rotating.
It is therefor a primary object of the present invention to provide apparatus for passing into the converter several different fluids and one solid material in form of fines from a set of static conduction lines located in the vicinity of a rotating system i.e. a converter of the basic oxygen type for treating molten metal, continuously and simultaneously at any stage of the process, particularly when the converter is tilting.
This apparatus for transporting a set of different fluids from a static set of conduction lines into a set of rotary conduit lines housed in a rotating system can be applied to a number of different processes under certain and very particular conditions.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of the converter vessel as an example of a rotating system to which fluids and solid particles are injected into the molten metal contained in such converter. FIG. 1 also shows the location of the mechanism in the trunnions of the converter that receives the static conduction lines (static system) and conveys the fluid into the rotating trunnion lines and from the trunnion to the bottom tuyeres.
FIG. 2 shows an enlarged longitudinal elevational cross sectional view of the rotating shaft with the moving channels, housed in the static sleeve, also showing the configuration of the sealing system between shaft and sleeve.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 of the drawings shows the rotating system in our preferred embodiment, comprising the converter vessel (1), the trunnions (2), the piping (3) and bottom tuyeres (4). In the outer ends of the trunnion (8A), the rotary joint mechanism (1 A) is located for receiving a set of incoming pipe lines (5) connected to a fixed sleeve (7) which connects conduits to rotary shaft channels.
According to FIG. 2, which describes in detail the apparatus of this invention, a set (more than 2) of pipe lines (5) for conducting gases connect a corresponding set of ports (6) located in a fixed sleeve (7) with fluid flow direction initially perpendicular to the axis of the sleeve (7) and trunnion (2).
The sleeve (7) envelops shaft (8) which rotates with converter tilting and it is fixed to the trunnion (2) by screws (9). The sleeve (7) is anchored to an external fixed structure (10), independent of the converter tilting system.
The shaft (8) attached to the end of the trunnion (2) rotates with the converter and has circumferential furrows or channels (11), namely half circles in section or other shape, machined about the circumference of the shaft (8). Both channels (11) and complete a circle section, namely the half circle channel (11) around the external circumference of the shaft, and half circle channel (12) around the internal circumference of the sleeve (7).
Each channel (12) of complete circle section (11) has a fixed port (6) for entering of the fluid through the fixed sleeve (7), and is also connected to a rotating fluid exit port (13) in the rotating shaft (8).
From rotating port (13), follows a bending conduct (13 A) inside the shaft (8), and then a straight part conduit (14) also in the shaft (8), connecting the fluid to the rest of the rotating piping system (15) that finally conveys the fluids to the bottom tuyeres.
Thus, a fluid flowing from the static outside line pipe system (5) to the converter rotating system (15) goes through the following path: The fluid enters ports (6) in sleeve (7) from static line pipe (5). Then the fluid flows to the channel ring (11-12) and enters in shaft port (13). As the shaft (8) rotates and therefore shaft port (13) also rotates, the fluid passes from the static system in the sleeve (7) to the rotating system in the shaft, from which fluid is conducted to the rest of the converter pipe system (15) and bottom tuyeres (4, FIG. 1).
Another conduit (16) for passing a fluid or a fluid carring solids in form of fines from the static to the rotating system, enters across the center and along the axis space (17) of the rotary joint apparatus. In this case the conduction line need be bigger than this passing through the center of the shaft, there is in principle no limitation in diameter.
Because in this central line (17) there is not one single bend, as in the case of the circumferential channeled lines (11-12), because of the larger size of line (17), and because the sealing mechanism of tube (19) is simpler and safer as explained below, it is possible to pneumatically convey solid fines from the static hose (18) through the central port (16) to the rotating shaft (8), and then to the rest of the rotating system (15).
The hose (18) connects to the port (16) which is bored in a plate (16A) also static as it is screwed (16B) to static sleeve (7). From port (16) a continued and static tube (19) goes through center bore (20) of the rotating shaft. So the tube (19) is static and center shaft bore (20) rotates as the converter is tilted, the seal between repose tube (19) and center shaft bore (20) is formed by sealing 0-rings or a proper sealing ring (21). Also the dynamics of the fluid in the exit of tube (19) decreases static pressure between tube (19) and bore (20) due to the contraction of the fluid jet when leaving tube (19).
The number of independent conduction lines from the static system to the tilting or rotating system (1, 2, 3, 4, FIG. 1) depend on each application and dictate the number of furrows or channels made in the shaft and sleeve. From FIG. 2, it is clear that when increasing the total number of conduction lines, the length of the rotary joint apparatus also increases.
In our preferred embodiment of a converter for treating liquid metal we can attach one rotary joint apparatus to the end (8A) of each trunnion (2) and handle several gases through the sleeve's ports (6) and solid fines through central port (16). For instance, at a given moment during the process of blow through bottom tuyeres it should be necessary to inject oxygen through a number of central bottom tuyeres; oxygen and lime through another set of bottom tuyeres, and propane through annular tuyeres located around each and every tuyere.
In this case a central conduit line (16, 19, 20) of the rotary apparatus mounted in middle trunnion conducts oxygen and lime to the central tube that rotates (when the converter is tilted) with the rotatable piping system (15) and from there to be corresponding bottom tuyeres for injection. The pure oxygen without lime will enter through ports (6) in sleeve (7) and flow by channel (11-12) to the rotating shaft (8) and system (15), and then to a corresponding tuyere or set of tuyeres for pure oxygen injection. Finally, the propane will be introduced by a rotary apparatus located on the other side of the converters trunnion, where propane gas is introduced through ports (6) and follows in separated lines, the same path as described for pure oxygen, but in this case, propane is conducted in system (15) of the other side (drive) trunnion for conducting propane to annular tuyeres around each oxygen and oxygen/lime tuyere.
A key point in this rotary apparatus is the sealing mechanism that makes the conduction lines independent of each other.
As can be seen from FIG. 2 lines (5) arrive in sleeve (7) independent of each other and stays that way through port (6) until the flow reaches conduct rings formed by channels (11-12). Within these rings the fluid with a certain pressure will tend to leak through slits (22) formed by the cyclindrical interface between static sleeve (7) and rotable shaft (8).
In order to avoid any flow of fluid from a given conduit ring (11-12), into a neighbour conduit ring (11,12), a sealing mechanism (23) between each conduct ring (11-12) is provided.
This mechanism (23) consist of a seal ring (24) shaped to seal by deformation when the whole apparatus is ensembled; that is when the sleeve (7) is mounted encasing the shaft (8), which is all ready attached to trunnion (2) by screws (9). Thus the seal is performed in two interface locations: One by the intimate contact (25) between seal ring (24) and interior part of sleeve (7), and by contact (26) between seal ring (2) and the cylindrical periphery of shaft (8) within a box specially prepared for housing the sealing mechanism (23).
The mechanism (23) also provides an improvement for tighter contacts (25) and (26) by means of a back pressure produced by springs (27), that in assembling the sleeve (7) compresses against a metal ring (28), which in turns transmits the force produced by springs deformation to the opening (24 A) by the penetration of rings protuberance (28 A). This further action improves the performance of the seal by increasing the pressure against the metallic sleeve and shaft components without much deterioration of the seal component as could be the case of an initial shape of ring (24) such that in assembling, could have a greater corresponding deformation for obtaining the same compression and equivalent seal.
The seal mechanism dictates the condition that the interface contacts (25) and (26) between ring seal (24) and metal must have a very low friction in rotation. This is achieved by providing a very low friction material in seal (24) using Teflon® seals for instance. Also in our preferred embodiment, the sealing material should be appropriate for oxygen handling as in certain cases the conduction lines in channel ring region (11, 12) will be transporting oxygen.
In the two extremes of the rotary joint apparatus the sealing mechanism is as follows:
In the extreme end, close to port (16). The channel ring is sealed by the same mechanism (23). From there to the atmosphere there is an O-ring (27) that seals the fixed plate (16A) with sleeve (7) so that no leakage passes to the atmosphere.
The other possible leakage could be through the gap between tube (19) and central shaft bore (20) after passing sleeve-shaft interface (22) and ball bearing support (32) for rotation. In such gap seal rings (21R) provide the final interruption of flow between last channel ring conduct and the central conduct line (17).
The other extreme of the rotary joint close to the trunnion end has a double packing seal (28). Between the two sealing elements in (28) there is a gap to which nitrogen gas is injected in order to provide a sealing gas for a possible leakage through the last portion of interface (29) between sleeve (7) and shaft (8).
In mounting the sleeve, screws (30) provide the necessary force to close sleeve (7) to shaft (8) working against the force produced in deformating the springs (27) as the sleeve is assembled to the shaft.
Finaly, screws (16 B) hold a plate that covers screws (30) and provides the port (16) for connecting static hose (18) for fluid or solid fines transportation. Port (31) might be used for nitrogen seal to improve isolation between ring (11, 12) and bore (20) of tube (19). | This invention relates to a rotary joint for introducing a plurality of different separated fluids from a first static system, to a second system that is rotating with respect to the first, namely for passing fluids and solid fines carried in fluids into a rotatable iron converter through rotary trunnion couplings. The separated different fluids are passed simultaneously through a stationary cylindrical sleeve surrounding a rotating core shaft coupled to the trunnion. Conduits housed in such stationary sleeve pass the fluids to separate circumferential channels axially located along the rotating shaft from which a set of independent lines transporting fluids axially through the trunnion which is rotating with respect to the receiving static sleeve. Between the separate channels in the rotating shaft there are seals that do not permit the passage of a fluid from a given channel conduit into any other. This makes the conduction of fluids in the lines and/or channels independent of each other. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to an elastic cover material which is used as a cover for pillows, cushions, benches, backrests, armrests, chairs, seats, beds, mattresses and the like.
BACKGROUND OF THE INVENTION
[0002] Conventional elastic cover materials according to the prior art include fabric, leather and the like, and are used to cover porous constructions such as urethane foam or other resin foams, stratified formations which are formed by stratifying polyester fiber or other fibers, as well as spring constructions formed from flat springs, coil springs or other springs.
[0003] A conventional elastic cover material effects an agreeable soft feeling, when one's limbs are weighted thereon due to balancing of pressed strain, which may be raised in its thickness direction, and elastic recovery force which may be raised in accordance with the pressed strain. However, in the case where the pressed strain rises relatively too little in comparison with elastic recovery force, hard and painful feeling may be effected. On the other hand, in the case where the pressed strain rises relatively too much in comparison with the elastic recovery force, fatigue may ensue since the limbs are supported in an unstable manner. In order for the conventional elastic cover material to effect an agreeable soft feeling due to the balancing of pressed strain and elastic recovery force, the conventional elastic cover material has to be thick. Thus, conventional elastic cover material, being thick and bulky occupies good deal of space and is difficult to transport in bulk. There is clearly a need to improve the conventional elastic cover material in this respect.
[0004] Therefore, the present invention is intended to provide an improved elastic cover material on which limbs are supported stably, and which is thin, lightweight and less bulky as a whole, and which is easy to handle.
SUMMARY OF THE INVENTION
[0005] An elastic fabric of the present invention is characterized by the following features:
[0000] (i) an elastic yarn is applied to warp yarns or weft yarns;
[0000] (ii) breaking elongation of the elastic yarn is more than 60%, and rate of elastic recovery after 15% elongation of the elastic yarn is more than 90%;
[0000] (iii) the elastic fabric has a stress at 10% elongation of more than 150 N/5 cm and less than 600 N/5 cm in the direction (X) lengthwise along the elastic yarn;
[0000] (iv) the rate of hysteresis loss A E which is calculated by the equation
Δ E= 100 ×C/V= 100×( V−W )/ V is 20˜45% (20≦ΔE≦45);
Wherein:
(i) V is an integral value which is calculated by integrating the load-elongation equation (f 0 (ρ)) from 0% to 10% elongation in the direction (X) lengthwise along the elastic yarn, where the load-elongation equation (f 0 (ρ)) is defined by the loading curve (f 0 ) of the hysteresis in a load-elongation diagram;
(ii) W is an integral value which is calculated by integrating the load-elongation equation (f 0 (ρ)) from 10% to 0% elongation in the direction (X) lengthwise along the elastic yarn, where the load-elongation equation (f 0 (ρ)) is defined by the load-reducing curve (f 1 ) of the hysteresis in a load-elongation diagram; and
(iii) C=V−W is the value of hysteresis loss which is calculated as the difference between the integral values V and W.
BRIEF DESCRIPTION OF DRAWINGS
[0006] FIGS. 1-4 are plan views of elastic fabrics in accordance with the present invention;
[0007] FIG. 5 is a sectional view of an elastic fabric in accordance with the present invention;
[0008] FIG. 6 is a load-elongation diagram of an elastic fabric in accordance with the present invention;
[0009] FIG. 7 is a perspective view of an elastic fabric in accordance with the present invention;
[0010] FIGS. 8 and 9 are plan views of conventional elastic fabric weaves in accordance with the prior art; and
[0011] FIGS. 10-20 are perspective views of elastic fabrics in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0012] A preferred embodiment of an elastic fabric according to the present invention has a bulk density (J=T×G; dtex/cm) more than 17000 dtex/cm. The bulk density (J=T×G) is defined as the product of average fineness of an elastic yarn (T; dtex/number) and the number of elastic yarns per unit length (G=M/L; number/cm) which is calculated by dividing the number of elastic yarns (M; number) by the length L (L; cm) in the direction (Y) orthogonal to the elastic yarns ( 11 ) (direction X).
[0013] Another embodiment of the present invention is an elastic fabric having a covering rate (K) more than 30% (K=100×M×D/1≧30%). The covering rate (K) is defined as 100 times the product (M×D) divided by the length l, wherein M is the number of elastic yarns per unit length in the X direction, D is the average diameter of the elastic yarns (D; cm), which is defined by the square root of the product (S×k) where (k=4×π−1) and S is the areas (S; cm 2 ) of the cross section of the elastic yarns which are disposed at regular intervals (L; cm) in the direction (Y) which is orthogonal to direction (X) the, lengthwise direction of elastic yarns ( 11 ), and 1 is the length in the Y direction.
[0014] In the case of a woven elastic fabric ( 10 ) ( FIGS. 4 and 8 ), elastic yarns may be applied to either warp yarns or weft yarns, inelastic yarns may be used for intersecting yarns ( 22 ) which are orthogonal to the elastic yarns ( 11 ). It is preferable to apply the woven elastic fabric to woven textile designs, where the continuity direction (R) of intersections ( 20 ) form zigzag lines or radial lines, such as pointed twill weaves, entwining twill weaves, herring-bone twill weaves, skip draft twill weaves, and modified twill weaves, or a woven textile design, for which the rate of intersection (H=P/m) is less than 0.5, such as mat weaves, matt weaves, basket weaves, hopsack weaves, warp-weft weaves, irregular or fancy mat weaves, stitched mat weaves and other modified plain weaves ( FIG. 4 ).
[0015] It is desirable to design the woven elastic fabric ( 10 ) in a manner where the rate of intersection (H=P/m), which is defined by dividing the number (P) of bending points (p- 1 ,p- 2 ,p- 3 ,p- 4 ) in front and/or in rear of intersections ( 20 ) in complete textile design of the woven elastic fabric ( 10 ) where the elastic yarn ( 11 ) and the intersecting yarn ( 22 ) bend and change their dispositions one another from surface side to back side or from back side to surface side, by the number (m) of the intersecting yarns ( 22 ), which consist complete textile design, is less than 0.5 (H=P/m≦0.5) ( FIG. 5 ). It is also desirable to design the woven elastic fabric ( 10 ) in a manner where product value (H×K) of rate of intersection (H) and covering rate (K) of the elastic yarn ( 11 ) is more than 0.1 (H×K≧0.1).
[0016] It is further desirable to design the woven elastic fabric ( 10 ) in a manner where the bulk density (J; dtex/cm) of the elastic yarn ( 11 ) is from 0.5 to 3.0 times the bulk density (j; dtex/cm) of the intersecting yarn ( 22 ) which is an inelastic yarn and is orthogonal to the elastic yarn ( 11 ) (0.5×j≦j≦3.0×j). The bulk (J; dtex/cm) of the elastic yarn is calculated as the product of average fineness (T; dtex) and density of the arrangement (G=n/L; number/cm) of the elastic yarn ( 11 ) which is calculated by dividing number of elastic yarns (n; number) by the length (L; cm) in the direction (Y) orthogonal to the direction in which the elastic yarns ( 11 ) extend. In the same way, the bulk (j; dtex/cm) of the intersecting yarn ( 22 ), which is an inelastic yarn, is calculated as the product of average fineness (t; dtex) and density of the arrangement (g=m/L; number/cm) of the intersecting yarn ( 22 ) which is calculated by dividing the number of intersecting yarns (m; number) by the length (L; cm) in the direction (X) where the elastic yarns ( 11 ) extend.
[0017] An elastic top material ( 62 ) (see FIG. 7 ) is formed by stretching and hanging the elastic fabric ( 10 ), which is applied for supporting limbs, between both frame parts ( 61 a , 61 b ) which are positioned at both sides of a frame ( 60 ) in a manner where both frame parts ( 61 a , 61 b ) are opposite to one another. The cushioning surface ( 63 ) of the elastic top material is formed from the elastic fabric ( 10 ) for supporting limbs. The elastic fabric ( 10 ) is stretched over the frame ( 60 ) by setting the lengthwise direction (X) of the elastic yarn ( 11 ) orthogonal to both frame parts ( 61 a , 61 b ), that is, by setting the lengthwise direction (X) in the width direction of the elastic top material ( 62 ).
[0018] The elastic fabric is designed by incorporating the elastic yarn ( 11 ) into the elastic fabric in a manner where the elastic yarns are located in line either lengthwise or crosswise, so that the elastic fabric has;
[0000] (i) a stress at 10% elongation (F) more than 150 N/5 cm and less than 600 N/5 cm (150≦F≦600; N/5 cm) in the lengthwise direction (X) where the incorporated elastic yarns are continuous without cut inside of the elastic fabric,
[0019] (ii) a stress at 10% elongation (B) in the 45 degree bias direction (Z), where the bias direction has an inclination of 45 degrees to the lengthwise direction (X), more than 5% and less than 20% in comparison with stress at 10% elongation (F) in the lengthwise direction (X), and
[0000] (iii) a rate of hysteresis loss (ΔE) at 10% elongation in the prolonging direction (X) within 20˜45% (20≦≢E≦45).
[0020] The elastic top material ( 62 ) is formed by stretching over and by fixing both edges of the elastic fabric ( 10 ) to the frame parts ( 61 a , 61 b ) which are positioned at both sides of frame ( 60 ) and are opposite one another. In the elastic top material ( 62 ), the elastic fabric is deflected into an arched shape in the lengthwise direction (X) of the elastic yarn ( 11 ) when limbs are put on there. Simultaneously, the elastic fabric is also deflected into an arched shape in the orthogonal direction (Y) at right angles to the lengthwise direction (X) of the elastic yarn ( 11 ) and is transformed into a moderate shape, the weight of limbs is dispersed in all directions of the elastic fabric. The elastic fabric does not effect a hard feeling but recovers its original form as soon as the weight of the limbs is removed. And, a load mark does not remain where the limbs have been put on for a long time.
[0021] In the case where stress at 10% elongation (F) of the elastic fabric is designed less than 150 N/5 cm, sagging of the elastic fabric due to the weight of limbs increases and the periphery of the sagged portion of the elastic fabric effects a cramped feeling. And, the capacity of the elastic fabric to recover its original form after the weight of limbs is removed diminished. And, a load mark, which may be effected by the weight of limbs, tends to remain over the elastic fabric and results from load-hysteresis fatigue due to the delay in recovering of the original form. On the other hand, in the case where stress at 10% elongation (F) of the elastic fabric is more than 600 N/5 cm, it becomes unbearable to put limbs on the elastic fabric for a long time, since the elastic fabric effects a hard feeling. In the present invention, a reason to design a rate of hysteresis loss (ΔE) at 10% elongation within 20˜45% (20≦ΔE≦45) is that when it is designed less than 20%, an elastic peculiarity of the elastic fabric becomes similar to that of a steel spring and the elastic fabric tends to effect a hard feeling through its elasticity. On the other hand, in the case where the rate of hysteresis loss (ΔE) at 10% elongation is designed more than 45%, the elastic fabric effects a deflected, sticky feeling when limbs are put on it, and it becomes hard for it to recover its original form, and load marks tends to remain over the elastic fabric after limbs are removed. Then, it becomes hard to obtain cushioning characteristics which are rich in soft feeling and load-hysteresis fatigue resistance. In consideration of these matters, the elastic fabric is designed so that stress at 10% elongation (F) is between 200˜400 N/5 cm and the rate of hysteresis loss (ΔE) at 10% elongation is about 25%.
[0022] The rate of hysteresis loss A E is calculated by dividing the hysteresis loss (C) by the value (V) wherein the hysteresis loss (C) is calculated as the difference between values (V) and (W). The value (V) is calculated by integrating the load-elongation equation f 0 (ρ) from 0% to 10% elongation in the direction (X) where the elastic yarn is continuous without cut in the elastic fabric, and where the load-elongation equation f 0 (ρ) is defined by the loading curve (f 0 ) of the hysteresis in the load-elongation diagram. The integral value (W) is calculated by integrating the load-elongation equation f 0 (ρ) from 10% to 0% elongation in the direction (X) where the elastic yarn is continuous without cut in the elastic fabric, and where the load-elongation equation f 0 (ρ) is defined by the load-reducing curve (f 1 ) of the hysteresis in the load-elongation diagram. Detailed calculation of the rate of hysteresis loss (ΔE) at 10% elongation is explained as follows.
[0023] (i) A test piece 50 mm in width and 250 mm in length is cut from the elastic fabric and is positioned between grips spaced 150 mm apart in a load-elongation testing machine where the loading-elongating velocity is adjusted to 150 mm/min. and an initial load is adjusted to 4.9 N.
[0000] (ii) The test piece is pre-elongated 10% by loading.
[0000] (iii) The test piece is conditioned by decreasing the load to the initial load.
[0000] (iv) After this conditioning, the test piece is elongated 10% and the loading curve (f 0 ) of the hysteresis is drawn in Cartesian coordinates with the elongation axis (X ρ ) and the load axis (YF).
[0024] Subsequently, load decreases until the initial load (F 0 ) is reached and the load-reducing curve (f 1 ) is drawn ( FIG. 6 ). In the Cartesian coordinates, the loading hysteresis area (V), which is bounded by the loading curve (f 0 ), the line (F 10 -ρ 10 ) which passes through the 10% elongation loading point (F 10 ) and crosses at right angles to the elongation axis (X ρ ), and the elongation axis (X ρ ), is measured. Also, the reducing hysteresis area (W) which is bounded by the load-reducing curve (f 1 ), the line (F 10 -ρ 10 ) which passes through the 10% elongation loading point (F 10 ) and crosses at right angles to the elongation axis (X ρ ), and the elongation axis (X ρ ), is measured. The hysteresis loss (C) is calculated as the difference (V-W) between the loading hysteresis area (V) and the reducing hysteresis area (W). Then, the rate of hysteresis loss (ΔE) is calculated by dividing the hysteresis loss (C) by the loading hysteresis area (V).
[0025] A reason to design fabric having stress at 10% elongation (B) in the 45 degree bias direction (Z), which has an inclination of 45 degrees to the lengthwise direction (X), to more than 5% and less than 20% in comparison with the stress at 10% elongation (F) in the lengthwise direction (X) is explained as follows. In the case where stress at 10% elongation (B) in the 45 degrees bias direction (Z) becomes less than 5% of the stress at 10% elongation (F) in the lengthwise direction (X), where the elastic yarn is continuous, the elastic fabric loses its capacity to recover its original form after the limbs are removed, and knitted textile designs or woven textile designs of the elastic fabric become transformable, that is, a distortion of so-called textile opening tends to occur due to slipping of yarns ( 11 , 22 ). On the other hand, in the case where stress at 10% elongation (B) in the 45 degree bias direction (Z) becomes more than 20% of the stress at 10% elongation (F) in the lengthwise direction (X), the elastic fabric tends to effect a hard feeling, since the distortion of knitted or woven textile designs of the elastic fabric is less, the weight of limbs loaded on the elastic fabric is not dispersed in all directions, and sagged recesses are hardly formed according to the shape of limbs at the portion where limbs are placed on the fabric, then limbs are not supported in a stable manner.
[0026] A reason to design the bulk density (J=T×G; dtex/cm) of the elastic yarn ( 11 ), which is defined as the product of the average fineness of an elastic yarn (T; dtex/number) and the density of the arrangement of the elastic yarn (G=M/L; number/cm), more than 17000 dtex/cm, is explained as follows. In the elastic fabric, when the elastic yarns are parallel and neighboring so closely as to touch one another, and when each of them does not stretch independently, and when tensile stress acts on every one of them, the tensile stress is distributed and acts on other neighboring yarns. In such a way, weight of the limbs is distributed from one yarn to another, so that only a few elastic yarns ( 11 ) do not slip at the extreme limits of the elastic fabric. Then, the elastic fabric is designed so that some distortion of the knitted or woven textile design is distributed over a lot of elastic yarns so that the elastic fabric returns to its original form after the limbs (or load or weight) are removed. Accordingly, the elastic fabric becomes rich in load-hysteresis fatigue resistance and load marks hardly remain in the portion of the fabric where the limbs were supported for a long time. In consideration of these matters, the bulk density (J=T×G; dtex/cm) of the elastic yarn ( 11 ) should have a value of more than 17000 dtex/cm, thus stress at 10% elongation (F) in the lengthwise direction (X), where the elastic yarn ( 11 ) is continuous, should have a value of more than 150 N/5 cm and less than 600 N/5 cm, and stress at 10% elongation (B) in the 45 degree bias direction (Z) should have a value of more than 5% and less than 20%. As a result, it becomes easy to set up the rate of hysteresis loss (ΔE) at 10% elongation in the lengthwise direction (X) within 20˜45%.
[0027] For the same reason, the covering rate (K) of the elastic yarn ( 11 ) should be more than 30%. When the covering rate (K) of the elastic yarn ( 11 ) is more than 30%, the elastic yarns, which are arranged densely, increase the elongation of the intersecting yarns ( 22 ), which are orthogonal to the elastic yarns ( 11 ). The elastic yarns act as a wedge which is inserted into the arrangement which is formed by the intersecting yarns ( 22 ). Therefore, the weight of limbs is easily distributed between every adjacent elastic yarn through the intersecting yarns ( 22 ). As a result, the elastic fabric becomes elastically conformable so as to fit the shape of limbs which are put thereon and also becomes soft and resilient.
[0028] The elastic yarn ( 11 ) is woven or knitted in the elastic fabric in a manner to be in continuous as a whole being intermittent partially in the width direction of the fabric or in a manner to be in continuous completely through the full width of the fabric, or in a manner to be in continuous as a whole being intermittent partially in the length direction of the fabric or in a manner to be in continuous completely through the full length of the fabric. It is desirable to set up the bulk density (J) of the elastic yarn to be more than 17000 dtex/cm by designing the average fineness (T) of the elastic yarn in thick and by designing the density (G) of the arrangement of the elastic yarn in loose so that the arranged situation of the elastic yarn is easily kept in line. It is also desirable to compose the elastic yarn as a type of monofilament yarn so that the arranged situation of the elastic yarn is easily kept in line. However, where the elastic yarn is composed of multiple fibers or yarns as a type of multifilament yarn, the number of the fibers or the number of single yarns of the elastic yarn should be set up less than 5 (threads). That is, the elastic yarn should be composed of several thick monofilament yarns in a shape as if these yarns were drawn in parallel. The elastic yarn may be composed together with elastic fibers and inelastic fibers in sheath core shape by twining and covering the elastic fibers with the inelastic fibers.
[0029] FIGS. 1-4 show examples of the textile design of the elastic fabrics. In the elastic fabric shown in FIG. 1 , the inelastic yarns (the intersecting yarns ( 13 )) form a base weft knitted fabric. The elastic yarns ( 11 ) are threaded in the base weft knitted fabric and pass under the space between the needle loops ( 40 , 40 ) of every neighboring wales in each course and are continuous in line in the knitting width direction (Γ). In the elastic fabric shown in FIG. 2 , the inelastic yarns (the intersecting yarns ( 13 )) form the base warp knitted fabric. The elastic yarns ( 11 ) are threaded in the base weft knitted fabric and pass through the space between the needle loop ( 40 ) and the sinker loop ( 50 ) and are in continuous in line in the knitting width direction (Γ). In the elastic fabric shown in FIG. 3 , the base warp knitted fabric is formed with the inelastic yarns ( 13 x ) which form the chain stitched rows in line in the knitting length direction and the inelastic inserted yarns (the intersecting yarns 22 a ) which are connecting the adjacent chain stitched rows. The elastic yarns ( 11 ) are threaded in the base warp knitted fabric and pass through the space between the adjacent chain stitched rows ( 39 , 39 ) in a manner of passing over the inelastic inserted yarn ( 22 a ) and passing under the inelastic inserted yarn ( 22 a ) in each course and are in continuous in line in the knitting length direction (Σ).
[0030] As shown in FIGS. 1-3 , in the elastic knitted fabric, it is desirable to apply inelastic yarn to all of the intersecting yarns ( 22 ) which cross the elastic yarns ( 11 ) which are continuous. Also, as shown in FIGS. 1-3 , in the elastic knitted fabric, the elastic yarn ( 11 ) may be arranged weftwise and warpwise. However, in the elastic woven fabric, in consideration of easiness in the weaving process, it is desirable to apply an elastic yarn ( 11 ) to the weft yarn, and to apply an inlastic yarn to the warp yarn (that is, the intersecting yarn 22 ). FIG. 4 shows the elastic woven fabric wherein the elastic yarn is applied to the weft yarn and the inlastic yarn is applied to the warp yarn.
[0031] The elastic knitted fabric is deformable lengthwise and crosswise, since the warp knitted fabric is formed with arched needle loops ( 40 ) and arched sinker loops ( 40 ) where the yarns are bent into arched shapes. Therefore, there is not a significant difference between the stress at 10% elongation (B 1 ) in the 45 degree leftwise bias direction (Z 1 ), which has a leftwise inclination of 45 degrees from the lengthwise direction (X), and the stress at 10% elongation (B 2 ) in the 45 degree rightwise bias direction (Z 2 ), which has a rightwise inclination of 45 degrees from the lengthwise direction (X). Thus, the weight of limbs, which is loaded on the elastic knitted fabric, is distributed in all directions. In this connection, however, in the elastic woven fabric, the difference between stress at 10% elongation (B 1 ) in the 45 degree leftwise bias direction (Z 1 ) and stress at 10% elongation (B 2 ) in the 45 degree rightwise bias direction (Z 2 ) becomes larger in accordance with the manner of the continuity of the intersection points ( 20 ) in the woven textile design. Therefore, the elastic woven fabric is lacking in load-hysteresis fatigue resistance in comparison with the elastic knitted fabric in accordance with the difference of stress at 10% elongation between the 45 degree leftwise bias direction (Z 1 ) and the 45 degree rightwise bias direction (Z 2 ). To decrease the difference of stress at 10% elongation, the satin weave, which lacks continuity in the disposition of the intersection points ( 20 ), may be applied to the elastic woven fabric. However, by the application of the satin weave, the elastic woven fabric, which is rich in load-hysteresis fatigue resistance, is not obtained, since the satin weave lacks fixity between the warp yarn and the weft yarn, so that stress is hardly distributed from one yarn to another between adjacent elastic yarns.
[0032] Thus, woven textile designs where the intersection points ( 20 ) are disposed in zigzag and/or radial manner in the continuity direction (R) such as pointed twill weaves, entwining twill weaves, herring-bone twill weaves, skip draft twill weaves and modified twill weaves, or woven textile designs for which the rate of the intersection (H=P/m) is less than 0.5, such as mat weaves, matt weaves, basket weaves, hopsack weaves, warp-weft weaves, irregular or fancy mat weaves, stitched mat weaves and other modified plain weaves, are applied to the elastic woven fabric. In the elastic woven fabric wherein such a weaving textile design is applied, the intersection points ( 20 ) continue in the 45 degree leftwise bias direction (Z 1 ) and in the 45 degree rightwise bias direction (Z 2 ) at the same rate. As a result, the fixity between the warp yarns and the weft yarns is maintained, and the manner of the continuity of the intersection points ( 20 ) in the 45 degree leftwise bias direction (Z 1 ) and in the 45 degree rightwise bias direction (Z 2 ) become even. Therefore, large differences in stress at 10% elongation (B) between those bias directions (Z 1 , Z 2 ) does not occur, and load-hysteresis fatigue resistance of the elastic woven fabric increases.
[0033] Furthermore, for an increment of the load-hysteresis fatigue resistance of the elastic woven fabric, the covering rate (K) of the elastic yarn ( 11 ) should be more than 30% so as to make slippage between the elastic yarns minimal so that the elastic yarns ( 11 a , 11 b , 11 c , etc.) stick fast to one another and are collected between the intersection points ( 20 m , 20 n ) by potential inside shrinking stress of the intersecting yarns ( 22 ). This is effected as a reaction stress when the intersecting yarns ( 22 ) are elongated between the intersection points ( 20 m , 20 n ). However, in the case where the covering rate (K) of the elastic yarn ( 11 ) is more than 30%, and when the fineness of the elastic yarn is thicker than regular fineness which should be limited in proportion to the weaving density, the elastic fabric which is rich in load-hysteresis fatigue resistance cannot be always obtained.
[0034] The reason for this is explained as follows. When the density of the warp yarns of the woven fabric is high, a plurality of warp yarns ( 22 a , 22 b , 22 c ), which comprise the complete textile design of the woven fabric, are constrained so as to maintain the width of the arrangement of the warp yarns between the intersections ( 20 a , 20 b ) by the weft yarns (elastic yarns 11 ). On the other hand, the weft yarns ( 11 ) are stretched due to the reaction from the plurality of warp yarns ( 22 a , 22 b , 22 c ) which are arranged in high density between the intersections ( 20 a , 20 b ) and which require a force to widen the width of the arrangement of the warp yarns. In the case of a plane and fine woven fabric for which the density of the warp is high, balance between the weft yarns ( 11 ) and the warp yarns ( 22 a , 22 b , 22 c ) is maintained, and a plane configuration of fabric is maintained. However, when the number of the warp yarns ( 22 a , 22 b , 22 c ) is more than the regular limitation, protuberances appear over the surface of the woven fabric. Since the weft yarns ( 11 ) are brought into extremely strained situation at the inside of the woven fabric, the potential inside shrinking stress, which acts to restore the regular length of the weft yarn ( 11 ) in proportion to the regular number of warp yarns (intersecting yarns 22 a , 22 b , 22 c ), arises at the inside of the woven fabric. Then, the weft yarns ( 11 ) are brought into the situation where they tend to shrink. On the other hand, the plurality of warp yarns ( 22 a , 22 b , 22 c ) also act to restore the regular width between the intersections ( 20 a , 20 b ) in proportion to the regular number of warp yarns. As a result, the warp yarns ( 22 ) tend to swell out in the thickness direction of the woven fabric. As explained above, in the case where the density of the warp yarns of the woven fabric is denser than the regular density which should be suitably designed in proportion to the fineness of yarn, the regular plane surface of the woven fabric is not maintained. It is the same in the case where the density of the weft is designed denser than the regular density which should be suitably designed in proportion to the fineness of the weft yarn ( 11 ).
[0035] The reason to design the rate of the intersection (H) less than 0.5 is that the intersecting yarns ( 22 ) which cross the elastic yarns ( 11 ) are not so far elongated between the intersections ( 20 m , 20 n ) that the undulatory puckers or crimps appear over the surface of the elastic fabric. Where the rate of the intersection (H) is more than 0.5, the frequency of the intersection points ( 20 ) formed together with the warp yarns ( 22 ) and the weft yarns (elastic yarns 11 ) is low, and the warp yarns ( 22 ) pass over a lot of weft yarns (elastic yarns 11 ) and float out of the surface of the elastic fabric. In the case where the length (U) of the floating portion of the warp yarn is long, elongation of the elastic yarns ( 11 a , 11 b , 11 c ) between the intersections ( 20 m , 20 n ) may be diminished. However, in such a case, a plurality of elastic yarns ( 11 a , 11 b , 11 c ), which may be included between the intersections ( 20 m , 20 n ), become free since the elastic yarns, ( 11 a , 11 b , 11 c ) are not tightly restricted by the intersecting yarns ( 22 ). Consequently, the weight of limbs loaded on the elastic fabric cannot be easily distributed from one elastic yarn to another.
[0036] Therefore, to increase the load-hysteresis fatigue resistance of the elastic woven fabric:
[0037] (i) the rate of intersection (H=P/m), which is defined by dividing the number of bending points (p- 1 ,p- 2 ,p- 3 ,p- 4 ) in the front and/or in the rear of the intersections ( 20 ) in the woven elastic fabric ( 10 ), where the elastic yarns ( 11 ) and the intersecting yarns ( 22 ) bend and change their dispositions from the surface side to the back side or from the back side to the surface side, by the number of the intersecting yarns ( 22 ) in the textile, is designed less than 0.5(H=P/m≦0.5), and (ii) the product (H×K) of the rate of intersection (H) and the covering rate (K) of the elastic yarn ( 11 ) is designed to be more than 0.1 (H×K≧0.1).
[0038] Furthermore and preferably for increasing the load-hysteresis fatigue resistance of the elastic woven fabric:
[0039] (iii) the bulk density (J; dtex/cm) of the elastic yarn ( 11 ) is designed from 0.5 to 3.0 times the bulk density (j; dtex/cm) of the intersecting yarn ( 22 ) which is an inelastic yarn and crosses the elastic yarn ( 11 ) at right angles (0.5×j≦J≦3.0×j). The bulk density (J; dtex/cm) of the elastic yarns is calculated as the product of the average fineness (T; dtex) and the density of the arrangement (G=n/L; number/cm) of the elastic yarns ( 11 ) which is calculated by dividing the number of elastic yarns (n; number) by the length (L; cm) in the direction (Y) orthogonal to the direction in which the elastic yarns ( 11 ) extend. In the same way, the bulk density (j; dtex/cm) of the intersecting yarns ( 22 ), which is an inelastic yarn, is calculated as the product of the average fineness (t; dtex) and density of the arrangement (g=m/L; number/cm) of the intersecting yarns ( 22 ) which is calculated by dividing the number of intersecting yarns (m; number) by the length (L; cm) in the lenghtwise direction (X) in which the elastic yarns ( 11 ) extend.
[0040] The reason to design the product (H×K) of the rate of intersection (H) and the covering rate (K) of the elastic yarn ( 11 ) to be more than 0.1 is to distribute the weight of limbs loaded on the elastic fabric between adjacent elastic yarns. Consequently, adjacent elastic yarns ( 11 , 11 ) are not restricted tightly by the intersecting yarns ( 22 ) but come into contact with one another. The weight of the limbs is distributed over all of the elastic fabric, and then, undulatory puckers or crimps which would otherwise result from the tension stress of the intersecting yarns ( 22 ) do not appear over the elastic fabric.
[0041] The rate of intersection (H) of individual elastic yarns may vary in the textile, but the average rate of the intersection (H) of the elastic yarns is designed to be less than 0.5, and the product of the average rate of the intersection (H) and the covering rate (K) is designed to be more than 0.1. In the case where the fabric has several kinds of elastic yarns which are different in fineness, the average diameter (D) is calculate by dividing the sum of the diameters (D 1 +D 2 +D 3 + . . . +D n ) by the number of different kinds of elastic yarns.
[0042] The reason to design the bulk density (J; dtex/cm) of the elastic yarns ( 11 ) from 0.5 to 3.0 times the bulk density (j; dtex/cm) of the intersecting yarns ( 22 ) (0.5×j≦J≦3.0×j) is to maintain balance between the weft yarns and the warp yarns. It is desirable to design the ratio (J/j) between the bulk density (J) of the elastic yarns ( 11 ) and the bulk density (j) of the intersecting yarns ( 22 ) to be between 1.0˜2.5, and more preferably about 1.0.
[0043] To maintain the arrangement of the elastic yarns ( 11 ) in line, the intersecting yarns ( 22 ), which cross the elastic yarns ( 11 ), should be thinner than the elastic yarns ( 11 ). The density of the arrangement (g) of the intersecting yarns ( 22 ) should denser, and the ratio (J/j) between the bulk density (J) of the elastic yarns ( 11 ) and the bulk density (j) of the intersecting yarns ( 22 ) should between 0.5˜3.0. Also, to maintain the arrangement of the elastic yarns ( 11 ) in line, it is desirable to use multi-fiber yarn made from multiple fibers as multifilament yarn, and spun yarn, for the intersecting yarns ( 22 ). Especially in the case where multi-fiber yarn is used for the intersecting yarns ( 22 ), the tension stress of the intersecting yarns ( 22 ) does not act to raise undulatory puckers or crimps over the elastic fabric. Although latent tension stress may be induced in the intersecting yarns ( 22 ) in the weaving process, this latent tension stress will gradually disappear with the passage of time if multi-fiber yarns are used, even if the number of the elastic yarns ( 11 ) which might be included between the intersections ( 20 m , 20 n ) are numerous and the intersecting yarns ( 22 ) might be elongated by many elastic yarns ( 11 ) which exist between the intersections ( 20 m , 20 n ). Thus, to make the elastic fabric dimensionally stable, it is desirable to use a multi-fiber yarn for the intersecting yarns ( 22 ).
Embodiment [A-1]
[0044] A polyester spun yarn (fineness: 2 ply/meter count of 10 in single yarn) is set in the warp direction with a density of 55/10 cm. A thermo adhesible sheath core conjugate polyetherester yarn (fineness: 2080 dtex, having the product name of “Dia-Flora” and is available from Toyobo Co. Ltd.) is used for the weft yarn. This “Dia-Flora” is composed of an elastic core component and a thermo adhesive sheath component of which the melting point is lower than the elastic core component. The fabric is woven in a herring-bone twill weave as shown in FIG. 4 , and is woven with a weft density of 155/10 cm. The woven fabric is finished as an elastic woven fabric by passing it through a dry-heating treatment at 190° C. for 3 minutes and by thermally adhering the warp yarns ( 11 ) and the weft yarns ( 22 ). The elastic cover material ( 62 ) is formed by hanging the elastic woven fabric ( 10 ) between frame parts and by fixing both edges of the fabric to the frame parts ( 61 a , 61 b ) which are positioned at both sides of a frame ( 60 ) apart from one another 50 cm and are located opposite to one another ( FIG. 7 ). The length of the frame part is 45 cm. The fabric ( 10 ) was tested by having a subject sit on it. As a result, the elastic woven fabric ( 10 ) was judged to effect a stable and comfortable feeling.
[0000] Comparison [A-1]
[0045] A polyester spun yarn (fineness: 2 ply/meter count of 10 in single yarn) is set in the warp direction with a density of 55/10 cm. The above-mentioned thermo adhesible sheath core conjugate elastic polyether-ester “Dia-Flora” used in the Embodiment [A-1] is used for the weft yarn. The fabric is woven in a twill weave, as shown in FIG. 8 , and is woven with a weft density of 155/10 cm. The woven fabric is finished as an elastic woven fabric by passing it through a dry-heating treatment at 190° C. for 3 minutes and by thermally adhering the warp yarns ( 11 ) and the weft yarns ( 22 ). The elastic cover material ( 62 ) is formed by hanging the elastic woven fabric ( 10 ) between frame parts and by fixing both edges of the fabric to the frame parts ( 61 a , 61 b ) which are positioned at both sides of the frame ( 60 ) apart from one another 50 cm and located opposite to one another ( FIG. 7 ). The length of the frame part is 45 cm. The fabric was tested by having a subject sit on it. As a result, the elastic woven fabric ( 10 ) was observed to have a difference of elongation between the leftwise bias direction and the rightwise bias direction which effected an unstable feeling, and was not comfortable.
[0000] Comparison [A-2]
[0046] A polyester multifilament yarn (fineness: 1333 dtex) is set in the warp direction with a density of 91/10 cm.
[0047] The above-mentioned thermo adhesible sheath core conjugate elastic polyether-ester yarn “Dia-Flora” used in the Embodiment [A-1] is used for the weft yarn.
[0048] The fabric is woven in a twill weave, shown in FIG. 8 , with a weft density of 155/10 cm.
[0049] The woven fabric is finished as an elastic woven fabric by passing it through a dry-heating treatment at 190° C. for 3 minutes and by thermally adhering the warp yarns ( 11 ) and the weft yarns ( 22 ).
[0050] The elastic cover material ( 62 ) is formed by hanging the elastic woven fabric ( 10 ) between frame parts and by fixing both edges of the fabric to the frame parts ( 61 a , 61 b ) which are positioned at both sides of a frame ( 60 ) apart one another 50 cm and are located opposite to one another ( FIG. 7 ).
[0051] The length of the frame part is 45 cm.
[0052] The fabric ( 10 ) was tested by having a subject sit on it.
[0053] As a result, the elastic woven fabric ( 10 ) was observed to raise a difference of elongation between the leftwise bias direction and the rightwise bias direction, effect an unstable and hard feeling, and was uncomfortable.
[0000] Comparison [A-3]
[0054] A polyester spun yarn (fineness: 2 ply/meter count of 10 in single yarn) is set in the warp direction with a density of 55/10 cm.
[0055] The above mentioned thermo adhesible sheath core conjugate elastic polyether-ester yarn “Dia-Flora” is used in the Embodiment [A-1] is used for the weft yarn.
[0056] The fabric is woven in a plain weave, shown in FIG. 9 , is woven with a weft density of 100/10 cm.
[0057] The woven fabric is finished as an elastic woven fabric by passing through a dry-heating treatment at 190° C. for 3 minutes and by thermally adhering the warp yarns ( 11 ) and the weft yarns ( 22 ).
[0058] The elastic cover material ( 62 ) is formed by hanging the elastic woven fabric ( 10 ) between frame parts and by fixing both edges of the fabric to the frame parts ( 61 a , 61 b ) which are positioned at both sides of a frame ( 60 ) apart from one another 50 cm and are located opposite to one another ( FIG. 7 ).
[0059] The length of the frame part is 45 cm.
[0060] The fabric ( 10 ) was tested by having a subject sit on it.
[0061] As a result, the elastic woven fabric ( 10 ) was observed not to raise a difference of elongation between the leftwise bias direction and the rightwise bias direction, but it effected an unstable and hard feeling, as well as a sticky feeling and was uncomfortable since the elastic fabric sagged significantly as a whole.
[0000] Property Datum of Embodiment and Comparison [A]
[0062] The following parameters for the above-mentioned embodiment and comparisons are shown in the following Table 1:
[0063] (i) stress at 10% elongation (F 1 ; N/5 cm) in the direction (X) where the elastic yarns ( 11 ) extend, (ii) rate of hysteresis loss (ΔE 1 ) at 10% elongation in the direction (X) where the elastic yarns ( 11 ) extend, (iii) stress at 10% elongation (F 2 ; N/5 cm) in the orthogonal direction (Y) to the direction (X) where the elastic yarns ( 11 ) extend, (iv) the rate of hysteresis loss (ΔE 2 ) at 10% elongation in the orthogonal direction (Y) to the direction (X) where the elastic yarns ( 11 ) extend, (v) 10% elongation stress (B 1 ; N/5 cm) in the 45 degree leftwise bias direction (Z 1 ) which has a left-wise inclination of 45 degrees to the direction (X), (vi) stress at 10% elongation (B 2 ; N/5 cm) in the 45 degree rightwise bias direction (Z 2 ) which has a rightwise inclination of 45 degrees to the direction (X), (vii) bulk density (J; dtex/cm) of the elastic yarns ( 11 ), (viii) bulk density (j; dtex/cm) of the inelastic yarns ( 22 ), (ix) ratio (J/j) between the bulk density (J) of the elastic yarns ( 11 ) and bulk density (j) of the intersecting inelastic yarns ( 22 ), (x) the covering rate (K) of the elastic yarns ( 11 ), (xi) the rate of intersection (H) of the elastic yarns ( 11 ), and (xii) the product (HX K) of the rate of intersection (H) and the covering rate (K) of the elastic yarns ( 11 ) of the elastic fabrics ( 10 ).
TABLE 1 embodi- com- com- com- ment parison parison parison A-1 A-1 A-2 A-3 stress at 10% 350 351 360 331 elongation in the direction(X) (F 1 ; N/5 cm) rate of hysteresis 30 32 28 35 loss in the direction(X) (ΔE 1 ) stress at 10% 147 152 320 58 elongation in the orthogonal direction(Y) (F 2 ; N/5 cm) rate of hysteresis 42 41 42 28 loss in the orthogonal direction(Y) (ΔE 2 ) stress at 10% 26 33 109 37 elongation in leftwise bias direction(Z 1 ) (B 1 ; N/5 cm) stress at 10% 25 20 86 38 elongation in rightwise bias direction(Z 2 ) (B 2 ; N/5 cm) bulk of the elastic 23920 23920 23920 20800 yarn (J; dtex/cm) bulk of the 11000 11000 12130 11000 inelastic yarn (j; dtex/cm) ratio of density(J) 2.17 2.17 1.97 1.89 and density(j) (J/j) covering rate of 52 52 52 46 the elastic yarn (K) rate of an 0.5 0.5 0.5 1.0 intersection of the elastic yarn (H) product value of 0.26 0.26 0.26 0.46 rate of intersection(H) and covering rate(K) (H × K) estimation good normal bad bad
[0064] Weft knitted fabric is more stretchable than both warp knitted fabric and woven fabric. It sags excessively and effects a cramped and unstable feeling when supporting limbs. When forming an elastic fabric ( 10 ) as a weft knitted fabric, it is advantageous if an inelastic yarn ( 13 ) is used as a base knit and an elastic yarn ( 11 ) is knitted in the base in a manner where the elastic yarn continues in line in the knitting width direction (r) over at least a plurality of wales of at least one course so that its stress at 10% elongation (F) in the knitting length direction (Σ) can be more than 25N/5 cm. In this case, the bulk density (J; dtex/cm) of the elastic yarn is calculated as the product of the average fineness (T; dtex) of the elastic yarns ( 11 ) and the density of the arrangement (G; number/cm) of the elastic yarns ( 11 ) which are arranged in the knitting length direction (Σ) and is more than 17000 dtex/cm (J≧17000 dtex/cm).
[0065] In this case, stress at 10% elongation (B) in the 45 degree bias direction (Z), which has an inclination of 45 degrees to the direction (X) of the elastic yarns ( 11 ) is more than 5% and less than 20% of the stress at 10% elongation (F) in the direction (X) of the elastic weft knitted fabric (0.05×F≦B≦0.20).
[0066] To knit an elastic yarn ( 11 ) in the base fabric in a manner where the elastic yarn continues in line in the knitting width direction (Γ) over at least a plurality of wales means that the elastic yarn may be knitted to form needle loops together with inelastic yarns every wale in a manner that continues in line in the knitting width direction (Γ) such that the second inelastic yarn ( 13 b ) forms needle loops together with the first inelastic yarns ( 13 a ) over a plurality of wales and continues without forming a needle loop over the wales as shown in FIG. 10 . In the case where the elastic yarn is knitted to form needle loops together with an inelastic yarn over every wale, it is possible to avoid forming the portion of the elastic yarn which continues in line over the wales without forming a needle loop slip aside from the knitting width direction (Γ). On the other hand, slippings of the needle loops and sinker loops formed of the inelastic yarns are restrained by the elastic yarns and sagging of the elastic fabric due to the weight of limbs increases. Then, the lower stretching elastic fabric which does not effect a painful cramped feeling can be obtained.
[0067] The textile design is not limited to a particular form of knitting. Plain stitch knitting, rib stitch knitting and purl stitch knitting may be used to form the base knitted fabric. The base knitted fabric formed as a plain stitch using a weft knit ( 10 ) is shown in FIG. 11 and is formed from the inelastic yarns ( 13 ) which are knitted in by replacing floating wales (σ 1 , σ 2 , σ 3 ) every one course. In the courses (φ 1 , φ 2 , φ 3 ), the first elastic yarn ( 11 a ) is inserted in the space between needle loops ( 40 , 40 ) of adjacent wales (σ 1 , σ 2 ). In the course (φ 4 , φ 5 ), the first elastic yarn ( 11 a ) and the second elastic yarn ( 11 b ) which have different elasticities are inserted in the space between needle loops ( 40 , 40 ) of adjacent wales (σ 1 , σ 2 ). In the course (φ 6 ), the first elastic yarn ( 11 a ), the second elastic yarn ( 11 b ) and the third elastic yarn ( 11 c ) which have different elasticities are inserted in the space between needle loops ( 40 , 40 ) of adjacent wales (σ 1 , σ 2 ).
[0068] In the case of the weft knitted fabric ( 10 ) shown in FIG. 10 , a float stitch knitting textile is formed from second inelastic yarns ( 13 b ). The second inelastic yarns ( 13 b ) form a needle loop together with the first inelastic yarns ( 13 a ) every 6 needle loops ( 40 a , 40 b , 40 c , 40 d , 40 e , 40 f ) in the course where the first inelastic yarn ( 13 a ) is knitted in. The sinker loop ( 50 ), which is formed from the second inelastic yarn ( 13 b ), extends in the knitting width direction (Γ) over 5 wales (σ 2 , σ 3 , σ 4 , σ 5 , σ 6 /σ 5 , σ 6 , σ 1 , σ 2 , σ 3 ) from the needle loop formed together with the first inelastic yarn ( 13 a ) and the second inelastic yarn ( 13 b ) to other needle loops formed together with the first inelastic yarn ( 13 a ) and the second inelastic yarn ( 13 b ).
[0069] In the case of the weft knitted fabric ( 10 ) shown in FIG. 10 , the second inelastic yarn ( 13 b ) does not form needle loops over several wales. Therefore, the elongation of the elastic yarn ( 11 ) is restrained by the second inelastic yarn ( 13 b ). Thus, the lower stretching elastic fabric, which does not cause undulating puckers or crimps and which does not effect a painful cramped feeling, can be obtained.
[0070] In the case of the weft knitted fabric ( 10 ) shown in FIG. 10 , the elastic yarn ( 11 ) is inserted in the space between needle loops of adjacent wales (σ 1 , σ 2 ) on every other course (φ 2 , φ 4 , φ 6 ) of the base knitted fabric which is formed from the inelastic yarn ( 13 ) by using a rib stitch knit and by replacing floating wales (σ 1 , σ 2 , σ 3 ) every course.
[0071] FIG. 12 shows the positional relationship of the needle loops ( 40 ) and the sinker loops ( 50 ) of the inelastic yarn ( 13 ) and the elastic yarn ( 11 ) which may be drawn in the knit wherein the needle loop and the sinker loop are drawn in the same shape. However, the appearance of the needle loop ( 40 ) and the sinker loop ( 50 ) of the weft knitted fabric are not the same. FIG. 13 shows the appearance of the weft knitted fabric which may be knitted according to the design shown in FIG. 12 . That is, in the weft knitted fabric shown in FIGS. 12 and 13 ,
[0072] (i) the average diameter of the elastic yarn ( 11 ) may be more than 1.5 times the average diameter of the inelastic yarn ( 13 ).
[0073] (ii) the average diameter of the elastic yarn is more than 1.1 times the average course interval (Lc) of the weft knitted fabric that is equal to the sum of the average diameter of the elastic yarn ( 11 ) and average diameter of the inelastic yarn ( 13 ),
[0074] (iii) the needle loops ( 40 ) and the sinker loops ( 50 ) are pushed out from the course (φ 2 ) toward the other adjacent course (φ 1 , φ 3 ), where the elastic yarn is not threaded in where loops are formed and the elastic yarn is threaded in by the elastic yarn ( 11 ) which is threaded in its course ( 2 ).
[0075] (iv) the portions ( 13 x ) of the inelastic yarn ( 13 ) on the course (φ 2 ) is inclined to the knitting width direction (Γ) and the knitting length direction (Σ).
[0076] (v) the inclined portions (13×) form a Λ-shaped appearance.
[0077] Therefore, a diamond pattern is drawn on the surface of the elastic weft knitted fabric by the portions ( 13 x ) of the inelastic yarn ( 13 ).
[0078] To this end,
[0079] (i) the average diameter of the elastic yarn ( 11 ) is more than 1.5 times the average diameter of the inelastic yarn ( 13 ),
[0080] (ii) the average diameter of the elastic yarn is more than 1.1 times of average course interval (Lc) of the weft knitted fabric that is equal to the sum of the average diameter of the elastic yarn ( 11 ) and the average diameter of the inelastic yarn ( 13 ),
[0081] (iii) the inelastic yarn is elongated where the tension induced in the inelastic yarn in the knitting process is stored inside of the inelastic yarn as latent tension stress,
[0082] (iv) the inelastic yarn does not return to its original relaxed length disturbed by the thick elastic yarn after the fabric is taken out from the weft knitting machine,
[0083] (v) the elongation of the inelastic yarn is maintained by the thick elastic yarn.
[0000] That is, the elastic yarn;
[0084] (vi) is established in the course (φ 2 ) as a wedge picked in between the front course (φ 1 ) and the rear course (φ 3 ),
[0085] (vii) widens the space between these two courses (φ 1 , φ 3 ) and stretches the needle loops ( 40 ) and the sinker loops ( 50 ) formed in the course (φ 2 ), then
[0086] (viii) the needle loops ( 40 ) and the sinker loops ( 50 ) formed in the course (φ 2 ) pull both front and rear needle loops ( 40 ) and sinker loops ( 50 ) formed in both front and rear courses (φ 1 , φ 3 ) toward the course (φ 2 ) and stretch these loops ( 40 , 50 ). As above, since the elastic yarn ( 11 ) is inserted in the course (φ 2 ) as a wedge and stretches the base knitted fabric through the needle loops and the sinker loops, the base knitted fabric, which is formed from inelastic yarns ( 13 ) and is telescopic in itself as a weft knitted products, is knitted up in telescopic. On the other hand, since the elastic yarn ( 11 ) is thicker than the inelastic yarn ( 13 ), it is hardly elongated in the knitting process, so that, it is not fixed in elongation through the knitting process, its elastic property is maintained after the knitting process. In this manner, the lower stretching elastic weft knitted fabric which does not effect a painful cramped feeling can be obtained.
[0087] Thick elastic monofilament yarn for which the fineness is more than 500 dtex, and preferably more than 1000 dtex, and further preferably more than 1650˜3000 dtex and which has stress at 10% elongation of more than 0.1 cN/dtex, preferably 0.3˜0.8 cN/dtex, is used for the elastic yarn ( 11 ) and is knitted in without significant elongation in the knitting process.
Embodiment [B-1]
[0088] An inelastic polyester multifilament yarn (fineness: 500 dtex) is applied to the base stitch yarn ( 13 ). The base knitted fabric is knitted using a plain stitch, shown in FIGS. 12 and 13 , having a density in the wale direction of 12 wales/25.4 mm and density in the course direction of 44 courses/25.4 mm. The above-mentioned thermo adhesible sheath core conjugate elastic polyether-ester yarn “Dia-Flora” used in the Embodiment [A-1] is used for the inserted yarn ( 11 ). The inserted yarn ( 11 ) is interknitted in line weftwise every other course (φ 2 , φ 4 , φ 6 ) in a manner where it passes over one needle loop ( 40 ) and passes under the next one needle loop ( 40 ) of the base knitted fabric. The weft knitted fabric is finished as an elastic weft knitted fabric by passing it through a dry-heating treatment at 190° C. for 3 minutes. In this manner, an elastic weft knitted fabric is obtained having an inserted yarn thermally adhered to the base knitted fabric.
[0000] Comparison [B-1]
[0089] An inelastic polyester multifilament yarn (fineness: 500 dtex) is applied to the base stitch yarn ( 13 ).
[0090] The base knitted fabric is knitted in a plain stitch, shown in FIGS. 12 and 13 , with a density the wale direction of 12 wales/25.4 mm and a density in the course direction of 44 courses/25.4 mm.
[0091] The above-mentioned thermo adhesible sheath core conjugate elastic polyether-ester yarn “Dia-Flora” used in the Embodiment [A-1] is used for the inserted yarn ( 11 ).
[0092] The inserted yarn ( 11 ) is interknitted in line weftwise every other course (φ 2 , φ 4 , φ 6 ) in a manner where it passes over one needle loop ( 40 ) and passes under the next one needle loop ( 40 ) of the base knitted fabric.
[0093] The weft knitted fabric is used for a elastic top material without dry-heating treatment.
[0000] Comparison [B-2]
[0094] An inelastic polyester multifilament yarn (fineness: 667 dtex) is applied to the base stitch yarn ( 13 ).
[0095] The base knitted fabric is knitted using a plain stitch, shown in FIG. 10 , with a density in the wale direction of 12 wales/25.4 mm and a density in the course direction of 44 courses/25.4 mm.
[0096] The above-mentioned thermo adhesible sheath core conjugate elastic polyether-ester yarn “Dia-Flora” used in the Embodiment [A-1] is used for the inserted yarn ( 11 ).
[0097] The inserted yarn ( 11 ) is interknitted in every third courses (φ 2 , φ 5 ) of 6 courses (φ 1 , φ 2 , φ 3 , φ 4 , φ 5 , φ 6 ) in line weftwise in a manner where it passes over one needle loop ( 40 ) and passes under the next one needle loop ( 40 ) of the base knitted fabric.
[0098] The weft knitted fabric is finished up as an elastic weft knitted fabric by passing through dry-heating treatment at 190° C. for 3 minutes.
[0099] In this manner, an elastic weft knitted fabric where the inserted yarn thermally adhered to the base knitted fabric is obtained.
[0000] Property Datum of Embodiment and Comparison [B]
[0100] The elastic cover material ( 62 ) is formed by hanging the elastic weft knitted fabric ( 10 ) obtained in above Embodiment [B-1], Comparison [B-1] and Comparison [B-2] between frame parts, of a frame ( 60 ) preferably made of aluminum pipe and having a length of 40 cm, where these frame parts are separated 40 cm. The test to determine cramped feeling, stable feeling, hardness, painful feeling and fatigued feeling is executed on the elastic top material ( 62 ) by sitting on the elastic fabric for 10 minutes.
[0101] In the case of the elastic fabric of Embodiment [B-1], the portion where it touches the buttocks sagged slightly, the resistance of the sagged portion was not so hard, and cramped feeling, unstable feeling, hardness, painful feeling and fatigued feeling were not felt.
[0102] In the case of the elastic fabric of Comparison [B-1], it elongated significantly in the knitting length direction, the portion where it touched the buttocks sagged significantly, and the periphery of the sagged portion effected a cramped feeling, a sticky feeling, and a fatigued feeling.
[0103] In the case of the elastic fabric of Comparison [B-2], even though a sticky feeling was not felt to the same degree as the case of Comparison [B-1], due to a roughness of the density of the arrangement of the elastic yarn, the portion where it touched the buttocks sagged significantly as a whole, and an unstable feeling was felt.
[0104] For the results shown in Table 2 below:
[0105] (i) stress at 10% elongation (FC; N/5 cm) in the knitting width direction (Γ),
[0106] (ii) stress at 10% elongation (FC; N/5 cm) in the knitting length direction (Σ),
[0107] (iii) the rate of hysteresis loss ΔE which is calculated by the equation ΔE=100×C/V=100×(V−W)/V;
[0108] wherein V is an integral value which is calculated by integrating the load-reducing equation (f 1 (ρ)), which is defined by the reducing curve (f 1 ) of the hysteresis in the load-elongation diagram, from 0% to 10% elongation in the knitting width direction (Γ). W is an integral value which is calculated by integrating the load-elongation equation (f 0 (ρ)), which is defined by the loading curve (f 0 ) of the hysteresis in the load-elongation diagram, from 0% to 10% elongation in the knitting width direction (Γ).
[0109] C=V−W is the value of hysteresis loss which is calculated as the difference between the integral values V and W.
[0110] (iv) estimation in the test of the elastic fabrics ( 10 ) in the above-mentioned embodiment and comparison are shown in the following table ( 2 ).
TABLE 2 embodiment comparison comparison B-1 B-1 B-2 stress at 10% elongation 392 349 277 in the direction (Γ) (FC; N/5 cm) stress at 10% elongation 35 10 23 in the direction (Σ) (FW; N/5 cm) density of wale (wales/cm) .9 .9 .9 density of arrangement elastic .98 .98 .94 yarn (number/cm) bulk of elastic yarn (J) 18678 18678 14435 (dtex/cm) average course interval (Lc) .58 .58 .77 (mm) fineness of inelastic yarn 500 500 667 (dtex) average diameter of inelastic .224 .224 .258 yarn (d) (mm) fineness of elastic yarn (T) 2080 2080 2080 (dtex) average diameter of elastic .458 .458 .458 yarn (D) (mm) rate of sum of diameter of .18 .18 .97 elastic yarn and inelastic yarn (D + d) to course interval(Lc) (D + d) ÷ Lc rate of hysteresis loss 35 44 34 in the direction(Γ) ΔE (%) adhered situation of yarn in adhered unadhere adhered fabric estimation by sensory test good bad bad
[0111] Sagging of the surface of the elastic fabric ( 10 ) and reaction from the elastic fabric ( 10 ) are partially changable according to the manner in which the elastic fabric ( 10 ) is stretched and loaded. To avoid this problem, it is desirable to form the elastic fabric ( 10 ) in a three-dimensional construction with a face fabric ( 32 ) formed from face yarns ( 31 ) and a back fabric ( 34 ) formed from back yarns ( 33 ) and to apply the elastic yarn ( 11 ) to the back yarns ( 33 ) at least as one kind of yarn.
[0112] Accordingly, the elongation of the elastic yarn applied to the back fabric is restrained by the face fabric formed from the inelastic yarn. The three-dimensional elastic cover material which does not partially elongate and sag is useful for sofas and mattresses.
[0113] In the case of forming the elastic fabric ( 10 ) in three-dimensional constructions, in the weaving or knitting process, the face fabric ( 32 ) and the back fabric ( 34 ) are simultaneously woven or knitted and are connected by one kind of face or back yarns. In the case of weaving, three-dimensional elastic double fabric may be woven as one kind of warp-weft-double woven fabrics by using a conventional loom. Three-dimensional elastic double fabric knitted by using the weft knitting machine is shown in FIG. 14 . At one portion of the fabric, a double stitch opening is formed with the face yarn ( 31 ) and the back yarn ( 33 ). The face fabric ( 32 ) and the back fabric ( 34 ) are connected through the double stitch opening. Between the face fabric ( 32 ) and the back fabric ( 34 ), the interspace stratum ( 36 ) is formed. Three-dimensional elastic double fabric woven by using the double moquette loom is shown in FIG. 15 . The face fabric ( 32 ) is formed in a plain weave textile design with the face warp yarn ( 31 y ) and the face weft yarn ( 31 x ). The back fabric ( 34 ) is formed in a plain weave textile design with the back warp yarn ( 33 y ) and the back weft yarn ( 33 x ). The interspace stratum ( 36 ) is formed between the face fabric ( 32 ) and the back fabric ( 34 ) which are connected by the connecting yarn ( 35 ).
[0114] Three-dimensional elastic double fabric knitted by using the double raschel warp knitting machine is shown in FIG. 16 . The face fabric ( 32 ) and the back fabric ( 34 ) are connected by the connecting yarn ( 35 ). The thickness of the interspace stratum ( 36 ) formed between the face fabric ( 32 ) and the back fabric ( 34 ) may be more than 0.3 mm. The elastic yarn is used for the back yarn ( 33 ) and the connecting yarn ( 35 ), and the inelastic yarn is used for the face yarn ( 31 ). The face yarns ( 31 ) form two kinds of chain stitch openings ( 38 a , 38 b ) alternating every several courses. The two kinds of chain stitch openings ( 38 a , 38 b ) are formed over several courses. One of the two kinds of chain stitch openings ( 38 a ) is formed together with one of the face yarns ( 31 a ) and the other face yarn ( 31 b ) which is adjacent to the left side of the one face yarn ( 31 a ) in the knitting width direction (Γ). Another one of the two kinds of chain stitch openings ( 38 b ) is formed together with the one face yarn ( 31 a ) and another face yarn ( 31 c ) which is adjacent to the right side of the one face yarns ( 31 a ) in the knitting width direction (Γ). Consequently, these two kinds of chain stitch openings ( 38 a , 38 b ) form the chain stitch opening row ( 39 ) extending in the knitting length direction (Σ) in a zigzag manner. And, openings ( 37 ) having an opening area more than 1 mm 2 are formed between adjacent chain stitch opening rows ( 39 , 39 ). Three-dimensional elastic double fabric is knitted up in mesh shape as a knitted net fabric. The back fabric ( 34 ) is formed with the ground stitch back yarn ( 33 a ) for forming the chain stitch opening row ( 39 ) extending in the knitting length direction (Σ) and the inserted back yarn ( 33 b ) is applied for connecting adjacent chain stitch opening rows ( 39 , 39 ) without forming a needle loop.
[0115] Three-dimensional elastic double fabric has superior insulating properties because the interspace stratum ( 36 ) having bag like openings is formed between the face fabric ( 32 ) and the back fabric ( 34 ). In the three-dimensional elastic double fabric, even though the back fabric ( 34 ) may be thick, the softness of the face fabric ( 32 ) is not adversely affected. Even though the face fabric ( 32 ) may be formed in a mesh shape as a knitted net fabric, the shape of the face fabric ( 32 ) is stably maintained by the thick back fabric ( 34 ).
[0116] The elastic top material ( 62 ) which provides superior cushioning, is not sticky and is useful for sofas and mattresses, and may be obtained by using the three-dimensional elastic double fabric ( 10 ) wherein the thickness of the stratum ( 36 ) is more than 0.3 mm. Such thick three-dimensional elastic double fabric ( 10 ) provides superior cushioning, insulation, and air-permeability so that air flows out from and into the interspace stratum ( 36 ) every time it is compressed and expanded.
[0117] Thus, the three-dimensional elastic double fabric, of which the face fabric is formed in a mesh shape, is suitable for sofas and mattresses.
[0118] The three-dimensional elastic double fabric, wherein the elastic yarn ( 11 ) is used as the connecting yarn ( 35 ), provides superior cushioning, and is especially suitable for sofas and mattresses, and does not effect a sticky feeling.
[0119] Limbs of the human body cannot be supported comfortably on a cushioning surface when the surface is stretched under significant strain on a frame so as to maintain a planar surface.
[0120] In this regard, in accordance with the present invention, the tensile stresses, which are induced in the yarns in two mutually orthogonal directions and also cause elongation of the elastic fabric at a known rate, are distributed in relation to the deformation of the fabric. That is, the elasticity of the cushioning surface varies in a manner such that at one portion, where heavy loads act, the fabric sags significantly and forms a deep recess, while at another portion, where heavy loads do not act, the fabric sags less and forms a shallow recess. In such a manner, the cushioning surface accommodates the shape of limbs. In accordance with the present invention, the elastic cover material ( 10 ) does not cause pain and fatigue when limbs are put on the cushioning surface for a long time.
[0121] In the present invention, the tensile stress at the regular degree of elongation of the elastic fabric (hence called “regular tensile strength”) is defined as the tensile stress which acts on the elastic fabric when it is elongated and its elongation reaches a degree of elongation that is necessary to compare the stretching elasticity of different portions of the cushioning surface which may be formed from the elastic fabric. It is preferable to set the “regular tensile strength” by the press load which is measured when the degree of elongation reaches the regular degree of elongation in a measuring process where the press load is applied to different portions of the cushioning surface where stretching elasticity is to be compared by increasing the press loads until the degree of elongation reaches the regular degree of elongation which may be between 3%˜10% elongation.
[0122] In the present invention, “portions spaced apart in at least two mutually orthogonal directions” means the following two portions;
[0123] (i) in the case of elastic fabric which is formed as a warp knitted fabric wherein the warp yarn ( 18 ) is continuous in the length direction (h) of the fabric, two portions (r- 1 , r- 2 ) which are apart from one another in the width direction (r), that is, portion (r- 1 ) formed with warp yarns ( 18 a ) is apart from portion (r- 2 ) formed with other warp yarns ( 18 b ) ( FIG. 17 ).
[0124] (ii) in the case of elastic fabric which is formed as a weft knitted fabric wherein the weft yarn ( 19 ) is continuous in the width direction (r) of the fabric, two portions which are apart from one another in the length direction (h), that is, portion (h- 1 ) formed with weft yarns ( 19 a ) is apart from portion (h- 2 ) formed with other weft yarns ( 19 b ) ( FIG. 18 ).
[0125] (iii) in the case of elastic fabric which is formed with warp yarns ( 18 ) which are continuous in the length direction (h) of the fabric and weft yarns ( 19 ) which are continuous in the width direction (r) of the fabric as a weft inserted warp knitted fabric and a woven fabric, two portions (r- 1 , r- 2 ) which are apart from one another in the width direction (r) and another 2 portions (hr- 1 , hr- 2 ) which are apart from one another in the length direction (h) of the fabric, that is, four portions (r- 1 , r- 2 , hr- 1 , hr- 2 ) wherein the yarns are different in connection with either warp yarns ( 18 ) or weft yarns ( 19 b ) ( FIG. 19 ).
[0126] As shown in FIG. 19 , it is desirable for the partial variation of the regular tensile strength to be achieved using various kinds of yarn in different orthogonal directions. That is, for the partial variation of the regular tensile strength between two portions, two kinds of yarn are threaded in parallel into the two portions which are apart from one another in the direction where other yarn is continuous in its length direction and is orthogonal to the two kinds of yarn.
[0127] Two such portions can be shown in FIG. 19 , wherein the elastic fabric is formed with the warp yarn ( 18 ) which is continuous in the length direction (h) of the fabric, and the weft yarn ( 19 ) which is continuous in the width direction (r) of the fabric, such as a weft inserted warp knitted fabric and a woven fabric. Therein, two kinds of yarn may be applied for the warp yarn ( 18 ) and the weft yarn ( 19 ). At either two portions (r- 1 , r- 2 ) which are apart from one another in the width direction (r) or other two portions (hr- 1 , hr- 2 ) which are apart from one another in the length direction (h) of the fabric, either the kind of warp yarns ( 18 ) of the portion (r- 1 ) and the portion (r- 2 ) or the kind of weft yarns ( 19 ) of the portion (hr- 1 ) and the portion (hr- 2 ) are varied.
[0128] In the present invention, two such portions being apart from one another in the direction orthogonal to the direction in which the regular tensile strength acts, that is, positions in which the regular tensile strength are different from one another, are called “regular strength different positions”. In the case of the weft knitted fabric shown in FIGS. 10-13 , the “regular strength different positions” are shown as the courses (φ 1 , φ 2 , φ 3 , φ 4 , φ 5 ) where several different kinds of yarn can be selectively threaded in for varying the “regular tensile strength” according to the kinds of yarn. In the case of the elastic cover material ( 62 ) which is formed by fitting the knitting width direction (Γ) to the width direction of the frame (i) and by stretching and hanging the elastic weft knitted fabric ( 10 ) between frame parts ( 61 a , 61 b ) ( FIG. 20 ), it becomes possible to vary the “regular tensile strength” in the width direction at every portion in the depth direction (q).
[0129] In the cases of the warp knitted fabric and the warp inserted warp knitted fabric shown in FIGS. 1-3 , the “regular strength different positions” are shown as the wales (σ 1 , σ 2 , σ 3 , σ 4 , σ 5 ) where several kinds of yarn can be selectively threaded in to vary the “regular tensile strength” according to the kind of yarn. In the case of the elastic cover material ( 62 ) which is formed by fitting the knitting length direction (Σ) to the width direction of the frame (i) and by stretching and hanging the elastic weft knitted fabric ( 10 ) between frame parts ( 61 a , 61 b ) ( FIG. 20 ), it becomes possible to vary the “regular tensile strength” in the width direction at every portion in the depth direction (q).
[0130] In the case of the weft inserted warp knitted fabric shown in FIG. 2 , the “regular strength different positions” are shown as the courses (φ 1 , φ 2 , φ 3 , φ 4 , φ 5 ) where several kinds of yarn can be selectively threaded in for the variation of the “regular tensile strength” according to the kinds of yarn. Similarly, to vary the “regular tensile strength” of the wales (σ 1 , σ 2 , σ 3 , σ 4 , σ 5 ), several kinds of yarn can be selectively threaded in, the variation being according to the kinds of yarn. Therefore, in the case of the elastic cover material ( 62 ) which is formed by fitting the knitting length direction (Σ) to the width direction of the frame (i) and by stretching and hanging the elastic knitted fabric between frame parts ( 61 a , 61 b ) ( FIG. 20 ), when the weft inserted warp knitted fabric wherein several kinds of yarn having different elasticity are selectively threaded in the wales (σ 1 , σ 2 , σ 3 , σ 4 , σ 5 ), it becomes possible to vary the “regular tensile strength” of the cushioning surface ( 74 ) in the width direction at every portion in the depth direction (q) of the elastic cover material ( 62 ) ( FIG. 2 ). Also, in the case of the weft inserted warp knitted fabric shown in FIG. 2 , when it is knitted by selectively threading several kinds of yarn, which have different elasticity, into the wales or the courses, a check pattern with crosswise stripes ( 75 ) and lengthwise stripes ( 76 ) is formed depending on the difference of the kind of the yarn and the variation in the “regular tensile strength” which may act in both width and depth directions (i, q) at the “regular strength different positions” ( FIG. 2 ). In the case of the weft inserted warp knitted fabric which is knitted by selectively threading several kinds of yarn, which have different elasticity, into the courses (φ 1 , φ 2 , φ 3 , φ 4 , φ 5 ), when the weft inserted warp knitted fabric is stretched and hung between frame parts ( 61 a , 61 b ) by fitting the knitting length direction (Σ) to the width direction of the frame (i), it is possible to vary the “regular tensile strength” in the depth direction (q), at every portion in the width direction (i).
[0131] For woven fabric, the “regular strength different positions” are different positions in the width direction (r) where several kinds of warp yarns ( 18 ) can be selectively arranged, and different positions in the weaving length direction (h) at which several kinds of weft yarn ( 19 ) can be selectively picked into the shed between warp yarns ( 18 , 18 ). Therefore, the woven fabrics shown in FIGS. 17-19 , are used for the elastic cover material, in the same way as the weft inserted warp knitted fabric shown in FIG. 2 . A check pattern with crosswise stripes ( 75 ) and lengthwise stripes ( 76 ), a crosswise stripe pattern and a lengthwise stripe pattern may be formed depending on the difference between yarns, and the “regular tensile strength” which acts in both width and depth directions (i, q) at the regular strength different positions.
[0132] When several kinds of yarn are selectively applied to the “regular strength different positions” of elastic fabric, check patterns and stripe patterns tend to appear on the cushioning surface in accordance with differences of characteristics of the yarn such as finenesses, degree of twist, material and the like ( FIG. 20 ).
[0133] To avoid such an appearance low stretch yarns and high stretch yarns, which are used, should be the same at the “regular strength different positions”, and for both woven and knitted fabric, the density of warp and weft yarns at the “regular strength different positions” should be equal. To further avoid the aforementioned appearance, the surface of the “regular strength different positions” can be covered with cut piles, loop piles, or tufts formed from the yarns which have the same dyeing properties, fineness, number of twist, material properties, and the like. When the elastic fabric is formed as a double fabric with a surface stratum formed from face yarns and a back stratum formed from back yarns, lower stretch yarns which have the same material properties, fineness, number of fibers, and degree of twist are preferably used for the surface stratum of the “regular strength different positions”.
[0134] The elastic yarn having a fineness of more than 300 dtex is bar shaped and has a flat, slippery surface. Therefore, the surface of the elastic fabric is also flat and slippery. And, when limbs are rested upon an elastic cover material formed from such elastic fabric, the limbs cannot be maintained in a comfortable posture, and fatigue occurs.
[0135] In accordance with the present invention, the average coefficient of friction (ω) of the surface of the elastic fabric is increased above 0.26 (0.26≦ω) by using a non-slip yarn, which has fine fibers with a single fiber fineness less than 30 dtex, to form the elastic fabric, and by floating the fine fibers over the surface of the elastic fabric so that the non-slip yarn exposes at least an area of 1 cm 2 (lengthwise 1 cm×crosswise 1 cm). The average coefficient of friction (ω) of the surface of the elastic fabric is calculated through following steps.
[0000] (Step i)
[0136] A rectangular test fabric is cut out from the elastic fabric, the test fabric having dimensions of 20 cm×20 cm, and is spread over and fixed on the surface of a metal plate which has a mirror finish and is supported horizontally.
[0000] (Step ii)
[0137] A stainless steel rectangular contact segment having dimensions of 10 mm×10 mm and 20 channels of width 0.1 mm and depth 0.1 mm across the undersurface, is put on the test fabric.
[0000] (Step iii)
[0138] A load of 50 gf is set on the test fabric through the contact segment.
[0000] (Step iv)
[0139] The contact segment is moved at a speed of 0.1 mm/second to and fro a distance of 30 mm in a direction perpendicular to the channels.
[0000] (Step v)
[0140] The coefficient of friction (ω 1 ) in the longitudinal direction of the elastic fabric is calculated by dividing the average value of the frictional force (F 1 ; gf) between the contact segment and the test fabric by the load (50 gf). The coefficient of friction (ω 2 ) in the lateral direction of the elastic fabric is calculated by dividing the average value of the frictional force (F 2 ; gf) between the contact segment and the test fabric by the load (50 gf). The average coefficient of friction (ω) of the surface of the elastic fabric is calculated as the average (0.5ω 1 +0.5ω 2 ) of the coefficient of friction (ω 1 ) in the longitudinal direction and the coefficient of friction (ω 2 ) in the lateral direction.
[0141] A reason to make the fine fibers float or to expose the non-slip yarn among the rectangular area of 1 cm 2 of the surface of the elastic fabric is that the elastic fabric may be formed similarly to conventional fabric which is made from a fiber of fineness less than 30 dtex.
[0142] A reason to set the size of the measuring area of the undersurface of the contact segment at 10 mm×10 mm is that a non-slip effect caused by the non-slip yarn cannot be achieved with a porous fabric for which the space between yarns is more than 10 mm. It is required to distribute the fine fibers of fineness less than 30 dtex uniformly over the whole surface of the elastic fabric to achieve the non-slip effect due to the non-slip yarn.
[0143] The present invention intends to minimize the ratio of the exposed area of the thick and slippery elastic yarn through the existence of the fine fibers of fineness less than 30 dtex.
[0144] However, it is not necessary to completely cover the surface of the elastic fabric with the fine fibers of fineness less than 30 dtex. Since the surface of the elastic fabric should be somewhat slippery to promote a comfortable and natural feel to the limbs which are not restrained on the surface. In consideration of these matters, an average coefficient of friction (co) of the surface of the elastic fabric should be less than 0.60 (0.26≦ω≦0.60), preferably within 0.30˜0.50 (0.30≦ω≦0.50), further preferably within 0.35˜0.40 (0.35≦ω≦0.40). to that end, the ratio of exposed area of the non-slip yarn to the measuring area, lengthwise 10 mm×crosswise 10 mm, may generally be less than 50%, preferably within 5%-30%, further preferably within 15%-25% (generally about 20%).
[0145] The following yarns can be used for the non-slip yarn.
[0146] (i) spun yarn and napped multifilament yarn having float tufts,
[0147] (ii) ring yarn having a ring like bumpy surface formed by annex yarns surrounding a core yarn,
[0148] (iii) slub yarn having a slub like bumpy surface formed by annex yarns surrounding a core yarn,
[0149] (iv) fuzzy ball yarn having a fuzzy ball-like bumpy surface formed by annex yarns climbing up a core yarn,
[0150] (v) sheath core conjugate yarn having a bumpy surface formed by covering core yarn by sheath yarn,
[0151] (vi) interlaced yarn having a bumpy surface formed by over feeding multifilament,
[0152] (vii) chenille yarn formed by fixing decorative yarn to a core yarn,
[0153] (viii) flocked yarn formed by electrostatically fixing fiber fragments to a core yarn,
[0154] (ix) cord yarn having a napped surface formed by cutting natural leather, synthetic leather, artificial leather, non-woven fabric and the like.
[0155] The elastic fabric may be finished by raising its surface to create a nap on the surface where the non-slip yarn is exposed. When conventional spun yarn and multifilament yarn are used for the non-slip yarn, the surface of the elastic fabric may be covered with piles formed by these conventional yarns. In this connection, it is desirable to use chenille yarns and flocked yarns as the non-slip yarn, since the surface of these yarns are covered with piles.
[0156] In the case where the elastic fabric is formed as a double fabric with a surface stratum formed from face yarns and a back stratum formed from back yarns, it is desirable to apply the elastic yarn to the back fabric ( 34 ) and apply the non-slip yarn to the face fabric ( 32 ).
[0000] Embodiment [C-1]
[0157] A polyester spun yarn (fineness: 2 ply/meter count of 10 in single yarn) is used in the warp direction with a warp density of 64/10 cm.
[0158] The above-mentioned thermo adhesible sheath core conjugate elastic polyether-ester yarn “Dia-Flora” used in the Embodiment [A-1] is used for the first weft yarn.
[0159] A chenille yarn (fineness: meter count of 1/2.8) is used for the second weft yarn. The chenille yarn comprises a decorative pile yarn for which a multifilament texturized yarn (fineness: 167 dtex) is used, and a core yarn for which a polyester spun yarn (fineness: cotton count of 20, single fiber 1.4 dtex) and a thermo adhesible nylon monofilament yarn (fineness: 78 dtex) are used.
[0160] The fabric is woven using a twill weave by inserting reciprocally the first weft yarn and the second weft yarn at every pick with a weft density of 120/10 cm.
[0161] The woven fabric is finished as an elastic woven fabric ( 10 ) by passing it through a dry-heating treatment at 190° C. for 3 minutes and by thermally adhering the warp yarns and the weft yarns.
[0162] Stress at 10% elongation (F) in the width direction (r) of the elastic woven fabric ( 10 ) is 217 (N/5 cm).
[0163] Coefficient of friction (ωh) in the weaving length direction of the elastic woven fabric ( 10 ) is 0.375.
[0164] Coefficient of friction (ωr) in the weaving width direction of the elastic woven fabric ( 10 ) is 0.387.
[0165] Average coefficient of friction (ω) of the surface of the elastic fabric is 0.381.
Embodiment [C-2]
[0166] A polyester spun yarn (fineness: 2 ply/meter count of 10 in single yarn) is set in warping with a warp density of 64/10 cm.
[0167] The above-mentioned thermo adhesible sheath core conjugate elastic polyether-ester yarn “Dia-Flora” is used for the first weft yarn.
[0168] The above-mentioned chenille yarn (fineness: meter count of 1/2.8) is used for the second weft yarn.
[0169] A ring yarn (fineness:meter count of 1/3.8) made by applying a polyester multifilament yarn (fineness: 501 dtex (167×3), single fiber fineness: 3.4 dtex) to an annex yarn, by applying a multifilament texturized yarn (fineness: 166 dtex (83×2), single fiber fineness: 3.4 dtex) to a core yarn, and by applying a multifilament texturized yarn (fineness: 83 dtex, single fiber fineness: 3.4 dtex) and a multifilament texturized yarn (fineness: 167 dtex, single fiber fineness: 3.4 dtex) to a binder yarn, is used for the third weft yarn (non-slip yarn).
[0170] The fabric is woven in a twill weave by inserting the first weft yarn and the second weft yarn and the third weft yarn in order with density in the weft direction of 136/10 cm.
[0171] The woven fabric is finished as an elastic woven fabric ( 10 ) by passing it through a dry-heating treatment at 190° C. for 3 minutes and by thermally adhering the warp yarn and the weft yarn.
[0172] Stress at 10% elongation (F) in the width direction (r) of the elastic woven fabric ( 10 ) is 266 (N/5 cm).
[0173] Coefficient of friction (ωh) in the weaving length direction of the elastic woven fabric ( 10 ) is 0.398.
[0174] Coefficient of friction (ωr) in the weaving width direction of the elastic woven fabric ( 10 ) is 0.391.
[0175] Average coefficient of friction (ω) of the surface of the elastic fabric is 0.385.
[0000] Comparison [C-1]
[0176] A polyester spun yarn (fineness: 2 ply/meter count of 10 in single yarn) is in the warp direction with a density of 64/10 cm.
[0177] The above-mentioned thermo adhesible sheath core conjugate elastic polyether-ester yarn “Dia-Flora” used in the Embodiment [A-1] is used for the weft yarn.
[0178] The fabric is woven in a twill weave with a density in the weft direction of 136/10 cm.
[0179] The woven fabric is finished as an elastic woven fabric ( 10 ) by passing it through a dry-heating treatment at 190° C. for 3 minutes and by thermally adhering the warp yarns and the weft yarns.
[0180] Stress at 10% elongation (F) in the width direction (r) of the elastic woven fabric ( 10 ) is 403 (N/5 cm).
[0181] Coefficient of friction (ωh) in the weaving length direction of the elastic woven fabric ( 10 ) is 0.202.
[0182] Coefficient of friction (ωr) in the weaving width direction of the elastic woven fabric ( 10 ) is 0.273.
[0183] Average coefficient of friction (ω) of the surface of the elastic fabric is 0.238.
[0184] In accordance with the present invention, the weight of limbs loaded on the elastic fabric is distributed in all directions, the fabric deforms to accommodate the shape of the limbs, the fabric does not feel sticky, undulatory puckers or crimps do not appear over the surface of the elastic fabric. Thus, an elastic fabric which provides a soft feeling and has high load-hysteresis fatigue resistance can be obtained. When the elastic fabric is hung over and fixed on both its edges to frame parts, which are positioned on both sides of a frame, and which are spaced apart from and opposite to one another, an elastic cover material which is small, easy to deal with, light weight, not bulky, and on which limbs may be supported stably can be obtained. | An elastic fabric useable for covering pillows, seats, mattresses and the like is disclosed. The fabric is formed from elastic yarns having a breaking elongation greater than 60%, a rate of elastic recovery after 15% elongation of more than 90% and a stress at 10% elongation greater than 150 N/5 cm and less than 600 N/5 cm oriented in a direction parallel to the elastic yarn, and a rate of hysteresis loss between 20% and 45%. The fabric may be woven or knitted and provides a stable, comfortable feeling for sitting or reclining and deforms when supporting weight but returns readily to its undeformed shape. | 3 |
FIELD OF THE INVENTION
The present invention relates to a data processing system, an electronic device and a method of cache replacement.
DESCRIPTION OF THE RELATED ART
With the increasing availability and success of portable devices like PDA, notebooks, mobile phones, portable MP3-player etc. the power consumption of these devices has become more and more important within modern integrated circuits and the design thereof and a considerable amount of investigation and design efforts have been conducted to reduce the power consumption. As the VLSI design of ICs used in such devices is shifting into the nanometer domain, the energy which is dissipated by the interconnect in a system-on-chip becomes a significant part of the overall system power consumption. Furthermore, a limiting factor for reducing the weight and size of portable devices correlate to the amount of batteries which are required to provide the power dissipated by the electronic circuits within the portable devices.
The power consumption of the interconnect, i.e. the bus or the network, is not only based on the physical properties of the interconnect, like the voltage swing, the wire delay, the topography of the interconnect or the like, but also on the data flow in the system-on-chip, i.e. the processor-processor communication and the processor-memory communication. This communication can be of the following origins: cache and memory transactions (data fetch from shared memory), cache coherence operations (updated data in a shared memory must be updated in all cache copies resulting in synchronization traffic), write back during cache victimization, packet segmentation overheads (segmenting dataflow into packets will introduce an additional data overhead) or contentions between packets (re-routing packets in case of a contention).
In “Low Power-Cache Replacement Algorithm” in Research disclosure, RD-4008050, April 1998, a method for minimizing a power dissipation resulted from bit changes in the content of a tag RAM during cache replacement is described.
SUMMARY
It is an object of the invention to reduce the power consumption within a data processing system or an electronic circuit comprising a plurality of processing units.
This object is solved by a data processing system according to claim 1 , an electronic device according to claim 6 and a method of cache replacement according to claim 7 .
Therefore, data processing system is provided comprising at least one processing unit for processing data, a memory means for storing data; and a cache memory means for caching data stored in the memory means. Said cache memory means is associated to at least one processing unit. An interconnect means is provided for connecting the memory means and the cache memory means. The cache memory means is adapted for performing a cache replacement based on reduced logic level changes of the interconnect means as introduced by a data transfer between the memory means and the cache memory means.
According to an aspect of the invention, said cache memory means comprises a plurality of cache lines and a cache controller for selecting those cache lines to be evicted based on the hamming distance between the values of the data send last and the data to be sent next over the interconnect means. Therefore, this provides an easy method for determining the minimum logic level changes in the interconnect.
According to a further aspect of the invention, the cache controller comprises an enabling/disabling unit for enabling/disabling the cache replacement optimized for power consumption. Accordingly, the cache replacement being optimized for power consumption can be disabled if time critical applications are to be processed by the data processing system.
The invention is also related to an electronic circuit comprising at least one processing unit for processing data, a memory means for storing data; and a cache memory means for caching data stored in the memory means. Said cache memory means is associated to at least one processing unit. An interconnect means is provided for connecting the memory means and the cache memory means. The cache memory means is adapted for performing a cache replacement based on reduced logic level changes of the interconnect means as introduced by a data transfer between the memory means and the cache memory means.
The invention further relates to a method of cache replacement within a cache memory means associated to at least one processing unit. The cache memory means is adapted for caching data stored in a memory means. The memory means and the cache memory means are connected by an interconnect means. A cache replacement within the cache memory means is preformed based on reduced logic level changes of the interconnect means as introduced by a data transfer between the memory means and the cache memory means.
The invention is based on the idea to perform a cache replacement based on reduced or minimum logic level changes of an interconnect between a memory and a cache.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention are apparent from and will be elucidated with reference to the embodiments described hereinafter.
FIG. 1 shows a block diagram of a basic architecture of a system on chip according to the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
FIG. 1 shows a block diagram of a basic architecture of a system on chip according to the invention. Such a system on chip may be implemented as or on an electronic device or a data processing system. The system on chip comprises at least one processing unit 10 (only one processing unit is depicted), a cache means 20 associated to the processing unit 10 . The cache means 20 is connected to a memory 40 via a bus 30 . The cache 20 serves to cache data from the memory, i.e. those data items, which will be needed during upcoming processing cycles are fetched from the memory before their actual processing.
The cache means 20 comprises m cache lines 25 or cache blocks as well as cache controller CC. The m cache line 25 may comprise the data D 1 , D 2 , . . . Dm. The last data D 0 which has been read from or has been written to the cache lines 25 is stored in the cache controller CC or in the cache means 20 .
Once a cache miss has occurred, a cache controller CC has to select the data item or the block currently stored in the cache, which is to be replaced with the desired data item or data block to be fetched. The actual cache replacement can be performed on a randomly basis, a least-recently used LRU basis or on a first in, first out FIFO basis. A further cache replacement policy is the least-frequently used technique; wherein the least-frequently used block is evicted from the cache to create space for newly prefetched data.
Regarding the cache replacement techniques two issues appear to be important, namely which data block should be fetched into the cache and which data block should be evicted from the cache such that the newly fetched data block can be stored in the cache instead of the evicted data block.
The cache controller CC selects one of the cache lines 25 with data D 1 -Dm which transfer over the interconnect 30 will result in reduced or minimum logic level changes. The cache controller CC compares the content of the data D 1 -Dm with the content of the data D 0 which was transferred last over the bus, i.e. the interconnect 30 . Once the respective cache line 25 and its corresponding data is selected, this cache line 25 is victimized and evicted. This is preformed by determining the hamming distance between the content of the data D 0 , i.e. the data previously being transferred to/from the cache 20 over the bus 30 , and the content of the data D 1 -Dm which is to be evicted and transferred over the bus 30 . The cache controller CC optionally comprises a victim buffer for storing the previously victimized (write-back) data such that its content can be compared to the contents of the cache lines 25 of the cache 20 .
A hamming distance corresponds to the minimum number of bits that have to be changed in order to convert one bit string into another. If x and y are two binary sequences of the same length, the hamming distance between these two sequences is the number of symbols that do not correspond to each other. For example, if x=10000110 and y=01101000, then the hamming distance is the number of bits which change from x to y. Here, this number is 6.
If the cache 20 comprises 4 cache lines 25 , then the cache lines 25 comprise data D 1 -D 4 . If new data is to be read into the cache one of the four cache lines 25 must be victimized and evicted. If the case is considered that the last evicted (and transferred over the bus 30 ) data is D 0 , then the cache controller CC determines the hamming function.
h (D 0 , D i ), where D i =D 1 , D 2 , . . . , D m (m=4 in this example) such that bit changes between D 0 and D i are minimum. The cache line 25 whose data (D i ) results in minimum hamming distance is selected for victimization and can be transferred over the bus.
For example,
if D 0 =10101010
and D 1 =11110000
D 2 =01010101
D 3 =10001010
D 4 =00110001
Here, the hamming distance is h (D 0 , D 1 )=4, h (D 0 , D 2 )=8, h (D 0 , D 3 )=1, h (D 0 , D 4 )=5, respectively. Hence, the cache line which is victimized and transferred over the bus corresponds to the data D 3 .
Optionally, a memory mapped input output MMIO register is arranged in the cache controller CC. This register is used to enable/disable the above-mentioned victimization scheme based on reducing the power consumption. This power-saving victimization scheme is activated if an application is to be processed with calculations which are not time-critical. However, if an application is to be processed which comprises time-critical calculations, the cache victimization scheme for reducing the power consumption can be disabled or switched off for a predetermined period of time or as long as the time-critical application is processed. Thereafter, the power reducing victimization scheme may be enabled or switched on again. The status of the power reducing victimization scheme may be stored in the MMIO register. Accordingly, the power-saving cache victimization scheme can be combined with other conventional cache replacement schemes. Depending on the criticality of the application, this mode can be switched off/on.
Reducing the logic level changes on a bus reduces the power consumption in the overall electrical circuit, as the overall power consumption of a bus is dominated by the power consumption during the switching of the logic levels of the bus. The power consumption due to the changes in logic level are dependent on the clock rate, the supply voltage, the node capacitance and the average number of times in each clock cycle that a node will make a power consumption transition from 0 to 1 or from 1 to 0. For more information regarding the power consumption of a bus please refer to “Minimizing power consumption in CMOS circuits” by Chandrakasan et al., in Proc. of the IEEE, Vol. 83, no. 4, April 1995.
Although the additionally required circuitry for the cache victimization may consume a certain amount of power, this amount will be significantly less as compared to the power consumption save by reducing the switching in the bus lines.
The above mentioned system on chip may be implemented in portable devices like mobile phones, PDA etc.
It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parenthesis shall not be construed as limiting the claim. The word “comprising” does not exclude the presence of elements or steps other than those listed in a claim. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. In the device claim in numerating several means, several of these means can be embodied by one and the same item of hardware. The mere fact that certain measures are resided in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
Furthermore, any reference signs in the claims shall not be constitute as limiting the scope of the claims. | A data processing system is provided comprising at least one processing unit for processing data; a memory means for storing data; and a cache memory means for caching data stored in the memory means. Said cache memory means is associated to at least one processing unit. An interconnect means is provided for connecting the memory means and the cache memory means. The cache memory means is adapted for performing a cache replacement based on reduced logic level changes of the interconnect means as introduced by a data transfer between the memory means and the cache memory means. | 8 |
BACKGROUND
1. Field
This invention relates generally to telecommunications, more specifically, to a method and system to provide location information for voice calls.
2. Related Art
Around the world there are many emergency telephone numbers. For example, in the United States of America, the three-digit telephone number “911” is designated as the universal emergency telephone number. In the case of an emergency, a person can call 911 to reach an operator who can dispatch appropriate emergency services. To help provide the timeliest response, it is helpful and often necessary to have the location of the caller reported to the emergency service dispatcher. This is feature is of utmost importance when the caller is a young child, someone who is very ill or injured or otherwise unable to effectively communicate their location to the emergency services dispatcher. For these services to function properly, the telephone service provider must have means of identifying and reporting the location of the emergency caller.
In a typical scenario, when a subscriber subscribes to a residential telephone service from a service provider, the service provider assigns a telephone number for that subscription and allocates an access line to the subscriber's residence for the service. The access line connects to a telephone system of the residential telephone service. A user connects a telephone to the access line and uses the telephone to receive the residential telephone service.
The location of the subscription is the connecting point of the access line and the telephone. The location is typically the street address of the subscriber's residence. The service provider submits the telephone number and the location of the subscription to create a record in an Automatic Location identity (ALI) database. The record maps the telephone number to the location of the subscription. One of the usages of ALI database is for Emergency call purpose.
When a caller uses the telephone to make an emergency call by dialing “911”, the telephone system determines the telephone number associated with the subscription. The telephone system sends a call request to a 911 selective router telephone system. The call request includes the telephone number.
The 911-selective router telephone system receives the telephone number in the call request and retrieves from the ALI database the location of the subscription based on the telephone number. The location is presumably where the caller of the emergency call is. The 911-selective router telephone system uses the location to select a Public Safety Answering Point (PSAP), which is a telephone system. The 911-selective router telephone system further sends the emergency call request to the PSAP. The call request also includes the telephone number.
The PSAP presents the emergency call to an emergency call agent. The PSAP also retrieves from the ALI database the location of the subscription based on the telephone number in the emergency call request, and informs the emergency call agent of the location from which the call originated. The agent uses the location to dispatch emergency personnel and services.
Recently, various service providers have been rolling out new telephone services. These telephone services include cellular telephone services, and Voice over IP (VoIP) telephone services. Although these telephone services are not the same as traditional residential telephone services, they are either marketed as residential telephone services or subscribers use them as if they are equivalent to residential telephone services. Many consumers mistakenly assume that 911 or emergency services will be available in these new telephone services as they are in traditional residential telephone services. However this is often not the case. Cellular and VoIP telephone services, due to their ability to move from one physical location to another, present a fairly complex problem when it come to providing emergency call services. Especially when those services are highly dependent on knowing from whence the emergency call is being made.
In the case of VoIP telephone service, a user receives VoIP telephone service by connecting an IP telephone to a VoIP telephone system via the Internet. In one scenario, the IP telephone may be connected to a home DSL broadband Internet access gateway. It is also possible to connect the same IP telephone to a neighbor's Cable Modem broadband Internet access gateway. As a further convenience, is it also possible to connect an IP telephone to the IP network of a hotel during an out-of-town trip. In each example, the IP telephone is used to receive VoIP telephone service. While the convenience of being able to travel to any location with an appropriate Internet access, there is a danger associated with assuming that emergency services will be available on the IP telephone as on a regular telephone. To illustrate this danger, consider the following scenario.
While out of town, a user has an accident or encounters an emergency. The user calls 911 on an IP telephone that they have brought from home. The user assumes the 911-emergency call center would know her location, and expects emergency services to arrive in a short period of time. When the emergency call is not answered or when emergency services do not arrive in an hour, the user panics. Whilst in the hotel, the user's spouse calls the user's IP telephone number from their home concerned that emergency services were dispatched to their home for her whilst she is away. From the IP telephone service, the emergency dispatch services had no way of knowing her location.
As shown in the new telephone services, there is a need for a fundamentally new solution to provide the correct location of a caller during an emergency call.
SUMMARY
Embodiments of the present include systems and methods for obtaining the location of a caller during a telephone call.
In one embodiment, a phone system obtains the subscriber access line identity of a subscriber access line and sends it to a subscriber location query system which then returns a subscriber location or a subscriber location record.
In another embodiment, subscriber phone equipment or phone can store a subscriber access line identity. The subscriber line identity stored in the subscriber phone equipment or phone can be used to retrieve the subscriber location record with the corresponding subscriber access line identity stored its subscriber access line identity attribute and a known location stored in its subscriber location attribute to compare to subscriber access line identities obtained during calls to determine if the subscriber phone equipment has changed location.
In yet another embodiment, the emergency call capabilities of a subscriber access line are determined by an emergency call test module sending out a test signal or query to a subscriber access line module, a phone system or subscriber access line.
Additional embodiments will be evident from the following detailed description and accompanying drawings, which provide a better understanding of the nature and advantages of the present invention
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram illustrating the connections between subscriber access line module and subscriber phone equipment through a subscriber access line.
FIG. 2 is a block diagram illustrating a subscriber location record.
FIG. 3 is a block diagram illustrating the connections between a subscriber location datastore and a subscriber location query system.
FIG. 4 is a block diagram illustrating a system for obtaining a subscriber location during a call.
FIG. 5 is a block diagram illustrating a system for handling an emergency call.
FIG. 6 is a block diagram illustrating a method of testing whether or not an emergency call can be made using a subscriber access line.
FIG. 7 is a block diagram illustrating a system for determining whether or not subscriber phone equipment has changed location.
DETAILED DESCRIPTION
Subscriber Phone Equipment, Subscriber Access Line, and Subscriber Access Line Module
FIG. 1 illustrates a subscriber access line module 130 connection to subscriber phone equipment 110 . Subscriber phone equipment 110 connects to subscriber access line module 130 via a subscriber access line 135 . Subscriber access line module 130 can connect to multiple subscriber phone equipment simultaneously through multiple subscriber access lines. Each subscriber access line 135 has a subscriber access line identity. Each subscriber access line 135 has a subscriber location. The subscriber location of a subscriber access line 135 is the location where the subscriber access line 135 connects to subscriber phone equipment 110 . In one embodiment, a subscriber location includes a street address. In another embodiment, a subscriber location includes a building number. In yet another embodiment, a subscriber location includes a room number. In one embodiment, a subscriber location includes a cubicle number. In a different embodiment, a subscriber location includes a geophysical location.
Subscriber access line module 130 manages the association between a subscriber access line 135 and the subscriber access line identity that identifies the subscriber access line 135 . In one embodiment, subscriber access line module 130 includes a Master Distribution Frame (MDF). In another embodiment, subscriber access line module 130 includes a Digital Access Line Access Module (DSLAM). In yet another embodiment, subscriber access line module 130 includes a Digital Loop Carrier (DLC). In a different embodiment, subscriber access line module 130 includes Cable Headend equipment, such as a Cable Modem Termination System (CMTS) or a Cable Data Modem Termination System (CDMTS). In another embodiment, subscriber access line module 130 includes radio network access equipment, such as base stations and base station controllers (BSC).
In one embodiment, subscriber access line 135 includes a copper local loop. In another embodiment, subscriber access line 135 includes a coaxial cable. In another embodiment, subscriber access line 135 includes a radio frequency band. In one embodiment, subscriber access line 135 includes a multiplex channel within the radio frequency band. In another embodiment, the multiplex channel is based on Time Division Multiplexing Access (TDMA) technology. In another embodiment, the multiplex channel is based on Code Division Multiplexing Access (CDMA) technology. In yet another embodiment, the multiplex channel is based on Frequency Division Multiplexing Access (FDMA) technology.
Subscriber Location Record and Subscriber Location Datastore
FIG. 2 illustrates a subscriber location record. A subscriber location record 280 comprises a subscriber access line identity attribute 285 and a subscriber location attribute 287 . In one embodiment, subscriber access line identity attribute 285 includes the subscriber access line identity of a subscriber access line. In one embodiment, subscriber location attribute 287 includes the subscriber location of the subscriber access line. The location stored in the subscriber location attribute can be a physical address such as a street address, a building number, a cubicle number, or geophysical location coordinates.
Subscriber Location Datastore and Subscriber Location Query System
FIG. 3 illustrates a process for querying a subscriber location. Subscriber location datastore 370 connects to a subscriber location query system 380 . Subscriber location datastore 370 includes a plurality of subscriber location records. Subscriber location query system 380 receives a query for a subscriber location. The query includes a subscriber access line identity 312 . In one embodiment, subscriber location query system 380 compares the subscriber access line identity with the subscriber access line identity attribute of multiple subscriber location records in subscriber location datastore 370 . If a matching subscriber location record exists, subscriber location query system 380 selects one or more of the matching subscriber location record 316 .
Subscriber location query system 380 sends the result 318 in response to the query. In one embodiment, the result 318 is the subscriber location extracted from the subscriber location attribute of the selected subscriber location record 316 . In another embodiment, the result is one or more of the selected subscriber location record 316 .
In one embodiment, subscriber location query system 380 receives the query from a network. In one embodiment, the network is a Signaling System 7 (SS7) network. In another embodiment, the network is an Internet Protocol (IP) network. In yet another embodiment, subscriber location query system 380 receives the query over a circuitry connection. In a different embodiment, subscriber location query system 380 receives the query over an Application Programming Interface (API). In a one embodiment, subscriber location query system 380 receives the query via a standard base database access protocol. In another embodiment, subscriber location query system 380 receives the query via a proprietary protocol.
A Method of Obtaining Subscriber Location During a Call
FIG. 4 illustrates a system for obtaining a subscriber location during a call.
Subscriber phone equipment 410 connects to a subscriber access line module 430 over a subscriber access line 435 . A phone 417 connects to subscriber access line module 430 over the subscriber access line 435 . Subscriber access line module 430 connects to a phone system 490 . A user uses phone 417 to make a call.
Phone system 490 receives and processes the call from phone 417 . Phone system 490 determines the subscriber access line identity of the subscriber access line as to where phone 417 is connected.
In one embodiment, phone system 490 determines the subscriber access line identity by correlating the resources in phone system 490 . In one embodiment, the resources include a line card and a port. In another embodiment, the resources include a multiplexing channel in the communications media between phone system 490 and subscriber access line module 430 .
In another embodiment, phone system 490 determines the subscriber access line identity by querying subscriber access line module 430 . In one embodiment, phone system 490 queries subscriber access line module 430 during processing of the call. In another embodiment, phone system 490 queries subscriber access line module 430 before the call.
In another embodiment, phone system 490 connects to subscriber phone equipment 410 . Subscriber phone equipment 410 obtains the subscriber access line identity of subscriber access line 435 from subscriber access line module 430 . Phone system 490 determines the subscriber access line identity by querying subscriber phone equipment 410 . In one embodiment, phone system 490 queries subscriber phone equipment 410 during processing of the call. In another embodiment, phone system 490 queries subscriber phone equipment 410 before the call.
In yet another embodiment, phone 417 stores, includes or otherwise has the subscriber access line identity of subscriber access line 435 . Phone system 490 determines the subscriber access line identity from phone 417 . In one embodiment, phone system 490 determines the subscriber access line identity from phone 417 during processing of the call. In another embodiment, phone system 490 determines the subscriber access line identity from phone 417 before the call.
In FIG. 4 , phone system 490 connects to a subscriber location query system 480 . Phone system 490 sends a query to subscriber location query system 480 . The query includes the determined subscriber access line identity. Phone system 490 receives a subscriber location from subscriber location query system 480 .
In one embodiment, phone system 490 connects to another phone system 495 . Phone system 490 sends a call request to phone system 495 . In one embodiment, phone system 490 includes the determined subscriber access line identity in the call request. phone system 495 receives the determined subscriber access line identity from phone system 490 . Phone system 495 determines the subscriber location from the received subscriber access line identity by querying subscriber location query system 480 .
A method of Obtaining the Location of a Caller During an Emergency Call.
FIG. 5 illustrates a method of handling an emergency call. Phone system 590 connects to an emergency response phone system 595 . Emergency response phone system 595 comprises one or more phone systems. Emergency response phone system 595 connects to subscriber location query system 580 . Subscriber phone equipment 510 connects to a subscriber access line module 530 over a subscriber access line 535 . phone 517 connects to subscriber access line module 530 over the subscriber access line 535 . Subscriber access line module 530 connects to phone system 590 .
A user makes an emergency call by dialing an emergency number at phone 517 . In one embodiment, the emergency number is “Emergency”. In another embodiment, the emergency number is “999”. In yet another embodiment, the emergency number is “911”. Phone system 590 receives the emergency call, and determines the subscriber access line identity of subscriber access line 535 as illustrated in FIG. 4 .
Phone system 590 routes the emergency call to emergency response phone system 595 and sends the determined subscriber access line identity to emergency response phone system 595 .
Emergency response phone system 595 receives the emergency call and the subscriber access line identity. Emergency response phone system 595 determines the subscriber location by querying the subscriber location query system 580 using the received subscriber access line identity. Emergency response phone system 595 presents the emergency call, including the subscriber location, to an agent. The agent dispatches emergency personnel to subscriber location. In one embodiment, the agent dispatches emergency personnel to the street address indicated in the subscriber location. In an embodiment, the agent dispatches emergency personnel to the cubical of a building indicated in the subscriber location. In a different embodiment, the agent dispatches emergency personnel to search in the geophysical location indicated in the subscriber location.
A Method of Obtaining if an Emergency Call can be Made Using a Subscriber Access Line
FIG. 6 illustrates a method of obtaining if an emergency call can be made using a subscriber access line. Subscriber phone equipment 610 includes an emergency call test module 615 . Subscriber phone equipment 610 connects to subscriber access line module 630 over subscriber access line 635 . Subscriber access line module 630 connects to a phone system 690 . Emergency call test module 615 performs a test to determine if an emergency call can be made using the subscriber access line 635 .
In one embodiment, emergency call test module 615 queries subscriber access line module 630 . Subscriber access line module 630 responds with an indication whether or not an emergency call can be made. Emergency call test module 615 checks the indication. If the indication is positive, emergency call test module 615 determines that an emergency call can be made using the subscriber access line 635 .
In another embodiment, subscriber phone equipment 630 connects to phone system 690 . Emergency call test module 615 queries phone system 690 . Phone system 690 responds with an indication whether or not an emergency call can be made. Emergency call test module 615 checks the indication. If the indication is positive, emergency call test module 615 determines that an emergency call can be made using the subscriber access line 635 .
In one embodiment, emergency call test module 615 sends an off hook signal towards subscriber access line 635 , and checks for an indication of a dial tone. If the indication is positive, emergency call test module 615 determines that an emergency call can be made using the subscriber access line 635 .
In one embodiment, emergency call test module 615 repeats the process a multiple times before determining if an emergency call can be made using the subscriber access line 635 .
In one embodiment, subscriber phone equipment 610 connects to a telephone. Subscriber phone equipment 610 informs the telephone if an emergency call can be made using the subscriber access line 635 .
In one embodiment, subscriber phone equipment 610 further includes an emergency call test indicator 613 . Emergency call test module 615 connects to an emergency call test indicator 613 . In one embodiment, emergency call test indicator 613 includes a visual indicator such as a light or display.
In one embodiment, emergency call test indicator 613 includes a LED as the visual indicator. If emergency call test module 615 determines that an emergency call can be made using the subscriber access line 635 , emergency call test module 615 turns the LED or other visual indicator to green. In one embodiment, if emergency call test module 615 cannot determine an emergency call can be made using the subscriber access line 635 , emergency call test module 615 turns the LED to red.
In another embodiment, emergency call test indicator 613 includes a text display panel. If emergency call test module 615 determines an emergency call can be made using the subscriber access line 635 , emergency call test module 615 displays “emergency call Test Succeeds” on the display panel. In one embodiment, emergency call test module 615 cannot determine that an emergency call can be made using the subscriber access line 635 emergency call test module 615 displays “emergency call Test fails” on the display panel.
In one embodiment, emergency call test module 615 determines repeatedly if an emergency call can be made using the subscriber access line 635 . In one embodiment, emergency call test module 615 performs the process every 30 minutes. In another embodiment, emergency call test module 615 performs the process every hour. In yet another embodiment, emergency call test module 615 performs the process when subscriber phone equipment 610 powers up. In a different embodiment, emergency call test module 615 performs the process when a telephone call is made.
A Method of Determining Whether or not Subscriber Phone Equipment has Changed Location
FIG. 7 illustrates a process to determine whether or not subscriber phone equipment has changed location. Subscriber phone equipment 710 includes a location test module 715 .
A Method of Determining Whether or not Subscriber Phone Equipment has Changed Location Based on Subscriber Access Line Identity
In one embodiment, location test module 715 determines whether or not subscriber phone equipment 710 has changed location by examining the subscriber access line identity of subscriber access line 735 . Subscriber phone equipment 710 connects to subscriber access line module 730 over subscriber access line 735 . Subscriber access line module 730 connects to a phone system 790 .
In one embodiment, location test module 715 connects to datastore 719 . Datastore 719 stores a stored subscriber access line identity 718 . The stored subscriber access line identity 718 is a subscriber access line identity identifying a subscriber access line with subscriber location being the correct location of the subscriber phone equipment 710 . In one embodiment, datastore 719 is a flash memory. In another embodiment, datastore is a hard disk. In yet another embodiment, datastore 719 is a memory.
Location test module 715 obtains the stored subscriber access line identity 718 and stores the stored subscriber access line identity 718 in datastore 719 . In one embodiment, the stored subscriber access line identity 718 is determined when the service provider establishes a service for the subscriber. In one embodiment, during service establishment, the service provider informs the location test module 715 of the stored subscriber access line identity 718 . In another embodiment, location test module 715 obtains from subscriber access line module 730 the stored subscriber access line identity 718 . In another embodiment, stored subscriber access line identity 718 is determined during a service change. In another scenario, the subscriber moves subscriber phone equipment 710 to a new location, and submits a new address to the service provider. The service provider determines a new stored subscriber access line identity 718 . In another embodiment, the service provider informs the location test module 715 of the new stored subscriber access line identity 718 . In yet another embodiment, location test module 715 obtains from subscriber access line module 730 the new stored subscriber access line identity 718 .
In one embodiment, location test module 715 connects to a phone system 790 . Location test module 715 obtains the stored subscriber line identity 718 from phone system 790 .
In one embodiment, location test module 715 connects to a phone 717 . Location test module 715 obtains stored subscriber access line identity 718 from phone 717 .
In one embodiment, location test module 715 is informed when a new stored subscriber line identity 718 is available. In another embodiment, location test module 715 checks for a new stored subscriber line identity 718 . In an embodiment, location test module 715 checks every 5 minutes. In a different embodiment, location test module 715 checks every hour.
Location test module 715 determines whether or not subscriber phone equipment 710 has changed location by matching the stored subscriber access line identity 718 against the subscriber access line identity of subscriber access line 735 . If the match succeeds, location test module 715 concludes that subscriber phone equipment 710 has not changed location.
In one embodiment, location test module 715 obtains the subscriber access line identity of subscriber access line 735 from subscriber access line module 730 . In another embodiment, location test module 715 obtains the subscriber access line identity of subscriber access line 735 from phone system 790 . In yet a different embodiment, location test module 715 obtains the subscriber access line identity of subscriber access line 735 from phone 717 .
A Method of Determining Whether or not Subscriber Phone Equipment has Changed Location in Voice Over IP (VoIP) Phone Services
In one embodiment, phone 717 connects to phone system 790 based on VoIP service. Phone 717 has an IP address. Phone 717 has an IP address as seen by phone system 790 .
In one embodiment, location test module 715 sends a message to phone 717 . In one embodiment, phone 717 responds with an indication about whether or not the IP address of phone 717 has changed. In another embodiment, phone 717 responds with an indication about whether or not the IP address of phone 717 as seen by phone system 790 has changed. Location test module 715 can determine based on the indication received from phone 717 whether or not subscriber phone equipment 710 has changed location.
In one embodiment, location test module 715 sends a message to phone system 790 . In one embodiment, phone system 790 responds with an indication about whether or not the IP address of phone 717 has changed. In another embodiment, phone system 790 responds with an indication about whether or not the IP address of phone 717 as seen by phone system 790 has changed. Location test module 715 can determine based on the indication received from phone 717 whether or not subscriber phone equipment 710 has changed location.
In one embodiment, location test module 715 sends a message to phone 717 and a message to phone system 790 . Location test module 715 concludes that subscriber phone equipment 710 has not changed location if phone 717 responds that the IP address of phone 717 has not changed and phone system 790 responds that the IP address of phone 717 as seen by phone system 790 has not changed.
In another embodiment, location test module 715 tests whether or not subscriber phone equipment 710 has changed location every 30 minutes. In another embodiment, location test module 715 tests whether or not subscriber phone equipment 710 has changed location every hour. In yet another embodiment, location test module 715 tests whether or not subscriber phone equipment 710 has changed location when subscriber phone equipment 710 powers up. In a different embodiment, location test module 715 tests whether or not subscriber phone equipment 710 has changed location when a user makes a telephone call.
In one embodiment, subscriber phone equipment 710 connects to phone 717 . Subscriber phone equipment 710 informs phone 717 whether or not subscriber phone equipment 710 has changed location. In one embodiment, subscriber phone equipment 710 further includes a location test indicator 713 . Location test module 715 connects to the location test indicator 713 .
In according to one embodiment, location test indicator 713 includes a visual indicator such as a light or a display. In one embodiment, the visual indicator is an LED. If location test module 715 determines that subscriber phone equipment 710 has not changed location, location test module 715 turns the LED to green. In one embodiment, if location test module 715 cannot determine that subscriber phone equipment 710 has not changed location, location test module 715 turns the LED to red. In another embodiment, the visual indicator is a display panel. If location test module 715 determines that subscriber phone equipment 710 has not changed location, location test module 717 displays “Location correct” on the display panel. If location test module 715 cannot determine that subscriber phone equipment 710 has not changed location, location Test module 717 displays “Location may be incorrect” on the display panel.
Combining Emergency Call Test and Location Test
In one embodiment, subscriber phone equipment includes an emergency call test module and a location test module. Subscriber phone equipment can perform both tests provided for by the emergency call test module and the location test module. In one embodiment, subscriber phone equipment further connects to a test indicator. The test indicator can include a visual indicator such as a light or a display.
In one embodiment, emergency call test module determines whether or not an emergency call can be made and location test module determines whether or not subscriber phone equipment has changed location. In one embodiment, emergency call test module determines that an emergency call can be made and determines that subscriber phone equipment has not changed locations; then subscriber phone equipment turns the visual indicator, such as an LED, to green. In another embodiment, emergency call test module determines that an emergency call can be made and location test module cannot determine whether or not subscriber phone equipment has changed location; then subscriber phone equipment turns the visual indicator, such as an LED, to yellow. In yet another embodiment, emergency call test module cannot determine that an emergency call can be made and location test module determines that subscriber phone equipment has not changed location; subscriber phone equipment turns the LED to amber. In one other embodiment, emergency call test module cannot determine that an emergency call can be made and location test module cannot determine that subscriber phone equipment has not changed location; subscriber phone equipment turns the LED to red.
In a different embodiment, the test indicator visual indicator is a display panel. Subscriber phone equipment displays corresponding messages on the display panel based on the combined test results of emergency call test module and location test module.
Subscriber Location Changes During an Emergency Call
While a user is making an emergency call, the user may move from a location to another location. The phone system handling the call can discover, from time to time, the subscriber access line identity of the subscriber access line to which the phone is connected. In one embodiment, after obtaining a subscriber access line identity, the phone system sends the subscriber access line identity to the emergency response phone system. In another embodiment, the phone system detects a change in subscriber access line identity, and sends the new subscriber access line identity to the emergency response phone system. The emergency response phone system further presents to the agent with an updated subscriber location.
A Method of Selecting a Phone System While Making Emergency Calls in a VoIP Service Scenario
In FIG. 5 , when a phone 517 makes an emergency call, phone 517 routes the emergency call to a phone system 590 . In one embodiment, the telephone service is a VoIP service. The VoIP service provider is typically not the service provider for the subscriber access line 535 . In one embodiment, the subscriber access line service provider offers telephone services and has a plurality of phone system from the subscriber access line service provider. When a user makes an emergency call, the user can select a phone system from the subscriber access line service provider to handle the emergency call.
In one embodiment, the phone 517 recognizes the emergency call and routes the emergency call to a phone system from the subscriber access line service provider. In another embodiment, the phone 517 is connected to the subscriber phone equipment 510 . The subscriber phone equipment 510 recognizes the emergency call and routes the emergency call to a phone system from the subscriber access line service provider.
In another embodiment, the subscriber access line module 530 recognizes the emergency call and routes the emergency call to a phone system from the subscriber access line service provider.
Types of Phone Calls that Require Subscriber Location Information
The above description applies to emergency calls that require subscriber location information. However, there are many other scenarios in which would be helpful, advantageous or necessary to obtain the subscriber location of a telephone call. In one embodiment, phone system can use subscriber access line identities to determine the location information for calls such as location specific directory services, marketing information for premium pay per use phone services and toll-free service calls.
Described herein are techniques for methods and systems of obtaining the location of a caller during an emergency phone call. In the following description, for purposes of explanation, numerous examples and specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention as defined by the claims may include some or all of the features in these examples alone or in combination with other features described below, and may further include obvious modifications and equivalents of the features and concepts described herein. | Methods and systems for obtaining the location of a caller during an emergency or other telephone call. Before or during a call, a phone system can obtain from one or more sources a subscriber access line identity associated with a subscriber location record that includes a subscriber access line identity attribute and a subscriber location attribute. A phone system can send a query that includes the subscriber access line identity to a subscriber location query system that returns a subscriber location record or a subscriber location to the phone system. The phone system can then display the caller location information to a phone system, an agent or operator so that emergency services can be quickly and accurately dispatched. Using similar procedure and a memory, phone systems can also determine if a subscriber phone has or is changing location. Methods for testing the emergency call capabilities of a subscriber access line. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. 119 of Danish application no. PA 2001 00894 filed on Jun. 8, 2001, and U.S. provisional application No. 60/299,091 filed on Jun. 18, 2001, the contents of which are fully incorporated herein by reference.
BACKGROUND
[0002] Yeast organisms produce a number of proteins that are transported through the secretory appatus (ER-Golgi-Secretory vesicles) and sorted to the medium or extracellular space. Such proteins are referred to as secreted proteins and they usually do a function outside the cell envelope. These proteins are initially expressed in the cytoplasm and cotranslationally translocated across the membrane of the endoplasmic reticulum (ER) in a precursor or a pre-form containing a pre-peptide sequence ensuring effective direction (translocation) of the expressed product across the membrane. The prepeptide, normally named a signal peptide, is generally cleaved off from the desired product during translocation. Small secreted proteins like the α-Mating Factor also contain a pro-region which is N-glycosylated providing proteolytic protection of the molecule, correct folding and transport and sorting. N-glycosylation takes place in the ER and in a cotranslational manner. Correctly folded molecules are further transported down the secretory pathway into the Golgi apparatus, where the core N-glycosylation is modified often leading to hyperglycosylated proteins. Finally proteolytic cleavage and modification can take place in a late Golgi compartment, as described for the α-Mating Factor, before the protein is sorted by different routes that lead to compartments such as the cell vacuole, or it can be routed out of the cell to be secreted to the external medium (Pfeffer et al. (1987) Ann. Rev. Biochem. 56:829-852).
[0003] Insulin is a polypeptide hormone secreted by β-cells of the pancreas and consists of two polypeptide chains, A and B, which are linked by two inter-chain disulphide bridges. Furthermore, the A-chain features one intra-chain disulphide bridge.
[0004] The hormone is synthesized as a single-chain precursor proinsulin (preproinsulin) consisting of a prepeptide of 24 amino acid followed by proinsulin containing 86 amino acids in the configuration: prepeptide -B-Arg Arg-C-Lys Arg-A, in which C is a connecting peptide of 31 amino acids. Arg-Arg and Lys-Arg are cleavage sites for cleavage of the connecting peptide from the A and B chains.
[0005] Three major methods have been used for the production of human insulin in microorganisms. Two involve Escherichia coli, with either the expression of a large fusion protein in the cytoplasm (Frank et al. (1981) in Peptides: Proceedings of the 7 th American Peptide Chemistry Symposium (Rich & Gross, eds.), Pierce Chemical Co., Rockford, Ill. pp 729-739), or use a signal peptide to enable secretion into the periplasmic space (Chan et al. (1981) PNAS 78:5401-5404). A third method utilizes Saccharomyces cerevisiae to secrete an insulin precursor into the medium (Thim et al. (1986) PNAS 83:6766-6770). The prior art discloses a limited number of insulin precursors which are expressed in either E. coli or Saccharomyces cerevisiae, vide U.S. Pat. No. 5,962,267, WO 95/16708, EP 0055945, EP 0163529, EP 0347845 and EP 0741188. The prior art further discloses expression of insulin precursors comprising certain N-terminal extensions and certain connecting peptides, vide WO 95/34666, WO 95/35384, WO 97/22706, EP 704527 and WO 98/28429.
[0006] The present invention provides for a method giving insulin precursors which are easy to handle in down stream purification steps such as centrifugation and filtration where it may be important that the product has a high solubility and a low tendency to form fibrils or a gel. The precursors will also be easy to separate by affinity chromatography. Finally, the precursors are expressed in high yields in transformed host cells.
SUMMARY OF THE INVENTION
[0007] The present invention features novel insulin precursors and insulin analogue precursors comprising a connecting peptide (C-peptide) and an N-terminal extension wherein the connecting peptide or the N-terminal extension or both comprise at least one glycosylation site. Such insulin precursors or insulin analogue precursors can then be converted into human insulin or an insulin analogue by one or more suitable, well known conversion steps.
[0008] The connecting peptide will be of up to 10 or up to 5-8 amino acid residues or up to three amino acid residues in length.
[0009] The connecting peptide is to be cleavable from the A- and B-chains and will contain a cleavage site at its C-terminal end enabling in vitro cleavage of the connecting peptide from the A chain. Such cleavage site may be any convenient cleavage site known in the art, e.g. a Met cleavable by cyanogen bromide or an Asn, Asn-Gly cleavable with hydroxylamine; a single basic amino acid residue (Lys or Arg) cleavable by trypsin or trypsin like proteases; a lysine residue cleavable with Achromobacter lyticus protease or a pair of basic amino acid residues (Lys or Arg) cleavable by kexin or yapsin from yeast or their homologues from other eukaryotic organisms. The cleavage site enabling cleavage of the connecting peptide from the A-chain is preferably a single basic amino acid residue Lys or Arg, preferably Lys.
[0010] Cleavage of the connecting peptide from the B chain may conveniently be accomplished by cleavage at the natural Lys B29 amino acid residue in the B chain giving rise to a desB30 insulin precursor. If the insulin precursor is to be converted into human insulin, the B30 Thr amino acid residue (Thr) can then be added by well known in vitro, enzymatic procedures.
[0011] Cleavage from the B-chain may also be accomplished by insertion of a suitable cleavage site at the C-terminal end of the connecting peptide such as Met cleavable by cyanogen bromide or an Asn, Asn-Gly cleavable with hydroxylamine; a single basic amino acid residue (Lys or Arg) cleavable by trypsin or trypsin like proteases; a lysine residue cleavable with Achromobacter lyticus protease or a pair of basic amino acid residues (Lys or Arg) cleavable by kexin or yapsin from yeast or their homologues from other eukaryotic organisms.
[0012] In one embodiment the connecting peptide will not contain two adjacent basic amino acid residues (Lys,Arg). In this embodiment, cleavage from the A-chain may be accomplished at a single Lys or Arg located at the N-terminal end of the A-chain and the natural Lys in position B29 in the B-chain.
[0013] The insulin precursors or insulin analogue precursors according to the present invention will be expressed as a fusion protein comprising an N-terminal extension immediately N-terminal to the B-chain. The N-terminal extension will typically be of up to 30 amino acid residues in length and may contain at least one glycosylation site. The N-terminal extension will contain a cleavage site enabling its cleavage from the precursor molecule. Such cleavage site may by any convenient cleavage site well known in the art, such as Met or a mono or dibasic amino acid sequence Lys, Arg.
[0014] Thus, the present invention relates to insulin precursors or insulin analogue precursors comprising a connecting peptide (C-peptide) being cleavable from the A and B chains and an N-terminal extension immediately N-terminal to the N-terminal amino acid residue in the B-chain, wherein the connecting peptide, the N-terminal extension or both contain at least one glycosylation site and wherein the connecting peptide is up to 10 amino acid residues in length.
[0015] In another embodiment, the connecting peptide is up to 9, 8, 7, or 6 amino acid residues in length.
[0016] In a further embodiment, the connecting peptide is up to 5 amino acid residues in length and in a still further embodiment, the connecting peptide is up to 3 amino acid residues in length.
[0017] The B-chain may the full length insulin B chain; B(1-30), or a shortened B-chain. Thus it is well known in the art that up to 5 amino acid residues may be removed from either the N-terminal end or the B-terminal end or both of the human insulin B-chain without affecting the insulin activity adversely.
[0018] The insulin precursors or insulin analogue precursors will typically only be glycosylated in the connecting peptide. Furthermore, the connecting peptide will typically only contain one glycosylation site.
[0019] In a more specific embodiment the present invention is related to insulin precursors or insulin analogue precursors comprising the formula:
X 1 -X 2 -B(6-26)-X 3 -X 4 -A(1-21)
[0020] wherein
[0021] X 1 is a peptide sequence of 2-30 amino acids,
[0022] X 2 is a peptide sequence comprising one or more of the amino acid residues B1 to B5 from the N-terminal end of the human insulin B-chain and a cleavage site enabling cleavage from X 1 ,
[0023] X 3 is a peptide sequence of up to 14 amino acid residues in length comprising one or more of the amino acid residues B27 to B30 from the C-terminal end of the human insulin B-chain, and
[0024] X 4 is a cleavage site,
[0025] B(6-26) is the human insulin B-chain from amino acid residue number 6 to amino acid residue number 26,
[0026] and A(1-21) is the human insulin A chain,
[0027] wherein the sequence X 1 -X 2 or X 3 or both contain at least one glycosylation site.
[0028] In one embodiment X 1 is 2-25, 2-20 or 2-15 amino acid residues in length. In another embodiment X 1 is 2-10 or 2-8 amino acid residues in length.
[0029] In another embodiment X 2 comprises the peptide sequence B(1-5), B(2-5), B(3-5), or B(4-5) of the human insulin B-chain. X 2 comprises preferably the peptide sequence B(1-5) and Lys or Arg as the cleavage site enabling cleavage from X 1 .
[0030] X 1 will preferably comprise at least one negatively charged amino acid residue, such as Glu or Asp.
[0031] Examples of insulin precursors or insulin analogue precursors according to the present invention are such wherein the sequence X 3 -X 4 is Ser-Asn-Thr-Thr-Lys (SEQ ID NO: 1), Ser-Ala-Asn-Asn-Thr-Lys (SEQ ID NO:4), Ser-Pro-Asn-Thr-Thr-Lys (SEQ ID NO:5), Ser-Ser-Asn-Thr-Thr-Lys (SEQ ID NO:6), Ser-Arg-Asn-Thr-Thr-Lys (SEQ ID NO:7) or Ala-Ala-Lys and the sequence X 1 -X 2 is Glu-Glu-Gly-Asn-Thr-Thr-Glu-Pro-Lys (SEQ ID NO:3) or Glu-Glu-Gly-Glu-Pro-Lys (SEQ ID NO:2).
[0032] X 3 has to be in vitro cleavable from the C-terminal amino acid residue in the B-chain. If B29 is Lys as in human insulin cleavage can be accomplished by use of trypsin or trypsin like proteases which will cleave at the C-terminal of a Lys residue. Cleavage may also be accomplished by introducing a cleavage site such as Met cleavable by cyanogen bromide, Asn, Asn-Gly cleavable with hydroxylamine; Lys cleavable with Ahcromobacter lyticus protease or Armillaria mellea protease or a pair of basic amino acid residues (Lys or Arg) cleavable by kexin or yapsin from yeast or their homologues from other eukaryotic organisms. X 3 is cleavable from the A-chain at the cleavage site X 4 . X 4 may be any convenient cleavage site, e.g. a Met cleavable by cyanogen bromide or an Asn, Asn-Gly cleavable with hydroxylamine; a single basic amino acid residue (Lys or Arg) cleavable by trypsin or trypsin like proteases; a lysine residue cleavable with Achromobacter lyticus protease or a pair of basic amino acid residues (Lys or Arg) cleavable by kexin or yapsin from yeast or their homologues from other eukaryotic organisms. The cleavage site X 4 enabling cleavage of X 3 from the A-chain is preferably a single basic amino acid residue Lys or Arg, preferably Lys.
[0033] Likewise, the N-terminal extension X 1 should be in vitro cleavable from the N-terminal end of the B-chain. This is accomplished by the sequence X 2 which comprises a cleavage site at its N-terminal end. X 2 may comprise any convenient cleavage site known in the art, e.g. a Met cleavable by cyanogen bromide or an Asn, Asn-Gly cleavable with hydroxylamine; a single basic amino acid residue (Lys or Arg) cleavable by trypsin or trypsin like proteases; a lysine residue cleavable with Ahcromobacter lyticus protease or a pair of basic amino acid residues (Lys or Arg) cleavable by kexin or yapsin from yeast or their homologues from other eukaryotic organisms.
[0034] Thus the insulin precursors may be X 1 -X 2 -B(6-29)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(5-29)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(4-29)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(3-29)-X 3 -X 4 -A(1-21); X 1-X 2 -B(2-29)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(1-28)-Lys-X 3 -X 4 -A(1-21); X 1 -X 2 -B(1-27)-Lys-X 3 -X 4 -A(1-21); X 1 -X 2 -B(1-26)-Lys-X 3 -X 4 -A(1-21); X 1 -X 2 -B(2-28)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(2-27)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(2-26)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(3-29)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(3-28)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(3-27)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(3-26)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(4-28)-X 3 -X 4 -A(1-21); X 1 -X 2 -B(4-27)-X 3 -X 4 -A(1-21); or X 1 -X 2 -B(4-26)-X 3 -X 4 -A(1-21) where X 1-4 have the above meanings.
[0035] Examples of combinations of C-peptides and N-terminal extensions according to the present invention are Ser-Asn-Thr-Thr-Lys (SEQ ID NO:1) (C-peptide) and Glu-Glu-Gly-Glu-Pro Lys (SEQ ID NO:2) (N-terminal extension), Ala-Ala-Lys (C-peptide) and Glu-Glu-Gly-Asn-Thr-Thr-Glu-Pro-Lys (SEQ ID NO:3) (N-terminal extension); Ser-Ala-Asn-Asn-Thr-Lys (SEQ ID NO:4) (C-peptide) and Glu-Glu-Gly-Glu-Pro Lys (SEQ ID NO:2) (N-terminal extension), Ser-Pro-Asn-Thr-Thr-Lys (SEQ ID NO:5) (C-peptide) and Glu-Glu-Gly-Glu-Pro Lys (SEQ ID NO:2) (N-terminal extension); Ser-Ser-Asn-Thr-Thr-Lys (SEQ ID NO:6) (C-peptide) and Glu-Glu-Gly-Glu-Pro Lys (SEQ ID NO:2) (N-terminal extension); or Ser-Arg-Asn-Thr-Thr-Lys (SEQ ID NO:7) (C-peptide) and Glu-Glu-Gly-Glu-Pro Lys (SEQ ID NO:2) (N-terminal extension).
[0036] The present invention is also related to polynucleotide sequences which code for the claimed insulin precursors or insulin analogue precursors. In a further aspect the present invention is related to vectors containing such polynucleotide sequences and host cell containing such polynucleotide sequences or vectors.
[0037] In another aspect, the invention relates to a process for producing the insulin precursors or insulin analogue precursors in a host cell, said method comprising (i) culturing a host cell comprising a polynucleotide sequence encoding the insulin precursors or insulin analogue precursors of the invention under suitable conditions for expression of said precursor; and (ii) isolating the precursor from the culture medium.
[0038] In still a further aspect, the invention relates to a process for producing insulin or insulin analogues in a host cell said method comprising (i) culturing a host cell comprising a polynucleotide sequence encoding an insulin precursor or insulin analogue precursors of the invention; (ii) isolating the precursor from the culture medium and (iii) converting the precursor into insulin or an insulin analogue by in vitro enzymatic conversion.
[0039] In one embodiment of the present invention the host cell is a yeast host cell and in a further embodiment the yeast host cell is selected from the genus Saccharomyces.
[0040] In a further embodiment the yeast host cell is selected from the species Saccharomyces cerevisiae.
DETAILED DESCRIPTION
[0041] Abbreviations and Nomenclature.
[0042] By “connecting peptide” or “C-peptide” is meant the connection moiety “C” of the B-C-A polypeptide sequence of a single chain preproinsulin-like molecule. Specifically, in the natural insulin chain, the C-peptide connects position 30 of the B chain and position 1 of the A chain. A “mini C-peptide” or “connecting peptide” such as those described herein, connect B29 or B30 to A1, and differ in sequence and length from that of the natural C-peptide.
[0043] By “N-terminal extension” is meant a peptide chain which is attached at its C-terminal end to the N-terminal end of the B-chain or the shortened B-chain. The N-terminal extension is typically at its N-terminal end linked to a propeptide which is cleaved of from the N-terminal extension during secretion from the host cell.
[0044] By “insulin precursor” is meant a single-chain insulin precursor in which a desB25-desB30 chain is linked to the A chain of insulin via a connecting peptide. The single-chain insulin precursor will contain correctly positioned disulphide bridges (three) as in human insulin.
[0045] With “desB30” or “B(1-29)” is meant a natural insulin B chain lacking the B30 amino acid residue. With “B(6-26)” is meant the natural insulin B chain lacking the B(27-30) and the B(1-5) residues. “B(5-26)” means the natural insulin B chain lacking the B(1-4) and the B(27-30) residues etc. “B(1-27)” means the natural B chain lacking the B28, B29, and B30 amino acid residues, “B(1-28)” means the natural B chain lacking the B29 and B30 amino acid residues etc. “A(1-21)” means the natural insulin A chain,”
[0046] The “insulin precursor” can by one or more subsequent chemical and/or enzymatic processes be converted into human insulin.
[0047] By “insulin analogue precursor” is meant an insulin precursor molecule having one or more mutations, substitutions, deletions and or additions of the A and/or B amino acid chains relative to the human insulin molecule. The insulin analogues are preferably such wherein one or more of the naturally occurring amino acid residues, preferably one, two, or three of them, have been substituted by another codable amino acid residue. In one embodiment, the instant invention comprises analogue molecules having position 28 of the B chain altered relative to the natural human insulin molecule. In this embodiment, position 28 is modified from the natural Pro residue to one of Asp, Lys, or Ile. In a preferred embodiment, the natural Pro residue at position B28 is modified to an Asp residue. In another embodiment Lys at position B29 is modified to Pro; Also, Asn at position A21 may be modified to Ala, Gln, Glu, Gly, His, Ile, Leu, Met, Ser, Thr, Trp, Tyr or Val, in particular to Gly, Ala, Ser, or Thr and preferably to Gly. Furthermore, Asn at position B3 may be modified to Lys. Further examples of insulin precursor analogues are des(B30) human insulin, insulin analogues wherein Phe B1 has been deleted; insulin analogues wherein the A-chain and/or the B-chain have an N-terminal extension and insulin analogues wherein the A-chain and/or the B-chain have a C-terminal extension. Thus one or two Arg may be added to position B1.
[0048] The term “immediately N-terminal to” is meant to illustrate the situation where an amino acid residue or a peptide sequence is directly linked at its C-terminal end to the N-terminal end of another amino acid residue or amino acid sequence by means of a peptide bond.
[0049] By N-glycosylation site is meant a site generally known to allow substitution of the amide Nitrogen group of Asn with an oligosaccharide which in yeast consists of 14 monosaccharides: glucose 3 mannose 9 N-acetylglucosamine 2
[0050] “POT” is the Schizosaccharomyces pombe triose phosphate isomerase gene, and “TPI1” is the S. cerevisiae triose phosphate isomerase gene.
[0051] By a “leader” is meant an amino acid sequence consisting of a pre-peptide (the signal peptide) and a pro-peptide.
[0052] The term “signal peptide” is understood to mean a pre-peptide which is present as an N-terminal sequence on the precursor form of a protein. The function of the signal peptide is to allow the heterologous protein to facilitate translocation into the endoplasmic reticulum. The signal peptide is normally cleaved off in the course of this process. The signal peptide may be heterologous or homologous to the yeast organism producing the protein. A number of signal peptides which may be used with the DNA construct of the invention including yeast aspartic protease 3 (YAP3) signal peptide or any functional analog (Egel-Mitani et al. (1990) YEAST 6:127-137 and U.S. Pat. No. 5,726,038) and the α-factor signal of the MFα1 gene (Thorner (1981) in The Molecular Biology of the Yeast Saccharomyces cerevisiae, Strathern et al., eds., pp 143-180, Cold Spring Harbor Laboratory, N.Y. and U.S. Pat. No. 4,870,00.
[0053] The term “pro-peptide” means a polypeptide sequence whose function is to allow the expressed polypeptide to be directed from the endoplasmic reticulum to the Golgi apparatus and further to a secretory vesicle for secretion into the culture medium (i.e. exportation of the polypeptide across the cell wall or at least through the cellular membrane into the periplasmic space of the yeast cell). The pro-peptide may be the yeast α-factor pro-peptide, vide U.S. Pat. Nos. 4,546,082 and 4,870,008. Alternatively, the pro-peptide may be a synthetic pro-peptide, which is to say a pro-peptide not found in nature. Suitable synthetic pro-peptides are those disclosed in U.S. Pat. Nos. 5,395,922; 5,795,746; 5,162,498 and WO 98/32867. The pro-peptide will preferably contain an endopeptidase processing site at the C-terminal end, such as a Lys-Arg sequence or any functional analog thereof.
[0054] The polynucleotide sequence of the invention may be prepared synthetically by established standard methods, e.g. the phosphoamidite method described by Beaucage et al. (1981) Tetrahedron Letters 22:1859-1869, or the method described by Matthes et al. (1984) EMBO Journal 3:801-805. According to the phosphoamidite method, oligonucleotides are synthesized, for example, in an automatic DNA synthesizer, purified, duplexed and ligated to form the synthetic DNA construct. A currently preferred way of preparing the DNA construct is by polymerase chain reaction (PCR).
[0055] The polynucleotide sequence of the invention may also be of mixed genomic, cDNA, and synthetic origin. For example, a genomic or cDNA sequence encoding a leader peptide may be joined to a genomic or cDNA sequence encoding the A and B chains, after which the DNA sequence may be modified at a site by inserting synthetic oligonucleotides encoding the desired amino acid sequence for homologous recombination in accordance with well-known procedures or preferably generating the desired sequence by PCR using suitable oligonucleotides.
[0056] The invention encompasses a vector which is capable of replicating in the selected microorganism or host cell and which carries a polynucleotide sequence encoding the insulin precursors or insulin analogue precursors of the invention. The recombinant vector may be an autonomously replicating vector, i.e., a vector which exists as an extra-chromosomal entity, the replication of which is independent of chromosomal replication e.g., a plasmid, an extra-chromosomal element, a mini-chromosome, or an artificial chromosome. The vector may contain any means for assuring self-replication. Alternatively the vector may be one which, when introduced into the host cell, is integrated into the genome and replicated together with the chromosome(s) into which it has been integrated. Furthermore, a single vector or plasmid or two or more vectors or plasmids which together contain the total DNA to be introduced into the genome of the host cell, or a transposon may be used. The vector may be linear or closed circular plasmids and will preferably contain an element(s) that permits stable integration of the vector into the host cell's genome or autonomous replication of the vector in the cell independent of the genome.
[0057] In a preferred embodiment, the recombinant expression vector is capable of replicating in yeast Examples of sequences which enable the vector to replicate in yeast are the yeast plasmid 2 μm replication genes REP 1-3 and origin of replication.
[0058] The vectors of the present invention preferably contain one or more selectable markers which permit easy selection of transformed cells. A selectable marker is a gene the product of which provides for biocide or viral resistance, resistance to heavy metals, prototrophy to auxotrophs, and the like. Examples of bacterial selectable markers are the dal genes from Bacillus subtilis or Bacillus licheniformis, or markers which confer antibiotic resistance such as ampicillin, kanamycin, chloramphenicol or tetracycline resistance. Selectable markers for use in a filamentous fungal host cell include amdS (acetamidase), argB (ornithine carbamoyltransferase), pyrG (orotidine-5′-phosphate de-carboxylase) and trpC (anthranilate synthase. Suitable markers for yeast host cells are ADE2, HIS3, LEU2, LYS2, MET3, TRP1, and URA3. A preferred selectable marker for yeast is the Schizosaccharomyces pompe TPI gene (Russell (1985) Gene 40:125-130).
[0059] In the vector, the polynucleotide sequence is operably connected to a suitable promoter sequence. The promoter may be any nucleic acid sequence which shows transcriptional activity in the host cell of choice including mutant, truncated, and hybrid promoters, and may be obtained from genes encoding extra-cellular or intra-cellular polypeptides either homologous or heterologous to the host cell.
[0060] Examples of suitable promoters for directing the transcription in a bacterial host cell, are the promoters obtained from the E. coli lac operon, Streptomyces coelicolor agarase gene (dagA), Bacillus subtilis levansucrase gene (sacB), Bacillus licheniformis alpha-amylase gene (amyL), Bacillus stearothermophilus maltogenic amylase gene (amyM), Bacillus amyloliquefaciens alpha-amylase gene (amyQ), and Bacillus licheniformis penicillinase gene (penP). Examples of suitable promoters for directing the transcription in a filamentous fungal host cell are promoters obtained from the genes for Aspergillus oryzae TAKA amylase, Rhizomucor miehei aspartic proteinase, Aspergillus niger neutral alpha-amylase, and Aspergillus niger acid stable alpha-amylase. In a yeast host, useful promoters are the Saccharomyces cerevisiae Ma1, TPI, ADH or PGK promoters.
[0061] The polynucleotide construct of the invention will also typically be operably connected to a suitable terminator. In yeast a suitable terminator is the TPI terminator (Alber et al. (1982) J. Mol. Appl. Genet. 1:419-434).
[0062] The procedures used to ligate the polynucleotide sequence of the invention, the promoter and the terminator, respectively, and to insert them into suitable yeast vectors containing the information necessary for yeast replication, are well known to persons skilled in the art. It will be understood that the vector may be constructed either by first preparing a DNA construct containing the entire DNA sequence encoding the insulin precursors or insulin analogue precursors of the invention, and subsequently inserting this fragment into a suitable expression vector, or by sequentially inserting DNA fragments containing genetic information for the individual elements (such as the signal, pro-peptide, mini C-peptide, A and B chains) followed by ligation.
[0063] The present invention also relates to recombinant host cells, comprising a polynucleotide sequence encoding the insulin precursors or the insulin analogue precursors of the invention. A vector comprising such polynucleotide sequence is introduced into the host cell so that the vector is maintained as a chromosomal integrant or as a self-replicating extra-chromosomal vector as described earlier. The term “host cell” encompasses any progeny of a parent cell that is not identical to the parent cell due to mutations that occur during replication. The choice of a host cell will to a large extent depend upon the gene encoding the polypeptide and its source. The host cell may be a unicellular microorganism, e.g., a prokaryote, or a non-unicellular microorganism, e.g., a eukaryote. Useful unicellular cells are bacterial cells such as gram positive bacteria including, but not limited to, a Bacillus cell, Streptomyces cell, or gram negative bacteria such as E. coli and Pseudomonas sp. Eukaryote cells may be mammalian, insect, plant, or fungal cells. In a preferred embodiment, the host cell is a yeast cell. The yeast organism used in the process of the invention may be any suitable yeast organism which, on cultivation, produces large amounts of the insulin precursor and insulin analogue precursors of the invention. Examples of suitable yeast organisms are strains selected from the yeast species Saccharomyces cerevisiae, Saccharomyces kluyveri, Schizosaccharomyces pombe, Sacchoromyces uvarum, Kluyveromyces lactis, Hansenula polymorpha, Pichia pastoris, Pichia methanolica, Pichia kluyveri, Yarrowia lipolytica, Candida sp., Candida utilis, Candida cacaoi, Geotrichum sp., and Geotrichum fermentans.
[0064] The transformation of the yeast cells may for instance be effected by protoplast formation followed by transformation in a manner known per se. The medium used to cultivate the cells may be any conventional medium suitable for growing yeast organisms. The secreted insulin precursor or insulin analogue precursors of the invention, a significant proportion of which will be present in the medium in correctly processed form, may be recovered from the medium by conventional procedures including separating the yeast cells from the medium by centrifugation, filtration or catching the insulin precursor or insulin analogue precursor by an ion exchange matrix or by a reverse phase absorption matrix, precipitating the proteinaceous components of the supernatant or filtrate by means of a salt, e.g. ammonium sulphate, followed by purification by a variety of chromatographic procedures, e.g. ion exchange chromatography, affinity chromatography, or the like.
[0065] After secretion to the culture medium the insulin precursors may conveniently be separated from the culture broth by affinity chromatography on a column which is capable of binding the sugar molecule(s) attached to the insulin precursor molecule.
[0066] After recovery, the insulin precursor or insulin analogue precursors of the invention will be subjected to various in vitro procedures to remove the N-terminal extension sequence and the C-peptide to give insulin or the desired insulin analogue as described above.
[0067] Cleavage of the connecting peptide from the B chain is preferably enabled by cleavage at the natural Lys B29 amino acid residue in the B chain giving rise to a desB30 insulin precursor or desB30 insulin analogue precursor. If the insulin precursor is to be converted into human insulin, the B30Thr amino acid residue can be added by well known in vitro, enzymatic procedures such methods include enzymatic conversion by means of trypsin or an Achromobacter lyticus protease in the presence of an L-threonine ester followed by conversion of the threonine ester of the insulin into insulin by basic or acid hydrolysis as described in U.S. Pat. Nos. 4,343,898 or 4,916,212. The desB30 insulin may also be converted into an acylated insulin as disclosed in U.S. Pat. No. 5,750,497 and U.S. Pat. No. 5,905,140 the disclosures of which are incorporated by reference hereinto.
[0068] The present invention is described in further detail in the following examples which are not in any way intended to limit the scope of the invention as claimed. The attached Figures are meant to be considered as integral parts of the specification and description of the invention. All references cited are herein specifically incorporated by reference for all that is described therein.
EXAMPLES
[0069] General Procedures
[0070] All expressions plasmids are of the C-POT type, similar to those described in EP 171,142, which are characterized by containing the Schizosaccharomyces pombe triose phosphate isomerase gene (POT) for the purpose of plasmid selection and stabilization in S. cerevisiae. The plasmids also contain the S. cerevisiae triose phosphate isomerase promoter and terminator. These sequences are similar to the corresponding sequences in plasmid pKFN1003 (described in WO 90/100075) as are all sequences except the sequence of the EcoRI-Xbal fragment encoding the fusion protein of the propeptide and the insulin precursor or insulin precursor analogue in question.
[0071] Yeast transformants were prepared by transformation of the host strain S. cerevisiae strain MT663 (MATa/MATα pep4-3/pep4-3 HIS4/his4 tpi::LEU2/tpi::LEU2 Cir + ). The yeast strain MT663 was deposited in the Deutsche Sammlung von Mikroorganismen und Zellkulturen in connection with filing WO 92/11378 and was given the deposit number DSM 6278.
[0072] MT663 was grown on YPGaL (1% Bacto yeast extract, 2% Bacto peptone, 2% galactose, 1% lactate) to an O.D. at 600 nm of 0.6. 100 ml of culture was harvested by centrifugation, washed with 10 ml of water, recentrifuged and resuspended in 10 ml of a solution containing 1.2 M sorbitol, 25 mM Na 2 EDTA pH=8.0 and 6.7 mg/ml dithiotreitol. The suspension was incubated at 30° C. for 15 minutes, centrifuged and the cells resuspended in 10 ml of a solution containing 1.2 M sorbitol, 10 mM Na 2 EDTA, 0.1 M sodium citrate, pH 0 5.8, and 2 mg Novozym®234. The suspension was incubated at 30° C. for 30 minutes, the cells collected by centrifugation, washed in 10 ml of 1.2 M sorbitol and 10 ml of CAS (1.2 M sorbitol, 10 mM CaCl 2 , 10 mM Tris HCl (Tris=Tris(hydroxymethyl)aminomethane) pH=7.5) and resuspended in 2 ml of CAS. For transformation, 1 ml of CAS-suspended cells was mixed with approx. 0.1 mg of plasmid DNA and left at room temperature for 15 minutes. 1 ml of (20% polyethylene glycol 4000, 10 mM CaCl 2 , 10 mM Tris HCl, pH=7.5) was added and the mixture left for a further 30 minutes at room temperature. The mixture was centrifuged and the pellet resuspended in 0.1 ml of SOS (1.2 M sorbitol, 33% v/v YPD, 6.7 mM CaCl 2 ) and incubated at 30° C. for 2 hours. The suspension was then centrifuged and the pellet resuspended in 0.5 ml of 1.2 M sorbitol. Then, 6 ml of top agar (the SC medium of Sherman et al. (1982) Methods in Yeast Genetics, Cold Spring Harbor Laboratory) containing 1.2 M sorbitol plus 2.5% plus 2.5% agar) at 52° C. was added and the suspension poured on top of plates containing the same agar-solidified, sorbitol containing medium.
[0073] [0073] S. cerevisiae strain MT663 was transformed with expression plasmids comprising DNA encoding the insulin precursor in question and was grown in YPD medium (2% Bacto yeast extract, 1% Bacto peptone, 6% glucose) for 72 h at 30° C. Quantitation of the insulin-precursor yield in the culture supernatants was performed by reverse-phase HPLC analysis with human insulin as an external standard (Snel & Damgaard (1988) Pro-insulin heterogenity in pigs. Horm. Metabol. Res. 20:476-488) after conversion to desB30 insulin after treatment with ALP enzyme.
Example 1
[0074] Expression of Insulin Analogue Precursors Wherein the B(1-29) Chain is Connected to the A(1-21) Chain via a Connection Peptide AAK, SEQ ID NO:1, SEQ ID NO:4, SEQ ID NO:5, SEQ ID NO:6 or SEQ ID NO:7.
[0075] Expression was conducted in yeast as described above. Strains were grown in 500 ml shake flasks approximately 200 ml YPD medium. The precursors have an N-terminal extension EEGNTTEPK (SEQ ID NO:3) or EEGEPK (SEQ ID NO:2). All insulin precursors according to the invention were furnished with the YAP3 signal and a synthetic leader sequence named TA39 as disclosed in WO 02/00191 or WO 02/00190 and were expressed as a fusion protein e.g.: “YAP3-signal-TA39-leader-N-terminally-extended-insulin-precursor”. The signal-leader sequence is cleaved off during secreting. Expression results of the N-terminally extended insulin precursor in question measured by HPLC are shown in Table 1 as a percent of the control which is the insulin precursor B(1-29)-Ala-Ala-Lys-A(1-21).
TABLE 1 Yield of N-terminally N-terminal extended insulin precursor extension C-peptide in mg/l in % of control No AAK 100 (control) EEGEPK AAK 273 (SEQ ID NO:2) EEGNTTEPK AAK 300 (SEQ ID NO:3) EEGEPK SNTTK 602 (SEQ ID NO:2) (SEQ ID NO:1) EEGNTTEPK SNTTK 446 (SEQ ID NO:3) (SEQ ID NO:1) EEGEPK SANNTK 488 (SEQ ID NO:2) (SEQ ID NO:4) EEGEPK SPNTTK 343 (SEQ ID NO:2) (SEQ ID NO:5) EEGEPK SSNTTK 654 (SEQ ID NO:2) (SEQ ID NO:6) EEGEPK SRNTTK 368 (SEQ ID NO:2) (SEQ ID NO:7)
[0076] [0076]
1
7
1
5
PRT
Artificial Sequence
Synthetic
1
Ser Asn Thr Thr Lys
1 5
2
6
PRT
Artificial Sequence
Synthetic
2
Glu Glu Gly Glu Pro Lys
1 5
3
9
PRT
Artificial Sequence
Synthetic
3
Glu Glu Gly Asn Thr Thr Glu Pro Lys
1 5
4
6
PRT
Artificial Sequence
Synthetic
4
Ser Ala Asn Asn Thr Lys
1 5
5
6
PRT
Artificial Sequence
Synthetic
5
Ser Pro Asn Thr Thr Lys
1 5
6
6
PRT
Artificial Sequence
Synthetic
6
Ser Ser Asn Thr Thr Lys
1 5
7
6
PRT
Artificial Sequence
Synthetic
7
Ser Arg Asn Thr Thr Lys
1 5 | Novel insulin precursors and insulin analogue precursors comprising a connecting C-peptide and an N-terminal extension are easy to handle in down stream processing and are expressed in high yields. The precursors are characterized in that the connecting peptide, the N-terminal extension or both contain at least one glycosylation site. | 2 |
FIELD OF THE INVENTION
[0001] This present invention generally relates to muscarinic receptor antagonists, which are useful, among other uses, for the treatment of various diseases of the respiratory, urinary and gastrointestinal systems mediated through muscarinic receptors. The invention also relates to the process for the preparation of disclosed compounds, pharmaceutical compositions containing the disclosed compounds, and the methods for treating diseases mediated through muscarinic receptors.
BACKGROUND OF THE INVENTION
[0002] Physiological effects elicited by the neurotransmitter acetylcholine are mediated through its interaction with two major classes of acetylcholine receptors—the nicotinic and muscarinic acetylcholine receptors. Muscarinic receptors belong to the superfamily of G-protein coupled receptors and five molecularly distinct subtypes are known to exist (M 1 , M 2 , M 3 , M 4 and M 5 ).
[0003] These receptors are widely distributed on multiple organs and tissues and are critical to the maintenance of central and peripheral cholinergic neurotransmission. The regional distribution of these receptor sub-types in the brain and other organs has been documented. (for example, the M 1 subtype is located primarily in neuronal tissues such as cereberal cortex and autonomic ganglia, the M 2 subtype is present mainly in the heart and bladder smooth muscle, and the M 3 subtype is located predominantly on smooth muscle and salivary glands ( Nature, 323, p. 411 (1986); Science, 237, p. 527 (1987)).
[0004] A review in Curr. Opin. Chem. Biol., 3, p. 426 (1999), as well as in Trends in Pharmacol. Sci., 22, p. 409 (2001) by Eglen et. al., describes the biological potentials of modulating muscarinic receptor subtypes by ligands in different disease conditions, such as Alzheimer's disease, pain, urinary disease condition, chronic obstructive pulmonary disease, and the like.
[0000] The pharmacological and medical aspects of the muscarinic class of acetylcholine agonists and antagonists are presented in a review in Molecules, 6, p. 142 (2001). Birdsall et. al. in Trends in Pharmacol. Sci., 22, p. 215 (2001) has also summarized the recent developments on the role of different muscarinic receptor subtypes using different muscarinic receptor of knock out mice.
[0005] Almost all the smooth muscles express a mixed population of M 2 and M 3 receptors. Although the M 2 -receptors are the predominant cholinoreceptors, the smaller population of M 3 -receptors appears to be the most functionally important as they mediate the direct contraction of these smooth muscles. Muscarinic receptor antagonists are known to be useful for treating various medical conditions associated with improper smooth muscle function, such as overactive bladder syndrome, irritable bowel syndrome and chronic obstructive pulmonary disease. However the therapeutic utility of antimuscarinics has been limited by poor tolerability as a result of treatment related, frequent systemic adverse events such as dry mouth, constipation, blurred vision, headache, somnolence and tachycardia. Thus, there exists a need for novel muscarinic receptor antagonists that demonstrate target organ selectivity.
[0006] WO 04/005252 discloses azabicyclo derivatives described as musacrinic receptor antagonists. WO 04/004629, WO 04/052857, WO 04/067510, WO 04/014853, WO 04/014363 discloses 3,6-disubstituted azabicyclo [3.1.0]hexane derivatives described as useful muscarinic receptor antagonists. WO 04/056811 discloses flaxavate derivatives as muscarinic receptor antagonists. WO 04/056810 discloses xanthene derivatives as muscarinic receptor antagonists. WO 04/056767 discloses 1-substituted-3-pyrrolidine derivatives as muscarinic receptor antagonists. WO 99/14200, WO 03/1027060, U.S. Pat. No. 6,200,991, and WO 00/56718 disclose heterocycle derivatives as muscarinic receptor antagonists. WO 04/089363, WO 04/089898, WO 04/069835, WO 04/089900 and WO 04/089364 disclose substituted azabicyclohexane derivatives as muscarinic receptor antagonists. WO 06/018708 disclose pyrrolidine derivatives as muscarinic receptor antagonists. WO 06/35303 discloses azabicyclo derivatives as muscarinic receptor antagonists.
[0000] J. Med. Chem., 44, p. 984 (2002), describes cyclohexylmethylpiperidinyl-triphenylpropioamide derivatives as selective M 3 antagonist discriminating against the other receptor subtypes. J. Med. Chem., 36, p. 610 (1993), describes the synthesis and antimuscarinic activity of some 1-cycloalkyl-1-hydroxy-1-phenyl-3-(4-substituted piperazinyl)-2-propanones and related compounds. J. Med. Chem., 34, p. 3065 (1991), describes analogues of oxybutynin, synthesis and antimuscarinic activity of some substituted 7-amino-1-hydroxy-5-heptyn-2-ones and related compounds. Bio - Org. Med. Chem. Lett., 15, p. 2093 (2005) describes synthesis and activity of analogues of Oxybutynin and Tolterodine. Chem. Pharm. Bull., 53(4), 437, 2005 discloses thiazole carboxamide derivatives.
[0007] The present invention fills the need of muscarinic receptor antagonists useful in the treatment of disease states associated with improper smooth muscle function and respiratory disorders.
SUMMARY OF THE INVENTION
[0008] In one aspect, there are provided muscarinic receptor antagonists, which can be useful as safe and effective therapeutic or prophylactic agents for the treatment of various diseases of the respiratory, urinary and gastrointestinal systems. Also provided are processes for synthesizing such compounds.
[0009] In another aspect, pharmaceutical compositions containing such compounds are provided together with acceptable carriers, excipients or diluents which can be useful for the treatment of various diseases of the respiratory, urinary and gastrointestinal systems.
[0010] The enantiomers, diastereomers, N-oxides, polymorphs, pharmaceutically acceptable salts and pharmaceutically acceptable solvates of these compounds as well as metabolites having the same type of activity are also provided, as well as pharmaceutical compositions comprising the compounds, their metabolites, enantiomers, diastereomers, N-oxides, polymorphs, solvates or pharmaceutically acceptable salts thereof, in combination with a pharmaceutically acceptable carrier and optionally included excipients.
[0011] Other aspects will be set forth in the description which follows, and in part will be apparent from the description or may be learnt by the practice of the invention.
[0012] In accordance with one aspect, there are provided compounds having the structure of Formula I:
[0000]
[0000] and its pharmaceutically acceptable salts, pharmaceutically acceptable solvates, enantiomers, diastereomers, polymorphs or N-oxides wherein
represents a single bond when G is —OH and double bond when G is —O;
R 1 and R 2 are independently selected from hydrogen, alkyl, alkenyl, alkynyl, aralkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, heterocyclylalkyl or heteroarylalkyl;
R 3 is selected from the group selected from hydrogen, hydroxy, alkoxy, alkenyloxy or alkynyloxy;
X is selected from oxygen, —NH, —NR (wherein R is alkyl, alkenyl, alkenyl, alkynyl or aryl), sulphur or no atom;
Het is heterocyclyl or heteroaryl;
n is an integer from 1 to 6;
With the proviso that when R 1 and R 2 are phenyl, R 3 is hydroxy and X is no atom, then Het cannot be a saturated heterocyclyl group.
The following definitions apply to terms as used herein:
[0013] The term “alkyl,” unless otherwise specified, refers to a monoradical branched or unbranched saturated hydrocarbon chain having from 1 to 20 carbon atoms. Alkyl groups can be optionally interrupted by atom(s) or group(s) independently selected from oxygen, sulfur, a phenylene, sulphinyl, sulphonyl group or —NR α —, wherein R a , can be hydrogen, alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, aryl, acyl, aralkyl, —C(═O)OR λ , SO m R ψ or —C(═O)NR λ R π . This term can be exemplified by groups such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, sec-butyl, t-butyl, n-pentyl, isopentyl, neopentyl, n-hexyl, n-decyl, tetradecyl, and the like. Alkyl groups may be substituted further with one or more substituents selected from alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, oxo, thiocarbonyl, carboxy, carboxyalkyl, aryl, heterocyclyl, heteroaryl, (heterocyclyl)alkyl, cycloalkoxy, —CH═N—O(C 1-6 alkyl), —CH═N—NH(C 1-6 alkyl), —CH═N—NH(C 1-6 alkyl)-C 1-6 alkyl, arylthio, thiol, alkylthio, aryloxy, nitro, aminosulfonyl, aminocarbonylamino, —NHC(═O)R λ , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —C(═O)heteroaryl, C(═O)heterocyclyl, —O—C(═O)NR λ R π {wherein R λ and R π are independently selected from hydrogen, halogen, hydroxy, alkyl, alkenyl, alkynyl, alkenyl, alkoxy, cycloalkyl, cycloalkenyl, aryl, aralkyl, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl or carboxy}, nitro or —SO m R ψ (wherein m is an integer from 0-2 and R ψ is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heterocyclyl, heteroaryl, heteroarylalkyl or heterocyclylalkyl). Unless otherwise constrained by the definition, alkyl substituents may be further substituted by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, —NR λ R π , —C(═O)NR λ R π , —OC(═O)NR λ R π , —HC(═O)NR λ R π , hydroxy, alkoxy, halogen, CF 3 , cyano, and —SO m R ψ ; or an alkyl group also may be interrupted by 1-5 atoms of groups independently selected from oxygen, sulfur or —NR α — (wherein R α , R λ , R π , m and R ψ are the same as defined earlier). Unless otherwise constrained by the definition, all substituents may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, carboxyalkyl, —NR λ R π , —C(═O)NR λ R π , —O—C(═O)NR λ R π , hydroxy, alkoxy, halogen, CF 3 , cyano, and —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier); or an alkyl group as defined above that has both substituents as defined above and is also interrupted by 1-5 atoms or groups as defined above.
[0014] The term “alkenyl,” unless otherwise specified, refers to a monoradical of a branched or unbranched unsaturated hydrocarbon group having from 2 to 20 carbon atoms with cis, trans or geminal geometry. Alkenyl groups can be optionally interrupted by atom(s) or group(s) independently chosen from oxygen, sulfur, phenylene, sulphinyl, sulphonyl and —NR α — (wherein R α is the same as defined earlier). In the event that alkenyl is attached to a heteroatom, the double bond cannot be alpha to the heteroatom. Alkenyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, —NHC(═O)R λ , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —O—C(═O)NR λ R π , alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, keto, carboxyalkyl, thiocarbonyl, carboxy, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, heterocyclyl, heteroaryl, heterocyclyl alkyl, heteroaryl alkyl, aminosulfonyl, aminocarbonylamino, alkoxyamino, hydroxyamino, alkoxyamino, nitro or SO m R ψ (wherein R λ , R π , m and R ψ are as defined earlier). Unless otherwise constrained by the definition, alkenyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, hydroxy, alkoxy, halogen, —CF 3 , cyano, —NR λ R π , —C(═O)NR λ R π , —O—C(═O)NR λ R π and —SO m R ψ (wherein R λ , R π , m and R ψ are as defined earlier). Groups, such as ethenyl or vinyl (CH═CH 2 ), 1-propylene or allyl (—CH 2 CH═CH 2 ), iso-propylene (—C(CH 3 )═CH 2 ), bicyclo[2.2.1]heptene, and the like, exemplify this term.
[0015] The term “alkynyl,” unless otherwise specified, refers to a monoradical of an unsaturated hydrocarbon, having from 2 to 20 carbon atoms. Alkynyl groups can be optionally interrupted by atom(s) or group(s) independently chosen from oxygen, sulfur, phenylene, sulphinyl, sulphonyl and —NR α — (wherein R α is the same as defined earlier). In the event that alkynyl groups are attached to a heteroatom, the triple bond cannot be alpha to the heteroatom. Alkynyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, oxo, thiocarbonyl, carboxy, carboxyalkyl, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, aminosulfonyl, aminocarbonylamino, hydroxyamino, alkoxyamino, nitro, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl, —NHC(═O)R λ , —NR λ R π , —NHC(═O)NR λ R π , —C(═O)NR λ R π , —O—C(═O)NR λ R π or —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier). Unless otherwise constrained by the definition, alkynyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, carboxyalkyl, hydroxy, alkoxy, halogen, CF 3 , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —C(═O)NR λ R π , cyano or —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier).
[0016] The term “alkoxy” denotes the group O-alkyl, wherein alkyl is the same as defined above.
[0017] The term “aryl,” unless otherwise specified, refers to aromatic system having 6 to 14 carbon atoms, wherein the ring system can be mono-, bi- or tricyclic and are carbocyclic aromatic groups. For example, aryl groups include, but are not limited to, phenyl, biphenyl, anthryl or naphthyl ring and the like, optionally substituted with 1 to 3 substituents selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, alkoxy, acyl, aryloxy, CF 3 , cyano, nitro, COOR ψ , NHC(═O)R λ , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —O—C(═O)NR λ R π , —SO m R ψ , carboxy, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl or amino carbonyl amino, mercapto, haloalkyl, optionally substituted aryl, optionally substituted heterocyclylalkyl, thioalkyl, —CONHR π , —OCOR π , —COR π , —NHSO 2 R π or —SO 2 NHR π (wherein R λ , R π , m and R ψ are the same as defined earlier). Aryl groups optionally may be fused with a cycloalkyl group, wherein the cycloalkyl group may optionally contain heteroatoms selected from O, N or S. Groups such as phenyl, naphthyl, anthryl, biphenyl, and the like exemplify this term.
[0018] The term “aralkyl,” unless otherwise specified, refers to alkyl-aryl linked through an alkyl portion (wherein alkyl is as defined above) and the alkyl portion contains 1-6 carbon atoms and aryl is as defined below. Examples of aralkyl groups include benzyl, ethylphenyl, propylphenyl, naphthylmethyl and the like.
[0019] The term “cycloalkyl,” unless otherwise specified, refers to cyclic alkyl groups of from 3 to 20 carbon atoms having a single cyclic ring or multiple condensed rings, which may optionally contain one or more olefinic bonds, unless otherwise constrained by the definition. Such cycloalkyl groups can include, for example, single ring structures, including cyclopropyl, cyclobutyl, cyclooctyl, cyclopentenyl, and the like or multiple ring structures, including adamantanyl, and bicyclo [2.2.1]heptane or cyclic alkyl groups to which is fused an aryl group, for example, indane, and the like. Spiro and fused ring structures can also be included. Cycloalkyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, aryloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, carboxyalkyl, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, aminosulfonyl, aminocarbonylamino, —NR λ R π , —NHC(═O)NR λ R π , —C(═O)NR λ R π , —O—C(═O)NR λ R π , nitro, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl or SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier). Unless otherwise constrained by the definition, cycloalkyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, hydroxy, alkoxy, halogen, CF 3 , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —OC(═O)NR λ R π , cyano or —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier). “Cycloalkylalkyl” refers to alkyl-cycloalkyl group linked through alkyl portion, wherein the alkyl and cycloalkyl are the same as defined earlier.
[0020] The term “carboxy” as defined herein refers to —C(═O)OH.
[0021] The term “aryloxy” denotes the group O-aryl, wherein aryl is as defined above.
[0022] The term “heteroaryl,” unless otherwise specified, refers to an aromatic ring structure containing 5 or 6 ring atoms or a bicyclic or tricyclic aromatic group having from 8 to 10 ring atoms, with one or more heteroatom(s) independently selected from N, O or S optionally substituted with 1 to 4 substituent(s) selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, acyl, carboxy, aryl, alkoxy, aralkyl, cyano, nitro, heterocyclyl, heteroaryl, —NR λ R π , CH═NOH, —(CH 2 ) w C(═O)R η {wherein w is an integer from 0-4 and R η is hydrogen, hydroxy, OR λ , NR λ R π , —NHOR ω or —NHOH}, —C(═O)NR λ R π —NHC(═O)NR λ R π , —SO m R ψ , —O—C(═O)NR λ R π , —O—C(═O)R λ , or —O—C(═O)R λ (wherein m, R ψ , R λ , and R π are as defined earlier and R ω is alkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl). Unless otherwise constrained by the definition, the substituents are attached to a ring atom, i.e., carbon or heteroatom in the ring. Examples of heteroaryl groups include oxazolyl, imidazolyl, pyrrolyl, 1,2,3-triazolyl, 1,2,4-triazolyl, tetrazolyl, thiazolyl, oxadiazolyl, benzoimidazolyl, thiadiazolyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, thienyl, isoxazolyl, triazinyl, furanyl, benzofuranyl, indolyl, benzthiazinyl, benzthiazinonyl, benzoxazinyl, benzoxazinonyl, quinazonyl, carbazolyl phenothiazinyl, phenoxazinyl, benzothiazolyl or benzoxazolyl, and the like.
[0023] The term “heterocyclyl,” unless otherwise specified, refers to a non-aromatic monocyclic or bicyclic cycloalkyl group having 5 to 10 atoms wherein 1 to 4 carbon atoms in a ring are replaced by heteroatoms selected from O, S or N, and optionally are benzofused or fused heteroaryl having 5-6 ring members and/or optionally are substituted, wherein the substituents are selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, acyl, optionally substituted aryl, alkoxy, alkaryl, cyano, nitro, oxo, carboxy, optionally substituted heterocyclyl, optionally substituted heterocyclylalkyl, optionally substituted heteroaryl, —O—C(═O)R λ , —O—C(═O)OR λ , —C(═O)NR λ R π , SO m R ψ , —O—C(═O)NR λ R π , —NHC(═O)NR λ R π , —NR λ R π , mercapto, haloalkyl, thioalkyl, —COOR ψ , —COONHR λ , —COR λ , —NHSO 2 R λ or SO 2 NHR λ (wherein m, R ψ , R λ and R π are as defined earlier) or guanidine. Heterocyclyl can optionally include rings having one or more double bonds. Such ring systems can be mono-, bi- or tricyclic. Carbonyl or sulfonyl group can replace carbon atom(s) of heterocyclyl. Unless otherwise constrained by the definition, the substituents are attached to the ring atom, i.e., carbon or heteroatom in the ring. Also, unless otherwise constrained by the definition, the heterocyclyl ring optionally may contain one or more olefinic bond(s). Examples of heterocyclyl groups include oxazolidinyl, tetrahydrofuranyl, dihydrofuranyl, benzoxazinyl, benzthiazinyl, imidazolyl, benzimidazolyl, tetrazolyl, carbaxolyl, indolyl, phenoxazinyl, phenothiazinyl, dihydropyridinyl, dihydroisoxazolyl, dihydrobenzofuryl, azabicyclohexyl, thiazolidinyl, dihydroindolyl, pyridinyl, isoindole 1,3-dione, piperidinyl, tetrahydropyranyl, piperazinyl, 3H-imidazo[4,5-b]pyridine, isoquinolinyl, 1H-pyrrolo[2,3-b]pyridine or piperazinyl and the like.
[0024] “Heteroarylalkyl” refers to alkyl-heteroaryl group linked through alkyl portion, wherein the alkyl and heteroaryl are as defined earlier.
[0025] “Heterocyclylalkyl” refers to alkyl-heterocyclyl group linked through alkyl portion, wherein the alkyl and heterocyclyl are as defined earlier.
[0026] “Acyl” refers to —C(═O)R″ wherein R″ is selected from hydrogen, alkyl, cycloalkyl, aryl, aralkyl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl.
[0027] “Thiocarbonyl” refers to —C(═S)H.
[0028] “Substituted thiocarbonyl” refers to —C(═S)R″ wherein R″ is selected is the same as defined earlier.
[0029] The term “leaving group” refers to groups that exhibit or potentially exhibit the properties of being labile under the synthetic conditions and also, of being readily separated from synthetic products under defined conditions. Examples of leaving groups include, but are not limited to, halogen (e.g., F, Cl, Br, I), triflates, tosylate, mesylates, alkoxy, thioalkoxy, or hydroxy radicals and the like.
[0030] The term “protecting groups” refers to moieties that prevent chemical reaction at a location of a molecule intended to be left unaffected during chemical modification of such molecule. Unless otherwise specified, protecting groups may be used on groups, such as hydroxy, amino, or carboxy. Examples of protecting groups are found in T. W. Greene and P. G. M. Wuts, “Protective Groups in Organic Synthesis”, 2 nd Ed., John Wiley and Sons, New York, N.Y., which is incorporated herein by reference. The species of the carboxylic protecting groups, amino protecting groups or hydroxy protecting groups employed are not critical, as long as the derivatised moieties/moiety is/are stable to conditions of subsequent reactions and can be removed without disrupting the remainder of the molecule.
[0031] The term “pharmaceutically acceptable salts” refers to derivatives of compounds that can be modified by forming their corresponding acid or base salts. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acids salts of basic residues (such as amines), or alkali or organic salts of acidic residues (such as carboxylic acids), and the like.
[0032] The term “pharmaceutically acceptable salts” also refers to salts prepared from pharmaceutically acceptable non-toxic inorganic or organic acid. Examples of such inorganic acids include, but are not limited to, hydrochloric, hydrobromic, hydroiodic, nitrous, nitric, carbonic, sulfuric, phosphoric acid, and the like. Appropriate organic acids include, but are not limited to aliphatic, cycloaliphatic, aromatic, heterocyclic, carboxylic and sulfonic classes of organic acids, for example, formic, acetic, propionic, succinic, glycolic, gluconic, lactic, malic, tartaric, citric, ascorbic, glucuronic, maleic, fumaric, pyruvic, aspartic, glutamic, benzoic, anthranilic, mesylic, salicylic, p-hydroxybenzoic, phenylacetic, mandelic, embonic, methanesulfonic, ethanesulfonic, benzenesulfonic, panthenic, toluenesulfonic, 2-hydroxyethanesulfonic acid and the like.
[0033] In accordance with a second aspect, there is provided a method for treatment or prophylaxis of an animal or a human suffering from a disease or disorder of the respiratory, urinary and gastrointestinal systems, wherein the disease or disorder is mediated through muscarinic receptors. The method includes administration of at least one compound having the structure of Formula I.
[0034] In accordance with a third aspect, there is provided a method for treatment or prophylaxis of an animal or a human suffering from a disease or disorder associated with muscarinic receptors, comprising administering to a patient in need thereof, an effective amount of a muscarinic receptor antagonist compound as described above.
[0035] In accordance with a fourth aspect, there is provided a method for treatment or prophylaxis of an animal or a human suffering from a disease or disorder of the respiratory system such as bronchial asthma, chronic obstructive pulmonary disorders (COPD), pulmonary fibrosis, and the like; urinary system which induce such urinary disorders as urinary incontinence, lower urinary tract symptoms (LUTS), etc.; and gastrointestinal system such as irritable bowel syndrome, obesity, diabetes and gastrointestinal hyperkinesis with compounds as described above, wherein the disease or disorder is associated with muscarinic receptors.
[0036] In accordance with a fifth aspect, there are provided processes for preparing the compounds as described above.
[0037] The compounds described herein exhibit significant potency in terms of their activity, as determined by in vitro receptor binding and functional assays and in vivo experiments using anaesthetized rabbits. The compounds that were found active in vitro were tested in vivo. Some of the compounds are potent muscarinic receptor antagonists with high affinity towards M 1 and M 3 receptors than M 2 and/or M 5 receptors. Therefore, pharmaceutical compositions for the possible treatment for the disease or disorders associated with muscarinic receptors are provided. In addition, the compounds can be administered orally or parenterally.
DETAILED DESCRIPTION OF THE INVENTION
[0038] The compounds disclosed herein may be prepared by methods represented by the reaction sequences, for example, as generally shown in Scheme I
[0000]
[0039] The compounds of Formula IV can be prepared, for example, by following the procedure as depicted in, for example, Scheme I wherein the reaction comprises reacting a compound of Formula II (wherein R 1 , R 2 and R 3 are the same as defined earlier) with a compound of Formula III [wherein n is an integer from 1-6 and Y is —OH, —Omesyl, —Otosyl, —Otriflyl or —NH 2 .HCl or —NHR. HCl wherein R is the same as defined earlier and R 1 ′ is selected from hydrogen, alkyl, alkenyl, alkynyl, aralkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, heterocyclylalkyl or heteroarylalkyl and is always a substitutent on the carbon atoms of imidazolyl ring) to give a compound of Formula IV (wherein X is the same as defined earlier). The compound of Formula IV can be further quaternized with a compound of Formula Q-Z (wherein Q can be selected from alkyl, alkenyl, alkynyl, cycloalkyl, heterocyclyl, aryl, heteroaryl, aralkyl, heteroarylalkyl or heterocyclylalkyl and Z is an anion disclosed in I nt. J. Pharmaceutics, 33 (1986), page 202, for example, but not limited to, acetate, tartarate, chloride, bromide, iodide, sulphate, phosphate, nitrate, carbonate, fumarate, glutamate, citrate, methanesulphonate, toulenesulphonate, benzenesulphonate, maleate or succinate) to give a compound of Formula IVa.
[0040] The coupling of a compound of Formula II with a compound of Formula III (when Y is —NH.HCl or —NHR.HCl) can be carried out in an organic solvent (for example, dimethylformamide, chloroform, tetrahydrofuran, diethyl ether or dioxane) in the presence of a base (for example, N-methylmorpholine, triethylamine, diisopropylethylamine or pyridine) with a condensing agent (for example, 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC.HCl) or dicyclohexylcarbodiimide (DCC)).
[0041] The coupling of a compound of Formula II with a compound of Formula III (when Y is —OH or —SH) can be carried out in an organic solvent, for example, tetrahydrofuran, dimethylformamide, diethyl ether or dioxane in the presence of a coupling agent, for example, carbonyldiimidazole 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC.HCl) or dicyclohexylcarbodiimide (DCC).
[0042] Alternatively, coupling of a compound of Formula II with a compound of Formula III (when Y is —OH or —SH) can be carried out in an organic solvent (for example, toluene, heptane or xylene) in the presence of a base (for example, sodium hydride or sodium methoxide) to give a compound of Formula IV.
[0043] The coupling of a compound of Formula II with a compound of Formula III (when Y is —Omesyl, —Otosyl or —Otriflyl) can be carried out in an organic solvent (for example, toluene, heptane or xylene) in the presence of a base (for example, 1,8-diazabicyclo[5.4.0]undecen-7-ene (DBU) or 1,4-diazabicyclo[2.2.2]octane) to give a compound of Formula IV.
[0044] The quaternization of a compound of Formula IV to give a compound of Formula IVa can be carried out by reacting the compound of Formula IV with a compound of Formula Q-Z in an optional organic solvent such as, for example acetonitrile, dichloromethane, dichloroethane, carbon tetrachloride, chloroform, toluene, benzene, DMF, DMSO. Particular illustrative compounds which may be prepared by, for example Scheme I include:
2-Cyclopentyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 1) 1H-Imidazol-1-ylmethyl cyclohexyl(hydroxy)(4-methylphenyl)acetate (Compound No. 2) 2-(4-Fluorophenyl)-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 3) 2-Cyclobutyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 4) 2-Cyclopentyl-2-(4-fluorophenyl)-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]acetamide (Compound No. 5) 2-Hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2,2-diphenylacetamide (Compound No. 6) 2-Cyclohexyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 7) 2-Cyclopentyl-2-hydroxy-N-[2-(2-isopropyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 8) 2-Cyclohexyl-2-hydroxy-N-[2-(2-isopropyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 9) 2-Hydroxy-N-[2-(2-isopropyl-1H-imidazol-1-yl)ethyl]-2-phenyl-2-pyridin-3-ylacetamide (Compound No. 10) 2-(4-Fluorophenyl)-2-hydroxy-N-[2-(2-isopropyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 11) 2-Hydroxy-N-[2-(2-isopropyl-1H-imidazol-1-yl)ethyl]-2,2-diphenylacetamide (Compound No. 12) 2-(2-Methyl-1H-imidazol-1-yl)ethyl cyclopentyl(hydroxy)phenylacetate (Compound No. 13) 2-(2-Methyl-1H-imidazol-1-yl)ethyl (2R)-cyclopentyl(hydroxy)phenylacetate (Compound No. 14) (2R)-2-cyclopentyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 16) 2-Hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2-phenyl-2-pyridin-3-ylacetamide (Compound No. 17) 2-Cyclopentyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 18) 2-Hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenyl-2-pyridin-3-ylacetamide (Compound No. 19) 2-Cyclohexyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 20) 2-(4-Fluorophenyl)-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 21) 2-Cyclopentyl-2-(4-fluorophenyl)-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]acetamide (Compound No. 22) 2-Cyclobutyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 23) 2-Hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2,2-diphenylacetamide (Compound No. 24) 3,3,3-Trifluoro-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-(4-methylphenyl)propanamide (Compound No. 25) N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2,2-diphenylacetamide (Compound No. 26) -Cyclopentyl-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 27) 2-Cyclopentyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-(4-methylphenyl)acetamide (Compound No. 28) 2-Cyclohexyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-(4-methylphenyl)acetamide (Compound No. 29) 2-Hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-(4-methylphenyl)-2-phenylacetamide (Compound No. 30) 2-Cyclopentyl-2-hydroxy-N-[3-(1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 31) 2-Cyclohexyl-2-hydroxy-N-[3-(1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 32) 2-Cyclopentyl-2-hydroxy-N-[3-(2-methyl-1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 33) 2-Cyclohexyl-2-hydroxy-N-[3-(2-methyl-1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 34) (2R)-2-(3,3-Difluorocyclopentyl)-2-hydroxy-N-[3-(2-methyl-1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 35) 2-Cyclopentyl-2-hydroxy-N-methyl-N-[3-(2-methyl-1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 36) 2-Cyclohexyl-2-hydroxy-N-methyl-N-[3-(2-methyl-1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 37) 2-Cyclopentyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-N-methyl-2-phenylacetamide (Compound No. 38) 1H-imidazol-1-ylmethyl cyclopentyl(hydroxy)phenylacetate (Compound No. 46) 1H-imidazol-1-ylmethyl cyclohexyl(hydroxy)phenylacetate (Compound No. 47) 1H-imidazol-1-ylmethyl (2R)-cyclopentyl(hydroxy)phenylacetate (Compound No. 48) 1H-Imidazol-1-ylmethyl cyclopentyl(hydroxy)(4-methoxyphenyl)acetate (Compound No. 49) 2-Cyclohexyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-N-methyl-2-phenylacetamide (Compound No. 57) 2-Cyclopentyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-N-methyl-2-phenylacetamide (Compound No. 58) 2-(2-Methyl-1H-imidazol-1-yl)ethyl cyclopentyl(phenyl)acetate (Compound No. 59) 2-(2-Methyl-1H-imidazol-1-yl)ethyl cyclohexyl(hydroxy)phenylacetate (Compound No. 60) 3-(2-Methyl-1H-imidazol-1-yl)propyl cyclopentyl(hydroxy)phenylacetate (Compound No. 61) 3-(2-Methyl-1H-imidazol-1-yl)propyl (2R)-[(1R)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 62) 3-(2-Methyl-1H-imidazol-1-yl)propyl 2R-2-(1S or 1R)(3,3-difluorocyclohexyl) (hydroxy)phenylacetate (Compound No. 63) 2-(2-Isopropyl-1H-imidazol-1-yl)ethyl cyclohexyl(hydroxy)phenylacetate (Compound No. 64) 2-(1H-Imidazol-1-yl)ethyl cyclopentyl(hydroxy)phenylacetate (Compound No. 65) 2-(2-Methyl-1H-imidazol-1-yl)ethyl (2R)-[(1S)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 66) 2-(1H-Imidazol-1-yl)ethyl cyclohexyl(hydroxy)phenylacetate (Compound No. 67) 2-(2-Isopropyl-1H-imidazol-1-yl)ethyl cyclopentyl(hydroxy)phenylacetate (Compound No. 68) 2-(2-Methyl-1H-imidazol-1-yl)ethyl (2R)-[(1R)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 69) 2-(2-Isopropyl-1H-imidazol-1-yl)ethyl cycloheptyl(hydroxy)phenylacetate (Compound No. 70) 2-(2-Methyl-1H-imidazol-1-yl)ethyl cycloheptyl(hydroxy)phenylacetate (Compound No. 71) 3-Benzyl-1-(2-{[cycloheptyl(hydroxy)phenylacetyl]oxy}ethyl)-2-isopropyl-1H-imidazol-3-ium bromide (Compound No. 72) 3-Benzyl-1-[2-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-isopropyl-1H-imidazol-3-ium bromide (Compound No. 73) 3-Benzyl-1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-isopropyl-1H-imidazol-3-ium bromide (Compound No. 74) 3-(4-Bromobenzyl)-1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-isopropyl-1H-imidazol-3-ium bromide (Compound No. 75) 3-Benzyl-1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 76) 3-(4-Bromobenzyl)-1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 77) 3-(4-Fluorobenzyl-1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 78) 3-Benzyl-1-(2-{[cycloheptyl(hydroxy)phenylacetyl]oxy}ethyl)-2-methyl-1H-imidazol-3-ium bromide (Compound No. 79). 3-(4-Bromobenzyl)-1-(2-{[cycloheptyl(hydroxy)phenylacetyl]oxy}ethyl)-2-methyl-1H-imidazol-3-ium bromide (Compound No. 80) 1-[2-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 81) 1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-3-(4-fluorobenzyl)-2-isopropyl-1H-imidazol-3-ium bromide (Compound No. 82) 1-(2-{[2-Cyclohexyl-2-hydroxy-2-phenylacetyl]oxy}ethyl)-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 83) 1-(2-{[Cyclopentyl (hydroxy)phenylacetyl]oxy}ethyl)-3-methyl-1H-imidazol-3-ium iodide (Compound No. 84) 1-[2-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 85) 1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 86) 1-(2-{[Cyclohexyl(hydroxy)phenylacetyl]oxy}ethyl)-3-methyl-1H-imidazol-3-ium iodide (Compound No. 87) 1-(2-{[Cyclopentyl(hydroxy)phenylacetyl]oxy}ethyl)-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 88) 1-(2-{[Cyclopentyl(hydroxy)phenylacetyl]amino}ethyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 89) 1-(2-{[Cyclohexyl(hydroxy)phenylacetyl]amino}ethyl)-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 90) 1-(2-{[Cycloheptyl(hydroxy)phenylacetyl]oxy}ethyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 91) 1-(2-{[Cycloheptyl(hydroxy)phenylacetyl]oxy}ethyl)-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 92.) 1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 93) 1-(3-{[(2R)-2-(3,3-difluorocyclopentyl)-2-hydroxy-2-phenylacetyl]amino}propyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 94) 1-(3-{[Cyclopentyl(hydroxy)phenylacetyl]amino}propyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 95) 1-(3-{[Cyclohexyl(hydroxy)phenylacetyl]amino}propyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 96) 1-(2-{[Cyclopentyl(hydroxy)phenylacetyl](methyl)amino}ethyl)-3-methyl-1H-imidazol-3-ium iodide (Compound No. 97) 1-(3-{[Cyclopentyl(hydroxy)phenylacetyl](methyl)amino}propyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 98) 1-(3-{[Cyclopentyl(hydroxy)phenylacetyl]oxy}propyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 99) 1-[3-({(2R)-2-[(1S)-3,3-Difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 100) 3-Benzyl-1-[3-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 101) 3-(4-Bromobenzyl)-1-[3-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 102) 1-[3-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 103) 3-Benzyl-1-[3-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 104). 3-(4-Bromobenzyl)-1-[3-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 105) 1-[3-({(2R)-2-[(1S or 1R)-3,3-difluorocyclohexyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2,3-dimethyl-1H-imidazol-3-ium bromide (Compound No. 106) 3-Benzyl-1-[3-({(2R)-2-[(1R or 1S)-3,3-difluorocyclohexyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 107) 3-(4-Bromobenzyl)-1-[3-({(2R)-2-[(1R or 1S)-3,3-difluorocyclohexyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 108) 1-(2-{[Cyclopentyl(hydroxy)phenylacetyl](methyl)amino}ethyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 109) 3-(2-Methyl-1H-imidazol-1-yl)propyl (2R)-[(1S)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 110) 1-(2-{[Cyclohexyl(hydroxy)phenyl acetyl]oxy}ethyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No 111) 2-(2-Isopropyl-1H-imidazol-1-yl)ethyl (2R)-[(1S)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 112), and 2-(2-Isopropyl-1H-imidazol-1-yl)ethyl (2R)-[(1R)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 113),
[0000]
[0143] The compounds of Formula VIII can be prepared, for example, by following the procedure as described in, for example, Scheme II wherein the reaction comprises reacting a compound of Formula II (wherein R 1 , R 2 and R 3 are the same as defined earlier) with a compound of Formula V (wherein Y, n and R 1 ′ are the same as defined earlier) to give a compound of Formula VI (wherein X is the same as defined earlier) which is reacted with a compound of Formula VII (wherein R 1 is the same as defined earlier and hal is Br, Cl or I) to give a compound of Formula VIII.
[0144] The coupling of a compound of Formula II with a compound of Formula V (when Y is —NH.HCl, —NHR.HCl) to give a compound of Formula VI can be carried out in an organic solvent (for example, dimethylformamide, chloroform, tetrahydrofuran, diethyl ether or dioxane) in the presence of a base (for example, N-methylmorpholine, triethylamine, diisopropylethylamine or pyridine) with a condensing agent (for example, 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC.HCl) or dicyclohexylcarbodiimide (DCC)).
[0145] The coupling of a compound of Formula II with a compound of Formula V (when Y is —OH or —SH) to give a compound of Formula VI can be carried out in an organic solvent, for example, dimethylformamide, tetrahydrofuran in the presence of carbonyldiimidazole and an optional base such as sodium hydride, triethylamine, N-ethyldiisopropylamine or pyridine.
[0146] Alternatively, coupling of a compound of Formula II with a compound of Formula V (when Y is —OH or —SH) can be carried out in an organic solvent (for example, toluene, heptane or xylene) in the presence of a base (for example, sodium hydride or sodium methoxide).
[0147] The coupling of a compound of Formula II with a compound of Formula V (when Y is —Omesyl, —Otosyl or —Otriflyl) to give a compound of Formula VI can be carried out in an organic solvent (for example, toluene, heptane or xylene) in the presence of a base (for example, 1,8-diazabicyclo[5.4.0]undecen-7-ene (DBU) or 1,4-diazabicyclo[2.2.2]octane).
[0148] The N-derivatization of a compound of Formula VI with a compound of Formula VII to give a compound of Formula VIII can be carried out in an organic solvent (for example, acetonitrile, dichloromethane, chloroform or carbon tetrachloride) in the presence of a base (for example, potassium carbonate, sodium carbonate or sodium bicarbonate).
[0149] Particular illustrative compounds which may be prepared, for example, by following Scheme II made:
2-Cyclopentyl-2-hydroxy-N-[2-(1H-imidazol-4-yl)ethyl]-2-phenylacetamide (Compound No. 39) N-[2-(1-benzyl-1H-imidazol-4-yl)ethyl]-2-cyclopentyl-2-hydroxy-2-(4-methylphenyl)acetamide (Compound No. 40) 2-Cyclopentyl-2-hydroxy-N-[2-(1H-imidazol-4-yl)ethyl]-2-(4-methylphenyl)acetamide (Compound No. 41) 2-Cyclohexyl-2-hydroxy-N-[2-(1H-imidazol-4-yl)ethyl]-2-(4-methylphenyl)acetamide (Compound No. 42) 2-Hydroxy-N-[2-(1H-imidazol-4-yl)ethyl]-2,2-diphenylacetamide (Compound No. 43) N-[2-(1-benzyl-1H-imidazol-4-yl)ethyl]-2-cyclohexyl-2-hydroxy-2-(4-methylphenyl)acetamide (Compound No. 44), and N-[2-(1-benzyl-1H-imidazol-4-yl)ethyl]-2-hydroxy-2,2-diphenylacetamide (Compound No. 45).
[0000]
[0157] The compounds of Formula XII can be prepared, for example, by following the procedure depicted in, for example, Scheme III wherein the compound of Formula II (wherein R 1 , R 2 and R 3 are the same as defined earlier) undergoes acylation to give a compound of Formula IX (wherein k is an integer from 0-3), which undergoes halogenation to give a compound of Formula X (wherein hal is the same as defined earlier), which undergoes coupling with a compound of Formula XI (wherein represents single bond or double bond and R 1 is the same as defined earlier) to give a compound of Formula XII.
[0158] The acylation of the compound of Formula II to give a compound of Formula IX can be carried out with alkyl lithium in an organic solvent (for example, tetrahydrofuran, dimethylformamide, dioxane or diethylether) in the presence of an optional base (for example, butyl lithium, N-methylmorpholine, pyridine or triethylamine).
[0159] The halogenation of a compound of Formula IX to give a compound of Formula X can be carried out with halogenating agent (for example, pyridinium tribromide, phosphorous pentachloride, phosphorous tribromide, phosphorous pentachloride or thionyl chloride) in an organic solvent (for example, tetrahydrofuran, dimethylformamide, diethylether or dioxane).
[0160] The coupling of a compound of Formula X with a compound of Formula XI to give a compound of Formula XII can be carried out in the presence of a base (for example, triethylamine, pyridine, N-methylmorpholine or diisopropylethylamine) in an organic solvent for example, dichloromethane, dichloroethane, carbon tetrachloride or chloroform.
[0161] Particular illustrative compounds include these shown below:
1-Cyclopentyl-1-hydroxy-1-(4-methoxyphenyl)-3-(2-methyl-1H-imidazol-1-yl)acetone (Compound No. 15) 1-Cyclohexyl-1-hydroxy-3-(1H-imidazol-1-yl)-1-phenylacetone (Compound No. 50) 1-Cyclohexyl-1-hydroxy-3-(2-methyl-1H-imidazol-1-yl)-1-phenylacetone (Compound No. 51) 1-Cyclopentyl-1-hydroxy-3-(2-isopropyl-1H-imidazol-1-yl)-1-(4-methoxyphenyl)acetone (Compound No. 52) 1-Cyclohexyl-1-hydroxy-3-(2-isopropyl-1H-imidazol-1-yl)-1-phenylacetone (Compound No. 53) 1-Cyclohexyl-1-hydroxy-3-(2-methyl-4,5-dihydro-1H-imidazol-1-yl)-1-phenylacetone (Compound No. 54) 1-Cyclopentyl-1-hydroxy-1-(4-methoxyphenyl)-3-(2-methyl-4,5-dihydro-1H-imidazol-1-yl)acetone (Compound No. 55), and 1-Cyclopentyl-1-hydroxy-3-(1H-imidazol-1-yl)-1-(4-methoxyphenyl)acetone (Compound No. 56),
[0170] In the above schemes, where specific bases, condensing agents, protecting groups, deprotecting agents, solvents, catalysts, temperatures, etc. are mentioned, it is to be understood that other bases, condensing agents, protecting groups, deprotecting agents, solvents, catalysts, temperatures, etc. known to those skilled in the art may be used. Similarly, the reaction temperature and duration may be adjusted according to the desired needs.
[0171] Suitable salts of the compounds represented by the Formula I were prepared so as to solubilize the compound in aqueous medium for biological evaluations, as well as to be compatible with various dosage formulations and also to aid in the bioavailability of the compounds. Examples of such salts include pharmacologically acceptable salts such as inorganic acid salts (for example, hydrochloride, hydrobromide, sulphate, nitrate and phosphate), organic acid salts (for example, acetate, tartarate, citrate, fumarate, maleate, tolounesulphonate and methanesulphonate). When carboxyl groups are included in the Formula I as substituents, they may be present in the form of an alkaline or alkali metal salt (for example, sodium, potassium, calcium, magnesium, and the like). These salts may be prepared by various techniques, such as treating the compound with an equivalent amount of inorganic or organic, acid or base in a suitable solvent.
[0172] The compounds described herein can be produced and formulated as their enantiomers, diastereomers, N-Oxides, polymorphs, solvates and pharmaceutically acceptable salts, as well as metabolites having the same type of activity. Pharmaceutical compositions comprising the molecules of Formula I or metabolites, enantiomers, diastereomers, N-oxides, polymorphs, solvates or pharmaceutically acceptable salts thereof, in combination with pharmaceutically acceptable carrier and optionally included excipient can also be produced.
[0173] Where desired, the compounds of Formula I and/or their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, stereoisomers, tautomers, racemates, prodrugs, metabolites, polymorphs or N-oxides may be advantageously used in combination with one or more other therapeutic agents. Examples of other therapeutic agents, which may be used in combination with compounds of Formula I of this invention and/or their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, stereoisomers, tautomers, racemates, prodrugs, metabolites, polymorphs or N-oxides include but are not limited to, corticosteroids, beta agonists, leukotriene antagonists, 5-lipoxygenase inhibitors, anti-histamines, antitussives, dopamine receptor antagonists, chemokine inhibitors, p38 MAP Kinase inhibitors, and PDE-IV inhibitors.
[0174] The compositions can be administered by inhalation. Compositions for inhalation or insufflation include solutions and suspensions in pharmaceutically acceptable, aqueous or organic solvents, or mixtures thereof, and powders. The liquid or solid compositions may contain suitable pharmaceutically acceptable excipients. The compositions can be administered by the nasal respiratory route for local or systemic effect. Compositions can be nebulized by use of inert gases. Nebulized solutions may be breathed directly from the nebulizing device or the nebulizing device can be attached to a face masks tent, or intermittent positive pressure breathing machine. Solution, suspension, or powder compositions can be administered nasally from devices, which deliver the formulation in an appropriate manner.
[0175] Alternatively, compositions can be administered orally, rectally, parenterally (intravenously, intramuscularly or subcutaneously), intracisternally, intravaginally, intraperitoneally or topically.
[0176] Solid dosage forms for oral administration may be presented in discrete units, for example, capsules, cachets, lozenges, tablets, pills, powders, dragees or granules, each containing a predetermined amount of the active compound. In such solid dosage forms, the active compound is admixed with at least one inert customary excipient (or carrier) such as sodium citrate or dicalcium phosphate or (a) fillers or extenders, as for example, starches, lactose, sucrose, glucose, mannitol and silicic acid, (b) binders, as for example, carboxymethylcellulose, alignates, gelatin, polyvinylpyrrolidone, sucrose and acacia, (c) humectants, as for example, glycerol, (d) disintegrating agents, as for example, agar-agar, calcium carbonate, potato or tapioca starch, alginic acid, certain complex silicates and sodium carbonate, (e) solution retarders, as for example paraffin, (f) absorption accelerators, as for example, quaternary ammonium compounds, (g) wetting agents, as for example, cetyl alcohol and glycerol monostearate, (h) adsorbents, as for example, kaolin and bentonite, and (i) lubricants, as for example, talc, calcium stearate, magnesium stearate, solid polyethylene glycols, sodium lauryl sulfate or mixtures thereof. In the case of capsules, tablets and pills, the dosage forms may also comprise buffering agents.
[0177] Solid compositions of a similar type may also be employed as fillers in soft and hard-filled gelatin capsules using such excipients as lactose or milk sugar as well as high molecular weight polyethylene glycols, and the like.
[0178] Solid dosage forms can be prepared with coatings and shells, such as enteric coatings and others well known in this art. They may contain opacifying agents, and can also be of such composition that they release the active compound or compounds in a certain part of the intestinal tract in a delayed manner. Examples of embedding compositions which can be used are polymeric substances and waxes.
[0179] The active compounds can also be in micro-encapsulated form, if appropriate, with one or more of the above mentioned excipients.
[0180] Liquid dosage forms for oral administration include pharmaceutically acceptable emulsions, solutions, suspensions, syrups and elixirs. In addition to the active compounds, the liquid dosage forms may contain inert diluents commonly used in the art, such as water or other solvents, solubilizing agents and emulsifiers, as for example, ethyl alcohol, isopropyl alcohol, ethyl carbonate, ethyl acetate, benzyl alcohol, benzyl benzoate, propylene glycol, 1,3-butylene glycol, dimethylformamide, oils, in particular, cottonseed oil, groundnut oil, corn germ oil, olive oil, castor oil and sesame oil, glycerol, tetrahydrofurfuryl alcohol, polyethylene glycols and fatty acid esters of sorbitan or mixtures of these substances, and the like.
[0181] Besides such inert diluents, the composition can also include adjuvants, for example, wetting agents, emulsifying and suspending agents, sweetening, flavoring and perfuming agents, colorants or dyes.
[0182] Suspensions, in addition to the active compounds, may contain suspending agents, as for example, ethoxylated isostearyl alcohols, polyoxyethylene sorbitol and sorbitan esters, microcrystalline cellulose, aluminium metahydroxide, bentonite, agar-agar and tragacanth, or mixtures of these substances, and the like.
[0183] Dosage forms for topical administration of a compound of this invention include powder, spray, inhalant, ointment, creams, salve, jelly, lotion, paste, gel, aerosol, or oil. The active component is admixed under sterile conditions with a pharmaceutically acceptable carrier and any needed preservatives, buffers or propellants as may be required. Opthalmic formulations, eye ointments, powders and solutions are also contemplated as being within the scope of this invention.
[0184] Compositions suitable for parenteral injection may comprise pharmaceutically acceptable sterile aqueous or nonaqueous solutions, dispersions, suspensions or emulsions and sterile powders for reconstitution into sterile injectable solutions or dispersions. These preparations may contain anti-oxidants, buffers, bacteriostats and solutes, which render the compositions isotonic with the blood of the intended recipient. Aqueous and non-aqueous sterile suspensions may include suspending agents and thickening agents. The compositions may be presented in unit-dose or multi-dose containers, for example sealed ampoules and vials, and may be stored in a freeze-dried or lyophilized condition requiring only the addition of the sterile liquid carrier, for example, saline or water-for-injection immediately prior to use. Examples of suitable aqueous and nonaqueous carriers, diluents, solvents or vehicles include water, ethanol, polyols (propylene glycol, polyethylene glycol, glycerol, and the like), suitable mixtures thereof, vegetable oils (such as olive oil) and injectable organic esters such as ethyl oleate. Proper fluidity can be maintained, for example, by the use of a coating such as lecithin, by the maintenance of the required particle size in the case of dispersions and by the use of surfactants.
[0185] These compositions may also contain adjuvants such as preserving, wetting, emulsifying, and dispensing agents. Prevention of the action of microorganisms can be ensured by various antibacterial and antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, and the like. It may also be desirable to include isotonic agents, for example sugars, sodium chloride and the like. Prolonged absorption of the injectable pharmaceutical form can be brought about by the use of agents delaying absorption, for example, aluminum monosterate and gelatin.
[0186] Suppositories for rectal administration of the compound of Formula I can be prepared by mixing the drug with a suitable nonirritating excipient such as cocoa butter and polyethylene glycols or a suppository wax, which are solid at ordinary temperatures but liquid at body temperature and which therefore melt in the rectum or vaginal cavity and release the drug.
[0187] If desired, and for more effective distribution, the compounds can be incorporated into slow release or targeted delivery systems such as polymer matrices, liposomes, and microspheres. They may be sterilized, for example, by filtration through a bacteria-retaining filter, or by incorporating sterilizing agents in the form of sterile solid compositions which can be dissolved in sterile water, or some other sterile injectable medium immediately before use.
[0188] Actual dosage levels of active ingredient in the compositions of the invention and spacing of individual dosages may be varied so as to obtain an amount of active ingredient that is effective to obtain a desired therapeutic response for a particular composition and method of administration. It will be understood, however, that the specific dose level for any particular patient will depend upon a variety of factors including the compound chosen, the body weight, general health, sex, diet, route of administration, the desired duration of treatment, rates of absorption and excretion, combination with other drugs and the severity of the particular disease being treated and is ultimately at the discretion of the physician.
[0189] The pharmaceutical compositions described herein can be produced and administered in dosage units, each unit containing a certain amount of at least one compound described herein and/or at least one physiologically acceptable addition salt thereof. The dosage may be varied over extremely wide limits, as the compounds are effective at low dosage levels and relatively free of toxicity. The compounds may be administered in the low micromolar concentration, which is therapeutically effective, and the dosage may be increased as desired up to the maximum dosage tolerated by the patient.
[0190] The examples mentioned below demonstrate general synthetic procedures, as well as specific preparations of particular compounds. The examples are provided to illustrate the details of the invention and should not be constrained to limit the scope of the present invention.
EXAMPLES
[0191] Various solvents, such as acetone, methanol, pyridine, ether, tetrahydrofuran, hexanes, and dichloromethane, were dried using various drying reagents according to procedures described in the literature. IR spectra were recorded as nujol mulls or a thin neat film on a Perkin Elmer Paragon instrument, Nuclear Magnetic Resonance (NMR) were recorded on a Varian XL-300 MHz or Bruker 400 MHz instrument using tetramethylsilane as an internal standard.
Synthesis of tert-butyl [2-(1H-imidazol-1-yl)ethyl]carbamate
Step a: Synthesis of tert-butyl (2-bromoethyl)carbamate
[0192] To a solution of hydrobromide salt of 2-bromoethylamine (20 g, 97 mmol) in dichloromethane (250 ml) was added triethyl amine (34.01 ml, 244 mmol) followed by the addition of tert-butoxycarbonyl anhydride (24.63 ml, 107 mmol) at 0-5° C. and the reaction mixture was stirred at room temperature overnight. The reaction mixture was washed with saturated sodium bicarbonate solution. The mixture was extracted with ethyl acetate and the organic layer was washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 20 g.
Step b: Synthesis of tert-butyl [2-(1H-imidazol-1-yl)ethyl]carbamate
[0193] Sodium hydride (2.23 g, 56 mmol) was added slowly to the precooled dimethylformamide (40 ml) followed by the addition of imidazole (4.55 g, 66.2 mmol) at 0-5° C. The resulting reaction mixture was stirred for 10-15 minutes. The reaction mixture was brought to room temperature and stirred for 30 minutes followed by cooling to 0° C. To the reaction mixture was added the compound obtained from step a above (5 g, 22.3 mmol) and the mixture was stirred at room temperature overnight. The reaction mixture was diluted with water and stirred for 10-15 minutes followed by the addition of dichloromethane. The reaction mixture was stirred for 30 minutes. The organic layer was washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 2 g.
[0194] The following illustrative compound(s) were prepared analogously,
Tert-butyl [2(2-isopropyl-1H-imidazol-1-yl)ethyl]carbamate
Tert-butyl [2-(2-methyl-1H-imidazol-1-yl)ethyl]carbamate
Synthesis of hydrochloride salt of 2-(1H-imidazol-1-yl)ethanamine (Formula III)
[0195] To the compound tent-butyl [2-(1H-imidazol-1-yl)ethyl]carbamate (2 g, 9.4 mmol) was added ethereal hydrochloric acid (15 ml) and stirred at room temperature for 2-3 hours. The solvent was evaporated under reduced pressure to furnish the title compound. Yield: 1.8 g.
[0196] The following illustrative compound(s) were prepared analogously,
Hydrochloride salt of 2-(2-isopropyl-1H-imidazol-1-yl)ethanamine
Hydrochloride salt of 2-(2-methyl-1H-imidazol-1-yl)ethanamine
Synthesis of 3(2-methyl-1H-imidazol-1-yl)propan-1-amine (Formula III)
Step a: Synthesis of 2-[3-(2-methyl-1H-imidazol-1-yl)propyl]-1H-isoindole-1,3(2H)-dione
[0197] To a solution of 2-methyl imidazole (306 mg, 3.7 mmol) and N-bromopropylpthalamide (1 g, 3.7 mmol) in dimethylformamide (50 ml) was added potassium carbonate (1.6 g, 11.2 mmol) and the reaction mixture was heated at 80° C. for 4 hours. The mixture was poured into water and extracted with ethyl acetate. The organic layer was washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography using 5% methanol in dichloromethane to furnish the title compound. Yield: 67 mg.
Step b: Synthesis of 3-(2-methyl-1H-imidazol-1-yl)propan-1-amine
[0198] To a solution of the compound obtained from step a above (1 g, 3.7 mmol) in ethanol (20 ml) was added hydrazine hydrate (1 ml, 20 mmol) and heated the reaction mixture at 65-70° C. for 3 hours. The reaction mixture was cooled and filtered through celite pad and washed with ethanol. The filtrate was concentrated under reduced pressure. The residue thus obtained was diluted with dichloromethane and filtered through celite pad. The filtrate was concentrated under reduced pressure to furnish the title compound. Yield: 340 mg.
Synthesis of hydrochloride salt of N-methyl-3-(2-methyl-1H-imidazol-1-yl)propan-1-amine (Formula III)
Step a: Synthesis of tert-butyl [3-(2-methyl-1H-imidazol-1-yl)propyl]carbamate
[0199] A solution of the compound 3-(2-methyl-1H-imidazol-1-yl)propan-1-amine (2.7 g, 19.4 mmol) in dichloromethane (100 ml) was cooled at 0° C. followed by the dropwise addition of triethylamine (5.42 ml, 38.8 mmol). The reaction mixture was stirred at the same temperature for 30 minutes followed by the addition of tert-butoxycarbonyl anhydride (4.9 ml, 21.3 mmol). The reaction mixture was stirred at 0° C. for 1 hour and then at room temperature for 1 hour and 30 minutes. The aqueous solution of sodium bicarbonate was added to the reaction mixture and was extracted with dichloromethane. The organic layer was separated and washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography using 5% methanol in dichloromethane to furnish the title compound. Yield: 2.2 g.
Step b: Synthesis of tent-butyl methyl[3-(2-methyl-1H-imidazol-1-yl)propyl]carbamate
[0200] To a solution of the compound obtained from step a above (500 mg, 2.1 mmol) in dry dimethylformamide (6 ml) was added sodium hydride (166 mg, 4.2 mmol) at 0° C. and stirred the reaction mixture for 30 minutes at the same temperature and then at room temperature for 30 minutes. The mixture was again cooled to 0° C. followed by the addition of iodomethane (0.2 ml, 2.5 mmol) in dimethylformamide (3 ml) and stirred at room temperature for 3 hours. Reaction mixture was quenched with water and extracted with ethyl acetate. The combined organic layer was washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography using 5% methanol in dichloromethane solvent mixture as eluent to furnish the title compound. Yield: 174 mg.
Step c: Synthesis of hydrochloride salt of N-methyl-3-(2-methyl-1H-imidazol-1-yl)propan-1-amine
[0201] To a solution of the compound obtained from step b above (174 mg, 0.75 mmol) in dry diethyl ether (15 ml) was added slowly ethereal solution of hydrochloric acid (5 ml) and was stirred the mixture at room temperature overnight. The mixture was concentrated under reduce pressure to furnish the title compound. Yield: 147 mg.
Synthesis of imidazol-1-yl-methanol
[0202] To a solution of the imidazole (1 g, 14.6 mmol) in dry tetrahydrofuran (30 ml) cooled to −10° C. was added butyl lithium (0.94 g, 14.6 mmol) dropwise at −30 to −20° C. The mixture was stirred for 30 minutes at −20° C. and subsequently cooled at −30° C. followed by the addition of paraformaldehyde (441 mg, 14.6 mmol). The reaction mixture was stirred for 30 minutes at −20° C. and then allowed to warm to room temperature. The resulting mixture was stirred overnight followed by the addition of water. The reaction mixture was extracted with ethyl acetate. The organic layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 450 mg.
Synthesis of methanesulphonic acid 2-(2-methyl-imidazol-1-yl)-ethyl ester
Step a: Synthesis of (2-bromo-ethoxy)-tert-butyl-dimethyl-silane
[0203] To a solution of the 2-bromoethanol (5 g, 40 mmol) in dimethylformamide (25 ml) was added tert-butydimethylsilyl chloride (7.29 g, 48 mmol) and imidazole (6.86 g, 100 mmol). The reaction mixture was stirred overnight followed by quenching with water and extraction with ethyl acetate. The organic layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 8 g.
Step b: Synthesis of 1-[2-(tert-butyl-dimethyl-silanyloxy)-ethyl]-2-methyl-1H-imidazole
[0204] Sodium hydride (8.4 g, 210 mmol) was added slowly to dry dimethylformamide (40 ml) precooled at −10° C. under nitrogen atmosphere. To the resulting suspension was added 2-methyl imidazole (20.67 g, 252 mmol) at −10° C. and the reaction mixture was allowed to warm to room temperature. The reaction mixture was stirred for 1 hour at room temperature followed by cooling to 0° C. To the mixture was added solution of the compound obtained from step a above (20 g, 84 mmol) in dimethylformamide (10 ml) and stirred overnight at room temperature. The mixture was quenched with aqueous ammonium chloride solution and extracted with dichloromethane. The dichloromethane layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound.
[0205] Yield: 12.5 g.
Step c: Synthesis of 2-(2-methyl-imidazol-1-yl)-ethanol
[0206] To a compound obtained from step b above (12.5 g, 55.6 mmol) was added a solution of ethanolic hydrochloric acid solution (2%, 90 ml) at room temperature and the mixture was stirred overnight. The reaction mixture was concentrated under reduced pressure. The residue thus obtained washed with diethyl ether to furnish the title compound. Yield: 3.9 g.
Step d: Synthesis of methanesulphonic acid 2-(2-methyl-imidazol-1-yl)-ethyl ester
[0207] To a solution of the compound obtained from step c above (4 g, 24.6 mmol) in dichloromethane (60 ml) was added triethylamine (10.27 ml, 73.8 mmol) and dimethylaminopyridine (150 mg) at 0° C. The reaction mixture was stirred until the compound obtained from step c above becomes completely soluble. The mixture was cooled down to −5° C. followed by the addition methane sulphonyl chloride (2.86 ml, 36.9 mmol) dropwise with stirring. The mixture was stirred for 3 hours at −5° C. and then overnight at room temperature. The mixture was diluted with sodium bicarbonate solution and extracted with dichloromethane. The dichloromethane layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure to furnish the title compound. Yield: 3.8 g.
Example 1
Synthesis of 2-Cyclopentyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 1)
[0208] To a solution of the hydrochloride salt of 2-(1H-imidazol-1-yl)ethanamine (0.5 g, 4.50 mmol) in chloroform (10 ml) was added N-methyl morpholine (2.96 ml, 27.02 mmol) and stirred the mixture for 5 to 10 minutes at the room temperature followed by the addition of 2-cyclopentyl-2-hydroxy-2-phenyl acetic acid (0.99 g, 4.5 mmol) and hydroxy benzotriazole (0.60 g, 4.5 mmol) at room temperature. The resulting reaction mixture was stirred for 30-45 minutes followed by the addition of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride and again stirred for over night. The mixture was diluted with water and stirred for 10-15 minutes followed by the addition of dichloromethane. The mixture was stirred for 15-20 minutes. The organic layer was separated, washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by preparative column chromatography using 10% methanol in dichloromethane as eluent to furnish the title compound. Yield: 70 mg.
[0209] 1 H NMR (CDCl 3 ) δ: 7.60-7.31 (5H, m), 6.99 (1H, s), 6.99 (1H, s), 6.65 (1H, s), 4.01-4.00 (2H, m), 3.99-3.49 (2H, m), 3.11-3.07 (1H, m), 1.64-1.42 (8H, m).
[0210] The following illustrative compounds were prepared analogously,
2-(4-Fluorophenyl)-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 3)
[0211] 1 H NMR (CD 3 OD) δ: 7.45-7.29 (8H, m), 7.04-6.97 (4H, m), 4.18-4.15 (2H, m), 3.64-3.61 (2H, m).
2-Cyclobutyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 4)
[0212] 1 H NMR (CDCl 3 ) δ: 7.50-7.24 (6H, m), 6.94 (1H, s), 6.81 (1H, s), 4.01-3.98 (2H, m), 3.54-3.42 (3H, m), 2.04-1.72 (6H, m).
2-Cyclopentyl-2-(4-fluorophenyl)-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]acetamide (Compound No. 5)
[0213] 1 H NMR (CD 3 OD) δ: 7.59-7.44 (3H, m), 7.04-7.02 (2H, m), 6.94 (1H, s), 6.88 (1H, s), 4.08-4.05 (2H, m), 3.50-3.47 (2H, m), 3.05-3.01 (1H, m), 1.68-1.21 (8H, m).
2-Hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2,2-diphenylacetamide (Compound No. 6)
[0214] 1 H NMR (CD 3 OD) δ: 7.58-7.27 (11H, m), 7.01 (s, 1H), 6.94 (s, 1H), 4.17-4.14 (2H, m), 3.63-3.60 (2H, m).
2-Cyclohexyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 7)
[0215] 1 H NMR (MeOD) δ: 7.66-7.53 (3H, m), 7.32-7.21 (3H, m), 6.91-6.89 (2H, m), 4.08-4.06 (2H, m), 3.50-3.30 (2H, m), 2.36 (1H, q), 1.60-1.10 (10H, m).
2-Cyclopentyl-2-hydroxy-N-[2-(2-isopropyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 8)
[0216] 1 H NMR (MeOD) δ: 7.59-7.57 (2H, m), 7.31-7.20 (3H, m), 6.74-6.73 (2H, m), 4.01-3.96 (2H, m), 3.47-3.30 (2H, m), 3.06-3.02 (2H, m), 1.57-1.51 (6H, m), 1.24-1.17 (8H, m).
2-Cyclohexyl-2-hydroxy-N-[2-(2-isopropyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 9)
[0217] 1 H NMR (MeOD) δ: 7.58-7.56 (2H, m), 7.36-7.20 (3H, m), 6.73-6.71 (2H, m), 3.99-3.96 (2H, m), 3.47-3.43 (2H, m), 3.29-3.01 (1H, m), 1.66-1.64 (1H, q), 1.40-1.17 (16H, m).
2-Hydroxy-N-[2-(2-isopropyl-1H-imidazol-1-yl)ethyl]-2-phenyl-2-pyridin-3-ylacetamide (Compound No. 10)
[0218] 1 H NMR (CD 3 OD) δ: 8.58-8.57 (1H, m), 8.46-8.44 (1H, m), 7.80-7.33 (1H, m), 7.33-7.26 (6H, m), 6.85-6.79 (2H, m), 4.11-4.07 (2H, m), 3.63-3.60 (2H, m), 3.29-3.07 (1H, m), 1.24-1.21 (6H, m).
2-(4-Fluorophenyl)-2-hydroxy-N-[2-(2-isopropyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 11)
[0219] 1 H NMR (CD 3 OD) δ: 7.36-7.28 (7H, m), 7.03-6.98 (2H, m), 6.85-6.80 (2H, m), 4.10-4.06 (2H, m), 3.61-3.58 (2H, m), 3.12-3.07 (1H, m), 1.28-1.21 (6H, m).
2-Hydroxy-N-[2-(2-isopropyl-1H-imidazol-1-yl)ethyl]-2,2-diphenylacetamide (Compound No. 12)
[0220] 1 H NMR (CD 3 OD) δ: 7.35-7.27 (10H, m), 6.83-6.79 (2H, m), 4.09-4.06 (2H, m), 3.60-3.57 (2H, m), 3.29-3.06 (1H, m), 1.29-1.21 (6H, m).
(2R)-2-cyclopentyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 16)
[0221] 1 H NMR (MeOD) δ: 7.54-7.52 (2H, m), 7.33-7.26 (5H, m), 4.19-4.08 (2H, m), 3.42-3.30 (2H, m), 3.04-2.90 (1H, m), 1.56-1.47 (8H, m).
2-Hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-2-phenyl-2-pyridin-3-ylacetamide (Compound no. 17)
[0222] 1 H NMR (CDCl 3 ) δ: 8.49 (s, 1H), 8.03-8.08 (m, 3H), 7.70-7.72 (m, 1H), 7.44-7.45 (m, 2H), 7.14-7.33 (m, 3H), 6.89-6.92 (m, 2H), 6.82 (s, 1H), 4.02-4.11 (m, 2H), 3.47-3.67 (m, 2H).
2-Cyclopentyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 18)
[0223] 1 H NMR (CDCl 3 ) δ: 7.58-7.60 (m, 2H), 7.26-7.37 (m, 3H), 6.88 (brs, 1H), 6.79 (s, 1H), 6.48 (s, 1H), 3.86-3.91 (s, 2H), 3.46-3.51 (s, 2H), 3.07-3.11 (q, 1H), 2.20 (s, 3H), 1.14-1.68 (m, 8H).
2-Hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenyl-2-pyridin-3-ylacetamide (Compound No. 19)
[0224] 1 H NMR (CDCl 3 ) δ: 8.48 (s, 1H), 8.13-8.15 (m, 1H), 7.71-7.75 (m, 2H), 7.16-7.44 (m, 5H), 6.62 (s, 1H), 6.55 (s, 1H), 3.68-3.99 (m, 2H), 3.54-3.66 (m, 2H), 2.06 (s, 3H).
2-Cyclohexyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 20)
[0225] 1 H NMR (CDCl 3 ) δ: 7.57-7.59 (m, 2H), 7.29-7.38 (m, 3H), 6.94 (brs, 1H), 6.82 (s, 1H), 6.49 (s, 1H), 3.86-3.92 (m, 2H), 3.47-3.51 (m, 2H), 2.42-2.45 (m, 1H), 2.21 (s, 3H), 0.83-1.82 (m, 10H).
2-(4-Fluorophenyl)-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 21)
[0226] 1 H NMR (CDCl 3 ) δ: 7.32-7.43 (m, 7H), 7.00-7.03 (m, 2H), 6.57 (s, 1H), 6.51 (s, 1H), 3.95-3.98 (m, 2H), 3.59-3.63 (m, 2H), 2.15 (s, 3H).
2-Cyclopentyl-2-(4-fluorophenyl)-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]acetamide (Compound No. 22)
[0227] 1 H NMR (CDCl 3 ) δ: 7.57-7.60 (m, 2H), 7.00-7.04 (m, 2H), 6.82 (s, 1H), 6.57 (s, 1H), 3.91-3.94 (m, 2H), 3.48-3.53 (m, 2H), 3.04-3.06 (q, 1H), 2.25 (s, 3H), 1.42-1.64 (m, 8H).
2-Cyclobutyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 23)
[0228] 1 H NMR (CDCl 3 ) δ: 7.50-7.52 (m, 2H), 7.27-7.36 (m, 3H), 6.88 (brs, 1H), 6.78 (s, 1H), 6.54 (s, 1H), 3.89-3.93 (m, 2H), 3.48-3.50 (m, 2H), 3.43-3.47 (m, 1H), 2.23 (s, 3H), 1.73-2.06 (m, 6H).
2-Hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2,2-diphenylacetamide (Compound No. 24)
[0229] 1 H NMR (CDCl 3 ) δ: 7.09-7.42 (m, 10H), 6.59 (s, 1H), 6.55 (s, 1H), 3.95-3.97 (m, 2H), 3.58-3.64 (m, 2H), 2.17 (s, 3H).
3,3,3-Trifluoro-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-(4-methylphenyl)propanamide (Compound No. 25)
[0230] 1 H NMR (CD 3 OD) δ: 7.47-7.49 (m, 2H), 7.17-7.20 (m, 2H), 6.81 (s, 1H), 6.73 (s, 1H), 3.99-4.02 (m, 2H), 3.41-3.65 (m, 2H), 2.34 (s, 3H), 2.21 (s, 3H).
N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2,2-diphenylacetamide (Compound No. 26)
[0231] 1 H NMR (CD 3 OD) δ: 7.21-7.31 (m, 10H), 6.83 (s, 1H), 6.76 (s, 1H), 4.00-4.03 (m, 2H), 3.52-3.55 (m, 2H), 2.17 (s, 3H).
2-Cyclopentyl-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-phenylacetamide (Compound No. 27)
[0232] 1 H NMR (CD 3 OD) δ: 7.22-7.31 (5H, m), 6.71 (s, 1H), 6.63 (s, 1H), 3.91-3.94 (m, 2H), 3.31-3.43 (m, 2H), 2.42-2.45 (m, 1H), 2.18 (s, 3H), 1.65-1.95 (m, 8H).
2-Cyclopentyl-2-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-(4-methylphenyl)acetamide (Compound No. 28)
[0233] 1 H NMR (MeOD) δ: 7.43-7.41 (2H, m), 7.12-7.10 (2H, m), 6.76 (1H, s), 6.71 (1H, s), 3.98-3.92 (2H, m), 3.46-3.44 (2H, m), 3.29 (1H, m), 2.31-2.30 (3H, m), 2.28-2.16 (3H, m), 1.53-1.24 (8H, m).
2-Cyclohexyl-2-hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-(4-methylphenyl)acetamide (Compound No. 29)
[0234] 1 H NMR (MeOD) δ: 7.43-7.41 (2H, m), 7.12-7.10 (2H, m), 6.75 (1H, s), 6.70 (1H, s), 3.98-3.91 (2H, m), 3.47-3.44 (2H, m), 2.30-2.29 (4H, m), 2.16-2.15 (3H, s), 1.30-1.19 (10, m).
2-Hydroxy-N-[2-(2-methyl-1H-imidazol-1-yl)ethyl]-2-(4-methylphenyl)-2-phenylacetamide (Compound No. 30)
[0235] 1 H NMR MeOD) δ: 7.35-7.27 (5H, m), 7.26-7.20 (2H, m), 7.18-7.09 (2H, m), 6.84 (1H, s), 6.75 (1H, s), 4.05-4.04 (2H, m), 3.60-3.57 (2H, m), 2.31-2.28 (3H, m), 2.22-2.15 (3H, m).
2-Cyclopentyl-2-hydroxy-N-[3-(1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 31)
[0236] 1 H NMR (CDCl 3 ) δ: 7.28-7.63 (m, 5H), 7.03 (s, 1H), 6.84 (s, 1H), 6.62 (s, 1H), 3.78-3.82 (t, 2H), 3.19-3.24 (t, 2H), 3.09 (m, 1H), 0.88-1.94 (m, 10H).
2-Cyclohexyl-2-hydroxy-N-[3-(1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 32)
[0237] 1 H NMR (CDCl 3 ) δ: 7.28-7.62 (m, 5H), 7.04 (s, 1H), 6.83 (s, 1H), 6.75 (s, 1H), 3.77-3.80 (t, 2H), 3.20-3.23 (t, 2H), 2.42-2.45 (m, 1H), 0.88-1.94 (m, 12H).
2-Cyclopentyl-2-hydroxy-N-[3-(2-methyl-1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 33)
[0238] 1 H NMR (CDCl 3 ) δ: 7.27-7.63 (m, 5H), 6.74 (m, 1H), 6.64 (s, 1H), 6.22 (s, 1H), 3.71-3.74 (t, 2H), 3.23-3.26 (t, 2H), 3.09 (m, 1H), 2.24 (s, 3H), 1.48-1.88 (m, 10H).
2-Cyclohexyl-2-hydroxy-N-[3-(2-methyl-1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 34)
[0239] 1 H NMR (CDCl 3 ) δ: 7.28-7.62 (m, 5H), 6.88 (s, 1H), 6.76 (s, 1H), 6.73 (s, 1H), 3.68-3.73 (t, 2H), 3.22-3.25 (t, 2H), 2.24 (m, 1H), 2.23 (s, 3H), 1.20-1.88 (m, 12H).
(2R)-2-(3,3-Difluorocyclopentyl)-2-hydroxy-N-[3-(2-methyl-1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 35)
[0240] 1 H NMR (CDCl 3 ) δ: 7.30-7.61 (m, 5H), 6.84 (s, 1H), 6.72 (s, 1H), 6.71 (m, 1H), 3.69-3.73 (t, 2H), 3.21-3.35 (m, 3H), 2.23 (s, 3H), 1.52-2.18 (m, 8H).
2-Cyclopentyl-2-hydroxy-N-methyl-N-[3-(2-methyl-1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 36)
[0241] 1 H NMR (CDCl 3 ) δ: 7.31-7.36 (m, 5H), 6.9 (s, 1H), 6.7 (s, 1H), 3.78 (bs, 2H), 3.35 (bs, 2H), 2.73 (bs, 3H), 2.29 (s, 4H), 1.25-1.17 (m, 10H).
2-Cyclohexyl-2-hydroxy-N-methyl-N-[3-(2-methyl-1H-imidazol-1-yl)propyl]-2-phenylacetamide (Compound No. 37)
[0242] 1 H NMR (CDCl 3 ) δ: 7.26-7.36 (m, 5H), 6.91 (s, 1H), 6.73 (s, 1H), 3.7-3.8 (bs, 2H), 3.33 (bs, 2H), 2.8 (s, 3H), 2.27 (s, 3H), 1.25-1.82 (m, 13H).
2-Cyclopentyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-N-methyl-2-phenylacetamide (Compound No. 38)
[0243] 1 H NMR (CDCl 3 ) δ: 7.29-7.77 (m, 6H), 7.00 (s, 1H), 6.77 (s, 1H), 4.11 (bs, 1H), 3.73 (bs, 1H), 3.49 (bs, 1H), 2.94-2.98 (m, 1H), 2.38-2.50 (m, 4H), 1.14-1.66 (m, 8H).
2-Cyclohexyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-N-methyl-2-phenylacetamide (Compound No. 57)
[0244] 1 H NMR (CDCl 3 ) δ: 7.19-7.43 (m, 5H), 6.96 (s, 1H), 4.04 (bs, 2H), 3.49-3.68 (bd, 2H), 2.60 (s, 3H), 2.38-2.45 (m, 1H, 1.17-1.63 (m, 10H).
2-Cyclopentyl-2-hydroxy-N-[2-(1H-imidazol-4-yl)ethyl]-2-phenylacetamide (Compound No. 39)
[0245] 1 H NMR (MeOD) δ: 7.59-7.57 (3H, m), 7.31-7.20 (3H, m), 6.69 (1H, s), 3.43-3.34 (2H, m), 3.08 (1H, q), 2.73-2.70 (2H, m), 1.62-1.25 (8H, m).
2-Cyclopentyl-2-hydroxy-N-[2-(1H-imidazol-4-yl)ethyl]-2-(4-methylphenyl)acetamide (Compound No. 41)
[0246] 1 H NMR (CD 3 OD) δ: 7.60 (s, 1H), 7.43-7.45 (dd, 2H, J=8 Hz), 7.09-7.11 (dd, 2H, J=8 Hz), 6.71 (s, 1H), 3.34-3.44 (m, 2H), 3.30 (q, 1H), 2.70-2.73 (m, 2H), 1.49-1.62 (m, 8H).
2-Cyclohexyl-2-hydroxy-N-[2-(1H-imidazol-4-yl)ethyl]-2-(4-methylphenyl)acetamide (Compound No. 42)
[0247] 1 H NMR (CD 3 OD) δ: 7.59 (s, 1H), 7.42-7.44 (dd, 2H, 8 Hz), 7.09-7.11 (dd, 2H, 8 Hz), 6.69 (s, 1H), 3.30-3.41 (m, 2H), 2.68-2.72 (m, 2H), 2.31 (m, 1H), 2.29 (s, 1H), 1.29-1.74 (m, 10H).
2-Hydroxy-N-[2-(1H-imidazol-4-yl)ethyl]-2,2-diphenylacetamide (Compound No. 43)
[0248] 1 H NMR (CD 3 OD) δ: 7.59 (s, 1H), 7.27-7.38 (m, 10H), 6.75 (s, 1H), 3.49-3.53 (m, 2H), 2.78-2.81 (m, 2H).
2-Cyclopentyl-2-hydroxy-N-[2-(1H-imidazol-1-yl)ethyl]-N-methyl-2-phenylacetamide (Compound No. 58)
[0249] 1 H NMR (CD 3 OD) δ: 7.27-7.42 (m, 5H), 6.83 (s, 1H), 6.60 (s, 1H), 3.96 (bs, 2H), 3.48-3.65 (bd, 2H), 2.97 (m, 1H), 2.62 (s, 3H), 2.30 (s, 3H), 1.5-1.69 (m, 8H).
Example 2
Synthesis of 1H-imidazol-1-ylmethyl cyclopentyl(hydroxy)phenylacetate (Compound No. 46)
[0250] To a solution of 2-cyclopentyl-2-hydroxy-2-phenyl acetic acid (400 mg, 1.8 mmol) in dry tetrahydrofuran (20 ml) under argon atmosphere was added carbonyldiimidazole (294 mg, 1.8 mmol) and stirred the mixture for 5 min. To the resulting reaction mixture was added imidazol-1yl-methanol (178 mg, 1.8 mmol) and stirred for 24 hours. The mixture was concentrated under reduced pressure and the residue thus obtained was washed with water and extracted with dichloromethane. The organic layer was washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography using 5% methanol in dichloromethane to furnish the title compound. Yield: 140 mg.
[0251] 1 H NMR (CD 3 OD) δ: 7.68 (s, 1H), 7.55-7.57 (m, 2H), 7.28-7.34 (m, 3H), 7.04-7.11 (m, 2H), 5.76-6.06 (m, 2H), 2.77-2.86 (m, 1H), 1.27-1.62 (m, 8H).
[0252] The following illustrative compounds were prepared analogously by coupling the appropriate acid (racemic or pure isomers, as applicable in each case) with an appropriate alcohol.
1H-Imidazol-1-ylmethyl cyclohexyl(hydroxy)(4-methylphenyl)acetate (Compound No. 2)
[0253] 1 H NMR (CDCl 3 ) δ: 7.72 (1H, s), 7.42-7.40 (2H, m), 7.16-7.03 (4H, m), 6.01-5.98 (1H, m), 5.81-5.78 (1H, m), 2.40-2.32 (3H, m), 2.04-2.02 (1H, m), 1.67-1.25 (10H, m).
1H-Imidazol-1-ylmethyl cyclohexyl(hydroxy)phenylacetate (Compound No. 47)
[0254] 1 H NMR (CDCl 3 ) δ: 7.68 (s, 1H), 7.54-7.56 (m, 2H), 7.27-7.34 (m, 3H), 6.97-7.05 (m, 2H), 5.80-6.97 (m, 2H), 2.16-2.18 (m, 1H), 0.88-1.62 (m, 10H).
1H-Imidazol-1-ylmethyl (2R)-cyclopentyl(hydroxy)phenylacetate (Compound No. 48)
[0255] 1 H NMR (CDCl 3 ) δ: 7.82 (s, 1H), 7.53-7.55 (m, 2H), 7.21-7.30 (m, 4H), 6.94 (s, 1H), 5.95-6.09 (m, 2H), 2.87-2.89 (m, 1H), 1.28-1.53 (m, 8H).
1H-Imidazol-1-ylmethyl cyclopentyl(hydroxy)(4-methoxyphenyl)acetate (Compound No. 49)
[0256] 1 H NMR (CDCl 3 ) δ: 7.68 (1H, s), 7.48-7.45 (2H, m), 7.07-7.04 (2H, m), 6.86-6.83 (2H, m), 6.05-6.03 (1H, m), 5.78-5.75 (1H, m), 3.82 (3H, s), 2.85-2.76 (1H, q), 1.62-1.25 (8H, m).
Example 3
Synthesis of 2-(2-methyl-1H-imidazol-1-yl)ethyl cyclopentyl(hydroxy)phenylacetate (Compound No. 13)
[0257] To a solution of the compound 2-cyclopentyl-2-hydroxy-2-phenyl acetic acid (388 mg, 1.7 mmol), methanesulphonic acid 2-(2-methyl-imidazol-1-yl)-ethyl ester (300 mg, 1.4 mmol) and toluene (15 ml) was added 1,8-diazabicyclo[5.4.0]undecen-7-ene (447 mg, 2.9 mmol) and stirred the mixture overnight under reflux. The organic solvent was evaporated under reduced pressure and the residue thus obtained was purified by column chromatography using 5% methanol in dichloromethane. Yield: 60 mg.
[0258] 1 H NMR (CDCl 3 ) δ: 7.52-7.54 (m, 2H), 7.28-7.35 (m, 3H), 6.90 (s, 1H), 6.71 (s, 1H), 4.36-4.39 (m, 2H), 4.06-4.09 (m, 2H), 2.81-2.85 (q, 1H), 2.31 (s, 3H), 1.33-1.57 (m, 8H).
[0259] The following illustrative compound(s) were prepared analogously by coupling the appropriate acid (racemic or pure isomers, as applicable in each case) with an appropriate ester.
2(2-Methyl-1H-imidazol-1-yl)ethyl (2R)-cyclopentyl(hydroxy)phenylacetate (Compound No. 14)
[0260] 1 H NMR (CDCl 3 ) δ: 7.51-7.53 (m, 2H), 7.30-7.44 (m, 3H), 6.92 (s, 1H), 6.56 (s, 1H), 4.31-4.41 (9m, 2H), 4.06-4.09 (m, 2H), 2.81-2.86 (m, 1H), 2.36 (s, 3H), 1.32-1.66 (m, 8H).
2-(2-Methyl-1H-imidazol-1-yl)ethyl cyclopentyl(phenyl)acetate (Compound No. 59)
[0261] 1 H NMR (CDCl 3 ) δ: 7.31-7.22 (5H, m), 6.82 (1H, s), 6.50 (1H, s), 4.25-4.21 (2H, m), 3.97-3.93 (2H, m), 2.25-2.51 (2H, m), 2.27 (3H, s), 1.94-1-90 (4H, m), 1.74-1.56 (4H, m).
2(2-Methyl-1H-imidazol-1-yl)ethyl cyclohexyl(hydroxy)phenylacetate (Compound No. 60)
[0262] 1 H NMR (CDCl 3 ) δ: 7.51-7.49 (2H, m), 7.34-7.22 (3H, m), 6.91 (1H, s), 6.59 (1H, s), 4.40-4.36 (2H, m), 4.08-4.05 (2H, m), 2.32 (3H, s), 2.17-2.12 (1H, m), 1.78-1.65 (5H, m), 1.42-1.11 (5H, m).
3-(2-Methyl-1H-imidazol-1-yl)propyl cyclopentyl(hydroxy)phenylacetate (Compound No. 61)
[0263] 1 H NMR (CD 3 OD) δ: 7.63-7.65 (m, 2H), 7.25-7.37 (m, 3H), 6.79-6.81 (m, 2H), 4.06-4.09 (t, 2H), 3.82-3.85 (t, 2H), 2.48 (m, 1H), 2.18 (s, 3H), 2.01 (q, 2H), 0.7-1.7 (m, 8H).
3-(2-Methyl-1H-imidazol-1-yl)propyl (2R)-[(1R)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 62)
[0264] 1 H NMR (CD 3 OD) δ: 7.62-7.63 (m, 2H), 7.28-7.61 (m, 3H), 6.78-6.79 (m, 2H), 4.08-4.88 (t, 2H), 3.83-3.86 (t, 2H), 3.24-3.25 (m, 1H), 2.17 (s, 3H), 1.28-2.06 (m, 8H).
3-(2-Methyl-1H-imidazol-1-yl)propyl 2R-2-(1S or 1R) (3,3-difluorocyclohexyl)(hydroxy)phenylacetate (Compound No. 63)
[0265] 1 H NMR (CD 3 OD) δ: 7.63-7.64 (m, 2H), 7.30-7.61 (m, 3H), 6.76-6.77 (m, 2H), 4.09-4.13 (m, 2H), 3.81-3.86 (m, 2H), 2.6 (m, 1H), 2.16 (s, 3H), 1.2-2.04 (m, 10H).
2(2-Isopropyl-1H-imidazol-1-yl)ethyl cyclohexyl(hydroxy)phenylacetate (Compound No. 64)
[0266] 1 H NMR (CDCl 3 ) δ: 7.50-7.52 (m, 2H), 7.26-7.35 (m, 3H), 6.94 (s, 1H), 6.63 (s, 1H), 4.36-4.41 (m, 2H), 4.11-4.14 (m, 2H), 2.94-2.98 (q, 1H), 2.15 (q, 1H), 1.09-1.65 (q, 16H).
2-(1H-Imidazol-1-yl)ethyl cyclopentyl(hydroxy)phenylacetate (Compound No. 65)
[0267] 1 H NMR (CD 3 OD) δ: 7.50-7.53 (m, 3H), 7.24-7.32 (m, 3H), 6.92-6.98 (m, 2H), 4.34-4.37 (m, 2H), 4.25-4.28 (m, 2H), 2.85-2.89 (q, 1H), 1.28-1.56 (m, 8H).
2(2-Methyl-1H-imidazol-1-yl)ethyl (2R)-[(1S)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 66)
[0268] 1 H NMR (CD 3 OD) δ: 7.45-7.47 (m, 2H), 7.25-7.40 (m, 3H), 6.99 (s, 1H), 6.61 (s, 1H), 4.20-4.59 (m, 4H), 3.07 (q, 1H), 2.53 (s, 3H), 1.44-2.25 (m, 6H).
2-(1H-Imidazol-1-yl)ethyl cyclohexyl(hydroxy)phenylacetate (Compound No. 67)
[0269] 1 H NMR (CDCl 3 ) δ: 7.28-7.75 (m, 6H), 7.05 (s, 1H), 6.75 (s, 1H), 4.40-4.43 (m, 2H), 4.15-4.19 (m, 2H), 1.08-2.20 (m, 11H).
2(2-Isopropyl-1H-imidazol-1-yl)ethyl cyclopentyl(hydroxy)phenylacetate (Compound No. 68)
[0270] 1 H NMR (CDCl 3 ) δ: 7.53-7.69 (m, 2H), 7.27-7.35 (m, 3H), 6.93 (s, 1H), 6.60 (s, 1H), 4.36-4.40 (m, 2H), 4.10-4.12 (m, 2H), 2.93-2.96 (m, 1H), 2.81-2.85 (m, 1H), 1.30-1.56 (m, 16H).
2-(2-Methyl-1H-imidazol-1-yl)ethyl (2R)-[(1R)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 69)
[0271] 1 H NMR (CD 3 OD) δ: 7.47-7.49 (m, 2H), 7.32-7.37 (m, 3H), 6.92 (s, 1H), 6.60 (s, 1H), 4.40-4.51 (m, 2H), 4.14-4.18 (m, 2H), 3.08-3.10 (q, 1H), 2.43 (s, 3H), 1.64-2.27 (m, 6H).
2-(2-Isopropyl-1H-imidazol-1-yl)ethyl cycloheptyl(hydroxy)phenylacetate (Compound No. 70)
[0272] 1 H NMR (CD 3 OD) δ: 7.45-7.47 (m, 2H), 7.23-7.30 (m, 3H), 6.82-6.85 (m, 2H), 4.22-4.37 (m, 4H), 3.11-3.13 (q, 1H), 2.3 (m, 1H), 1.22-1.55 (m, 18H).
2-(2-Methyl-1H-imidazol-1-yl)ethyl cycloheptyl(hydroxy)phenylacetate (Compound No. 71)
[0273] 1 H NMR (CD 3 OD) δ: 7.45-7.48 (m, 2H), 7.23-7.31 (m, 3H), 6.88 (s, 1H), 6.77 (s, 1H), 4.18-4.37 (m, 4H), 2.35 (m, 1H), 2.30 (s, 3H), 1.21-1.81 (m, 12H).
3-(2-Methyl-1H-imidazol-1-yl)propyl (2R)-[(1S)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 110)
[0274] 1 H NMR (CD 3 OD) δ: 7.63-7.64 (m, 2H), 7.28-7.40 (m, 3H), 6.78-6.80 (m, 2H), 4.08-4.09 (t, 2H), 3.82-3.87 (t, 2H), 3.22-3.24 (m, 1H), 2.17 (s, 3H), 1.28-2.16 (m, 8H).
2-(2-Isopropyl-1H-imidazol-1-yl)ethyl (2R)-[(1S)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 112)
[0275] 1 H NMR (CD 3 OD) δ: 7.32-7.47 (m, 2H), 7.26-7.32 (m, 3H), 6.80-6.81 (m, 2H), 4.36-4.40 (m, 2H), 4.23-4.26 (m, 2H), 3.06-3.11 (m, 2H), 1.23-2.06 (m, 12H).
2-(2-Isopropyl-1H-imidazol-1-yl)ethyl (2R)-[(1R)-3,3-difluorocyclopentyl](hydroxy)phenylacetate (Compound No. 113)
[0276] 1 H NMR (CD 3 OD) δ: 7.45-7.48 (m, 2H), 7.26-7.33 (m, 3H), 6.85 (s, 1H), 6.83 (s, 1H), 4.36-4.42 (m, 2H), 4.25-4.28 (m, 2H), 3.10-3.12 (m, 2H), 1.24-2.06 (m, 12H).
Example 4
Synthesis of N-[2-(1-benzyl-1H-imidazol-4-yl)ethyl]-2-cyclopentyl-2-hydroxy-2-(4-methylphenyl)acetamide (Compound No. 40)
[0277] To a solution of the Compound No. 41 (0.15 g, 0.45 mmol) in methanol (2 ml) and acetone (15-20 ml) was added potassium carbonate (0.189 g, 1.37 mmol) and tetra-butyl ammonium bromide (catalytic amount) and stirred the mixture at room temperature for 1 hour. To the resulting mixture was added benzyl bromide (0.054 ml, 0.00045 mol) and stirred at room temperature for overnight. The reaction mixture was filtered and the filtrate was concentrated under reduced pressure. The residue thus obtained was purified by column chromatography using 5% methanol in dichloromethane as an eluent to furnish the title compound. Yield: 80 mg.
[0278] 1 H NMR (CD 3 OD) δ: 7.48-7.46 (3H, m), 7.39-7.37 (3H, m), 7.15-7.09 (4H, m), 6.52 (1H, s), 5.01 (2H, s), 3.45-3.42 (2H, m), 2.95-2.93 (1H, q), 2.69-2.63 (2H, m), 2.30 (3H, m), 1.60-1.27 (8H, m).
[0279] The following illustrative compounds were prepared similarly,
N-[2-(1-benzyl-1H-imidazol-4-yl)ethyl]-2-cyclohexyl-2-hydroxy-2-(4-methylphenyl)acetamide (Compound No. 44)
[0280] 1 H NMR (CDCl 3 ) δ: 7.09-7.48 (m, 10H), 6.50 (s, 1H), 5.01 (s, 2H), 3.40-3.48 (m, 2H), 2.64-2.68 (m, 2H), 2.30 (s, 3H), 1.65-1.71 (m, 1H), 0.95-1.57 (m, 10H).
N-[2-(1-benzyl-1H-imidazol-4-yl)ethyl]-2-hydroxy-2,2-diphenylacetamide (Compound No. 45)
[0281] 1 H NMR (CDCl 3 ) δ: 7.08-7.41 (m, 16H), 6.49 (s, 1H), 4.96 (s, 2H), 3.55-3.61 (m, 2H), 2.69-2.73 (m, 2H).
Example 5
Synthesis of 1-cyclohexyl-1-hydroxy-3-(1H-imidazol-1-yl)-1-phenylacetone (Compound No. 50)
Step a: Synthesis of 1-cyclohexyl-1-hydroxy-1-phenylacetone
[0282] The compound methyl lithium (1.879 g, 85.4 mmol) was added dropwise to dry tetrahydrofuran (75 ml) under argon atmosphere at room temperature under constant stirring. To the resulting mixture was added a solution of 2-cyclohexyl-2-hydroxy-2-phenyl acetic acid (5 g, 21.36 mmol) in dry tetrahydrofuran (55 ml) slowly. The mixture was stirred at room temperature for 2 hours and then refluxed for approx. 3-4 hours. The reaction mixture was cooled followed by the addition of hydrochloric acid (10%, 500 ml) under constant stirring. The reaction mixture was extracted with ethyl acetate. The organic layer was concentrated under reduced pressure. The residue thus obtained was purified by column chromatography using 3% ethyl acetate in hexane to furnish the title compound. Yield: 2.7 g.
Step b: Synthesis of 3-bromo-1-cyclohexyl-1-hydroxy-1-phenylacetone
[0283] To a solution of the compound obtained from step a above (2.7 g, 11.63 mmol) in dry tetrahydrofuran (30 ml) under argon atmosphere was added a solution of pyridinium tribromide (5.68 g, 15.1 mmol) in tetrahydrofuran (50 ml) dropwise over 2 hours. The reaction mixture was stirred for 24 hours. The solid thus obtained was filtered. The filtrate was concentrated under reduced pressure and the residue thus obtained was washed with water and extracted with ethyl acetate. The ethyl acetate layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure. The residue thus obtained was purified by column chromatography to furnish the title compound. Yield: 2.2 g.
Step c: Synthesis of 1-cyclohexyl-1-hydroxy-3-(1H-imidazol-1-yl)-1-phenylacetone (Compound No. 50)
[0284] To a solution of the compound imidazole (71 mg, 1.05 mmol) in dichloromethane (5 ml) was added triethylamine (0.25 ml, 1.77 mmol) followed by the addition of a solution of the compound obtained from step b above (250 mg, 0.8 mmol) in dichloromethane (5 ml) dropwise under constant stirring. The reaction mixture was stirred for overnight. The organic solvent was evaporated under reduced pressure and the residue thus obtained was purified by column chromatography using 5% methanol in dichloromethane.
[0285] 1 H NMR (CDCl 3 ) δ: 7.31-7.54 (m, 6H), 7.01 (s, 1H), 6.64 (s, 1H), 4.86-5.02 (m, 2H), 2.43-2.46 (m, 1H), 0.99-1.82 (m, 10H).
[0286] The following illustrative analogues were prepared similarly,
1-Cyclopentyl-1-hydroxy-1-(4-methoxyphenyl)-3-(2-methyl-1H-imidazol-1-yl)acetone (Compound No. 15)
[0287] 1 H NMR (CDCl 3 ) δ: 7.47-7.45 (2H, dd, J=8 Hz), 6.93-6.91 (2H, dd, J=8 Hz), 6.85 (1H, s), 6.56 (1H, s), 4.94-4.78 (2H, m), 3.82 (3H, s), 3.07-3.01 (1H, q), 2.17 (3H, s), 1.67-1.25 (8H, m).
1-Cyclohexyl-1-hydroxy-3-(2-methyl-1H-imidazol-1-yl)-1-phenylacetone (Compound No. 51)
[0288] 1 H NMR (CDCl 3 ) δ: 7.30-7.55 (m, 5H), 6.85 (s, 1H), 6.56 (s, 1H), 4.95-4.99 (dd, 1H, 16 Hz), 4.80-4.84 (dd, 1H, 16 Hz), 2.41-2.47 (m, 1H), 1.82 (s, 3H), 1.03-1.70 (m, 10H).
1-Cyclopentyl-1-hydroxy-3-(2-isopropyl-1H-imidazol-1-yl)-1-(4-methoxyphenyl)acetone (Compound No. 52)
[0289] 1 H NMR (CDCl 3 ) δ: 7.46-7.48 (2H, dd, 8 Hz), 6.92-6.94 (2H, dd, 8 Hz), 6.90 (s, 1H), 6.51 (s, 1H), 4.81-4.99 (m, 2H), 3.83 (s, 3H), 3.05-3.09 (m, 1H), 2.25-2.27 (m, 1H), 1.58-1.66 (m, 8H), 1.07-1.12 (m, 6H).
1-Cyclohexyl-1-hydroxy-3-(2-isopropyl-1H-imidazol-1-yl)-1-phenylacetone (Compound No. 53)
[0290] 1 H NMR (CDCl 3 ) δ: 7.32-7.55 (m, 5H), 6.93 (s, 1H), 6.50 (s, 1H), 4.93-4.98 (dd, 1H, 20 Hz), 4.80-4.85 (dd, 1H, 20 Hz), 2.50 (m, 1H), 2.17-2.20 (m, 1H), 1.34-1.72 (m, 10H), 0.99-1.09 (m, 6H).
1-Cyclohexyl-1-hydroxy-3-(2-methyl-4,5-dihydro-1H-imidazol-1-yl)-1-phenylacetone (Compound No. 54)
[0291] 1 H NMR (CDCl 3 ) δ: 7.49-7.51 (m, 2H), 7.29-7.39 (m, 3H), 4.39-5.04 (m, 2H), 3.85-3.90 (m, 2H), 3.60-3.65 (m, 2H), 2.24 (m, 1H), 2.07 (s, 3H), 1.10-1.81 (m, 10H).
1-Cyclopentyl-1-hydroxy-1-(4-methoxyphenyl)-3-(2-methyl-4,5-dihydro-1H-imidazol-1-yl)acetone (Compound No. 55)
[0292] 1 H NMR (CDCl 3 ) δ: 7.43-7.45 (dd, 2H, 8 Hz), 6.88-6.90 (dd, 2H, 8 Hz), 4.41-5.07 (m, 2H), 3.80-3.88 (m, 2H), 3.65 (s, 3H), 3.17-3.19 (m, 2H), 2.93 (m, 1H), 2.16 (s, 3H), 1.31-1.63 (m, 8H).
1-Cyclopentyl-1-hydroxy-3-(1H-imidazol-1-yl)-1-(4-methoxyphenyl)acetone (Compound No. 56)
[0293] 1 H NMR (CDCl 3 ) δ: 7.46-7.44 (2H, m), 7.27-7.25 (1H, m), 7.02 (1H, s), 6.94-6.92 (2H, m), 6.64 (1H, s), 4.88 (2H, s), 3.83 (3H, s), 3.05 (1H, q), 1.68-1.25 (8H, m).
Example 6
3-Benzyl-1-(2-{[cycloheptyl(hydroxy)phenylacetyl]oxy}ethyl)-2-isopropyl-1H-imidazol-3-ium bromide (Compound No. 72)
[0294] To the solution of the Compound No. 70 (25.0 mg) in acetonitrile (1.5 ml), benzylbromide (excess) was added and the reaction mixture was stirred at 55° C. overnight and subsequently at room temperature for further 24 hours. The reaction mixture was then concentrated under reduced pressure. The residue was washed with diethyl ether several times and dried under vacuum to furnish the desired compound. Yield: 34 mg
[0295] 1 H NMR (CD 3 OD) δ: 7.63-7.42 (5H, m), 7.28-7.22 (6H, m), 7.07 (1H, s), 5.46 (2H, s), 4.53-4.51 (4H, m), 3.62-3.68 (1H, m), 2.42-2.45 (1H, m), 1.56-1.49 (9H, m), 1.35-1.32 (9H, m).
[0296] Following analogues were prepared similarly,
3-Benzyl-1-[2-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-isopropyl-1H-imidazol-3-ium bromide (Compound No. 73)
[0297] 1 H NMR (CD 3 OD) δ: 7.50-7.41 (5H, m), 7.31-7.28 (4H, m), 7.23-7.22 (2H, m), 7.15-7.14 (1H, m), 5.45 (2H, s), 4.55-4.51 (4H, m), 3.69-3.65 (1H, m), 3.12-3.11 (1H, m), 2.06-2.01 (4H, m), 1.57-1.54 (1H, m), 1.38-1.28 (7H, m).
3-Benzyl-1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-isopropyl-1H-imidazol-3-ium bromide (Compound No. 74)
[0298] 1 H NMR (CD 3 OD) δ: 7.49-7.42 (5H, m), 7.30-7.27 (6H, m), 7.12-7.11 (1H, m), 5.45 (2H, s), 4.56-4.51 (4H, m), 3.67-3.65 (1H, m), 3.13-3.12 (1H, m), 2.06-1.30 (12H, m).
3-(4-Bromobenzyl)-1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-isopropyl-1H-imidazol-3-ium bromide (Compound No. 75)
[0299] 1 H NMR (CD 3 OD) δ: 7.61-7.59 (1H, m), 7.50-7.47 (2H, m), 7.33-7.28 (5H, m), 7.15-7.10 (3H, m), 5.43 (2H, s), 4.57-4.50 (4H, m), 3.67-3.63 (1H, m), 3.19-3.18 (1H, m), 2.16-1.76 (6H, m), 1.34-1.30 (6H, m).
3-Benzyl-1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 76)
[0300] 1 H NMR (CD 3 OD) δ: 7.46-7.25 (12H, m), 5.30 (2H, s), 4.54-4.49 (2H, m), 4.43-4.41 (2H, m), 3.13-3.12 (1H, m), 2.48 (3H, s), 1.78-1.74 (6H, m).
3-(4-Bromobenzyl)-1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 77)
[0301] 1 H NMR (CD 3 OD) δ: 7.61-7.59 (2H, m), 7.48-7.45 (3H, m), 7.32-7.30 (4H, m), 7.21-7.18 (2H, m), 5.30 (2H, s), 4.55-4.43 (4H, m), 3.13-3.11 (1H, m), 2.47 (3H, s), 2.18-1.95 (2H, m), 1.81-1.73 (4H, m).
3-(4-Fluorobenzyl-1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 78)
[0302] 1 H NMR (CD 3 OD) δ: 7.48-7.46 (2H, m), 7.38-7.31 (6H, m), 7.25-7.24 (1H, m), 7.20-7.15 (2H, m), 5.29 (2H, m), 4.55-4.43 (4H, m), 3.15-3.11 (1H, m), 2.49 (3H, s), 2.18-1.73 (6H, m).
3-Benzyl-1-(2-{[cycloheptyl(hydroxy)phenylacetyl]oxy}ethyl)-2-methyl-1H-imidazol-3-ium bromide (Compound No. 79).
[0303] 1 H NMR (CD 3 OD) δ: 7.20-7.66 (m, 12H), 5.31 (m, 2H), 4.41-4.47 (m, 4H), 2.42-2.47 (m, 4H), 1.21-1.75 (m, 12H).
3-(4-Bromobenzyl)-1-(2-{[cycloheptyl(hydroxy)phenylacetyl]oxy}ethyl)-2-methyl-1H-imidazol-3-ium bromide (Compound No. 80)
[0304] 1 H NMR (CD 3 OD) δ: 7.18-7.68 (m, 11H), 5.28-5.29 (m, 2H), 4.41-4.55 (m, 4H), 2.40-2.47 (m, 4H), 1.19-1.59 (m, 12H).
1-[2-({(2R)-2-[(1R)-3,3-Difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-3-(4-fluorobenzyl)-2-isopropyl-1H-imidazol-3-ium bromide (Compound No. 82)
[0305] 1 H NMR (CD 3 OD) δ: 7.10-7.67 (m, 11H), 5.43 (s, 2H), 4.47-4.57 (m, 4H), 3.66-3.69 (q, 1H), 3.19 (m, 1H), 1.28-2.10 (m, 12H).
3-Benzyl-1-[3-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 101)
[0306] 1 H NMR (CD 3 OD) δ: 7.60-7.62 (m, 2H), 7.27-7.48 (m, 10H), 5.34 (s, 2H), 4.12-4.16 (m, 2H), 4.05-4.10 (m, 2H), 3.20 (m, 1H), 2.42 (s, 3H), 1.26-2.15 (m, 8H).
3-(4-Bromobenzyl)-1-[3-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 102)
[0307] 1 H NMR (CD 3 OD) δ: 7.58-7.63 (m, 4H), 7.20-7.49 (m, 7H), 5.32 (s, 2H), 4.07-4.16 (m, 4H), 3.27-3.28 (m, 1H), 2.42 (s, 3H), 2.12-2.16 (p, 2H), 1.17-2.00 (m, 6H).
3-Benzyl-1-[3-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 104).
[0308] 1 H NMR (CD 3 OD) δ: 7.60-7.62 (m, 2H), 7.27-7.48 (m, 10H), 5.34 (s, 2H), 4.13-4.17 (m, 2H), 4.05-4.08 (m, 2H), 3.27 (m, 1H), 2.42 (s, 3H), 1.5-2.16 (m, 8H).
3-(4-Bromobenzyl)-1-[3-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 105)
[0309] 1 H NMR (CD 3 OD) δ: 7.58-7.62 (m, 4H), 7.20-7.50 (m, 7H), 5.33 (s, 2H), 4.13-4.17 (m, 2H), 4.05-4.10 (m, 2H), 3.26 (m, 1H), 2.42 (s, 3H), 1.5-2.16 (m, 8H).
3-Benzyl-1-[3-({2R)-2-[(1R or 1S)-3,3-difluorocyclohexyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 107)
[0310] 1 H NMR (CD 3 OD) δ: 7.60-7.63 (m, 2H), 7.26-7.48 (m, 10H), 5.34 (s, 2H), 4.13-4.18 (m, 2H), 4.06-4.07 (m, 2H), 2.6 (m, 1H), 2.41 (s, 3H), 2.13-2.16 (p, 2H), 1.28-2.15 (m, 8H).
3-4-bromobenzyl-1-[3-({(2R)-2-[(1R or 1S)-3,3-difluorocyclohexyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2-methyl-1H-imidazol-3-ium bromide (Compound No. 108)
[0311] 1 H NMR (CD 3 OD) δ: 7.57-7.63 (m, 4H), 7.19-7.49 (m, 7H), 5.32 (s, 2H), 4.13-4.18 (m, 2H), 4.06-4.07 (m, 2H), 2.6 (m, 1H), 2.41 (s, 3H), 2.13-2.16 (p, 2H), 1.28-2.15 (m, 8H).
Example 7
Synthesis of 1-(2-{[cyclohexyl(hydroxy)phenyl acetyl]oxy}ethyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 111)
[0312] To the solution of Compound No. 60 (43.5 mmoles) in dichloromethane and methanol, methyl iodide (20 equivalent, 875 mmoles) was added and reaction mixture was stirred at room temperature overnight. The reaction mixture was concentrated under reduced pressure. The residue thus obtained was washed with diethyl ether and dried under vacuum to yield the desired compound. Yield: 8 mg.
[0313] 1 H NMR (CD 3 OD) δ: 7.22 (s, 1H), 7.23-7.35 (m, 4H), 7.48-7.51 (m, 2H), 4.38-4.51 (m, 4H), 3.70 (s, 3H), 2.40 (s, 3H), 2.15-2.30 (m, 1H), 1.62-1.84 (m, 3H), 1.14-1.40 (m, 7H).
[0314] The following illustrative analogues were prepared similarly,
1-[2-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 81)
[0315] 1 H NMR (CD 3 OD) δ: 7.48-7.51 (m, 2H), 7.31-7.36 (m, 4H), 7.10 (s, 1H), 4.47-4.87 (m, 4H), 3.85 (s, 3H), 3.61 (q, 1H), 3.10 (q, 1H), 1.27-1.41 (m, 12H).
1-(2-{[2-Cyclohexyl-2-hydroxy-2-phenylacetyl]oxy}ethyl)-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 83)
[0316] 1 H NMR (CD 3 OD) δ: 7.03 (s, 1H), 7.24-7.34 (m, 4H), 7.48-7.50 (m, 2H), 4.46-4.51 (m, 4H), 3.85 (s, 3H), 3.59-3.63 (q, 1H), 2.15-2.25 (m, 1H), 1.62-1.82 (m, 3H), 1.14-1.48 (m, 13H).
1-(2-{[Cyclopentyl (hydroxy)phenylacetyl]oxy}ethyl)-3-methyl-1H-imidazol-3-ium iodide (Compound No. 84)
[0317] 1 H NMR (CD 3 OD) δ: 7.29-7.36 (m, 4H), 7.44-7.54 (m, 3H), 4.43-4.54 (m, 4H), 3.80 (s, 3H), 2.92 (q, 1H), 1.27-1.56 (m, 8H).
1-[2-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 85)
[0318] 1 H NMR (CD 3 OD) δ: 7.48-7.51 (m, 2H), 7.26-7.38 (m, 5H), 4.47-4.50 (m, 2H), 4.39-4.42 (m, 2H), 3.70 (s, 3H), 3.08-3.10 (q, 1H), 2.43 (s, 3H), 1.54-2.41 (m, 6H).
1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 86)
[0319] 1 H NMR (CD 3 OD) δ: 7.33-7.68 (6H, m), 7.23 (1H, s), 4.49-4.52 (m, 2H), 4.38-4.41 (m, 2H), 3.70 (s, 3H), 3.12-3.14 (m, 1H), 3.13 (s, H), 1.76-2.22 (m, 6H).
1-(2-{[cyclohexyl(hydroxy)phenylacetyl]oxy}ethyl)-3-methyl-1H-imidazol-3-ium iodide (Compound No. 87)
[0320] 1 H NMR (CD 3 OD) δ: 9.71 (s, 1H), 7.59-7.61 (m, 2H), 7.33-7.42 (m, 3H), 6.93 (s, 1H), 6.65 (s, 1H), 4.52-4.81 (m, 4H), 3.87 (s, 3H), 3.70 (brs, 1H), 2.25 (m, 1H), 1.08-1.77 (m, 10H).
1-(2-{[Cyclopentyl(hydroxy)phenylacetyl]oxy}ethyl)-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 88)
[0321] 1 H NMR (CD 3 OD) δ: 7.49-7.52 (m, 2H), 7.24-7.34 (m, 4H), 7.01 (s, 1H), 4.45-4.49 (m, 4H), 3.85 (s, 3H), 3.58-3.62 (q, 1H), 2.95 (q, 1H), 1.28-1.56 (m, 14H).
1-(2-{[Cyclopentyl(hydroxy)phenylacetyl]amino}ethyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 89)
[0322] 1 H NMR (CD 3 OD) δ: 7.55-7.57 (m, 2H), 7.28-7.36 (m, 3H), 7.05-7.09 (m, 2H), 4.09-4.20 (m, 2H), 3.75 (m, 1H), 3.59 (s, 3H), 3.39-3.43 (m, 1H), 3.02-3.05 (m, 1H), 2.31 (s, 3H), 1.17-1.56 (m, 8H).
1-(2-{[cyclohexyl(hydroxy)phenylacetyl]amino}ethyl)-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 90)
[0323] 1 H NMR (CD 3 OD) δ: 7.53-7.55 (m, 2H), 7.27-7.34 (m, 3H), 6.82-6.90 (m, 2H), 4.25-4.87 (m, 2H), 3.77 (s, 3H), 3.30-3.57 (m, 3H), 2.25 (m, 1H), 1.15-1.64 (16H).
1-(2-{[cycloheptyl(hydroxy)phenylacetyl]oxy}ethyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 91)
[0324] 1 H NMR (CD 3 OD) δ: 7.50-7.52 (m, 2H), 7.30-7.36 (m, 4H), 7.20 (s, 1H), 4.37-4.51 (m, 4H), 3.71 (m, 3H), 2.41 (m, 4H), 1.20-1.57 (m, 12H).
1-(2-{[cycloheptyl(hydroxy)phenylacetyl]oxy}ethyl)-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 92.)
[0325] 1 H NMR (CD 3 OD) δ: 7.50-7.65 (m, 2H), 7.25-7.35 (m, 4H), 7.02 (s, 1H), 4.47-4.51 (m, 4H), 3.86 (s, 3H), 3.62 (q, 1H), 2.45 (m, 1H), 1.24-1.57 (m, 18H).
1-[2-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)ethyl]-2-isopropyl-3-methyl-1H-imidazol-3-ium iodide (Compound No. 93)
[0326] 1 H NMR (CD 3 OD) δ: 7.47-7.51 (m, 2H), 7.32-7.37 (m, 3H), 7.25 (s, 1H), 7.06 (s, 1H), 4.47-4.53 (m, 4H), 3.85 (s, 3H), 3.59-3.63 (m, 1H), 3.13-3.15 (m, 1H), 1.38-2.15 (m, 12H).
1-(3-{[(2R)-2-(3,3-difluorocyclopentyl)-2-hydroxy-2-phenylacetyl]amino}propyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 94)
[0327] 1 H NMR (CD 3 OD) δ: 7.61-7.65 (m, 2H), 7.27-7.40 (m, 5H), 3.90-3.94 (q, 2H), 3.74 (s, 3H), 3.47-3.48 (m, 2H), 3.16-3.24 (m, 1H), 2.35 (s, 3H), 1.92-1.99 (m, 6H), 1.55 (m, 2H).
1-(3-{[Cyclopentyl(hydroxy)phenylacetyl]amino}propyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 95)
[0328] 1 H NMR (CD 3 OD) δ: 7.63-7.66 (m, 2H), 7.24-7.40 (m, 5H), 3.91-3.96 (m, 2H), 3.74 (s, 3H), 3.22-3.24 (m, 2H), 3.14-3.17 (m, 1H), 2.36 (s, 3H), 1.93-1.97 (m, 2H), 1.2-1.63 (8H).
1-(3-{[Cyclohexyl(hydroxy)phenylacetyl]amino}propyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 96)
[0329] 1 H NMR (CD 3 OD) δ: 7.62-7.64 (m, 2H), 7.25-7.39 (m, 4H), 7.24-7.25 (m, 1H), 3.88-3.92 (m, 2H), 3.74 (s, 3H), 3.14-3.24 (m, 2H), 2.5 (m, 1H), 2.32 (s, 3H), 1.66-1.68 (m, 2H), 1.02-1.37 (m, 10H).
1-(2-{[Cyclopentyl(hydroxy)phenylacetyl](methyl)amino}ethyl)-3-methyl-1H-imidazol-3-ium iodide (Compound No. 97)
[0330] 1 H NMR (CD 3 OD) δ: 8.78 (s, 1H), 7.48-7.54 (d, 2H), 7.33-7.38 (m, 4H), 7.26-7.27 (m, 1H), 4.62 (s, 1H), 4.32 (s, 1H), 3.89 (s, 4H), 3.72-3.78 (m, 1H), 2.87 (s, 3H), 2.78-2.80 (m, 1H), 1.49-1.53 (m, 1H), 3.1-1.38 (m, 3H), 0.99-1.23 (m, 4H)
1-(3-{[Cyclopentyl(hydroxy)phenylacetyl](methyl)amino}propyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 98)
[0331] 1 H NMR (CD 3 OD) δ: 7.68 (s, 1H), 7.21-7.52 (m, 6H), 4.90 (bs, 1H), 4.20 (s, 2H), 3.90 (s, 3H), 3.45-3.50 (m, 2H), 3.00 (m, 1H), 2.81-2.83 (m, 6H), 2.15-2.17 (m, 2H), 1.41-1.69 (m, 6H), 1.19-1.22 (m, 2H).
1-(3-{[Cyclopentyl(hydroxy)phenylacetyl]oxy}propyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 99)
[0332] 1 H NMR (CD 3 OD) δ: 7.64-7.66 (m, 2H), 7.21-7.41 (m, 5H), 4.11-4.16 (m, 2H), 4.03-4.04 (m, 2H), 3.76 (s, 3H), 3.0-3.1 (m, 1H), 2.41 (s, 3H), 2.09-2.12 (q, 2H), 1.22-1.66 (m, 8H).
1-[3-({(2R)-2-[(1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 100)
[0333] 1 H NMR (CD 3 OD) δ: 7.62-7.64 (m, 2H), 7.23-7.41 (m, 5H), 4.14-4.18 (m, 2H), 4.03-4.08 (m, 2H), 3.76 (s, 3H), 3.22-3.29 (m, 1H), 2.43 (s, 3H), 1.5-2.15 (m, 8H).
1-[3-({(2R)-2-[(1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 103)
[0334] 1 H NMR (CD 3 OD) δ: 7.61-7.63 (m, 2H), 7.23-7.41 (m, 5H), 4.14-4.18 (m, 2H), 4.03-4.08 (m, 2H), 3.76 (s, 3H), 3.22 (m, 1H), 2.41 (s, 3H), 1.5-2.15 (m, 2H).
1-[3-({(2R)-2-[(1S or 1R)-3,3-difluorocyclohexyl]-2-hydroxy-2-phenylacetyl}oxy)propyl]-2,3-dimethyl-1H-imidazol-3-ium bromide (Compound No. 106)
[0335] 1 H NMR (CD 3 OD) δ: 7.63-7.64 (m, 2H), 7.22-7.61 (m, 5H), 4.14-4.21 (m, 2H), 4.01-4.07 (m, 2H), 3.75 (s, 3H), 2.6 (m, 1H), 2.41 (s, 3H), 2.10-2.13 (p, 2H), 1.16-2.15 (m, 6H).
1-(2-{[Cyclopentyl(hydroxy)phenylacetyl](methyl)amino}ethyl)-2,3-dimethyl-1H-imidazol-3-ium iodide (Compound No. 109)
[0336] 1 H NMR (CD 3 OD) δ: 7.51-7.52 (m, 1AR-H), 7.32-7.35 (m, 5H), 7.18 (s, 1H), 4.42 (m, 2H), 4.16 (m, 1H), 3.98 (s, 3H), 3.65-3.66 (m, 1H), 2.96 (s, 4H), 2.83 (s, 3H), 1.19-1.67 (m, 8H).
Biological Activity
Radioligand Binding Assays:
[0337] The affinity of test compounds for M 1 , M 2 and M 3 muscarinic receptor subtypes was determined by [ 3 H]-N-methylscopolamine binding studies using rat heart and submandibular gland respectively as described by Moriya et al., ( Life Sci , (1999), 64(25): 2351-2358) with minor modifications. In competition binding studies, specific binding of [ 3 H]NMS was also determined using membranes from Chinese hamster ovary (CHO) cells expressing cloned human M 1 , M 2 , M 3 , M 4 and M 5 receptors. Selectivities were calculated from the Ic values obtained on these human cloned membranes.
[0338] Membrane preparation: Submandibular glands and heart were isolated and placed in ice-cold homogenizing buffer (HEPES 20 mM, 10 mM EDTA, pH 7.4) immediately after sacrifice. The tissues were homogenized in 10 volumes of homogenizing buffer and the homogenate was filtered through two layers of wet gauze and filtrate was centrifuged at 500 g for 10 minutes at 4° C. The supernatant was subsequently centrifuged at 40,000 g for 20 min. at 4° C. The pellet thus obtained was resuspended in assay buffer (HEPES 20 mM, EDTA 5 mM, pH 7.4) and were stored at −70° C. until the time of assay.
[0339] Ligand binding assay: The compounds were dissolved and diluted in DMSO. The membrane homogenates (150-250 μg protein) were incubated in 250 μl of assay volume (HEPES 20 mM, pH 7.4) at 24-25° C. for 3 hours Non-specific binding was determined in the presence of 1 μM atropine. The incubation was terminated by vacuum filtration over GF/B fiber filters (Wallac). The filters were then washed with ice-cold 50 mM Tris HCl buffer (pH 7.4). The filter mats were dried and bound radioactivity retained on filters was counted. The IC 50 & K d were estimated by using the non-linear curve fitting program using G Pad Prism software. The value of inhibition constant K i was calculated from competitive binding studies by using Cheng & Prusoff equation ( Biochem. Pharmacol ., (1973), 22: 3099-3108), K i =IC 50 /(1+L/K d ), where L is the concentration of [ 3 H]NMS used in the particular experiment. pK i is −log [K i ].
[0340] Compounds described herein showed activity towards M3 receptors in the range of from about 1000 nM to about 0.02 nM, for example from about 100 nM to about 0.02 nM, or for example, from about 50 nM to about 0.02 nM, or for example, from about 10 nM to about 0.02 nM, or for example, from about 1 nM to about 0.02 nM.
[0341] Particular compounds described herein (compound Nos. 2, 8, 9, 13-16, 18, 20, 22-25, 27-31, 33-38, 46-60, 64-69, 72-109 and 111) also showed activity towards M2 receptors in the range of from about 1000 nM to about 0.3 nM, or for example, from about 500 nM to about 0.3 nM, or for example, from about 100 nM to about 0.3 nM, or for example, from about 50 nM to about 0.3 nM, or for example, from about 10 nM to about 0.3 nM, or for example, from about 1 nM to about 0.3 nM.
[0342] The ratio of M2/M3 activities (the division of the M2 activity value by the M3 activity value) for tested compounds (compound Nos. 2, 8, 9, 13-16, 18, 20, 22-25, 27-31, 33-38, 46-60, 64-69, 72-109 and 111) ranged from about 2 to about 128, or for example, from about 10 to about 128, or for example, from about 25 to about 128.
Functional Experiments Using Isolated Rat Bladder:
Methodology:
[0343] Animals are euthanized by overdose of thiopentone and whole bladder is isolated and removed rapidly and placed in ice cold Tyrode buffer with the following composition (mMol/L) NaCl 137; KCl 2.7; CaCl 2 1.8; MgCl 2 0.1; NaHCO 3 11.9; NaH 2 PO 4 0.4; Glucose 5.55 and continuously gassed with 95% O 2 and 5% CO 2 .
[0344] The bladder is cut into longitudinal strips (3 mm wide and 5-6 mm long) and mounted in 10 ml organ baths at 30° C., with one end connected to the base of the tissue holder and the other end connected through a force displacement transducer. Each tissue is maintained at a constant basal tension of 1 g and allowed to equilibrate for 1 1/2 hour during which the Tyrode buffer is changed every 15-20 minutes. At the end of equilibration period the stabilization of the tissue contractile response is assessed with 1 μmol/L of carbachol till a reproducible response is obtained. Subsequently a cumulative concentration response curve to carbachol (10 −9 mol/L to 3×10 −4 mol/L) was obtained. After several washes, once the baseline is achieved, cumulative concentration response curve is obtained in presence of NCE (NCE added 20 minutes prior to the second cumulative response curve.
[0345] The contractile results are expressed as % of control E max. ED 50 values are calculated by fitting a non-linear regression curve (Graph Pad Prism). pK b values are calculated by the formula pK b =−log [(molar concentration of antagonist/(dose ratio−1))]
[0000] where,
dose ratio=ED 50 in the presence of antagonist/ED 50 in the absence of antagonist.
In-Vitro Functional Assay
Animals and Anaesthesia:
[0346] Procure Guinea Pig (400-600 g) and remove trachea under anesthesia (sodium pentobarbital, 300 mg/kg i.p) and immediately keep it in ice-cold Krebs Henseleit buffer. Indomethacin (10 uM) is present throughout the KH buffer to prevent the formation of bronchoactive prostanoids.
Trachea Experiments:
[0347] Clean the tissue off adherent fascia and cut it into strips of equal size (with approx. 4-5 tracheal rings in each strip). Remove the epithelium by careful rubbing, minimizing damage to the smooth muscle. Open the trachea along the mid-dorsal surface with the smooth muscle band intact and make a series of transverse cuts from alternate sides so that they do not transect the preparation completely. Tie opposite end of the cut rings with the help of a thread. Mount the tissue in isolated tissue baths containing 10 ml Krebs Henseleit buffer maintained at 37° C. and bubbled with carbogen, at a basal tension of 1 g. Change the buffer 4-5 times for about an hour. Equilibrate the tissue for 1 hr for stabilization. After 1 hour, challenge the tissue with 1 uM carbachol. Repeat this after every 2-3 washes till two similar consecutive responses are obtained. At the end of stabilization, wash the tissues for 30 minutes followed by incubation with suboptimal dose of MRA/Vehicle for 20 minutes prior to contraction of the tissues with 1 μM carbachol. Record the contractile response of tissues either on Powerlab data acquisition system or on Grass polygraph (Model 7). Express the relaxation as percentage of maximum carbachol response. Express the data as mean±s.e. mean for n observations. Calculate the EC 50 as the concentration producing 50% of the maximum relaxation to 1 μM carbachol. Compare percent relaxation between the treated and control tissues using non-parametric unpaired t-test. A p value of <0.05 is considered to be statistically significant.
[0000] In-Vitro Functional Assay to Evaluate Efficacy of “MRA” in Combination with “PDE-IV Inhibitors”
Animals and Anaesthesia:
[0348] Procure Guinea Pig (400-600 g) and remove trachea under anesthesia (sodium pentobarbital, 300 mg/kg i.p) and immediately keep it in ice-cold Krebs Henseleit buffer. Indomethacin (10 uM) is present throughout the KH buffer to prevent the formation of bronchoactive prostanoids.
[0349] Particular compounds described herein (compound Nos. 69, 76-78, 82, 86, 91, 93, 103-105, 107, and 108) showed p KB of from about 7.53±0.08 to about 9.56±0.20.
Trachea Experiments:
[0350] Clean the tissue off adherent fascia and cut it into strips of equal size (with approx. 4-5 tracheal rings in each strip). Remove the epithelium by careful rubbing, minimizing damage to the smooth muscle. Open the trachea along the mid-dorsal surface with the smooth muscle band intact and make a series of transverse cuts from alternate sides so that they do not transect the preparation completely. Tie opposite end of the cut rings with the help of a thread. Mount the tissue in isolated tissue baths containing 10 ml Krebs Henseleit buffer maintained at 37° C. and bubbled with carbogen, at a basal tension of 1 g. Change the buffer 4-5 times for about an hour. Equilibrate the tissue for 1 hour for stabilization. After 1 hour, challenge the tissue with 1 uM carbachol. Repeat this after every 2-3 washes till two similar consecutive responses are obtained. At the end of stabilization, wash the tissues for 30 minutes followed by incubation with suboptimal dose of MRA/Vehicle for 20 minutes prior to contraction of the tissues with 1 μM carbachol and subsequently assess the relaxant activity of the PDE-IV inhibitor [10 −9 M to 10 −4 M] on the stabilized developed tension/response. Record the contractile response of tissues either on Powerlab data acquisition system or on Grass polygraph (Model 7). Express the relaxation as percentage of maximum carbachol response. Express the data as mean±s.e. mean for n observations. Calculate the EC 50 as the concentration producing 50% of the maximum relaxation to 1 μM carbachol. Compare percent relaxation between the treated and control tissues using non-parametric unpaired t-test. A p value of <0.05 is considered to be statistically significant.
In-Vivo Assay to Evaluate Efficacy of MRA Inhibitors
[0351] Male Guinea pig were anesthetized with urethane (1.5 g/kg, i.p.). Trachea was cannulated along with jugular vein (for carbachol challenge) and animals were placed in the Plethysmograph-Box (PLY 3114 model; Buxco Electronics, Sharon, USA.). Respiratory parameters were recorded using Pulmonary Mechanics Analyzer, Biosystems XA software (Buxco Electronics, USA), which calculated lung resistance (R L ) on a breath-by-breath basis. Bronchoconstriction was induced by injections of Carbachol (10 μg/kg) delivered into the jugular vein. Increase in R L over a period of 5 minutes post carbachol challenge was recorded in presence or absence of MRA or vehicle at 2 hours and 12 hours post treatment and expressed as % increase in R L from basal.
[0000] In-Vivo Assay to Evaluate Efficacy of MRA in Combination with PDE-IV Inhibitors
Drug Treatment:
[0352] MRA (1 μg/kg to 1 mg/kg) and PDE-IV inhibitor (1 μg/kg to 1 mg/kg) are instilled intratracheally under anesthesia either alone or in combination.
Method:
[0353] Male wistar rats weighing 200±20 g are used in the study. Rats have free access to food and water. On the day of experiment, animals are exposed to lipopolysaccharide (LPS, 100 μg/ml) for 40 minutes One group of vehicle treated rats is exposed to phosphate buffered saline (PBS) for 40 minutes Two hours after LPS/PBS exposure, animals are placed inside a whole body plethysmograph (Buxco Electronics, USA) and exposed to PBS or increasing acetylcholine (1, 6, 12, 24, 48 and 96 mg/ml) aerosol until Penh values (index of airway resistance) of rats attained 2 times the value (PC-100) seen with PBS alone. The respiratory parameters are recorded online using Biosystem XA software, (Buxco Electronics, USA). Penh, at any chosen dose of acetylcholine is, expressed as percent of PBS response and the using a nonlinear regression analysis PC100 (2 folds of PBS value) values are computed. Percent inhibition is computed using the following formula.
[0000]
%
Inhibition
=
PC
100
LPS
-
PC
100
TEST
PC
100
LPS
-
PC
100
PBS
×
100
[0354] Where,
[0000] PC100 LPS =PC100 in untreated LPS challenged group
PC100 TEST =PC100 in group treated with a given dose of test compound
PC100 PBS =PC100 in group challenged with PBS
[0355] Immediately after the airway hyperreactivity response is recorded, animals are sacrificed and bronchoalveolar lavage (BAL) is performed. Collected lavage fluid is centrifuged at 3000 rpm for 5 minutes at 4° C. Pellet is collected and resuspended in 1 ml HBSS. Total leukocyte count is performed in the resuspended sample. A portion of suspension is cytocentrifuged and stained with Leishmann's stain for differential leukocyte count. Total leukocyte and Neutrophil counts are expressed as cell count (millions cells ml −1 of BAL). Percent inhibition is computed using the following formula.
[0000]
%
Inhibition
=
NC
LPS
-
NC
TEST
NC
LPS
-
NC
CON
×
100
[0356] Where,
[0000] NC LPS =Percentage of neutrophil in untreated LPS challenged group
NC TEST =Percentage of neutrophil in group treated with a given dose of test compound
NC CON =Percentage of neutrophil in group not challenged with LPS
[0357] The percent inhibition data is used to compute ED 50 vales using Graph Pad Prism software (Graphpad Software Inc., USA).
[0000] In-Vivo Assay to Evaluate Efficacy of MRA in Combination with Corticosteroids
Ovalbumin Induced Airway Inflammation:
[0358] Guinea pigs are sensitised on days 0, 7 and 14 with 50-μg ovalbumin and 10 mg aluminium hydroxide injected intraperitoneally. On days 19 and 20 guinea pigs are exposed to 0.1% w v −1 ovalbumin or PBS for 10 minutes and with 1% ovalbumin for 30 minutes on day 21. Guinea pigs are treated with test compound (0.1, 0.3 and 1 mg kg −1 ) or standard 1 mg kg −1 or vehicle once daily from day 19 and continued for 4 days. Ovalbumin/PBS challenge is performed 2 hours after different drug treatment.
[0359] 24 hours after the final ovalbumin challenge BAL is performed using Hank's balanced salt solution (HBSS). Collected lavage fluid is centrifuged at 3000 rpm for 5 minutes at 4° C. Pellet is collected and resuspended in 1 ml HBSS. Total leukocyte count is performed in the resuspended sample. A portion of suspension is cytocentrifuged and stained with Leishmann's stain for differential leukocyte count. Total leukocyte and eosinophil count are expressed as cell count (millions cells ml −1 of BAL). Eosinophil is also expressed as percent of total leukocyte count. % inhibition is computed using the following formula.
[0000]
%
Inhibition
=
Eos
OVA
-
Eos
TEST
Eos
OVA
-
Eos
CON
×
100
[0360] Where,
[0000] Eos OVA =Percentage of eosinophil in untreated ovalbumin challenged group
Eos TEST =Percentage of eosinophil in group treated with a given dose of test compound
Eos CON =Percentage of eosinophil in group not challenged with ovalbumin.
In-Vivo Assay to Evaluate Efficacy of “MRA” in Combination with P38 Map Kinase Inhibitors
[0361] Lipopolysaccharide (LPS) induced airway hyperreactivity (AHR) and neutrophilia:
Drug Treatment:
[0362] MRA (1 μg/kg to 1 mg/kg) and p38 MAP kinase inhibitor (1 μg/kg to 1 mg/kg) are instilled intratracheally under anesthesia either alone or in combination.
Method:
[0363] Male wistar rats weighing 200±20 gM are used in the study. Rats have free access to food and water. On the day of experiment, animals are exposed to lipopolysaccharide (LPS, 100 μg/ml) for 40 minutes One group of vehicle treated rats is exposed to phosphate buffered saline (PBS) for 40 minutes Two hours after LPS/PBS exposure, animals are placed inside a whole body plethysmograph (Buxco Electronics, USA) and exposed to PBS or increasing acetylcholine (1, 6, 12, 24, 48 and 96 mg/ml) aerosol until Penh values (index of airway resistance) of rats attained 2 times the value (PC-100) seen with PBS alone. The respiratory parameters are recorded online using Biosystem XA software, (Buxco Electronics, USA). Penh, at any chosen dose of acetylcholine is, expressed as percent of PBS response and the using a nonlinear regression analysis PC100 (2 folds of PBS value) values are computed. Percent inhibition is computed using the following formula.
[0000]
%
Inhibition
=
PC
100
LPS
-
PC
100
TEST
PC
100
LPS
-
PC
100
PBS
×
100
[0364] Where,
[0000] PC100 LPS =PC100 in untreated LPS challenged group
PC100 TEST =PC100 in group treated with a given dose of test compound
PC100 PBS =PC100 in group challenged with PBS
[0365] Immediately after the airway hyperreactivity response is recorded, animals are sacrificed and bronchoalveolar lavage (BAL) is performed. Collected lavage fluid is centrifuged at 3000 rpm for 5 minutes, at 4° C. Pellet is collected and resuspended in 1 ml HBSS. Total leukocyte count is performed in the resuspended sample. A portion of suspension is cytocentrifuged and stained with Leishmann's stain for differential leukocyte count. Total leukocyte and Neutrophil counts are expressed as cell count (millions cells ml −1 of BAL). Percent inhibition is computed using the following formula.
[0000]
%
Inhibition
=
NC
LPS
-
NC
TEST
NC
LPS
-
NC
CON
×
100
[0366] Where,
[0000] NC LPS =Percentage of neutrophil in untreated LPS challenged group
NC TEST =Percentage of neutrophil in group treated with a given dose of test compound
NC CON =Percentage of neutrophil in group not challenged with LPS
[0367] The percent inhibition data is used to compute ED 50 vales using Graph Pad Prism software (Graphpad Software Inc., USA).
[0000] In-Vivo Assay to Evaluate Efficacy of “MRA” in Combination with β2-Agonists
Drug Treatment:
[0368] MRA (1 μg/kg to 1 mg/kg) and long-acting β 2 agonist are instilled intratracheally under anesthesia either alone or in combination.
Method
[0369] Wistar rats (250-350 gm) or balb/C mice (20-30 gM) are placed in body box of a whole body plethysmograph (Buxco Electronics., USA) to induce bronchoconstriction. Animals are allowed to acclimatise in the body box and are given successive challenges, each of 2 min duration, with PBS (vehicle for acetylcholine) or acetylcholine (i.e. 24, 48, 96, 144, 384, and 768 mg/ml). The respiratory parameters are recorded online using Biosystem XA software, (Buxco Electronics, USA) for 3 minutes A gap of 2 minutes is allowed for the animals to recover and then challenged with the next higher dose of acetylcholine (ACh). This step is repeated until Penh of rats attained 2 times the value (PC-100) seen with PBS challenge. Following PBS/ACh challenge, Penh values (index of airway resistance) in each rat/mice is obtained in the presence of PBS and different doses of ACh. Penh, at any chosen dose of ACh is, expressed as percent of PBS response. The Penh values thus calculated are fed into Graph Pad Prism software (Graphpad Software Inc., USA) and using a nonlinear regression analysis PC100 (2 folds of PBS value) values are computed. % inhibition is computed using the following formula.
[0000]
%
Inhibition
=
PC
100
TEST
-
PC
100
CON
768
-
PC
100
CON
×
100
[0370] Where,
[0000] PC100 CON =PC100 in vehicle treated group
PC100 TEST =PC100 in group treated with a given dose of test compound
768=is the maximum amount of acetylcholine used.
[0371] While the present invention has been described in terms of its specific embodiments, certain modification and equivalents will be apparent to those skilled in the art and are intended. | Compounds of Formula (I), wherein represents a single bond when G is —OH and double bond when G is —O; R 1 and R 2 are independently selected from hydrogen, alkyl, alkenyl, alkynyl, aralkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, heterocyclylalkyl or heteroarylalkyl; R 3 is selected from the group selected from hydrogen, hydroxy, alkoxy, alkenyloxy or alkynyloxy; X is selected from oxygen, —NH, —NR (wherein R is alkyl, alkenyl, alkenyl, alkynyl or aryl), sulphur or no atom; Het is heterocyclyl or heteroaryl; n is an integer from 1 to 6; are muscarinic receptor antagonists, which are useful, among other uses, for the treatment of various diseases of the respiratory, urinary and 4 i gastrointestinal systems mediated through muscarinic receptors. | 2 |
This application is a Division of application Ser. No. 07/582,818, now U.S. Pat. No. 5,214,298 filed Sep. 14, 1990, which is a continuation of Ser. No. 06/913,872, now abandoned filed Sep. 30, 1986.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electronic semiconductor devices and integrated circuits, and, more particularly, to complementary field effect transistors with heterostructure insulated gates and integrated circuits including them and methods of fabrication.
2. Description of the Related Art
Very large scale integrated semiconductor memory and logic devices are being pushed for ever higher speed switching, lower power consumption, and larger noise margins. Thus there has been considerable effort to combine the intrinsic high switching speed and semiinsulating properties of gallium arsenide (GaAs) with the inherent large noise margins and low standby power dissipation of complementary field effect transistor (FET) logic. Complementary GaAs JFET circuits have shown very low standby power dissipation, but the low hole mobility of GaAs leads to low extrinsic transconductance of the p-channel devices and relatively low switching speeds; see, for example, R. Zuleg et al. 5 IEEE Elec. Dev. Lett. 21 (1984).
High hole mobilities have been obtained in modulation doped aluminum gallium arsenide/gallium arsenide (Al x Ga 1-x As/GaAs) heterojunction FET WHICH relay on a channel consisting of a two-dimensional hole gas at the heterojunction: see, for example, H. Stormer et al. 44 Appl. Phys. Lett. 1062 (1984). This is the complement of the modulation doped heterojunction FET which utilizes a two-dimensional electron gas (HEMT. MODFET, etc.). However, the threshold voltages of these modulation doped heterojunction devices depend critically on the thickness and doping concentration of the Al x Ga 1-x As layer, and reported variations in HEMT threshold voltages across a two inch wafer typically have a standard variation in the range of 0.15 V to 0.4 V; see K. Arai et al. 7 IEEE Elec. Dev. Lett. 158 (1986). Even the use of pulse doping of the Al x Ga 1-x As (see, Hueschen et al, 1984 IEDM Tech. Digest 348) does not solve the problem. Consequently, heterostructure insulated gate FETs (HFETs). which use an undoped Al x Ga 1-x As layer as a gate insulator in a MIS-like structure have appeared; see, P. Solomon et al, 5 IEEE Elec. Dev. Lett. 379 (1984). HFETs have the advantage of uniformity and reproducibility of threshold voltage because the threshold voltage is primarily determined by the gate material and is independent of the Al x Ga 1-x As layer thickness.
Complementary HFET devices, using a two-dimensional electron gas for the n channel device and a two-dimensional hole gas for the p channel device, have been fabricated on a single undoped Al x Ga 1-x As/GaAs substrate: see N. Cirillo et al. 1985 IEDM Tech. Digest 317-320. Both the n and p channel devices use tungsten silicide (WSi is used to represent the various silicides of tungsten) Schottky barrier gates on the undoped Al x Ga 1-x As and are relatively easy to fabricate. However, the threshold voltage for the WSi Schottky barrier gate is about 0.8-1.0 V for the n-channel device and about -0.7--0.4 V for the p-channel device: whereas for 1 V power supply operation the n-channel threshold should be about 0.2-0.3 V and the p-channel threshold should be about -0.3--0.2 V.
In contrast, K. Matsumoto et al. 7 IEEE Elec. Dev. Lett. 182 (1986), have fabricated complementary HFET devices with Al x Ga 1-x As as the insulator and n + and p + GaAs gates for the n and p channel devices, respectively. This yields low threshold voltages (about 0 V), but the fabrication requires a mesa etch and epitaxial refill.
In either case, the threshold voltage may be adjusted by uniformly doping the GaAs layer which would be analogous to the channel implants in MOSFET technology to adjust threshold voltage. However, to adjust the threshold voltage by 0.1 V would require a doping level of about 5×10 15 /cm 3 . which is too low to be reproducibly controlled by the growth techniques used to fabricate the basic heterostructure (i.e., by molecular beam epitaxy (MBE) or metalorganic chemical vapor deposition (MOCVD)).
Thus it is a problem to fabricate complementary HFET devices with desirable threshold voltages by a simple process.
SUMMARY OF THE INVENTION
The present invention provides complementary heterostructure insulated-gate field effect transistors (HFETs) and fabrication methods which have planar structure and adjustable threshold voltages. Preferred embodiments include gallium arsenide (GaAs) sources, drains, and channels with aluminum gallium arsenide (Al x Ga 1-x As) gate insulators and GaAs gates; the gates for the n-channel and p-channel HFETs are both formed from a common n+ layer of GaAs but the p-channel HFET has its gate converted to a p+ gate by diffusion of zinc from an overlying tungsten silicide zinc alloy. This provides a simple fabrication method for complementary HFETs with small threshold voltages which are reproducible because the n-channel threshold voltage is determined by the n+ GaAs layer doping level as grown and the p-channel threshold voltage is determined by the p+ doping level arising from the zinc diffusion and can be performed by precision rapid thermal annealing. And no mesa etches or epitaxial refill is needed plus the planar surface makes for easy interconnections.
Threshold voltages are adjusted by pulse doping of the GaAs channel away from the two-dimensional electron and hole gas channels. Such threshold adjustment uses high doping concentrations in thin layers to overcome the reproducibility limitations of low concentration uniform doping, and may also be used on single HFETs and Schottky gate HFETs.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings are schematic for clarity.
FIG. 1 illustrates in cross sectional elevation view a pair of complementary HFETs with connected drains;
FIGS. 2A-B are energy band diagrams for the pair of FIG. 1;
FIGS. 3A-B are plan and cross sectional elevation views of a first preferred embodiment pair of complementary HFETs;
FIGS. 4A-D illustrate a first preferred embodiment method of fabrication of the pair of FIGS. 3A-B;
FIG. 5 is a cross sectional elevation view of a second preferred embodiment HFET; and
FIG. 6 is a energy band diagram for the second preferred embodiment HFET.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic cross sectional elevation view of a pair of complementary heterostructure insulated gate field effect transistors (HFETs) with the drain of the n-channel HFET (lefthand portion of FIG. 1) connected to the drain of the p-channel HFET (righthand portion of FIG. 1). The metal gates form Schottky barriers with the undoped Al x Ga 1-x As, and the two-dimensional electron (hole) gas is created at the undoped Al x Ga 1-x As/GaAs interface by a positive (negative) voltage applied to the metal gate of the n-channel (p-channel) HFET. Of course, the gate voltage only bends the conduction and valence bands as shown in FIGS. 2A-B, and the electrons and holes to form the two-dimensional gasses are primarily supplied by the heavily doped regions. FIG. 2A is the band diagram along line A--A of FIG. 1, and FIG. 2B is the band diagram along line B--B of FIG. 1. The carrier density in the two-dimensional gasses is controlled by the magnitudes of the gate voltages V g which determine the depths of the potential wells at the heterojunctions, and source to drain current flows under applied bias analogous to current in complementary MOSFETs with the two-dimensional gasses the analogs of the inversion layers.
A first approximation for the threshold voltages of the HFETs (i.e., ignore the voltage drop across the Al x Ga 1-x As and bend the GaAs conduction band edge down to the Fermi level) is:
V.sub.Tn =+φ.sub.n -ΔE.sub.c /q
V.sub.Tp =-φ.sub.p +ΔE.sub.v /q
where V Tn is the threshold voltage for the n-channel HFET. V Tp is the p-channel HFET threshold, qφ n and qφ p are the Schottky barrier heights for the n and p gates, respectively, and ΔE c and ΔE v are the discontinuities of the conduction and valence band edges at the heterojunction, respectively. Note that the GaAs and Al x Ga 1-x As beneath the gates are undoped so the band edges have small curvature and the depletion charge in the Al x Ga 1-x As is small. For WSi gates, Al x Ga 1-x As with x=0.3, and the band edge discontinuity appearing 60% in the conduction band and 40% in the valence band, the threshold voltages should be about V Tn =+0.8 V and V Tp =-0.7 V. Note that with GaAs gates (n + for the n-channel and p + for the p-channel) the threshold voltages should be about V Tn =V Tp =0.
If the GaAs between the source and drain were uniformly doped to an acceptor concentration of N A , then the threshold voltage would be raised by approximately ##EQU1## where d is the thickness of the Al x Ga 1-x As gate insulator, φ s is the surface potential, and ε is the permittivity of the GaAs. However, to reproducibly adjust the threshold voltages to within a 0.1 V range by doping the GaAs would require control of the doping concentration to within a range of about ±2×10 15 /cm 3 , which is beyond MBE and MOCVD reproducibility.
A first preferred embodiment pair of complementary HFETs, generally denoted 30, is illustrated schematically in plan and cross sectional elevation views in FIGS. 3A-B and includes semi-insulating GaAs 32: GaAs buffer epilayer 34 of thickness 1 μm and of various dopings: n + in regions 42 and 44, p + in regions 52 and 54, and undoped in the remainder; Al x Ga 1-x As with x=0.3 epilayer 36 of thickness 0.05 μm and of various dopings: n + in regions 42 and 44, p + in regions 52 and 54, and undoped in the remainder; n + GaAs gate 40 and pad 62 of thickness 0.5 μm; p + gate 50 and pad 64 of thickness 0.5 μm: ohmic contacts 46, 48, 56, and 58; and WSi:Zn gate cap 51. Epilayers 34 and 36 have been boron bombarded in regions 60 to convert the GaAs and Al x Ga 1-x As to high resistivity material by lattice damage; this high resistivity material provides isolation of the n and p channel HFETs from each other and from other adjacent devices. Passivation layers and packaging are not shown for clarity. The n-channel HFET has region 42 in layers 34 and 36 as its source, region 44 in layers 34 and 36 as its drain, gate 40 as its gate which has a length (right-to-left in FIGS. 3A-B) of 1 μm and a width (top-to-bottom in FIGS. 3A-B) of 8 μm, and an undoped portion of layer 36 as its gate insulator; and the p-channel HFET has region 52 in layers 34 and 36 as its source, regions 54 in layers 34 and 36 as its drain, gate 50 as its gate which has a length (right-to-left in FIGS. 3A-B) of 1 μm and a width (top-to-bottom in FIGS. 3A-B) of 8 μm, and an undoped portion of layer 36 as its gate insulator. Thus the n-channel HFET has an n + GaAs gate and the p-channel HFET has a p + GaAs gate; so the threshold voltages to first approximation are both about 0 V.
Gate cap 51 also covers pad 64. Note that gate cap 51 could be removed without affecting the operation of pair 30: conversely, gate 40 could have a gate cap of material such as WSi. Such gate caps keep the resistance of the gates low, and with wider gates or thinner gates such gate caps are preferred. The two-dimensional electron and hole gas channels are formed in layer 34 at the interface with layer 36 as illustrated in FIG. 3B. The heavy doping in sources and drains 42, 44, 52, and 54 implies that the heterojunction between layers 34 and 36 has sharp band bending and provides only a minimal tunneling barrier for majority carriers from layer 34 to the ohmic contacts; further, the alloying formation of ohmic contacts 46, 48, 56, and 58 leads to diffusion of contact metal through layer 36 and into layer 34 which additionally limits the heterojunction barrier of layer 36.
The operation and characteristics of HFETs 30 can be further understood in connection with the following first preferred embodiment method of fabrication as illustrated in cross sectional elevation views in FIGS. 4A-D:
(a) Start with a undoped semi-insulating GaAs substrate 32 which has a planar (100) oriented surface, and grow by molecular beam epitaxy (MBE) a layer 34 of undoped (p - ) GaAs to a thickness of 1 μm followed by a layer 36 of undoped (p - ) Al x Ga 1-x As with x=0.3 to a thickness of 0.05 μm and lastly a layer 38 of n + Si-doped GaAs to a thickness of 0.5 μm. See FIG. 4A for a schematic illustration of the layered structure. The Si concentration in layer 38 is 1×10 18 /cm 3 , it is difficult to grow layers with much higher doping levels; and the p - residual carrier concentration in undoped layers 34 and 36 is typically about 1×10 14 /cm 3 and arises from residual carbon doping.
(b) Zinc and W 5 Si 3 are cosputter deposited on the layered structure to a thickness of 0.3 μm and a composition of 10% zinc: the deposited layer sticks well to GaAs. Then the deposited metal layer is photolithographically patterned and etched by CF 4 /O 2 reactive ion etching (RIE) to form gate cap 51 to locate gate 50 and pad 64 of the p-channel HFET. Next photoresist is spun onto the layered structure and gate cap 51 and photolithographically patterned to define the location of gate 40 and pad 62 of the n-channel HFET. The patterned photoresist and gate cap 51 are then used as a mask to selective plasma etch layer 38 to define gate 40, pad 62, gate 50, and pad 64; the selective etch of layer 38 can be a mixture of H 2 O 2 and NH 4 OH which rapidly etches GaAs but is inhibited on Al x Ga 1-x As. Note that a slight overetch that removes a portion of the Al x Ga 1-x As will not affect the heterointerface where the two-dimensional electron gas will be located. See FIG. 4B.
(c) Photoresist is again spun on and patterned to define a mask for implanting source 42 and drain 44 of the n-channel HFET; gate 40 will also be part of the implant mask and is thicker than the range of the implant, so the portion of Al x Ga 1-x As layer 36 below gate 40 will remain undoped. Then Si is implanted at 60 keV with a dose of 5×10 13 /cm 2 to form source 42 and drain 44. Note that the source 42 and drain 44 are self-aligned to gate 40 and the implanted Si will be activated by a later rapid thermal anneal. See FIG. 4C which illustrates the extent of the Si implant by dashed lines; the peak of the implant is at depth of about 0.05 μm which is at the heterointerface of layers 34 and 36.
(d) The existing photoresist is ashed and new photoresist is spun on and photolithographically patterned to define a mask for implanting source 52 and drain 54 of the p-channel HFET; gate cap 51 and gate 50 are also used as part of the mask. Then Be is implanted at 50 keV with a dose of 3×10 13 /cm 2 to form source 52 and drain 54. The photoresist is ashed and silicon nitride cap 53 of 0.1 μm thickness is deposited by LPCVD. A rapid thermal anneal at 750° C. for 13 seconds with silicon nitride cap both activates the Si and Be implants and diffuses zinc out of gate cap 51 and through gate 50 to about Al x Ga 1-x As layer 36. The zinc diffusion converts gate 50 from n+ to p+. Note that the activation of the implants is not as time critical as the zinc diffusion, so the rapid thermal anneal time is selected to have the zinc diffusion stop just at the interface of layers 36 and 38. Zinc diffuses in GaAs interstitially and follows a D∝ N 2 law where D is the diffusion constant and N is the zinc concentration: the N 2 dependence arises from the charge state change of two in the dissociation reaction (zinc on a Ga site to zinc in an interstitial site). The D∝N 2 law implies the zinc diffuses in GaAs with a concentration profile that is roughly constant from the zinc source to an abrupt diffusion front: and the distance the front has progressed after a time t is proportional to √t. The roughly constant concentration is about 1×10 20 /cm 3 ; this is much greater than the Si concentration of 1×10 18 /cm 3 in layer 38 and easily converts it to p + . See FIG. 4D which illustrates the conversion of gate 50 to p+ and the extent of the Be implant by dashed lines; the peak of the implant is at depth of about 0.05 μm which coincides with the heterointerface of layers 34 and 36.
(e) The silicon nitride cap 53 is removed and device isolation is defined photolithographically and formed by boron implantation 60 which disrupts the crystal lattice and thereby raises the resistivity. Note that the boron does not penetrate gate cap 51 and is masked away from gate 40, so the boron does not affect the resistivity of gates 40 and 50. Then, metal contacts and interconnections are formed by photolithographic patterning, metal evaporation, and liftoff; ohmic contacts 46 and 48 to n regions are alloyed Ni/Ge/Au and ohmic contacts 56 and 58 to p regions are alloyed Au/Zn/Au. These steps are all low temperature procedures and do not cause further diffusion of the zinc in gate 50. See FIG. 3B for the completed pair 30 of complementary HFETs with their drains 44 and 54 connected. Passivation and interconnection insulation layers such as silicon nitride are not shown for clarity.
Note that if in step (d) the zinc diffusion front were about 0.05 μm short of reaching layer 36, then there would be a residual n - layer about 0.05 μm thick and abutting gate insulator Al x Ga 1-x As 36. This n + layer would not fully deplete (the Debye length is about 40 Å at this doping level, and the depletion layer is about ten Debye lengths thick at room temperature) and would cause enough band bending to decrease V Tp by about the bandgap of GaAs (roughly, V Tp decreases from about 0 V to about -1.4 V). In more detail and with an approximation of the zinc diffusion front as sharp and located 500 Å from the Al x Ga 1-x As, at the p + /n + interface the p + will be depleted to a depth of 4 Å and the n + to a depth of 400 Å, and at the n + /p - interface the n + will be depleted to a depth of 4 Å and the p - to a depth of 4 μm (the thickness of the Al x Ga 1-x As is negligible compared to the depletion depth in the undoped GaAs and has been ignored). Thus the effect of the zinc diffusion front being short of the Al x Ga 1-x As by at least 400 Å is to have a threshold voltage for the p-channel as if there were an n + GaAs gate. Similarly, if the zinc diffusion front extended into Al x Ga 1-x As layer 136, then V Tp would be increased and a depletion-mode device may result. Of course, the valence band discontinuity at the heterointerface is much less than the bandgap of GaAs (it is about 0.3 eV for Al x Ga 1-x As with x=0.3), so V Tp will not increase beyond about +0.3 V. The zinc diffusion front must be controlled to within less than 50 Å, which is about 1% of the total diffusion distance. Note that the rapid thermal anneal to diffuse the zinc may be carried out in more than one step at more than one temperature. For example, an initial diffusion for 12 seconds at 750° C. can be performed and the resulting threshold voltages probed; then a short secondary diffusion at 675° C. can bring the threshold voltage to the desired level.
Use of a thinner GaAs layer to form gates 40 and 50 permits more accurate control of the zinc diffusion, and the resistivity of the gates can be kept low by WSi caps. In particular, if layer 38 were only 0.1 μm thick and if the photoresist in step (b) were used instead to liftoff a gate cap that defined gate 40, then the zinc diffusion of step (d) controlled to within 1% would give a ±10 Å location of the zinc front.
A second preferred embodiment HFET, generally denoted 130, is schematically shown in cross sectional elevation view in FIG. 5, and includes semi-insulating GaAs 132; GaAs buffer layer 134 of thickness 1 μm and of various dopings: n+ in regions 142 and 144, p in the portion of sublayer 135 not in regions 142 and 144, and undoped in the remainder; Al x Ga 1-x As with x=0.3 layer 136 of thickness 0.05 μm and of two dopings: n+ in regions 142 and 144 and undoped in the remainder; n+ GaAs layer 138 of thickness 0.5 μm which has been etched away to form gate 140: and ohmic contacts 146 and 148. Proton bombardment in regions 160 of layers 134 and 136 convert them to high resistivity for isolation.
As with HFETs 30, the portion of n - GaAs layer 138 between self-aligned regions 142 and 144 forms gate 140 of HFET 130 and has length 1.0 μm. Regions 142 and 144 form the source and drain of HFET 130, and the undoped portion of layer 136 beneath gate 140 forms the gate insulator. The conduction channel is a two-dimensional electron gas formed in layer 134 at the heterojunction with layer 136 and between regions 142 and 144; the p doped sublayer 135 increases the threshold voltage of HFET 130 as follows: ##EQU2## where w' is the thickness of sublayer 135 and N A is the acceptor concentration in sublayer 135. Thus with w'=500 Å and N A =5.5×10 17 /cm 3 , ΔV T =0.1 V. Of course, sublayer 135 must be within the depletion region of layer 134 to affect the threshold voltage, but with a residual doping of less than 10 15 /cm 3 for the nominally undoped layer 134, this means that sublayer 135 could be in the order of 1.000 Å from the heterojunction. Also, the depletion of sublayer 135 prevents the sublayer from forming a short circuit from source to drain even if the sublayer were n doped (to lower the threshold). Sublayer 135 should not be closer than about 100 Å to the two-dimensional electron gas to avoid scattering of electrons in the gas. Doping sublayer 135 to N A =5.5×10 17 /cm 3 during an MBE or MOCVD growth of layer 134 is routine. See FIG. 6 for a schematic band diagram for HFET 130 along line 6--6 of FIG. 5. The portions of the bands corresponding to the various layers of HFET 130 are referenced along the horizontal axis with the corresponding layer reference numeral: note that the change in curvature of the bands due to sublayer 135 is difficult perceive in FIG. 6.
HFET 130 can be fabricated with the method of fabrication of HFETs 30 with the extra step of providing dopant during a portion of the growth of the GaAs buffer layer.
The pulse doping to adjust threshold voltage is also useful for Schottky barrier gate HFET, although a threshold change of perhaps 0.4 V may be needed which would be a 1.000 Å thick sublayer in the above example.
For complementary HFETs a p-doped sublayer in the GaAs layer will algebraically increase the threshold voltages for both the n-channel and p-channel HFETs (and an n-doped sublayer will decrease both), so with mixed gate material the p-doped sublayer may bring both threshold voltages to desired levels. For example, with an n + GaAs gate for an n-channel HFET and a WSi gate for a p-channel HFET, the threshold voltages would be about V Tn =0 V and V Tp =-0.7 V; and with sufficient p doping to lift the thresholds about 0.35 V, the thresholds would be about V Tn =+0.35 V and V Tp =-0.35 V. A further example: if the diffusion of zinc in step (d) for pair 30 does not reach the heterointerface and makes V Tp about -0.5 V, then a p pulse doping to raise thresholds by about 0.25 V will bring the thresholds up to ideal: +0.25 V for n-channel and -0.25 V for p-channel.
If in pair 30 the gates 40 and 50 were made of Al x Ga 1-x As with x=0.1, then V Tn would become negative, V Tp positive, and the HFETs would be depletion mode devices. Conversely, if in pair 30 the buffer layer 34 were Al x Ga 1-x As with x=0.1, then V Tn would be about +0.1 V and V Tp would about -0.1 V.
MODIFICATIONS AND ADVANTAGES
Various modifications of the preferred embodiment devices and methods may be made while retaining the threshold adjustment features of a pulse doped layer near a two-dimensional gas channel and of a conductivity type-changing diffusion forming a gate from a common layer of material forming the other conductivity type gates in a complementary device arrangement. Some examples: the dimensions and shapes of the devices could be varied such as the source and drain of each HFET forming an interdigited pattern with portions connected by air bridges and with gate widths of thousands of microns: the materials could be varied such as the substrate being epitaxial GaAs grown on silicon or such as other III-V or II-VI compounds (binary, ternary, or quarternary) grown on strained layer superlattices or germanium on silicon: the dopant rapidly diffusing out of the capping layer could be magnesium diffusing out of a mixture of MgO (20% by weight) and silicon dioxide which is deposited by sputtering: circuits of various complexity can be monolithically integrated using HFETs with the pulse doping or conductivity type-changing diffusion: the pulse doping can be of differing dopants in multiple sublayers: and the gate caps could be metals such as molybdenum, tungsten, and titanium or alloys of silicides.
The advantages of the threshold adjustments of the present invention include the control and reproducibility of pulse doping during growth of epilayers and the simplicity of gate conductivity-type conversion for complementary devices so both type gates can be formed from a common layer. | Complementary heterostructure field effect transistors (30) with complementary devices having complementary gates (40, 50) and threshold adjusting dopings are disclosed. Preferred embodiment devices include a p + gate (50) formed by diffusion of dopants to convert n + gate material to p + , and a pulse-doped layer adjacent the two-dimensional carrier gas channels to adjust threshold voltages. Further preferred embodiments have the conductivity-type converted gate (50) containing a residual layer of unconverted n + which cooperates with the pulse-doped layer threshold shifting to yield threshold voltages which are small and positive for n-channel and small and negative for p-channel devices. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is based upon pending U.S. Provisional Application, Ser. No. 61/237,604 filed Aug. 27, 2009, and entitled “System And Method For Dispensing Items In An Automated Retail Store Or Other Self-Service System (Including Vending And Self-Service Check-Out Or Kiosk Platforms)”: by co-inventors Darrell Scott Mockus, Mara Segal and Russell Greenberg, and priority based on said application is claimed.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to automated and modularized vending machines that can be custom deployed in diverse configurations. More specifically, the present invention relates to automated vending systems utilizing a common, robotic dispensing module and associated modules that can be assembled and configured to create diverse vending arrangements, with components linked together via a virtual integrated network.
2. Description of the Related Art
Numerous prior art vending machines exist for selling or vending diverse products through an automated, or ‘self-service’ format. Vending reached popularity in the late 1800's with coin-operated devices dispensing diverse merchandise. More recently vending machines have evolved to include robotic dispensing components, and/or PCs and virtual interfaces. These new vending platforms have emerged in the marketplace under the popular descriptions “automated retail,” “interactive retail,” and/or “interactive retail displays.” Such vending machines may be deployed within a variety of commercial or public settings. They typically include illuminated displays that seek to showcase merchandise and offer convenient purchasing.
In the vending arts, machines historically have a similar design and orientation that make them unable to easily change machine sizes and configurations, inventory storage sizes and product form factors without rebuilding or redesigning the machine. Typically machines are “one size fits all”. There are some models of traditional vending machines that allow additional inventory areas to be added on, but these models do not utilize a robotic dispensing unit to move the product from the shelf to the collection area and rely on gravity (drop) systems. Because of the expense of robotic delivery systems and the configuration of these systems, these machines have been constrained to serving one user at a time through one side of the machine. In addition the machines come in a single size format and two machines have to be stacked adjacently to expand site capacity. In more modern robotic machines, the size of the machines tends to be larger than traditional vending and units cannot be reduced based on the robotic architecture and production of the machine. In all of these machines, the robotic dispensing system is built as a continuation of the inventory system and cannot be easily separated.
This invention introduces an isolated and centralized robotic dispensing system that can support multiple inventory areas and technologies within those areas. The system provides a single collection area (central column) that can be used with a number of different typed and sized inventory areas, solo or in any combination. With its orientation and modular design, it can be easily configured to vend out of multiple sides of the machine allowing more than one person to simultaneously conduct transactions within the same machine, or to contract into a half-sized machine (one inventory wing vs. two) Its design also allows for display components to be separately operating as independent merchandising displays that can be placed in a field apart from the centralized dispensing totem and connect to this totem via wireless connectivity, increasing merchandising capability.
There is great value in having a centralized and isolated universal system for collecting and dispensing items. Various inventory areas can be used with the same dispensing system allowing a great deal of flexibility in how the machine is configured. A machine can be composed of inventory elements, display units and a central dispensing area “strung together” enabling the machine footprint to grow/contract depending on environmental constraints. Inventory solutions can be updated and reconfigured to work with the central dispensing mechanism without significant customization of the dispensing mechanism, allowing for rapid accommodation of new types and amounts of merchandise for purchase or promotion.
This central dispensing system design allows greater reliability of dispensing by providing a uniform broader surface area (landing pad) for products to dispense. It also reduces axes of motion by 1 (e.g. X, Y, and Z reduces to Y and Z motion) by eliminating excess movement through inefficient placement of inventory and robotic components. Elimination of excess movement reduces potential points of failure and additional calibration and programming, along with increasing power efficiency and delivery speed. This design also affords the ability to dispense out of multiple sides of the machine allowing more than one user to use the machine at the same time.
It is thus desirable to provide a method and system that centralizes the robotic dispensing components into a separate area that can be combined with various numbers and sizes of inventory areas and various display doors to dynamically create a vending unit or automated retail store.
BRIEF SUMMARY OF THE INVENTION
The invention comprises apparatus design and a method to construct a vending machine or automated retail store where the robotic dispensing unit is separated in a componentized unit that can attach to any number of differently sized areas containing inventory and various display units. The invention consists of a series of physical merchandise displays, promotional/digital signage, automated mechanical/dispensing, and/or transactional modules that can be assembled and configured to create an automated retail store, vending unit, or interactive retail display of any size and link together via a virtual integrated network. The invention allows for a highly customizable vending machine of different sizes and configurations all utilizing a common robotic dispensing module.
In accordance with one aspect of the invention, there is a robotic elevator operated by one or more motors that delivers a landing platform to meet items that are located in various inventories at a close height proximity that prevents items from being damaged as they are dispensed from their holding area onto the platform.
In accordance with another aspect of the invention, the platform consists of a conveyor that rotates in either direction to move the collected item to a designated user collection area.
In accordance with another aspect of the invention, the conveyor delivers the item into a secure designated collection area that consists of a space to receive the dispensed items and a way to close off or secure the internal dispensing mechanism to prevent tampering by a user, or injury to the user.
In accordance with another aspect of the invention, the inventory areas are attached to the centralized robotic dispensing mechanism. These inventory areas can vary in size to accommodate different product mixes but attach to the central robotic dispensing system in the same manner.
In accordance with another aspect of the invention, the display areas can vary in size and appearance to fit the products or items being merchandised.
This system and design improves the efficiency of dispensing items by allowing one or more inventory areas of various sizes to be attached to a centrally located and common robotic collection and dispensing system. Because of this design, there is no need for redundancy of expensive robotic components when increasing the inventory size. By isolating the inventory retrieval and dispensing mechanism from the inventory storage area, a multitude of different inventory areas can be attached without the need to redesign this subcomponent when altering machine size or configuration. These inventory areas can employ various mechanisms that feed into the dispensing mechanism. These inventory areas can also be of various sizes accommodating a wide range of items in quantity and size.
This invention also provides a common robotic dispensing system to service more than one user in parallel. By providing an isolated and centrally located mechanism, multiple users can engage with a system simultaneously and purchased items are queued based on time of transaction and dispensed accordingly. This provides a great advantage by removing the constraint of one user at a machine at one time. This is a pronounced advantage in crowded or popular venues, where queues may form in front of machines. The dual-sided machine allows for almost double the users to be serviced in the same amount of time by providing two portals for transaction and product dispensing within a single machine platform. It also enables greater flexibility in merchandising/designing the machine in that each side of the machine can take on a different look/feel, but be accessed by the same robotic mechanism. This invention enables separation of the purchasing/transactional components of the vending platform with the dispensing components, allowing inventory and completion of the process to occur in a different location from the selection of merchandise and payment transaction. One such scenario is that a physical space is inhabited by a central dispensing mechanism that attaches to adjacent inventory dispensing towers and users are able to retrieve their purchases out of multiple sides of this mechanism after completing the transaction at screens set up within this location or located remotely.
This new centralized robotic vending method increases the flexibility in dispensing capability in product size, shape, and orientation. In addition, it decreases the axes of motion and potential points of error by creating a more efficient process of dispense and mechanism. As a result, the machine's size, capacity and shape can change without duplication of the expensive robotic components. This design also allows multiple users to simultaneously purchase items in the machine at two different parallel locations at the machine, while utilizing the same robotic dispensing mechanism. This doubles the service capacity of the machine. This also establishes a modular machine assembly convention whereby the robotic dispensing mechanisms are housed in one distinct section of the machine (the totem) and the inventory sections are separate segments that can affixed to the totem to expand or contract the machine depending on space and business considerations, without necessitating redesign of the machine's hardware or software.
Objects of the present inventions are to provide a product vending machine, automated retail machine, or self-service machine where items are stored inside a secure area and delivered to a user upon a successful transaction in an automated manner.
A basic object is to provide an improved design for product dispensing that cost effectively increases versatility, efficiency, and reliability of the system. This includes, improved product containment systems to increase product storage capacity, ease and efficiency of product handling, dispensing, structural integrity, modularity, customization, shipping/assembly, access and loading of the machine.
Another basic object of the invention is to provide a more effective and flexible vending machine design that can be adapted for its deployment environment by reusing a common dispensing component.
The preferred invention provides a system and method to efficiently configure and deploy a vending system that accomplishes the following:
a) To provide a system design that can efficiently and effectively dispense a wide range of items (various sizes, shapes and types) in an automated (self-service) platform. b) To optimize the inventory storage space inside of an automated retail machine, vending machine or other type of self-service machine. c) To optimize the configuration of the machine into one of several formats including half-size (single inventory tower+totem), dual-sided dispensing (two sides of the machine activated to dispense) and isolated display+totem (spreading merchandising components away from the storage and mechanical dispensing of the machine. d) To minimize the floor space required (e.g. footprint) of an automated dispensing system while maximizing the amount of inventory that can be stored and dispensed. e) To provide a design for a single robotic dispensing system to support multiple iterations of inventory/storage systems in a flexible and easily configurable/alterable manner. f) To provide a design for a single robotic dispensing system to support one or more inventory areas that can “plug into” or be built onto a secondary dispensing system. g) To provide a design for a single robotic dispensing system that can support multiple configurations (size, shape, etc.) in an automated retail, vending or self-service system based on optimizing the machine for the venue, or merchandising program. h) To provide a design for a single robotic system/machine platform to vend items out of multiple sides of a machine enabling more than one user to use the machine simultaneously. i) To build a system that can efficiently and effectively allow more than one user to use a single automated retail store machine (or vending machine or self service machine) concurrently. j) To provide a cost-effective system design that increases the efficiency of product delivery by opening multiple transaction portals in a machine that utilizes the same centralized mechanism. k) To provide a system where a common robotic dispensing system can support multiple users in an automated retail store, or vending machine, or self-service machine. l) To provide a system that isolates a robotic dispensing mechanism from the rest of an automated retail, vending or self-service machine so it can be used with a variety of inventory configurations. m) To design a system that identifies inventory mechanisms and dispensing mechanisms as independent “building blocks” that can be linked together in multiple configurations to efficiently increase size and/or accessibility to a self-service, vending, and/or automated retail platform. n) To design a system that allows for a larger envelope of products to dispense in the same area, by increasing the surface area for products to dispense and decreasing physical barriers (probable jam locations) within the dispensing mechanism. o) To design a system that reduces the number of potential moves or axes of motion (e.g. reduces robotic movement to Y and Z vs. X, Y and Z motion) that a product and or robot need to make in order to dispense an object in a self-service, vending, and/or automated retail platform utilizing robotic technology. p) To design a system that reduces the distance of robotic movement needed to dispense an object in a self-service, vending, and/or automated retail platform utilizing robotic technology. q) To design a system that utilizes inventory “zones” where multiple inventory technologies can be leveraged to dispense an item to a central robotic dispensing mechanism. r) To design a central dispensing mechanism that perceptually distances automated retail and self-service from existing vending technologies. s) To design an independent dispensing mechanism that is contained in a smaller area of a machine in order to independently ship and assemble the inventory and robotic/dispensing components of a system for greater efficiency in deployment. t) To design a centralized dispensing mechanism that is less subject to the forces of torque/structure across a machine by consolidation of mechanism in a “central core”. u) To eliminate one axis of movement in a robotic dispensing mechanism in an automated retail/self-service machine. v) To design a centralized dispensing mechanism in order to enable peripheral merchandising capabilities (displaying merchandise on both sides of a customer) when they are shopping at an automated retail machine's touch screen, or transaction portal. w) To design a vending, or automated retail machine that allows co-branding (2 distinct branded wings/sides and 2 distinct branded faces—two fronts) to exist within the same machine as created by a modularized store (delineation of display) and dual-sided dispensing capability driven by a centralized robotic design.
These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:
FIG. 1A is an isometric assembly view of a preferred robotic gantry module used with the vending machines of the invention, with portions thereof omitted for clarity and brevity;
FIG. 1B is a fragmentary isometric view that enlarges the bottom portion of FIG. 1A ;
FIG. 1C is a longitudinal sectional view of the preferred robotic gantry module used with the vending machines of the invention showing components hidden in FIG. 1A ;
FIG. 1D is a fragmentary sectional view that enlarges the bottom portion of FIG. 1C ;
FIG. 1E is a fragmentary, bottom isometric view of robotic gantry module, with portions thereof broken away for clarity, showing the components of FIG. 1D ;
FIG. 2A is front elevational view of a modular vending machine assembly with a two connected inventory modules;
FIG. 2B is a top view of a vending machine assembly illustrating the connection of the various components.
FIG. 3 is a generalized block diagram of the preferred software of the system;
FIG. 4 is a diagrammatic view showing the preferred interconnection of the system computer and communication hardware;
FIG. 5 is a block diagram of the preferred electrical power supply arrangement;
FIG. 6 is a software block diagram of the preferred machine runtime initialization process;
FIG. 7 is a software block diagram of the preferred machine runtime dispensing process;
FIG. 8 is an isometric view of an assembled vending machine module with two attached inventory components and an alternative display door design;
FIG. 9 is an isometric view of an assembled vending machine module configured for dual sided vending with two inventory cabinets;
FIG. 10 is an isometric view of an assembled vending machine module with one attached inventory component; and;
FIG. 11 is an isometric view of an assembled vending machine module configured for dual sided vending with one common inventory cabinet.
DETAILED DESCRIPTION OF THE INVENTION
For purposes of disclosure, the three following co-pending U.S. utility applications, which are owned by the same assignee as in this case, are hereby incorporated by references, as if fully set forth herein:
(a) Pending U.S. utility application Ser. No. 12/589,277, entitled “Interactive and 3-D Multi-Sensor Touch Selection Interface For an Automated Retail Store, Vending Machine, Digital Sign, or Retail Display,” filed Oct. 21, 2009, by coinventors Mara Segal, Darrell Mockus, and Russell Greenberg, that was based upon a prior pending U.S. Provisional Application, Ser. No. 61/107,829, filed Oct. 23, 2008, and entitled “Interactive and 3-D Multi-Sensor Touch Selection Interface for an Automated Retail Store, Vending Machine, Digital Sign, or Retail Display”;
(b) Pending U.S. utility application Ser. No. 12/589,164, entitled “Vending Machines With Lighting Interactivity And Item-Based Lighting Systems For Retail Display And Automated Retail Stores,” filed Oct. 19, 2009 by coinventors Mara Segal, Darrell Mockus, and Russell Greenberg, that was based upon a prior pending U.S. Provisional Application, Ser. No. 61/106,952, filed Oct. 20, 2008, and entitled “Lighting Interactivity And Item-Based Lighting Systems In Retail Display, Automated Retail Stores And Vending Machines,” by the same coinventors; and,
(c) Pending U.S. utility application Ser. No. 12/798,803, entitled “Customer Retention System and Process in a Vending Unit, Retail Display or Automated Retail Store” filed Apr. 12, 2010, by coinventors Mara Segal, Darrell Mockus, and Russell Greenberg, that was based upon a prior pending U.S. Provisional Application, Ser. No. 61/168,838 filed Apr. 13, 2009, and entitled “Customer Retention System And Automated Retail Store (Kiosk, Vending Unit, Automated Retail Display And Point-Of-Sale)”, by coinventors Darrell Scott Mockus, Mara Segal and Russell Greenberg.
With initial reference directed to FIGS. 1A-1E of the appended drawings, a robotized gantry 100 is adapted to be integrated into a multiple-module vending machine or automated retail store. Gantry 100 comprises a rigid, upright frame consisting of an upper square portion 101 , supported by vertical upright C-Channel support beams 102 attached to a gantry base 110 . An internal elevator comprises a transverse conveyor 105 resting upon an elevator conveyor tray 107 within the gantry 100 . Conveyor 105 comprises a flexible sheet looped and entrained about a pair of spaced apart rollers 105 B that are journalled in the frame at 120 ( FIG. 1D ). The elevator is supported by two brackets 109 disposed on opposite ends of conveyor tray 107 . The elevator, and thus conveyor 105 and tray 107 can be raised or lowered using pulleys 103 ( FIG. 1A ) that are attached atop the vertical support beams 102 and which entrain 9 mm wide and 3605 mm long belts 104 .
Preferably conveyor tray 107 has a pair of retractable, product collection wings 106 that open in response to wing hinge assembly 108 when the elevator is in place to collect items that are dispensed from inventory area(s) in modules placed on either side of the dispensing gantry 100 . Wings 106 span the distance between the conveyor and the inventory shelves caused by the necessary existence of the frame structure to support the conveyor elevator.
FIGS. 1C and 1D clarify how gantry components are driven. The conveyor belt 105 is driven by a conveyor stepper motor 111 that uses a 9 mm. wide belt 121 ( FIG. 1E ) to power a drive pulley connected to a roller bar 112 and feeds the conveyor belt around the conveyor rollers 105 B that are journalled at 120 . The flexible conveyor fabric is wrapped around the conveyor drive roller 112 and the rollers 105 B.
The generally rectangular product collection wings 106 are disposed on either side of the conveyor 105 to direct selected products upon the conveyor to deliver a vend. The retractable wings 106 are actuated by the wing motor 113 ( 514 FIG. 5 ) connected to the wing hinge assembly 108 ( FIG. 1A ) which comprises a wing drive shaft 114 that distributes power from the motor to a series of levers 115 that are connected to hinges 116 secured to the product collection wings 106 . As the motor turns from the closed position, the support levers 115 are pulled downwardly, causing the upper portion of the levers 115 to slide within stabilizer follower slots ( FIG. 1B ) in hinges 116 . This opens the collection wings 106 to a predetermined width that allows the conveyor 105 to collect products from inventory areas attached to either side of the central gantry dispensing assembly 100 . The motor can be reversed to close the product collection wings.
The elevator motor 117 ( 507 FIG. 5 ) is connected to a pulley wheel and uses a 9 mm. wide belt to drive the elevator drive shaft 118 turning two pulleys 119 mounted on either side of the subassembly that drives the elevator belt 104 which loops around the top pulleys 103 thereby raising or lowering the elevator. After a product is collected from the inventory shelf, the elevator is aligned with the collection area compartment behind the collection area opening 204 ( FIG. 2A ) in the totem door 211 ( FIG. 2A ). FIG. 1E provides additional reference for FIGS. 1A through 1D . In this view, the belt 121 that drives the roller bar 112 that moves the conveyor 105 can be seen.
With additional reference directed to FIGS. 2A and 2B , a vending machine constructed in accordance with the best mode of the invention has been generally designated by the reference numeral 200 ( FIG. 2A ). Much of the hardware details are explained in the aforementioned pending applications that have been incorporated by reference herein. Display module 210 can be attached with a hinge to an inventory area covered by control panel 211 , comprised of a rigid upright cabinet, or the module 210 can be mounted to a solid structure as a stand-alone retail display. The display module 210 forms a door hinged to an adjacent cabinet such as an inventory cabinet 212 A adjacent gantry 100 which is covered by control column 211 .
A variety of door configurations known in the art can be employed. For example, the display doors can be smaller or larger, and they can be located on one or both sides of the control column 211 . The display doors can have multiple square, oval, circular, diamond-shaped, rectangular or any other geometrically shaped windows. Alternatively, the display area can have one large display window with shelves inside.
A customizable, lighted logo area 201 ( FIG. 2A ) is disposed at the top of column 211 . Touch screen display 202 is located below area 201 . Panel 203 locates the machine payment system, coin acceptor machine or the like. Additionally panel 203 can secure a receipt printer, keypad, headphone jack, fingerprint scanner or other access device. The product retrieval area 204 is disposed beneath the console 211 in a conventional collection area compartment (not shown). A key lock 205 , which can be mechanical or electrical such as a punch-key lock, is disposed beneath the face of the module 210 . One or more motion sensors 214 are disposed within smaller display tubes within the console interior. A plurality of generally circular product viewing areas 207 and a plurality of generally diamond shaped viewing areas 206 are defined upon the outer the face of the casing 208 that are aligned with internal display tubes behind the product viewing surface areas, though the shape of the viewing areas may alter with various merchandising concepts. However, the convention of framing merchandising offerings is consistent to enable intuitive interfacing whether a physical or virtual representation of the merchandise display. The reference numeral 209 designates an exterior antenna that connects to a wireless modem inside the machine providing connectivity. 213 shows inventory shelves which may be mounted in the inventory cabinet 212 . These inventory shelves may contain any mechanism such as conveyors or spiral vending systems as long as they can push a product off the edge of the inventory tray.
Speakers 215 are mounted in the column 211 . A camera 216 capable of capturing video and still images is also mounted in the column 211 . The machine components are set on casters 217 with feet that can be retracted for moving or lowered to position a machine in a deployed location.
FIG. 2B shows a standard configuration of the assembly. The robotized modular gantry 100 is shown connected to an inventory cabinet 212 A by bolting the upright C-Channel structures 102 of the modular gantry 100 to upright C-Channel beams 219 which are then affixed to the upright C-Channel structures 220 of the inventory cabinet using additional bolts. Power and controls are routed to the modular gantry via a wiring harness (not depicted) located on the bottom of the modular gantry. The CPU and power supplies (detailed in FIGS. 4 and 5 ) are located in the bottom of the main inventory cabinet that is attached to a modular gantry. A second inventory cabinet 212 B can also be attached to the other side of the robotized modular gantry 100 using the same method of bolting the upright supports of the inventory cabinets 220 and the upright supports of the gantry 102 to a common upright C-Channel support 219 .
Display doors 210 can be attached to the inventory cabinets via a piano hinge 218 running the full height of the door. The necessary electrical and control wiring connects via a wiring harness 221 located on the interior of the inventory cabinet near the hinge connection. These piano style hinges are located on the exterior corners of the inventory cabinets. They are covered with simple metal paneling if they are not in use. The totem doors 211 are attached in a similar manner using a piano hinge 218 . The necessary electrical and control wiring connect to a wiring harness located in the interior of the totem door (wiring harness not depicted).
With primary reference directed to FIG. 3 , a system consisting of a plurality of automated retail machines connected via a data connection to a centralized, backend operations center system has been designated by the reference numeral 300 . At least one automated retail machine 301 is deployed in a physical environment accessible by a consumer who can interact with the machine 301 directly. There can be any number of machines 301 , all connected to a single, remote logical operations center 330 via the Internet 320 (or a private network). The operations center 330 can physically reside in a number of locations to meet redundancy and scaling requirements.
The machine software is composed of a number of segments that all work in concert to provide an integrated system. Logical area 302 provides the interface to deal with all of the machine's peripherals such as sensors, keypads, printers and touch screen. Area 303 handles the monitoring of the machine and the notifications the machine provides to administrative users when their attention is required. Area 304 controls the reporting and logging on the machine. All events on the machine are logged and recorded so they can be analyzed later for marketing, sales and troubleshooting analysis. Logical area 305 is responsible for handling the machine's lighting controls.
Logical area 306 is the Inventory Management application. It allows administrative users on location to manage the inventory. This includes restocking the machine with replacement merchandise and changing the merchandise that is sold inside the machine. Administrative users can set the location of stored merchandise and the quantity.
Logical area 307 is the retail store application. It is the primary area that consumers use to interface with the system. Logical area 308 handles the controls required to physically dispense items that are purchased on the machine or physically dispense samples that are requested by a consumer. This area reads the data files that tell the machine how many and what types of inventory systems are connected to the machine. Logical area 309 controls the inventory management system allowing authorized administrative users to configure and manage the physical inventory in the machine. Area 310 controls the payment processing on the machine. It manages the communication from the machine to external systems that authorize and process payments made on the machine. Area 311 is an administrative system that allows an authorized user to manage the content on the machine. This logical area handles the virtual administrative user interface described previously. The content can consist of text, images, video and any configuration files that determine the user's interaction with the machine.
The latter applications interface with the system through an application layer designated in FIG. 3 by the reference numeral 312 . This application layer 312 handles the communication between all of these routines and the computer's operating system 313 . Layer 312 provides security and lower level messaging capabilities. It also provides stability in monitoring the processes, ensuring they are active and properly functioning. Logical area 331 is the user database repository that resides in the operations center 330 . This repository is responsible for storing all of the registered user data that is described in the following figures. It is logically a single repository but physically can represent numerous hardware machines that run an integrated database. The campaign and promotions database and repository 332 stores all of the sales, promotions, specials, campaigns and deals that are executed on the system. Both of these databases directly interface with the real-time management system 333 that handles real-time requests described in later figures. Logical area 334 aggregates data across all of the databases and data repositories to perform inventory and sales reporting. The marketing management system 335 is used by administrative marketing personnel to manage the marketing messaging that occurs on the system; messages are deployed either to machines or to any e-commerce or digital portals. Logical area 336 monitors the deployed machines described in FIG. 2 , and provides the tools to observe current status, troubleshoot errors and make remote fixes. Logical area 337 represents the general user interface portion of the system. This area has web tools that allow users to manage their profiles and purchase products, items and services. The content repository database 338 contains all of the content displayed on the machines and in the web portal. Logical area 339 is an aggregate of current and historical sales and usage databases comprised of the logs and reports produced by all of the machines in the field and the web portals.
FIGS. 4 and 5 illustrate system wiring to interconnect with a computer 450 such as Advantech's computer engine with a 3 Ghz CPU, 1 GB of RAM memory, 320 GB 7200 RPM hard disk drive, twelve USB ports, at least one Serial port, and an audio output and microphone input. The computer 450 ( FIGS. 4 , 5 ) communicates to the lighting system network controller via line 479 . Through these connections, the lighting system is integrated to the rest of system. Power is supplied through a plug 452 that powers an outlet 453 , which in turn powers a UPS 454 such as TripLite's UPS (900 W, 15VA) (part number Smart1500LCD) that conditions source power, which is applied to input 455 via line 456 . Power is available to accessories through outlet 453 and UPS 454 .
Computer 450 ( FIG. 4 ) is interconnected with a conventional payment reader 458 via cabling 459 . A pin pad 485 such as Sagem Denmark INT1315-4240 is connected to the CPU 450 via a USB cable. An optional web-accessing camera 461 such as a LOGITECH webcam (part number 961398-0403) connects to computer 450 via cabling 462 . Audio is provided by transducers 464 such as Happ Controls four-inch speakers (part number 49-0228-00R) driven by audio amplifier 465 such a Happ Controls Kiosk 2-Channel Amplifier with enclosure (part number 49-5140-100) with approximately 8 Watts RMS per channel at 10% THD with an audio input though a 3.5 mm. stereo jack connected to computer 450 . A receipt printer 466 such as Epson's EU-T300 Thermal Printer connects to the computer 450 via cabling 467 . The printer is powered by a low voltage power supply such as Epson's 24VDC power supply (part number PS-180). A remote connection with the computer 450 is enabled by a cellular link 470 such as Multitech's Verizon CDMA cellular modem (part number MTCBA-C-IP-N3-NAM) powered by low voltage power supply 472 . The cellular link 470 is connected to an exterior antenna 209 . A touch enabled liquid crystal display 474 such as a Ceronix 22″ Widescreen (16:10) Touch Monitor for computer operation also connects to computer 450 . A Bluetooth adapter 487 such as D-Link's DBT-120 Wireless Bluetooth 2.0 USB Adapter is attached to the CPU allowing it to send and receive Bluetooth communication. A wireless router 488 such as Cisco-Linksys' WRT610N Simultaneous Dual-N Band Wireless Router is connected to the CPU to allow users to connect to the machine via a private network created by the router.
Digital connections are seen on the right of FIG. 4 . Gantry-Y (conveyor elevator), stepper motor controller such as the Arcus Advanced Motion Driver+Controller USB/RS485 (part number Arcus ACE-SDE) connection is designated by the reference numerals 476 . 477 connects to the conveyor motor controller which can also be something similar to an Arcus Advanced Motion Driver+Controller USB/RS485 (part number Arcus ACE-SDE). Dispenser control output is designated by the reference numeral 478 which operates the product collection wings motor 113 ( FIG. 1B ). The LED lighting control signals communicate through USB cabling to a DMX controller 479 that transmits digital lighting control signals in the RS-485 protocol to the display tube lighting circuit board arrays. An ENTTEC-brand, model DMX USB Pro 512 I/F controller is suitable. Cabling 480 leads to vending control. One or more inventory systems can be connected to the vending control depending on the configuration. Dispenser door control is effectuated via cabling 481 . Façade touch sensor inputs arrive through interconnection 482 . Motion sensor inputs from a motion sensor such as Digi's Watchport/D (part number Watchport/D 301-1146-01) are received through connection 483 . A USB connection connects the product weight sensor 484 such as Sartorius (part number FF03 VF3959) that is located in the collection area to determine the presence of a dispensed item.
FIG. 5 illustrates a detailed power distribution arrangement 500 . Because of the various components needed, power has to be converted to different voltages and currents throughout the entire system. The system is wired so that it can run from standard 110 V.A.C. power used in North America. It can be converted to run from 220 V.A.C. for deployments where necessary. Power from line-in 455 supplied through plug 452 ( FIG. 4 ) powers a main junction box 453 with multiple outlets ( FIGS. 4 , 5 ) that powers UPS 454 which conditions source power, and outputs to computer 450 line 456 . Power is available to accessories through main junction box 453 and Ground-fault current interrupt AC line-in 455 . An additional AC outlet strip 501 such as Triplite's six position power strip (part number TLM606NC) powers LED lighting circuits 502 and a touch system 503 . Power is first converted to 5 volts to run the lighting board logic using a converter 540 . Another converter, 541 , converts the AC into 24 Volt power to run the lights and touch system.
An open frame power supply 505 ( FIG. 5 ) provides 24VDC, 6.3 A, at 150 watts. Power supply 505 powers Y-controller 506 such as the Arcus Advanced Motion Driver+Controller USB/RS485 (part number Arcus ACE-SDE), that connects to Y axis stepper motor 507 ( 117 FIGS. 1C & 1D ). A suitable stepper 507 can be a Moons-brand stepper motor (part number Moons P/N 24HS5403-01N). Power supply 505 also connects to a conveyor controller 508 , which can be an Arcus-brand Advanced Motion Driver+Controller USB/RS485 (part number Arcus ACE-SDE), that connects to a conveyor stepper 509 ( 111 in FIG. 1C & FIG. 1D ). A Moons-brand stepper motor (part number Moons P/N 24HS5403-01N) is suitable for stepper 509 .
Power supply 505 ( FIG. 5 ) also powers dispenser controller 510 , dispenser door control 511 , and vending controller 512 . Controller 510 powers collection wing motor 514 ( 113 FIGS. 1C & 1D ) and door motor 515 . Motors 514 and 515 can be Canon-brand DC gear motors (part number 05S026-DG16). Controller 512 operates conveyor motors 516 such as Micro-Drives DC Gear Motor (Part Number M32P0264YSGT4). The logo space 201 ( FIG. 2 ) is illuminated by lighting 518 ( FIG. 5 ) powered by supply 505 . Supply 505 also powers LCD touch screen block 520 ( FIG. 5 ) such as a Kristel 22″ Widescreen (16:10) LCD Touch Monitor with USB connection for the touch panel. UPS 454 ( FIG. 5 ) also powers an AC outlet strip 522 that in turn powers a receipt printer power supply 523 such as Epson's 24VDC power supply (part number PS-180) that energizes receipt printer 524 such as Epson's EU-T300 Thermal Printer, an audio power supply that powers audio amplifier 527 such a Happ Controls Kiosk 2-Channel Amplifier with enclosure (part number 49-5140-100), and a low voltage cell modem power supply 530 that runs cellular modem 531 such as Multitech's Verizon CDMA cellular modem (part number MTCBA-C-IP-N3-NAM). A proximity sensor 214 ( FIG. 2 ) such as a Digi Watchport/D part number 301-1146-01 is connected to the CPU 450 . 532 is a door sensor and actuator such as Hamlin's position and movement sensor (part 59125) and actuator (part 57125) which are connected to the CPU 450 .
Subroutine 600 ( FIG. 6 ) illustrates the preferred method of initializing the machine and inventory and dispensing system at system runtime. The process begins at step 601 when the system application is launched. Step 602 reads in and parses the lighting XML file 603 . The lighting file contains a sequence of lighting sequences to be performed for various user actions on the system such as selecting a product or category, adding to the virtual shopping bag and removing it from the shopping bag. These lighting sequences dictate both the onscreen coloring of products in the virtual display and the lighting of products in the physical display. These values are cached in local memory as an application variable. Step 604 checks if there are any fatal errors. Fatal errors are ones that prevent the system from allowing a user to complete a transaction. All errors are logged using the reporting and logging system 303 ( FIG. 3 ). Non-fatal errors are noted in the log file so they can be examined later to correct the issue. If the error is fatal, the process goes to step 605 where the user is notified of an error and given customer support information and an alert notification is sent out to the notification system 303 ( FIG. 3 ). The system is placed in an idle state where the touch screen will display a message noting that the machine is currently not in service. The system will attempt to recover in step 606 by attempting to start the application process again and reinitialize the system. If there are no fatal errors, the process continues to step 607 that reads in and parses the planogram file 608 . The planogram file contains the product identification number, or item identification number, a product name and a Boolean value if it is active or not for each display slot number. These values are cached in local memory as an application variable. Step 609 checks if there are any fatal errors. If there are fatal errors, it routes to step 605 , otherwise the process continues at step 610 . Step 610 reads in all of the inventory XML files. These files instruct the system on what inventory cabinets are attached to the machine and what inventory is in what inventory slots. Each inventory slot is designated by the cabinet it is located in, the shelf it is on, the size of the inventory slot and the motors that drive the dispensing mechanism. Using this information, the application can determine the shelf location (height). The XML file information is cached and then accessed during product dispensing to guide the robotic gantry elevator to the correct shelf height to collect a product.
The dispensing motor information is used by the dispenser control to turn on the motor that dispenses the product until a mechanical switch is activated determining the product has been dispensed to the gantry elevator. Because of the centralized layout of the robotic gantry, it does not matter which inventory system is connected or even what side from which the product is being dispensed. It only matters what shelf the product is on so the elevator can move to the correct height to collect the product. Step 610 reads in all of the screen templates 611 that determine the layout of the visual selection interface. Step 612 checks if there are any fatal errors. If there are fatal errors, it routes to step 605 , otherwise the process continues at step 613 . Step 613 reads in all of the screen templates 611 that determine the layout of the user interface and all of the screen asset files 614 associated with the screen templates 611 .
These asset files can be images or extended markup files that represent buttons, header banners graphics that fit into header areas, directions or instructions that are displayed in designated areas, image map files that determine which area on an image corresponds represents which area on the physical facade or images representing the physical façade. These assets are cached into local memory in the application. Step 615 checks if there are any fatal errors. If there are fatal errors, it routes to step 605 , otherwise the process continues at step 616 . Step 616 reads and parses the product catalog files 617 . The product catalog stores all of information, graphics, specifications, prices and rich media elements (e.g. video, audio, etc.) for each item or product in the system. Each element is organized according to its identification number. These elements can be stored in a database or organized in a file folder system. These items are cached in application memory. Step 618 checks if there are any fatal errors. If there are fatal errors, it routes to step 605 , otherwise the process continues at step 619 . Step 619 reads in all of the system audio files 620 and the file that the stores the actions with which each audio file is associated. Audio files can be of any format, compressed or uncompressed such as WAV, AIFF, MPEG, etc. An XML file stores the name of the application event and the sound file name and location. Step 621 checks if there are any fatal errors. If there are fatal errors, it routes to step 905 , otherwise the process continues at step 622 . Step 622 does a system wide hardware check by communicating with the system peripherals and controllers 302 and 308 ( FIG. 3 ). Step 623 checks if there are any fatal errors. If there are fatal errors, it routes to step 605 , otherwise the process continues at step 624 . Step 624 launches the application display on the touch screen interface. The system then waits for user input 625 .
Subroutine 700 ( FIG. 7 ) illustrates the preferred runtime method the machine uses to dispense items to an end user during a user session. The process begins at step 701 after a user completed a transaction that purchases the merchandise about to be vended. This process assumes that a separate process has already checked that the inventory is available for vending and it has been paid for. The routine is passed a list of items to be dispensed. For items that have multiple quantities, each item is listed as a separate item. Step 702 reads this list into the process memory. Step 703 determines if the dispensing system is busy processing another request. If the dispensing system is busy for any reason, step 704 pings the resource until it is free and then directs the process to step 708 where the first (or next) item in the list is read. Step 705 is a timer that monitors step 704 to determine if the wait for the resource times out to a preset time. If it does, the process is considered to have an error and it directs control to step 706 that sends out an alert using the notification system designated by 303 ( FIG. 3 ). Step 707 attempts the recovery of the system by running any preprogrammed diagnostics and self repairing routines that check and restart power and communication links to the system. If the system cannot automatically recover, the machines goes into an idle state and a message is displayed on the main screen indicating the machine is currently out of service preventing users from using the system. If the system resources are free, step 708 reads the next item to be vended from the list and retrieves its associative information into memory. This information was originally loaded into the system as the inventory XML file 611 ( FIG. 6 ) read into memory in step 610 . The item, or product id is used to retrieve this information. Information associated with the identification number includes the items location in the inventory system (shelf height and corresponding elevator position represented as the position the elevator needs to be in to properly collect the dispensed product), the dispensing motors associated with vending the item from the inventory shelf and item details such as its name to prompt the user and its weight and dimensions which is used in conjunction with the product weight sensor 484 ( FIG. 6 ) to determine a successful vend.
Step 709 uses this information to move the elevator tray assembly 107 ( FIG. 1A ) to the correct shelf height for the current item being vended. The elevator height is determined by preset position values that tell the stepper motor where to position itself on the vertical aspect of the gantry. The stepper motor has an encoder that communicates with the controller to verify the position. This combination of hardware allows the software to set a height value and have the stepper motor and the stepper controller ensure the correct position is attained. If there is a detectable error with the elevator mechanics, an error message is generated and sent out by step 706 . Step 707 will again try to recover if possible. If the elevator assembly reaches the correct height and position as designated by the product information record, the product collection wings 106 ( FIGS. 1A and 1B ) are expanded to create an extended landing area that will catch products coming off the inventory trays 213 ( FIG. 2 ). If an error in this process is detected, an error message is generated and step 706 will send out an alert. Otherwise, if the elevator is in position and the production collection wings are extended, step 711 will use the information retrieved in the product record to activate the motor(s) associated with that item of inventory. A mechanical switch is used to indicate that the motor has revolved enough times to properly dispense the product or item off the shelf at which point it falls on to the product collection wings and into the conveyor 105 ( FIGS. 1A and 1B ). Errors are again detected if present and routed to the notification system in step 706 . Step 712 retracts the product collection wings so the elevator can freely move up and down in the dispensing assembly. This step also assists positioning the product on the conveyor where it can be delivered to the user later in the process. Any detected errors in this step are routed to step 706 . If there are no errors, step 713 moved the elevator gantry to the user collection area. The movement of the elevator mechanically opens up the product collection area by activating levers that open the top and back of the area. If no errors are detected, step 714 notes which control activated the dispensing process. This is only relevant when the machine is configured for dual sided vending (see FIGS. 9 and 11 ). Step 715 then spins the conveyor in the direction of the user that initiated the dispensing process. If no errors were detected, step 716 repositions the elevator that reverses the mechanical operation that opened the back of the collection area and closed it sealing off the internal components of the machine from the user. If no errors were detected, step 717 turns on the lights in the collection area 204 ( FIG. 2 ) and opens the exterior collection area door. Step 718 prompts the user on the screen 202 ( FIG. 2 ) to collect their product. Step 719 monitors signals from the product weight sensor 484 ( FIG. 4 ) records the weight and matches it against the product weight information stored in the inventory XML file 611 ( FIG. 6 ). This sensor could also be a motion or light curtain sensor. If the item was not removed for a preset amount of time, the user is prompted again to collect their item in step 718 . If user does not collect their product after a set number of attempts, an error is generated. If the sensor determines the user has removed their item, the process continues to step 720 where the exterior door is closed and the product collection area lights are turned off. The system again monitors for any mechanical errors in this process (line to step 706 not shown). Step 721 determines if there are any additional items in the list of items to be vended. If there are additional items to be vended, the process routes back to step 703 where it begins again for the next item. If there are no more items to be vended, the process ends at step 722 .
With reference directed to FIG. 8 , an alternative vending machine 800 constructed in accordance with the best mode of the invention incorporates a variant on the display module designated as 210 in FIG. 2A . In this version the display module has a plurality of generally square product viewing areas 801 that present an alternative display, different from the diamond and circle display windows designated at 206 and 207 respectively in FIG. 2A .
With reference directed to FIG. 9 , an alternative 900 ( FIG. 9 ) shows an alternative configuration of the machine where it has been outfitted to dispense merchandise out of both the front and back of the machine. This machine has display modules 210 affixed to both sides of the inventory cabinet 212 . It also has a vertical control column 211 affixed to both sides of the central robotic gantry 100 . This configuration allows the unit to serve two people at the same time.
With reference directed to FIG. 10 , alternative machine 1000 represents a similar configuration but with only one inventory cabinet 212 and display module 210 . These are once again attached to the common centralized robotic dispensing gantry 100 . In this configuration a simple metal plate 1001 (not shown) cut the size of the dispensing system tower is affixed to the side where the inventory cabinet was attached in FIG. 8 using the same bolts to secure the system.
With reference directed to FIG. 11 , another configuration of a vending machine 1100 utilizes the centralized robotic dispensing gantry 100 with one inventory cabinet and two display modules 210 and two vertical control columns 211 . As in FIG. 9 , this configuration allows for two users to simultaneously interact with the machine while using only one robotic dispensing mechanism and sharing a common inventory cabinet. | A vending arrangement for computerized vending machines, retail displays, automated retail stores, utilizes a centralized, robotic gantry associated with companion modules for vending a plurality of selectable products. The modularized design enables deployment of half-sized or larger, full sized machines. The robotic gantry is deployed in a centralized module disposed adjacent display and inventory modules. Inventory modules can be fitted to both gantry sides, and doors can be fitted to the gantry front or rear. The gantry comprises an internal, vertically displaceable elevator utilizing a central conveyor for laterally, horizontally moving selected items from associated display and inventory positions to a vending position. Computerized software enables the display and vending functions, and controls elevator movement to dispense products from twin sides of the gantry by appropriately controlling the conveyor. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention pertains generally to tools for servicing electric generators and more particularly to a tool for removing the endplate from a WESTAC electric generator.
[0003] 2. Related Art
[0004] Commonly large electric generator stators are made up of a tandem array of iron laminations that are held in compression between endplates. Most generators of that type have through bolts holding the endplates and the laminated core together. The through bolts allow for easy removal and access to the core for field maintenance inspections and servicing. However, WESTAC electric generators, manufactured by Siemens Power Generation, Inc., do not have through bolts. This latter type of electric generators core is held together by 15 key bars or blocks that maintain an endplate in compression against the core laminations. In order to remove the endplate, which is a large Bellville washer, it is necessary to compress and flatten the endplate to relieve the pressure off of the key bars so that they may be removed. The current method of flattening the endplate is by the use of a single four inch by 93 inch diameter plate that weights over 7,000 pounds (3175.14 kg.). FIG. 1 shows a planned view of a skeleton of an electric generator oriented in the vertical position normally used for stacking the laminations, with the prior art compression plate 12 in place. The compression plate 12 is held in position against the endplate 24 by a first end portion of all thread 14 . All thread 14 passes through the compression plate 12 and extends past the length of the core where it is captured at a second end by a leverage plate 15 that spans the opposite end of the generator frame. A hydraulic jack 20 fits over the all thread 14 and seats against the compression plate 12 . The hydraulic jack 20 is locked in position on the all thread 14 by a jack nut 16 and a thrust washer 18 . The hydraulic jack 20 exerts a compressive force on the endplate 24 through a cast iron spider 22 that extends between the back face of the compression plate 12 and the hydraulic jack 20 . This current system requires the use of a large overhead crane to position the 7000 lb. (3175.14 kg.) compression plate. In addition, it has only been used in the factory with the WESTAC frame in the vertical position. It could probably be adapted for use in the field with the generator frame in the horizontal position, but extensive modifications would be required to install and use this large compression tool for field applications. Cranes large enough to install the compression tool typically cost upwards of $1,000 (E822.45) per day, so it is important to minimize such auxiliary equipment costs.
[0005] Accordingly, an improved tool is desired that will enable compression of a WESTAC endplate without the use of an overhead crane.
[0006] Furthermore, a new tool is desired that is easier to use in the field than the methods currently being employed and that will reduce costs.
SUMMARY OF THE INVENTION
[0007] This invention provides an improved method of removing the endplate of an electric generator that is held in compression against a core of the generator at a first end by a plurality of key bars that are supported in place against the generator frame. Each key bar has a slot which captures a peripheral arc of the circumference of the endplate to hold the endplate in compression. The plurality of key bars are substantially evenly spaced around the circumference of the generator frame. The method of this invention is more amendable to field maintenance procedures and less costly to operate than the methods heretofore employed. The method comprises simultaneously leveraging a separate compression tool independently off of the generator frame adjacent each key bar to apply a compressive load upon an exposed surface of the endplate sufficient to loosen the endplate from the key bars. Once the endplate is sufficiently compressed the key bars and the endplate can be removed from the generator frame. Preferably, each compression tool is pivotally attached to an end portion of the generator frame adjacent the corresponding key bar that the compression tool is associated with.
[0008] In the preferred embodiment, the compression tool comprises a housing having a first end of a laterally extending arm pivotally attached proximate to one end of the housing. A second end of the laterally extending arm is attached to the end portion of the frame adjacent the corresponding key bar. Desirably, the laterally extending arm comprises two parallel plates that are attached proximate to the one end of the housing with a pivot pin. The end portion of the generator frame adjacent the key bar is captured between the two parallel plates of the second end of the laterally extending arm with a pivot pin that extends through aligned bores in each of the parallel plates and the end portion of the generator frame. An anchor rod extends through the interior of the generator and is anchored at a first end of the anchor rod against a second axial end of the generator and connected at a second end of the anchor rod proximate to a second end of the housing of the compression tool such that the second end of the housing can move axially along the anchor rod. A portion of the housing, intermediate the first and second ends of the housing, contacts the endplate. The endplate is compressed by moving the second end of the housing axially along the second end of the anchor rod in the direction of the interior of the generator. Means are provided for moving the second end of the housing along the second end of the anchor rod, comprising a hollow hydraulic cylinder that captures the anchor rod within its piston. Preferably, the portion of the housing intermediate the first and second ends of the housing that contacts the endplate is a stand-off or pedestal that protrudes from the housing and is rigidly attached thereto. Once the endplate has been removed the core laminations may be held in place with a plurality of anchor rods respectively positioned with wood slot filler in empty coil slots in the core laminations.
[0009] In another embodiment of the invention, where core laminations have been replaced, the separate compression tools may be used to compress intermediate stacks of the laminations together. In this embodiment, the separate compression tools are leveraged off of the generator frame at a plurality of locations around the circumference of the generator at the same time to apply a compressive load upon a face of an exposed lamination. To that end, the compression tool comprises a housing having a first end pivotally attached to the generator frame. An anchor rod that extends through the interior of the generator and is anchored at a first end of the anchor rod against a second axial end of the generator is connected at a second end of the anchor rod proximate to a second end of the housing of the compression tool such that the second end of the housing can move axially along the anchor rod. A push rod extends axially from and is supported by the housing intermediate the first and second ends of the housing The push rod, at an extended end, contacts the face of the generator lamination and compresses the laminations when the housing is moved axially along the second end of the anchor rod in the direction of the laminations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A further understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
[0011] FIG. 1 is a planned view of the shell of a WESTAC electric generator in a vertical position with a prior art compression loading plate in place;
[0012] FIG. 2 is a perspective view of an end section of a WESTAC generator with a single compression tool of this invention connected between the end of the generator frame adjacent a key bar and an anchor rod;
[0013] FIG. 2A is an enlarged view of the endplate-key bar-frame extension connection;
[0014] FIG. 3 is a perspective view of the compression tool of this invention;
[0015] FIG. 4 is a perspective view of the endplate of a WESTAC generator with a plurality of compression tools in place engaging the generator frame adjacent the key bars, and the anchor rods;
[0016] FIG. 5 is a planned view of a support structure and trolley system for moving the endplate of a WESTAC generator away from the core; and
[0017] FIG. 6 is a perspective view of a rear portion of a WESTAC generator with a portion of the core iron removed and the compression tool of this invention in place to compress the exposed laminations.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] FIG. 2 shows a perspective view of a portion of the end of a WESTAC generator with the external housing and the internal rotor removed. The stator core 30 is made up of a large number of iron laminations that are stacked in tandem and held in compression by the endplate 24 , which is an extremely large Bellville washer under in excess of 1,160,000 pounds of compression. The stator core is restrained in the circumferential direction by the generator frame 28 . The endplate 24 is captured in position and maintained under compression by key blocks or bars 26 that capture the peripheral edge of the endplate 24 in a notched groove. The key bars 26 are wedged between the endplate 24 and the frame extensions 27 . FIG. 2A shows an enlarged view of the endplate-key bar-frame extension interface. The endplate 24 has a circumferential lip 25 that the key bar 26 is wedged against to retain the endplate in compression. The key bar 26 , in turn, is captured in position by a groove in the underside of the frame extension 27 .
[0019] The stator core laminations form a plurality of transverse slots 32 that extend axially the length of the core and are positioned around the entire internal circumference of the stator. The slots house the stator windings.
[0020] FIG. 2 shows a single compression tool 40 of this invention in position to compress the endplate 24 . The compression tool 40 has a housing 48 that is connected at a first end 50 through a laterally extending arm 44 to the generator frame extension 27 by means of a connecting pin 46 which extends through a hole in the laterally extending arm 44 that matches with a mating hole 42 in the frame extension 27 . The laterally extending arm 44 is pivotally connected to the first end 50 of the housing 48 through a pivot pin 54 . An anchor rod 34 , e.g., a 1.25 in. (3.18 cm) all thread, extends through a second end 52 of the housing 48 and fits in an empty coil winding slot and runs the length of the generator core. The all thread anchor rod 34 is reacted off the opposite end of the generator core by being bolted to plates which span adjacent to the generator finger plates 35 . A hollow hydraulic cylinder 36 is placed over the end of the anchor rod that passes through the second end 52 of the housing 48 and is captured by an anchor nut 34 . A pedestal or stand-off 56 extends outward from the housing 48 intermediate the first and second ends of the housing 50 and 52 in line with the endplate 24 and contacts the endplate. As the hydraulic cylinder 36 expands it will react off of the pin 54 and press inward on the endplate 24 transmitting a compressive load through the stand-off 56 . In producing the WESTAC generators, the specifications call for a final nominal press of the core of 580 tons (5.16 MN). This works out to approximately 77,333 pounds (343.99 KN) of force required at each key 26 to be able to flatten the endplate 24 . Through calculations, it is determined that approximately 2,800 psi (19.3 newtons/sq. mm.) at the location of the hydraulic cylinder is required to obtain the necessary force. A 30 ton (266.89 KN) hollow hydraulic cylinder, such as the Enerpac RCH 302 is sufficient for this purpose. The 2,800 psi (19.3 newtons/sq. mm.) was calculated for a hydraulic cylinder having a piston surface area equal to that of the RCH 302 . The pressure will have to be adjusted for different piston surface areas. The RCH 302 hollow hydraulic cylinder is available from Enerpac, a Division of Actuant Corp., Milwaukee, Wis. However, it should be appreciated that other mechanical, pneumatic, or electrive motive forces can be employed to move the second end 52 of the housing 48 along the anchor rod 34 to provide a compressive load to the endplate 24 . Wood slot filler and all thread is used in the empty winding slots 32 to hold the rest of the core together so that the endplate 24 can be removed after the keys 26 are taken out.
[0021] FIG. 3 provides a perspective view of the compression tool 40 of this invention showing a better view of the laterally extending arm 44 which is made up of two parallel plates 62 and 64 that capture the hole 42 within the generator frame extension 27 therebetween through insertion of the pin 46 . The anchor rod 34 passes through the slot 58 in the housing 48 . In addition, there is a bore 60 that extends completely through the housing 48 for supporting a push rod, not shown in FIG. 3 , which will be described in more detail hereafter.
[0022] In a WESTAC generator there are 15 key bars that are equidistantly spaced around the circumference of the electric generator. FIG. 4 illustrates that separate compression tools 40 are provided for each of the 15 key bars and operate simultaneously at their respective key bar locations to compress the endplate 24 .
[0023] FIG. 5 illustrates a trolley set-up that can be employed to move the endplate 24 away from the generator 10 . A trolley 70 rides on an I-beam 68 which is held in position by support columns 66 . Preferably the I-beam is constructed out of a high strength aluminum alloy. A hook 74 can support a strap 72 which is wrapped around the endplate 24 . Employing this arrangement the endplate 24 can be moved sufficiently away from the end of the generator 10 to permit access to the core for core iron replacement by standard techniques.
[0024] After the core has been worked on, it will be necessary to compress the stacked tandem laminations ten times to 400 tons (3.56 MN) for every 18 inches of new iron replaced. The compression tool 40 of this invention is able to adapt itself to perform these intermediate presses as well. FIG. 6 illustrates a configuration of the tool 40 in position to perform a single intermediate press. A push rod 76 is supported by the housing 48 intermediate the first and second ends 50 and 52 and extends out parallel to the anchor rod 34 towards the core iron 30 . The distal end of the push rod 76 is connected to an end plate 78 which spreads the load on the exposed surface of the core iron 30 . The housing 48 is suspended and supported by the frame 28 at its first end 50 . A longitudinal frame strut 29 is captured by the first end 50 of the housing 48 by insertion of the pin 54 . The tool 40 functions in the same manner as previously explained for employing a compressive load to the end plate 24 . However, in the embodiment shown in FIG. 6 the compressive load is imparted by the push rod 76 through the endplate 78 . The push rod 76 can be retracted through the housing 48 through the housing slot 60 as more laminations are added, to further compress the core. Though only one compressive tool 40 is shown, it should be appreciated that the 15 identical compressive tools 40 , as previously shown in FIG. 4 , can function in this embodiment to provide compressive loads simultaneously around the circumference of the face of the exposed core iron.
[0025] After the core has been adequately compressed, the endplate can be restored employing the same method that was used for removing the endplate. The compression tools 40 will be used to flatten the endplate by simultaneously applying a compressive load around the circumference of the endplate so the keys may be replaced between the periphery of the endplate and the frame extensions 27 . Accordingly, an improved method and apparatus is provided that does not require an overhead crane. Each of the 15 assemblies weighs approximately 65-70 pounds (29.48-31.75 kg.) and can easily be maneuvered by two people. One complete assembly can be readily set up in under 10 minutes and the cost of materials is significantly less than that of the 7,000 lb. prior art compression plate.
[0026] While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular embodiments disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. | A method and apparatus for compressing the endplate of an electric generator to relieve the restraining force on a plurality of key blocks that restrain the endplate in compression. The method includes simultaneously applying independent compressive loads at each of the key block locations to the endplate to relieve pressures on the key blocks and removing the key blocks so the endplate can be removed. | 8 |
FIELD OF THE INVENTION
This invention relates generally to pedestrian platforms, walkways, and sidewalks and the like, and specifically to textured tiles which assist pedestrians, particularly those who are blind, visually or physically impaired, young children or the elderly in following a walkway or in detecting the location of a sidewalk edge, platform edge or other similar hazard.
BACKGROUND OF THE INVENTION
In connection with pedestrian platforms, walkways, and sidewalks in locations such as subway or railway stations, loading docks, stages, speaking platforms, stairways, sidewalks, school crossings, airports, curb ramps, crosswalks and roadway crossings, etc. there is a requirement for pedestrians to be able to safely navigate and avoid hazards. The requirement is particularly acute in attempting to make such facilities accessible and safe for blind or visually impaired persons.
In the 1980's a series of studies were undertaken in the United States to improve the design of buildings and transportation facilities to improve the mobility of the visually impaired. These studies culminated in recommendations on making potential hazards detectable to the visually impaired either by use of the long cane or underfoot.
Americans with Disabilities Act (ADA): Accessibility Guidelines for Buildings and Facilities set the requirements for the use of detectable warnings to warn visually impaired persons of hazards. The Guidelines require that detectable warnings shall consist of raised truncated domes of prescribed diameter, height and center-to-center spacing and shall contrast visually with adjoining surfaces. Detectable warnings used on interior surfaces are required to differ from adjoining surfaces in resiliency or sound-on-cane contact. Various tactile tiles having raised truncated domes in compliance with the ADA Guidelines or the equivalent have been developed such as those shown in U.S. Pat. Nos. 4,715,743 and 5,303,669.
SUMMARY OF THE INVENTION
The present invention provides improved tactile tiles providing enhanced directional guidance features and greater color contrast from the surrounding walkway to improve detection and recognition.
Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, the preferred embodiments will now be described in detail by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a top plan view of one embodiment of an ADA compliant detectable tile according to the present invention featuring a border of contrasting color to the tile.
FIG. 2 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring a border and domes of contrasting color within the border.
FIG. 3 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring a contrasting color border and centering and directional element.
FIG. 4 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring a contrasting color border with directional features.
FIG. 5 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring a contrasting color border with a thicker border on one side to convey a sense of direction as well as a signal to STOP.
FIG. 6 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring a contrasting color symbol to provide directional input.
FIG. 7 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring contrasting color symbols to provide directional input.
FIG. 8 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring a contrasting color lateral edge to provide directional input.
FIG. 9 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring a contrasting color symbol to convey a signal to STOP.
FIG. 10 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring a centrally located contrasting color symbol to convey a signal to STOP.
FIG. 11 is a schematic of another embodiment of an ADA compliant detectable tile according to the present invention featuring domes of contrasting color framing the tile.
FIG. 12 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring brightly colored domes and frame and background of contrasting color.
FIG. 13 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring luminescent domes and frame and background of contrasting color according to the present invention.
FIG. 14 is a schematic view of domes on an ADA compliant detectable tile according to the present invention featuring domes co-molded of contrasting color.
FIG. 15 is a schematic view of domes on an ADA compliant detectable tile according to the present invention featuring domes co-molded of contrasting color with contrasting colored grooves on the side of the domes.
FIG. 16 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring a centering groove on the tile to provide directional information.
FIG. 17 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring texture between domes of contrasting density to provide directional information.
FIG. 18 is a top plan view of another embodiment of an ADA compliant detectable tile according to the present invention featuring texture between domes in the form of lineal grooves to provide directional information.
FIG. 19 a - d are top plan views of other embodiments of ADA compliant detectable tiles according to the present invention featuring added grooves between domes to provide directional and other information.
FIG. 20 is a top plan view of another embodiment of ADA compliant detectable tiles according to the present invention featuring a photoluminescent strip on one edge of the tile to detect the base of a curb ramp, edge or platform, or the location of a hazardous vehicular way.
FIG. 20 a is a side view of a raised section on one edge of the of the tile to provide a warning or to detect the base of the curb ramp and contains drainage grooves.
FIG. 21 is a top plan view of another embodiment of ADA compliant detectable tiles according to the present invention featuring photoluminescent strips on each end of the tile and on the base of the tile to provide direction of travel guidance.
FIG. 22 is a top plan view of another embodiment of ADA compliant detectable tiles according to the present invention featuring photoluminescent strips on each end of the tile to provide direction of travel guidance.
FIG. 23 is a top plan view of another embodiment of ADA compliant detectable tiles according to the present invention featuring photoluminescent strips on each and in the centre of the tile to provide direction of travel guidance.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , one embodiment of an ADA compliant detectable tile, generally indicated at 1 , according to the present invention, generally similar to the type of tiles described in U.S. Pat. Nos. 5,303,669 and 5,775,835 or the like, has a top surface 2 with a plurality of rows of raised truncated domes 3 . The tile 1 , of the present invention, features a symbol, generally indicated at 4 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 4 is formed with an internal border 5 of contrasting color around the periphery 6 of the top surface 2 of the tile. The border provides contrast and draws the eye of the pedestrian to ensure a visual warning is provided and to add directional guidance to the intended path. The color of the tiles is preferably selected from the group consisting of Federal Yellow, Ochre Yellow, Brick Red, Colonial Blue, Ocean Blue, Onyx Black, Dark Gray, Light Gray or Pear White (as identified on the www.armor-tile.com web site). Where the tile is for example Federal Yellow the internal border can be Onyx Black to provide the desired level of contrast. The border is preferably molded into the tile.
FIG. 2 illustrates another embodiment of a ADA compliant detectable tile, generally indicated at 10 , according to the present invention similar to the one shown in FIG. 1 that has a top surface 12 with a plurality of rows of raised truncated domes 13 . The tile 10 features a symbol, generally indicated at 14 , of contrasting color to the top surface of the tile. In this embodiment the symbol 14 is an internal border 15 of contrasting color to the top surface of the tile. In this embodiment, the tops 16 of the domes 17 within the border are of contrasting color to the border and preferably the same color as the rest of the top surface of the tile. The border 15 with different colored domes 17 provides contrast and draws the eye of the pedestrian to ensure a visual warning is provided and to add directional guidance to the intended path. For example where the tile is Federal Yellow the internal border can be Onyx Black and the tops of the domes can be Federal Yellow to provide the desired level of contrast. The border is preferably molded into the tile.
FIG. 3 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 20 , according to the present invention similar to the one shown in FIG. 1 that has a top surface 22 with a plurality of rows of raised truncated domes 23 . The tile 20 features a symbol, generally indicated at 24 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 24 features an internal border 25 of contrasting color to the top surface of the tile. In this embodiment, a thick stroke 26 of the same color as the border is added to center and provide direction to the pedestrian regarding the intended path, in the direction indicated by stroke 26 .
FIG. 4 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 30 , according to the present invention similar to the one shown in FIG. 1 that has a top surface 32 with a plurality of rows of raised truncated domes 33 . The tile 30 features a symbol, generally indicated at 34 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 34 is an internal border 35 of contrasting color to the top surface of the tile. In this embodiment, the side edges 36 , 37 of the border 35 are wider than the other two sides 38 , 39 . This provides directional guidance to the intended path, between the side edges 36 , 37 .
FIG. 5 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 40 , according to the present invention similar to the one shown in FIG. 1 that has a top surface 42 with a plurality of rows of raised truncated domes 43 . The tile 40 features a symbol, generally indicated at 44 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 44 is an internal border 45 of contrasting color to the top surface 42 of the tile. In this embodiment, the side 46 of the border 45 closest to the hazard (platform edge, roadway etc.) is wider than the other sides, 47 , 48 , 49 of the border 45 to convey a sense of direction as well as a signal to STOP.
FIG. 6 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 50 , according to the present invention similar to the one shown in FIG. 1 that has a top surface 52 with a plurality of rows of raised truncated domes 53 . The tile 50 features a symbol, generally indicated at 54 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 54 , in this case is a triangle 55 , of contrasting color formed on the top surface of the tile. Where the tile is for example Federal Yellow the triangle can be Onyx Black to provide the desired level of contrast. The symbol is preferably molded into the tile. The contrasting colored triangle provides contrast and draws the eye of the pedestrian to convey a strong sense of direction and centering to the intended path.
FIG. 7 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 60 , according to the present invention similar to the one shown in FIG. 6 that has a top surface 62 with a plurality of rows of raised truncated domes 63 . The tile 60 features a symbol, generally indicated at 64 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 64 , in this case is a series of nested chevrons 65 , of contrasting color formed on the top surface of the tile. Where the tile is for example Federal Yellow the series of nested chevrons can be Onyx Black to provide the desired level of contrast. The contrasting colored triangles 65 provide contrast and draw the eye of the pedestrian to convey a strong sense of direction and centering to the intended path while at the same time showing more of the base color of the tile surface.
FIG. 8 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 70 , similar to the one shown in FIG. 1 that has a top surface 72 with a plurality of rows of raised truncated domes 73 . The tile 70 features a symbol, generally indicated at 74 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 74 , in this case is colored lateral edges 75 , 76 , of contrasting color formed on the top surface of the tile. The contrasting colored edges provide contrast and draw the eye of the pedestrian to convey a strong sense of direction and centering to the intended path.
FIG. 9 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 80 , according to the present invention similar to the one shown in FIG. 1 that has a top surface 82 with a plurality of rows of raised truncated domes 83 . The tile 80 features a symbol, generally indicated at 84 , of contrasting color to the top surface of the tile. In the embodiment illustrated the symbol is a colored “X” 85 , of contrasting color formed on the top surface of the tile. The contrasting colored “X” provides contrast and draws the eye of the pedestrian to convey a sense of centering to the intended path to convey a signal to STOP.
FIG. 10 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 90 , according to the present invention similar to the one shown in FIG. 9 that has a top surface 92 with a plurality of rows of raised truncated domes 93 . The tile 90 features a symbol, generally indicated at 94 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 94 is a colored “X” 95 with colored side arrows 96 , 97 , both of contrasting color to the top surface of the tile. Where the tile is for example Federal Yellow, the “X” 95 and side arrows 96 , 97 can be Onyx Black to provide the desired level of contrast. The contrasting colored “X” 95 provides contrast and draws the eye of the pedestrian to convey a sense of centering to the intended path and to convey a signal to STOP. The side arrows 96 , 97 reinforce the centering aspect and STOP signal. For further emphasis, the tops 98 of the domes 99 within the side arrows 96 , 97 may be of contrasting color to the side arrows and preferably the same color as the top surface 92 of the tile.
FIG. 11 illustrates another embodiment of an ADA compliant detectable tile according to the present invention, generally indicated at 100 , similar to the one shown in FIG. 1 that has a top surface 102 with a plurality of rows of raised truncated domes 103 . The tile 100 , of the present invention, features a symbol, generally indicated at 104 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 104 features contrasting color indicators. In this embodiment, internal rows of domes 107 forming an internal border 108 are of contrasting color to the other domes 109 on the top surface of the tile. Where the tile is for example Federal Yellow the internal border of domes can be Onyx Black to provide the desired level of contrast. The different colored domes provides contrast and draws the eye of the pedestrian to ensure a visual warning is provided and to add directional guidance to the intended path.
FIG. 12 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 110 , according to the present invention similar to the one shown in FIG. 1 that has a top surface 112 with a plurality of rows of raised truncated domes 113 . The tile 110 , of the present invention, features a symbol, generally indicated at 114 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 114 is brightly colored domes 113 and outer frame 115 of contrasting color to the top surface 112 of the tile 110 . In this embodiment the brightly colored domes 113 and frame 110 provide contrast and draw the eye of the pedestrian to ensure a visual warning is provided and to add directional guidance to the intended path.
FIG. 13 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 120 , according to the present invention similar to the one shown in FIG. 12 having a top surface 122 with a plurality of rows of raised truncated domes 123 . The tile 120 , of the present invention, features a symbol, generally indicated at 124 , of contrasting color to the top surface of the tile. In the embodiment illustrated, the symbol 124 is brightly colored domes 123 and outer frame 125 of contrasting color to the top surface 122 of the tile. In this embodiment the brightly colored domes 123 and frame 125 are luminescent.
FIG. 14 illustrates another method according to the present invention of providing contrasting color on the top surface 132 of a tile 130 having a plurality of rows of raised truncated domes 133 to give visual contrast. FIG. 14 illustrates schematically, domes, generally indicated at 133 , on the top surface 132 of a section of an ADA compliant detectable tile 130 (partial section shown only) where the domes 133 are co-molded of contrasting color. In addition the domes 133 could be made of different material from the rest of the tile to provide durability from loads and forces experienced under load, to provide a better non-skid surface, change the texture or feel of the domes etc. In the embodiment illustrated the sides 135 of the domes are a contrasting color to the top 136 of the domes and the tile surface 132 . Where the tile is for example Federal Yellow the sides of the domes can be Onyx Black to provide the desired level of contrast. In addition the sides of the domes could be made of different material from the rest of the tile to provide enhanced durability from loads and forces experienced under load, to provide a better non-skid surface, change the texture or feel of the domes etc.
FIG. 15 illustrates another method according to the present invention of providing contrasting color on the top surface 142 of a tile 140 having a plurality of rows of raised truncated domes, generally indicated at 143 , to give visual contrast. FIG. 15 schematically shows domes 143 on a section of an ADA compliant detectable tile 140 where the domes 143 are co-molded of contrasting colors and have side grooves 144 (or alternatively rings, not shown) molded into the side walls 145 of the domes 143 and being of a different color to the rest of the side wall 145 of the domes. This provides a shadow effect to the dome rendering it more visible. Where the tile is for example Federal Yellow the sides of the domes can be Onyx Black and the side grooves Federal Yellow to provide the desired level of contrast. A similar use of contrasting colored grooves or rings or depressions or modified dome shape can be applied to the top of the dome or around the base of the dome to make them more visible. If directional information is required it may be possible to make the domes elliptical to add directional input.
FIG. 16 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 150 , according to the present invention and generally of the type described in U.S. Pat. Nos. 5,303,669 and 5,775,835 or the like, that has a top surface 152 with a plurality of rows of raised truncated domes 153 . The tile 150 features a symbol or other indicia, generally indicated at 154 , applied to the top surface of tile. In the embodiment illustrated the tile 150 is formed where the symbol or indicia is a centering groove 151 in the top surface 152 of the tile between adjacent rows of domes 153 . A visually impaired pedestrian can use his or her cane to follow the groove 152 along the intended direction of travel. The centering groove 151 can be made photo luminescent to be more visible to the sighted.
FIG. 17 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 160 , according to the present invention and generally of the type described in U.S. Pat. Nos. 5,303,669 and 5,775,835 or the like, that has a top surface 162 with a plurality of rows of raised truncated domes 163 . The tile 163 features a symbol or indicia, generally indicated at 164 , on the top surface of the tile to provide directional guidance. In the embodiment illustrated, the tile 160 has texture, generally indicated at 165 , between rows of domes 163 to provide an anti-slip surface to the top surface 162 of tile 160 . According to the present invention in the embodiment illustrated, the tile 160 is formed with texture 165 between domes of contrasting density to provide directional information. On the rear side 166 (side facing away from the hazard) of the tile the density of the texture between domes is less than between domes on the street side 167 (side facing the hazard) of the tile. The transitional density of the texture provides audible location awareness when the difference in density is detected by cane. Low density texture between domes at the rear of the tile provides slower vibration feedback and tones from the cane. As density increases faster vibration feedback and tones are received.
FIG. 18 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 170 , according to the present invention having a top surface 172 with a plurality of rows of raised truncated domes 173 . The tile 170 features indicia, generally indicated at 174 , to provide additional direction information. In the embodiment illustrated, the indicia 174 comprises texture between domes 173 in the form of lineal grooves 175 to provide directional information. The texture rather than being individual dimples as in FIG. 18 is in the form of lineal grooves between domes. The lineal grooves provide slip resistance but have a lower profile than the use of dimples in FIG. 18 . This provides improved detectability and traction. The lineal grooves can be used to provide guidance information as well and can also be photo luminescent.
FIGS. 19A-D illustrate other embodiments of ADA compliant detectable tiles, generally indicated at 190 , according to the present invention and generally of the type described in U.S. Pat. Nos. 5,303,669 and 5,775,835 or the like, that have a top surface 192 with a plurality of rows of raised truncated domes 193 . The tiles 190 features a symbol or indicia, generally indicated at 194 , on the top surface of the tile to provide additional directional information. In the embodiment illustrated the tiles 190 are formed with one or more grooves 195 in the top surface 192 of the tile between adjacent rows of domes 193 forming a pattern. For example in FIG. 19A the grooves 195 form a pattern of chevrons indicating an intended direction of travel. In FIG. 19B the pattern is of two pairs of oppositely aligned chevrons 196 , 197 indicating “entry-exit”. In FIG. 19C the grooves form a hexagon 198 indicating the pedestrian should STOP. In FIG. 19D the grooves form an outline for an “X” 199 indicating a railway crossing. A visually impaired pedestrian can use his or her cane to identify the pattern of grooves to obtain the guidance information. The pattern of grooves can be made photo luminescent.
FIG. 20 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 210 according to the present invention that has a top surface 212 with a plurality of rows of raised truncated domes 213 . The tile 210 features a symbol or other indicia, generally indicated at 214 , to provide a visual contrast and or directional information. In the embodiment illustrated, the symbol 214 is a photoluminescence strip 215 on one edge 116 of the tile to assist with the ability of the pedestrian to detect the base of a curb ramp or edge of the platform or location of hazardous vehicular way that the tile is intended to provide notice of the both visually impaired and sighted pedestrians. FIG. 20A illustrates the tile 210 of FIG. 20 in cross-section. In the embodiment illustrated the photoluminescence strip 215 is raised relative to the top surface 212 of the tile. The provision of a raised photoluminescence strip 215 on one edge 217 of the tile will enable detection by cane to warn the visually impaired of the base of the curb ramp, edge of platform, or location of a hazardous vehicular way. The photoluminescence strip 215 may be provided with drainage grooves 216 to eliminate ponding of water and will help reduce ice forming on the top surface 212 of the tile.
FIG. 21 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 220 according to the present invention that has a top surface 222 with a plurality of rows of raised truncated domes 223 . The tile 220 features a symbol or other indicia, generally indicated at 224 , to provide a visual contrast and or directional information. In the embodiment illustrated, the symbol 224 is photoluminescence strips 225 , 226 , 227 on the edges 228 , 229 , 230 of the tile to assist with the ability of the pedestrian to not only detect the base of a curb ramp or edge of the platform or location of hazardous vehicular way at edge 229 but to provide directional information between edges 228 , 230 . Where each of the photoluminescence strips 225 , 226 , 227 is raised relative to the top surface 222 of the tile the strips will be detectable by cane to warn the visually impaired and/or provide guidance information. FIG. 22 is a variation of the tile of FIG. 21 with the photoluminescence strips 225 , 227 along edges 228 and 230 .
FIG. 23 illustrates another embodiment of an ADA compliant detectable tile, generally indicated at 240 according to the present invention that has a top surface 242 with a plurality of rows of raised truncated domes 243 . The tile 240 features a symbol or other indicia, generally indicated at 244 , to provide a visual contrast and or directional information. In the embodiment illustrated, the symbol 244 is photoluminescence strips 245 , 246 , 247 on the edges 248 , 249 , and center 250 of the tile to provide directional information between edges 248 , 249 . Where each of the photoluminescence strips 245 , 246 , 247 is raised relative to the top surface 242 of the tile the strips will be detectable by cane.
Having illustrated and described preferred embodiments of the invention and certain possible modifications thereto, it should be apparent to those of ordinary skill in the art that the invention permits of further modification in arrangement and detail. It will be appreciated that the dimensions can be varied widely subject to the ADA Guidelines, as desired to suit the particular application. Tile size, length, width, thickness, color, ribbing and surface profiles can be modified to suit specific project requirements. In addition combinations of tiles with different indicia can be used. All such modifications are covered by the scope of the invention. | The present invention relates to an ADA compliant detectable warning or guidance tile for pedestrian platforms, walkways, and sidewalks and the like having a detectable warning surface containing raised truncated domes detectable by the visually impaired in accordance with Americans with Disabilities Act (ADA): Accessibility Guidelines for Buildings and Facilities and being provided with one or more additional means on the top surface of the tile to provide visual or tactile information to sighted and visually impaired pedestrians. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 13/842,110 filed Mar. 15, 2013 which is incorporated herein by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to systems and methods for the secure provision of services to devices and in particular to a method and apparatus for embedding and using secret information in digital certificates.
[0004] 2. Description of the Related Art
[0005] The widespread availability of digital means for disseminating information has placed an increasingly important emphasis on assuring the authenticity of a digital message, document, or data before providing access to other data. Authentication may be used as a part of a conditional access or digital rights management (DRM) scheme that protects information by requiring certain criteria to be met before the content can be stored, copied, played back, or otherwise used. The ability to satisfy this criteria is controlled so that only those entities authorized to use the information are able to do so.
[0006] Authentication of the source of information assures the recipient that the apparent or represented source is indeed the actual source. One of the techniques used for both conditional access and authentication is a public-key infrastructure (PKI).
[0007] In typical public-key infrastructure (PKI) usage, a digital certificate is used to cryptographically bind an identity of an entity (e.g. device) to an associated public key of an asymmetric cryptographic algorithm, such as RSA or elliptic curve cryptography (ECC). At a minimum the certificate includes the identity of the entity, the public key, and a signature of the issuing authority (over those parameters), typically referred to as a Certificate Authority (CA).
[0008] One of the problems with digital certificates is that standard procedures to revoke the licenses or conditional access system permissions cannot be easily re-used in systems that make use of cryptographic secrets that are symmetric-algorithm based. One problem, for example, is that for traditional asymmetric-based digital certificates, an efficient way to revoke devices is to group devices by a Sub-CA, so that devices of the same class or model are issued certificates from the same Sub-CA. In case of revocation, the corresponding Sub-CA can be revoked, rather than revoking individual devices. This mechanism, however, is not directly usable for systems where devices make use of symmetric-based cryptographic secrets.
[0009] What is needed is a system and method for grouped devices using symmetric keys for authorization to be revoked by revoking sub-CA issued digital certificates in the chain of trust rather than revoking the authorization of individual devices. The present invention satisfies this need.
SUMMARY OF THE INVENTION
[0010] To address the requirements described above, the present invention discloses a method and apparatus for enabling provision of a service to a first entity such as a device. In one embodiment, the method comprises receiving a service request in a second entity from the first entity, the service request comprising a leaf digital certificate generated and digitally signed by a certification entity and provided to the first entity, the leaf digital certificate having a unique identifier of the first entity and a two-way cryptographic function of a secret generated according to a provision key unknown to the first entity and the digital certificate digitally signed by a private key of the certification entity according to an asymmetric crypto algorithm, recovering the secret in the second entity from the leaf digital certificate, and enabling provision of the service to the first entity according to the recovered secret.
[0011] The foregoing may also be embodied in an apparatus having a communications module and a processor for executing instructions stored in a memory communicatively coupled to the processor, wherein the communications module transceives information comprising a service request from the first entity, the service request comprising a leaf digital certificate generated and digitally signed by a certification entity and provided to the first entity, the leaf digital certificate having a unique identifier of the first entity and a two-way cryptographic function of a secret generated according to a provision key unknown to the first entity, and the processor instructions include instructions for recovering the secret in the second entity from the leaf digital certificate, and enabling provision of the service to the first entity according to the recovered secret.
[0012] The disclosed system and method provides for embedding secret information and/or a function of the secret information in a digital certificate. In one aspect of the invention, a system and method is provided wherein a function F(S) of a secret information S, which is to be associated with an entity, is included into a digital certificate issued to the entity. In one or more embodiments, the function is a one-way function, such as a cryptographic hashing function H(S) (e.g. SHA 1 or SHA256). In one or more other embodiments, the function is a two-way function, such as an encryption function E(S) (e.g. AES or RSA using global encryption/decryption keys).
[0013] The systems and methods described herein are useful in many scenarios, for example, in allowing the use of a standard certificate revocation mechanism even for a system where each entity may not be configured with a public/private key pair, but instead is configured with a symmetric secret. The system and method allows for the reuse of a standard digital certificate and standard revocation mechanism for devices that make use of cryptographic secrets that are based on symmetric cryptographic algorithms. This solution is not only applicable to conditional access systems or digital rights management systems, but any communication system where authentication is required for access.
[0014] In one or more embodiments, a system and method is provided for embedding symmetric keying secrets into a standard X.509 certificate (encrypted via a “global symmetric key” or “global asymmetric key” stored at the certification entity). In exemplary applications, this may be used as an alternative to standard certificate-based asymmetric key methods. The advantage is that some devices only support the use of symmetric keys (e.g. AES or 3DES) and such hardware limitations prevent the use of asymmetric key approaches.
[0015] Additionally, a same sub-CA based certificate revocation may be utilized as well. A sub-CA may be used for different categories of devices (e.g. based on location, device model, etc). In such a case, revoking a particular device model or devices made from a particular location is as easy as revoking the corresponding Sub-CA. Revoking a single Sub-CA certificate is much more scalable and less error-prone as opposed to maintaining a huge list of revoked devices which are all devices of the same model.
[0016] In other exemplary applications, the system and method is used with a CAS or DRM system (e.g. Motorola™ Secure Media™) that relies on hardware-protected symmetric keys to authenticate a device. In some cases, an operator may require all DRM keys to remain in the hardware/device, but the chip hardware only supports symmetric algorithms, such as AES or 3DES.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
[0018] FIG. 1 is a diagram illustrating one embodiment of a conditional access/authentication system;
[0019] FIG. 2 is a diagram illustrating further details regarding the authentication process using a one-way cryptographic function of a secret embedded in a digital certificate;
[0020] FIG. 3 is a diagram illustrating a typical 3-level certificate hierarchy;
[0021] FIG. 4 is a diagram illustrating further details of an exemplary embodiment of an authentication process using a two-way cryptographic function F C [] of a secret embedded in a digital certificate; and
[0022] FIG. 5 is a diagram illustrating an exemplary computer system that could be used to implement elements of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] In the following description, reference is made to the accompanying drawings which form a part hereof, and which is shown, by way of illustration, several embodiments of the present invention. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
Overview
[0024] FIG. 1 is a diagram illustrating one embodiment of a conditional access system 100 . The conditional access system 100 comprises a certification entity 102 , which may comprise a certificate authority (CA) or a key manager (IKMI), one or more service entities or devices 104 (hereinafter alternatively referred to as device or devices), and a service enabling entity 106 , which may be a server or analogous system.
[0025] The certification entity 102 , device 104 and service enabling entity 106 each may comprise an associated processing module 110 A- 110 C respectively, and an associated communications module 112 A- 112 C, respectively, for performing processing and communication functions as described further herein. Further, each device 104 may be associated with an identifier (ID) such as a serial number, electric serial number, or other identifier.
[0026] The service enabling entity 102 provides the device 104 with conditional access information necessary to access and use content, other information, or services, stored, received or processed by the device 104 . Such information may include algorithms, keys, secrets, or other information for use in decoding content. Typically, the device 104 sends a message to the service enabling entity 106 requesting the conditional access information, and service enabling entity, after verifying the identity of the requesting device 104 , the service enabling entity 106 transmits the conditional access information or a secure means by which such information may be obtained to the device 104 . The service enabling entity 106 may be the same entity that provides the content to the device 104 , or may be an independent third party contracted by the content provider to provide the conditional access information in accordance with the security directives of the content provider of the author of the content itself.
[0027] An important aspect of the process of providing conditional access information to the device is for the different entities to establish that the entities from which they communicate information are, in fact, the entities they represent to be. This aspect is enabled, at least in part, by digital certificates issued to one or both of the device 102 and service enabling entity 106 by a trusted third party such as the certification entity 102 .
Device Secrets Embedded in Certificates Using a One-Way Cryptographic Function
[0028] During device 104 manufacturing (or entity provisioning in general), the certification entity 102 or key management function is responsible for provisioning the devices 104 with device identifiers ID D and secrets S D for use in obtaining requested services. This may be accomplished by providing the device 104 with a digital certificate embedded with a one-way cryptographic function of the secret S D . Optionally, the certification entity 102 may also provide the secret S D to the device 104 .
[0029] Ordinarily, digital certificates issued from a certification authority include a public key, but the aforementioned certificate issued by the certification authority 102 need not include a public key. Otherwise the digital certificate contains the usual information such as a serial number of the digital certificate, an identity for the device 104 , the certification entity 102 identity, as well as a digital signature covering the certificate and signed by the certification entity 102 .
[0030] In order to allow the service enabling entity 106 to communicate with the devices 104 using the digital certificates, a list of device (ID, secret) pairs are delivered to the service enabling entity 106 . The service enabling entity 106 will store this information in its database.
[0031] In addition, a certificate revocation list (CRL) may be issued by the certification entity 102 as needed or on a regular basis, and transmitted to the service enabling entity 106 . The CRL includes serial numbers of certificates that have been revoked, and may follow the standard X.509 specification.
[0032] To obtain service, the device 104 may authenticate itself to the service enabling entity 106 by presenting its digital certificate and other information generated using the device secret, according to a pre-agreed authentication protocol. Upon receiving the digital certificate from the device 104 , the service enabling entity 106 performs a verification in which it (1) looks up the identifier ID D of the device 104 making the request in the database to retrieve the secret S D associated with the requesting device 104 ; (2) computes a one way cryptographic function matching the one-way cryptographic function the certification entity 102 used to generate the data embedded in the digital certificate provided to the device 104 and provided to the service enabling entity 106 with the service request; (3) apply the same cryptographic function to the secret S D associated with the requesting device 104 received from the certification entity 102 ; (4) verifies the resulting value against the value embedded in the certificate; (5) performs standard certificate chain validation such as verifying the signature, validity period, and that the certificate chains up to the trusted Root certificate. If the value of the one way cryptographic function computed at the service enabling entity 106 matches the value of the one way cryptographic function computed at the certification entity 102 , and the standard chain validation is successful, the serial number of the device certificate is compared to the most recently received CRL to make sure that the device 104 certificate (and any CA certificate in the certificate chain) is not on the latest CRL, and that any Sub-CA certificate on the chain that links the device certificate to the trusted Root certificate has not been revoked.
[0033] If verification is successful and the certificate has not been revoked, the service enabling entity 106 may proceed to make use of the secret in enabling the provision of the requested service to the device 104 . For example, the service enabling entity 106 may proceed to verify other authentication-related information provided by the device 104 , based on the pre-agreed authentication protocol. If verification is not successful, the requested service may be denied.
[0034] FIG. 2 is a diagram illustrating further details regarding the authentication process using a one-way cryptographic function of a secret embedded in a digital certificate. The device 104 is associated with at least one identifier ID D . In one embodiment, the identifier ID D is unique to the device 104 , however, the identifier ID D may be unique to a class of devices 104 to be authenticated as well. For example, one of the identifiers ID D may be unique to devices 104 having a particular software version installed, to devices having a particular functional capability, devices manufactured in a particular location, or devices manufactured within a particular time range. In another embodiment, the device is associated with multiple identifiers ID D1 , ID D2 . . . ID Dn wherein one of the identifiers is unique to the device 104 and another identifier is unique to a class of the devices 104 .
[0035] The certification entity 102 includes a database or other memory storing each of the device identifiers ID D for each of the devices 104 . The database also stores a secret S D for each device 104 . In one embodiment, the secret S D is unique to the device 104 . The secret S D may be generated by the certification entity 102 or simply provided to the certification entity by a third party such as the entity that will ultimately provide the content to the device 104 .
[0036] The certification entity 102 stores or has access to one or more cryptographic functions F C [] that are also known to or accessible by the service enabling entity 106 . The certification entity 102 applies one of the cryptographic function F C [] to the secret S D , thereby generating a cryptographic function of the secret, F C [S D ]. In one embodiment, the cryptographic function is a one-way cryptographic function such as a hashing operation H[]. For exemplary purposes, the one way cryptographic function is described hereafter as a hash, H[] but as described above, the function may be any one-way cryptographic function. Further, although the same hash function H[] may be used to hash or otherwise operate on the all of the secrets S D for all devices 104 , different hash operations H[] may be used for different devices 104 or different device 104 classes to enhance security or to provide further authentication options, so long as the association between the hash functions H[] implemented in the certification entity 102 and the service enabling entity 106 and the device identifiers ID D is preserved.
[0037] For purposes of simplicity, the operations described below are described with respect to the transmission and use of a single device ID/secret pair. However, it is noted that these operations apply as well in cases where multiple device ID/secret pairs are transmitted and used.
[0038] As shown in block 202 , the certification entity 202 transmits a device identifier ID D and the associated secret S D to the service enabling facility 106 . In one embodiment, this device identifier ID D and S D are paired and transmitted together from the certification entity 102 to the service enabling entity 106 , but this need not be the case, so long as the information is transmitted such that the association between the device identifier ID D and the secret S D is known by the service enabling entity 106 , whether inferentially or explicitly. Since the secret S D is private between the certification entity 102 and the service enabling entity 106 , the means by which the device ID/secret pair(s) are transmitted is preferably as secure as the desired security by which the service itself is provisioned to the device 104 . In embodiments wherein the transmission of the device ID/secret pair is accomplished via insecure communication channels, the device/secret pair may be encrypted by the certification entity 102 before transmission and decrypted by the service enabling entity 106 after receipt. Encryption may be by use of public/private key pairs, SSL, or any other suitable means. In other embodiments, the device ID/secret pair may be transmitted by providing a copy of the ID/secret pairs in a tangible medium by secure means (e.g. courier). The certification entity 102 may also transmit a certificate revocation list (CRL) having information indicating which digital certificates have been revoked.
[0039] In block 204 , the service enabling entity 106 receives the device identifier/secret, (and the CRL if supplied) and stores them for later use. In block 206 , the certification entity 102 generates a cryptographic function of the secret H[S D ] CE .
[0040] Then, in block 208 , the certification entity 102 generates a digital certificate having the identifier ID D of the device 104 and the cryptographic function of the secret H[S D ] CE . The resulting leaf certificate C[ID D , H[S D ] CE ]CE PrCE , may be signed, for example, with the certification entity's private key Pr and along with the secret S D , is transmitted from the certification entity 102 to the device 104 as shown in block 208 .
[0041] The device 104 receives the signed digital leaf certificate C[ID D , H[S D ] CE ]CE PrCE and the secret S D and stores this information for later use, as shown in block 210 . The secret S D is transmitted to the device 104 securely, either by using a secure transmission channel or by securing the data itself via encryption. The transmission of the signed digital leaf certificate C[ID D , H[S D ] CE ]CE PrCE may likewise be accomplished by secure means.
[0042] The device 104 then transmits a service request to the service enabling entity 106 , as shown in block 212 . The service request includes the signed digital leaf certificate C[ID D , H[S D ] CE ]CE PrCE that the device 104 received from the certification entity 102 , and other information generated using the device secret S D according to a pre-agreed authentication protocol. The service enabling entity 106 receives the service request, as shown in block 214 .
[0043] The service enabling entity 106 may be the entity that provides the service itself (for example the service enabling entity 106 itself may transmit the desired information to the device 104 ). However, the service enabling entity 106 may simply provide the information required to enable the device 104 to receive the desired information, while another entity (such as a content provider) provides the desired information itself.
[0044] In block 216 , the service enabling entity 106 determines whether there are any certificates from the leaf certificate to a root of trust certificate that are unverified or revoked. This can be accomplished by performing certificate chain validation to verify that the leaf certificate chains up to the trusted root certificate. This process includes verifying the signature of the leaf certificate using the public key of the CA certificate issuing this certificate, and the other attributes in the leaf certificate such as validity period; verifying the next level CA certificate in the same way until the next level CA certificate is the trusted root certificate.
[0045] FIG. 3 is a diagram illustrating a typical 3-level certificate hierarchy a Root Certificate Authority (CA) self issuing a root certificate 302 and issuing a number of Subordinate CA (Sub-CA) certificates 304 - 1 through 304 - n . Each Sub-CA 304 - 1 through 304 - n is then used to issue leaf certificates 304 - 1 - 1 through 304 - n - z for a group or a class of devices. When a group or class of device certificates are to be revoked, (the serial number of) the Sub-CA certificate can be described by the CRL, instead of putting all (the serial numbers of) the device certificates into the CRL. Note that this mechanism exists for digital certificates that includes the public key of the entity to which the certificate is issued to. The current invention allows the same mechanism to be used for digital certificates that include a cryptographic function of a shared secret instead of a public key. Note that in the certificate hierarchy, the Root 302 and Sub-CA 304 - 1 through 304 - n certificates may be traditional standard digital certificates with public keys. Only the leaf certificates have the embedded cryptographic function of the secrets S D .
[0046] All of the certificates 302 , 304 - 1 through 304 - n , and 304 - 1 - 1 through 304 n - z may be issued and managed by different certification entities 106 or the same certification entity 106 . The root certificate 302 forms the root of trust and is communicated to the service enabling entity 106 using a secure channel, and thereby establishing the root of trust at the service enabling entity 106 . The root certification entity issues the sub-certification entity digital certificates 304 - 1 through 304 - n having an ID of the sub-certification entity (CEn), the public key of the sub-certification entity, and is signed by the private key of the entity issuing the root certificate. The public key of the entity issuing the root certificate can be used by to validate the sub-certification entity digital certificates 304 - 1 through 304 - n , thus rendering those digital certificates as trusted, by virtue of the root of trust. The sub-certification entities can issue the leaf digital certificates 304 - 1 - 1 through 304 - n - z , which are typically signed by the private key of sub-certification entity issuing the leaf certificate and include the identifier of the first entity 106 and a one-way cryptographic function of the secret S D . The leaf digital certificates 304 - 1 - 1 through 304 - n - z having the cryptographic function Fc (one way or two way) of the secret S D can be verified via the public key of the sub-certification entity issuing the leaf digital certificates.
[0047] The certification entity 102 may provide a list of a set of previously issued digital certificates that have been revoked. This certificate revocation list (CRL) may provided to the service enabling agency 106 periodically, aperiodically, in response to different service enablement requirements, as the devices 104 are enabled or disabled or simply as deemed necessary. In one embodiment, the CRL comprises a list revoked certificate serial numbers. However, in other embodiments, the CRL may comprise identifiers ID D of devices for which the certificates have been revoked instead of or in addition to the serial numbers of the revoked certificates. Alternatively, the certification authority may simply provide an updated list of valid certificate numbers, with the service enabling entity 106 simply presuming that a certificate has been revoked it if it is not included on the list. In yet another embodiment, the certification entity 102 revokes a Sub-CA that was used to issue certificates for a class or group of devices instead of listing the individual devices on the CRL.
[0048] Once verified, leaf digital certificate is determined to be sourced by the sub-certificate entity, and though further verification of the sub-CA certificate obtained from the certification entity 106 issuing the root certificate 302 , all of the digital certificates chained up to the root of trust can be determined to be verified. Further, each certificate up the chain of trust to the root certificate can be checked against a list of the serial numbers or identifiers or revoked certificates to determine if the certificate is revoked. For example, leaf certificate 304 - 2 - 3 may be verified though the root of trust issuing the root certificate 302 by verifying leaf certificate 304 - 2 - 3 and sub-CA certificate 304 - 2 , and assuring neither certificate has been revoked.
[0049] Returning to FIG. 2 , if any of the digital certificates from the leaf certificate to the root of trust are unverified or revoked, service is denied, as shown in blocks 216 and 222 . If not, the first entity identifier ID D and hashed secret H(S D ) CE is recovered from the verified leaf digital certificate, as shown in block 216 .
[0050] The service enabling entity 106 uses the device identifier ID D to look up the secret S D associated with the device 104 that sent the service request, and, using the same cryptographic function H[] as the certification entity generates its own version of the cryptographic function of the secret H[S D ] SEE , as shown in block 218 .
[0051] In block 220 , the service enabling entity-generated version of the cryptographic function of the secret associated with the identifier of the device 104 making the service request H[S D ] SEE is compared to the certification entity-generated version of the secret obtained from the digital certificate H[S D ] CE . If H[S D ] CE and H[S D ] SEE do not match, either the cryptographic function H[*] employed by the certification entity 102 and the service enabling entity 106 do not match, or the secrets operated on by those cryptographic functions do not match. Either case indicates a compromise or error, and block 220 passes processing to block 222 , in which the requested service is not provided. A message indicating that the requested service has been denied may be sent to the device 104 for presentation to the user of the device 104 , allowing the user of the device 104 to take remedial action, perhaps by contacting the provider of the requested service.
[0052] It is noted that ordinarily the expected match is such that H[S D ] CE and H[S D ] SEE are identical, but this need not be the case. In some circumstances only a portion of H[S D ] CE and H[S D ] SEE need to be equal for to establish a “match,” hence, for purposes of this disclosure the term “match” is used to convey that H[S D ] CE and H[S D ] SEE are close enough in relevant character to conclude that the same secret was used to generate both values.
[0053] Other embodiments are possible in which the same revocation functionality is provided with different CRL content or without the need for a CRL. For example, rather than transmitting a CRL, the certification entity 102 may occasionally transmit the device identity ID D and secret S D for all approved devices 104 to the service enabling entity 106 , and revocation of a particular device 104 may be effected by excluding the device identity ID D from that transmission. Or, the device identity ID D of devices 104 or the certificate serial numbers for which service is no longer approved may be included in the transmission, but the secret S D associated with revoked devices 104 set to zero or another value that will not result in the match described above. Further, an analogous functionality can be effected via change in the cryptographic function H[] instead of or in addition to the secret S D . For example, service enablement of all of the devices 104 or a particular class of devices 104 may be disabled if the cryptographic function H[] associated with those devices 104 is changed. The new cryptographic function H[] may be communicated to the service enabling entity 106 , thus invalidating any previously issued digital certificates C[] issued using the previous cryptographic function H[].
[0054] If H[S D ] CE and H[S D ] SEE match, the logic of block 220 enables provision of the requested service, as shown in block 224 . Such enablement may be made by the transmission of other information to the certification entity 102 , the device 104 or the entity actually providing the service to the device 104 . Alternatively, the service enabling entity 106 may make use of the secret as a shared secret to authenticate the device 104 using a predetermined authentication protocol. The secret S D may also include secret information about the device 104 such as device functional capabilities or the location of sensitive data stored by the device 104 , and this information can be used to enable the requested service.
Device Secrets Embedded in Certificates Using a Two-Way Cryptographic Function
[0055] This embodiment functions similarly to the embodiment described above except that a two-way cryptographic function is employed instead of a one-way cryptographic function. During device 104 manufacturing (or entity provisioning in general), the certification entity 102 or a key management function is responsible for provisioning identities ID D and secrets S D into devices 104 . In this case, the device 104 is provisioned with a digital certificate (C[]). The digital certificate C[] may not contain a public key as typically the case. Instead, a two-way cryptographic function of the secret S D is embedded in the digital certificate C[]. The two-way function may be a cryptographic secure function such as a symmetric encryption operation such as AES-encryption using a global AES provisioning key K known only to the certification entity 102 , and the service enabling entity 106 . The two-way function may also be a cryptographic function such as an asymmetric encryption operation such as RSA-encryption using a global RSA key pair: K e and K d , where the K e is an RSA public key used for encryption; and K d is a corresponding RSA private key used for decryption. Otherwise, the digital certificate C[] may include the usual information such as a serial number identifying the digital certificate, an identity for the device 104 , the identity of the certification entity 106 , as well as a digital signature covering the certificate and signed by the certification entity 102 .
[0056] The device 104 is then provided with the certificate with the embedded encrypted secret, and the secret S D . In this embodiment, the certification entity 102 need not provide a list of the device identifier/secret (ID D /S D ) pairs to the service enabling entity 106 , but provides (to the service enabling entity 106 ) the global provisioning key K that was used to encrypt the secrets S D embedded in the digital certificates provided to each device 104 . Alternatively, if the encryption algorithm (for encrypting the secret) is asymmetric, the certification entity and the service enabling entity may agree on the global pair of encryption and decryption keys, such that the certification entity 102 will use the encryption key (K e ) for encrypting the secret S D , and the service enabling entity 106 will use the corresponding decryption key (K d ) for decrypting the secret. One way of achieving this is for the service enabling entity to generate the key pair (K e and K d ), and then share the encryption key (K e ) with the certification entity.
[0057] To enable revocation of issued certificates, the certification entity 102 may provide a certificate revocation list (CRL) to the service enabling entity 106 . This CRL includes the serial number of the leaf digital certificates 304 - 1 - 1 though 304 - n - x that have been revoked or the identifiers of devices having revoked certificates, and may follow the standard X.509 specification. The certification entity 102 may also revoke one or more of the Sub-CAs 304 - 1 through 304 - n that was used to issue leaf certificates 304 - 1 - x through 304 - n - x for a class or group of devices 104 instead of listing the individual devices 104 on the CRL, thus revoking the certificates for all the devices 104 in that class or group. For example, revoking sub-CA certificate 304 - 1 will effectively revoke the digital certificates for leaf certificates 304 - 1 - 1 though 304 - 1 - x.
[0058] To obtain service, the device 104 makes a service request to the service enabling entity 106 , using a combination of its secret S D and its digital certificate to authenticate to the service enabling entity 104 , based on a predetermined authentication protocol. The service enabling entity 106 then performs a verification that includes (1) a standard certificate chain validation, which may include verifying the signature, validity period, and that the certificate chains up to the trusted root certificate 302 , and (2) verifying that the leaf digital certificate and all of the digital certificates chaining up to the root certificate have not been revoked according to the CRL. This may be accomplished by assuring that the serial number of the device certificate or any Sub-CA certificates linking the device certificate to the trusted root certificate is not on the CRL.
[0059] If successful, the service enabling entity 106 may extract the encrypted secret embedded in the certificate and decrypt it using the global decryption key K (or K d in the case of asymmetric encryption) provided by or agreed with the certification entity 102 , thus recovering the secret S D . The service enabling entity 106 may then use of the secret S D to enable the provision of the requested service to the device 104 . For example, the secret S D may used to authenticate the device using a pre-determined authentication protocol. In addition, secrets S D may contain secret information about the device 104 such as device capabilities.
[0060] FIG. 4 is a diagram illustrating further details of an exemplary embodiment of an authentication process using a two-way cryptographic function F C [] of a secret embedded in a digital certificate. In this embodiment, the device 104 is also associated with at least one identifier ID D , which may be unique to the device 104 or a class of devices 104 to be authenticated. Each device 104 may also be associated with multiple identifiers ID D1 , ID D2 . . . ID Dn wherein one of the identifiers is unique to the device 104 and another identifier is unique to a class or subset of the devices 104 .
[0061] The certification entity 102 includes a database or other memory storing each of the device identifiers ID D for each of the devices 104 . The database also stores a secret S D for each device 104 . In one embodiment, the secret S D is unique to the device 104 . Accordingly, at least one secret S D that is uniquely associated with a particular device 104 can be ascertained by the certification entity 102 .
[0062] As with the embodiment using the one-way cryptographic function, the certification entity 102 and service enabling entity 106 of this embodiment also stores or has access to one or more cryptographic functions F C [], and the certification entity 102 applies the cryptographic function F C [] to the secret S D , thereby generating a cryptographic function of the secret F C [S D ]. In this embodiment however, the cryptographic function is a two-way cryptographic function. For exemplary purposes, the two way cryptographic function is described hereafter as a encryption operation, E K [] but as described above, the two-way cryptographic function may be any two-way cryptographic function. Although the same encryption function E K [] may be used to encrypt or otherwise operate on the all of the secrets S D for all devices 104 , different encryption functions or encryption functions employing different provisioning keys KD may be used for different devices 104 or different device 104 classes to enhance security or to provide further authentication options. Further, as described above, the encryption function E K [] may be symmetric, e.g. the same provisioning key K is used to encrypt the data as is used to decrypt it D K []. Or, the encryption function may be asymmetric with keys Ke and Kd wherein Ke is an encryption key for the encryption function E Ke [] and Kd is an associated decryption key for the associated decryption function D Kd [].
[0063] As was the case with the one way cryptographic function embodiment the operations described below are described with respect to the enabling of a single device 104 , but it is noted that these operations apply as well in cases where multiple devices 104 are enabled.
[0064] Preliminary to the illustrated operations, the certification entity 102 and the service enabling facility 106 agree on the provisioning key or keys. If a symmetric encryption algorithm is used, the same provisioning key K is used for both encryption key and decryption, whereas if an asymmetric encryption algorithm is used, an encryption key Ke is used for encryption and a decryption key Kd is used for decryption. Hence, the symmetric encryption algorithm embodiment may be seen as a special case of the asymmetric encryption algorithm embodiment wherein Ke=Kd. FIG. 4 is discussed with regard to the asymmetric encryption algorithm embodiment, but an analogous result may be realized in the symmetrical algorithm embodiment wherein the provisioning key K=Ke=Kd.
[0065] Either entity may generate the provisioning key K for use with symmetric encryption algorithms and securely share with the other entity. Or both entities may execute a key agreement algorithm to arrive at the same key together (e.g. using the Diffie-Hellman algorithm).
[0066] If an asymmetric encryption algorithm is used, then a key pair including an encryption key Ke and an associated decryption key Kd is needed. In this case, the certification entity 106 needs to know the encryption key Ke, while the service enabling facility needs to know the decryption key Kd. One way of achieving this is for the service enabling entity 106 to generate the key pair (Ke and Kd), and then share the encryption key (Ke) with the certification entity.
[0067] In block 406 , the certification entity 102 generates a two-way cryptographic function of the secret E Ke [S D ], wherein the encryption key Ke equals the decryption key Kd in the symmetric encryption algorithm embodiment. The two-way cryptographic function may comprise an AES-encryption function performed according to key Ke or an RSA-encryption function performed according to key Ke.
[0068] Then, in block 408 , the certification entity 102 generates a digital certificate having the identifier ID D of the device 104 and the cryptographic function of the secret E Ke [S D ]. The resulting certificate C[ID D , E Ke [S D ]] is signed by the private key of the certification entity to produce C[ID D , E Ke [S D ]]CE PrCE and is transmitted from the certification entity 102 to the device 104 as shown in block 408 .
[0069] The device 104 receives the digital certificate C[ID D , E Ke [S D ]]CE PrCE and the secret S D , and stores this information for later use, as shown in block 410 . Preferably, this information is transmitted by secure means, either by using a secure transmission channel or by securing the data itself via encryption. In a preferred embodiment, the secret S D and signed digital certificate C[ID D , E Ke [S D ]]CE PrCE are transmitted in the same message, but this need not be the case.
[0070] The device 104 then transmits a service request to the service enabling entity 106 , as shown in block 412 . The service request includes the signed digital certificate C[ID D , E Ke [S D ]]CE PrCE that the device received from the certification entity 102 and may include other information generated based on the secret S D according to a predetermined authentication algorithm. The service enabling entity 106 receives the service request, as shown in block 414 .
[0071] As before, the service enabling entity 106 may be the entity that provides the service itself (for example the service enabling entity 106 itself may transmit the desired information to the device 104 ). However, the service enabling entity 106 may simply provide the information required to enable the device 104 to receive the desired data, while another entity provides the desired data itself.
[0072] As shown in block 416 , the service enabling entity 106 then verifies the leaf digital certificate and all the certificates in the chain of certificates extending to the root of trust, and assures that the certificates in the chain are not revoked. This can be accomplished using the CRL transmitted to the service enabling entity 106 in blocks 402 - 404 . If any certificate in the chain is unverified or revoked, service is denied, as shown in block 418 . If all of the certificates in the chain are verified and unrevoked. The service enabling agency 106 recover the device 104 identifier ID D and the cryptographic function of the secret created by the certification entity, E Ke [S D ] from the digital certificate C[ID D , E Ke [S D ]] to, as shown in block 416 .
[0073] The service enabling entity 106 then decrypts the value E Ke [S D ] using the cryptographic function D Kd [E Ke [S D ]] to recover the secret S D , as shown in block 422 .
[0074] This certificate revocation list (CRL) is provided to the service enabling agency 106 as needed, and may be transmitted periodically, aperiodically, in response to different service enablement requirements, or as the devices 104 are enabled or disabled. In one embodiment, the CRL comprises a list of device 104 identified by the serial number of the digital certificates. In another embodiment, the CRL may also comprise serial numbers of Sub-CA certificates that have been revoked. In this case, all device certificates issued under a revoked Sub-CA will also be considered revoked, although the serial numbers of the individual device certificates may not listed in the CRLs. This approach allows an efficient way of revoking a group or a class of devices. In block 424 , the service enabling entity 106 checks to see if the device has been revoked according to the CRL. If so, block 424 routes processing to block 422 .
[0075] Other embodiments are possible in which the same revocation functionality is provided with different CRL content or without the need for a CRL, as described with respect to the one way cryptographic function embodiment.
[0076] If the device 104 making the request is not revoked according to the previous described check based on the CRL, block 424 uses the secret S D for enabling provision of the requested service. For example, the service enabling entity 106 may make use of the secret as a shared secret to authenticate the device 104 using a predetermined authentication protocol. The secret S D may also include secret information about the device 104 such as device functional capabilities or the location of sensitive data stored by the device 104 , and this information can be used to enable the requested service.
[0077] The foregoing embodiments permit the use of standard digital certificates and revocation mechanisms for use in devices 104 that use symmetric cryptographic secrets rather than encryption techniques such as public/private key pairs. Further, the foregoing also permits issuance of digital certificates under a Sub-CA certificate for a class or category of devices (e.g. based on device 104 model, country where the device 104 is licensed to be used, manufacturer, or manufacturer location). This permits revocation of the digital certificates for a particular device class as easily as revoking the Sub-CA certificate. Revoking a single digital certificate is more scalable and less error prone than maintaining an extensive list of devices 104 and their certificate status or a list of devices with revoked certificates, when such devices can be grouped by class.
[0078] To assist in the generation and revocation of certificates applied to a category or class of device 104 , the certification entity 102 may be logically partitioned into one or more sub-certification entities 102 S 1 , 102 S 2 , each of which sub-certification entities may issue, manage, and revoke digital certificates applied to a subset of the devices 104 S 1 and 104 S 2 , respectively as described above. For example, certification sub-entity 102 S 1 may issue, manage, and revoke digital certificates 304 - 1 through 304 - x for device subset 104 S 1 , which may include, for example, x devices of a particular model number or a particular capability.
Hardware Environment
[0079] FIG. 5 is a diagram illustrating an exemplary computer system 500 that could be used to implement elements of the present invention, including the certification entity 102 , the device 104 and the service enabling entity 106 . The computer 502 comprises a general purpose hardware processor 504 A and/or a special purpose hardware processor 504 B (hereinafter alternatively collectively referred to as processor 504 ) and a memory 506 , such as random access memory (RAM). The computer 502 may be coupled to other devices, including input/output (I/O) devices such as a keyboard 514 , a mouse device 516 and a printer 528 .
[0080] In one embodiment, the computer 502 operates by the general purpose processor 504 A performing instructions defined by the computer program 510 under control of an operating system 508 . The computer program 510 and/or the operating system 508 may be stored in the memory 506 and may interface with the user and/or other devices to accept input and commands and, based on such input and commands and the instructions defined by the computer program 510 and operating system 508 to provide output and results.
[0081] Output/results may be presented on the display 522 or provided to another device for presentation or further processing or action. In one embodiment, the display 522 comprises a liquid crystal display (LCD) having a plurality of separately addressable pixels formed by liquid crystals. Each pixel of the display 522 changes to an opaque or translucent state to form a part of the image on the display in response to the data or information generated by the processor 504 from the application of the instructions of the computer program 510 and/or operating system 508 to the input and commands. Other display 522 types also include picture elements that change state in order to create the image presented on the display 522 . The image may be provided through a graphical user interface (GUI) module 518 A. Although the GUI module 518 A is depicted as a separate module, the instructions performing the GUI functions can be resident or distributed in the operating system 508 , the computer program 510 , or implemented with special purpose memory and processors.
[0082] Some or all of the operations performed by the computer 502 according to the computer program 510 instructions may be implemented in a special purpose processor 504 B. In this embodiment, some or all of the computer program 510 instructions may be implemented via firmware instructions stored in a read only memory (ROM), a programmable read only memory (PROM) or flash memory within the special purpose processor 504 B or in memory 506 . The special purpose processor 504 B may also be hardwired through circuit design to perform some or all of the operations to implement the present invention. Further, the special purpose processor 504 B may be a hybrid processor, which includes dedicated circuitry for performing a subset of functions, and other circuits for performing more general functions such as responding to computer program instructions. In one embodiment, the special purpose processor is an application specific integrated circuit (ASIC).
[0083] The computer 502 may also implement a compiler 512 which allows an application program 510 written in a programming language such as COBOL, C++, FORTRAN, or other language to be translated into processor 504 readable code. After completion, the application or computer program 510 accesses and manipulates data accepted from I/O devices and stored in the memory 506 of the computer 502 using the relationships and logic that was generated using the compiler 512 .
[0084] The computer 502 also optionally comprises an external communication device such as a modem, satellite link, Ethernet card, or other device for accepting input from and providing output to other computers.
[0085] In one embodiment, instructions implementing the operating system 508 , the computer program 510 , and/or the compiler 512 are tangibly embodied in a computer-readable medium, e.g., data storage device 520 , which could include one or more fixed or removable data storage devices, such as a zip drive, floppy disc drive 524 , hard drive, CD-ROM drive, tape drive, or a flash drive. Further, the operating system 508 and the computer program 510 are comprised of computer program instructions which, when accessed, read and executed by the computer 502 , causes the computer 502 to perform the steps necessary to implement and/or use the present invention or to load the program of instructions into a memory, thus creating a special purpose data structure causing the computer to operate as a specially programmed computer executing the method steps described herein. Computer program 510 and/or operating instructions may also be tangibly embodied in memory 506 and/or data communications devices 530 , thereby making a computer program product or article of manufacture according to the invention. As such, the terms “article of manufacture,” “program storage device” and “computer program product” or “computer readable storage device” as used herein are intended to encompass a computer program accessible from any computer readable device or media.
[0086] Of course, those skilled in the art will recognize that any combination of the above components, or any number of different components, peripherals, and other devices, may be used with the computer 502 .
[0087] Although the term “computer” is referred to herein, it is understood that the computer may include portable devices such as cellphones, portable MP3 players, video game consoles, notebook computers, pocket computers, or any other device with suitable processing, communication, and input/output capability.
CONCLUSION
[0088] This concludes the description of the preferred embodiments of the present invention. The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching.
[0089] It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. The above specification, examples and data provide a complete description of the manufacture and use of the apparatus and method of the invention. Since many embodiments of the invention can be made without departing from the scope of the invention, the invention resides in the claims hereinafter appended. | A method and system is provided for embedding cryptographically modified versions of secret in digital certificates for use in authenticating devices and in providing services subject to conditional access conditions. | 7 |
BACKGROUND OF THE INVENTION
German Patent Application (OS) No. 1,506,473 describes a safety brake which decelerates an elevator when a predetermined speed of rotation of the transmission shaft is exceeded and which is driven via a gear wheel meshing with a rack as guide means. The safety brake comprises a speed limiter in the form of a centrifugal governor with centrifugal weights mounted on the transmission shaft to be decelerated, a brake structure in the form of a bell which surrounds the speed limiter and which is engaged by the centrifugal weights of the speed limiter when a predetermined speed of rotation is exceeded and which is mounted for rotation in a housing, a means for axial displacement of the brake bell, and a means for decelerating the transmission shaft when the brake bell is axially shifted. In such prior art safety brake the centrifugal weights snugly engage the inside of the brake bell to thereby rotate it. The means for axial displacement of the brake bell consists of a spindle with a spindle sleeve secured against rotation which urges the brake bell against a stationary brake member thereby to decelerate it when it is caused to rotate by actuation of the centrifugal brake. Since the braking force is transmitted via the centrifugal weights to the transmission shaft, the operational safety of the safety brake depends on the snug engagement of the centrifugal weights. The edges of the centrifugal weights responsible for the form-locking engagement may partially break away during engagement so that snug fit becomes difficult. Moreover, during the braking operation the braking force constantly increases. For a short stopping distance the braking force therefore must be very high at the end of the braking operation, which puts the elevator guidance and all supporting parts under heavy stress.
SUMMARY OF THE INVENTION
The object of the present invention resides in the provision of a safety brake which reliably responds within a vary narrow speed range of the transmission shaft and whose entire braking operation takes place at substantially constant braking force or deceleration.
This object is realized in that the centrifugal weights are in force-locking engagement with the inside of a brake bell and the transmission shaft is directly decelerated by a brake disc mounted thereon, the bottom of the brake bell serving as a stationary brake member, after the brake bell has come to a standstill which previously was caused to rotate by the centrifugal brake and axially shifted.
Preferably a means is provided by which the brake bell is secured against rotation as long as the torque generated by the centrifugal brake does not exceed a predetermined level. Preferably a means is provided to limit the amount of rotation of the brake bell and thus the braking force.
DESCRIPTION OF THE DRAWINGS
Examples of the invention will be described in more detail with reference to the drawings wherein:
FIG. 1 is a safety brake in longitudinal section;
FIG. 2 shows a section along line 2--2 in FIG. 1;
FIG. 3 is a perspective view of one of the conical spiral discs serving to axially shift the brake bell;
FIG. 4 illustrates an embodiment of the safety brake with safety switch and limitation of the amount of rotation of the brake bell;
FIG. 5 shows details of the brake disc; and
FIG. 6 is a perspective view of a brake bell.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The safety brake is connected via the transmission shaft 1 to a worm or spur gear mechanism which converts the normal speed of travel of the elevator of 0.2 m/sec., for example, to 1400 rpm of the transmission shaft, for instance. Said worm or spur gear mechanism is independent of the drive unit of the elevator or the cableway. The transmission shaft 1 is driven, for example, via the worm or spur gear mechanism, by a gear engaging a perforated rail mounted to the elevator guide means.
The safety brake comprises a speed limiter 2 and a brake disc 3 both of which are mounted on the transmission shaft 1, the brake disc 3 being fixedly mounted on the transmission shaft 1, while the speed limiter 2 is axially slidable thereon, of a brake bell 4 surrounding the speed limiter 2 and the brake disc 3, two conical spiral discs 5 and a housing 6 which surrounds the entire safety brake. One of the conical spiral discs is mounted at the outside of the brake bell 4, the other one at the bottom of the housing 6.
The speed limiter 2 is shown in detail in FIG. 2. The speed limiter has a profile hub 10 seated on the transmission shaft 1 and is caused to rotate by the transmission shaft through a follower key 7, but the hub 10 being slidable on shaft 1. Cup springs 20 urge the speed limiter 2 away from the cap 8 of the worm or spur gear mechanism. The profile hub 10, when viewed in cross section, comprises two oppositely disposed regions 11 of reduced radius and two oppositely disposed regions 12 of increased diameter. The transition from a region 11 of reduced diameter to a region 12 of increased diameter each forms one radially extending step. The speed limiter 2 further comprises centrifugal weights 13 which are held by tension springs 14 and bear against the regions 11 of reduced diameter. In FIG. 2 two tension springs 14 are shown which are fastened to the two centrifugal weights. The centrifugal weights have the cross section of ring segments and the outer surface of each centrifugal weight 13 is provided with a brake lining 15.
The speed limiter 2 acts as a centrifugal brake. The profile hub 10 and the centrifugal weights 13 urged against the profile hub are caused to rotate by the transmission shaft 1. The tensile force of the springs is dimensioned such that at normal speed of travel it exceeds the centrifugal force exerted by the centrifugal weights 13. At normal speed of travel the centrifugal weights 13 bear against the regions 11 of reduced diameter of the profile hub. When the normal speed of travel is exceeded the centrifugal force exerted by the centrifugal weights 13 becomes greater than the tensile force of the tension springs 14 and the centrifugal weights 13 move away from the profile hub 10. The brake linings 15 of the centrifugal weights 13 thereby come to lie against the inner periphery of the brake bell 4 causing it to rotate.
Furthermore, on the transmission shaft 1 a brake disc 3 is mounted. The mounting if effected suitably also by the follower key 7. In contrast to the speed limiter 2 the brake disc 3 is not axially slidable. The brake disc 3 is mounted at the end of the transmission shaft 1 and is of cylindrical shape. The diameter of the brake disc 3 corresponds to the diameter of the speed limiter 2 determined by the brake linings 15, or is somewhat less than that.
The speed limiter 2 and the brake disc 3 are surrounded with small clearance by a brake bell 4. The brake bell 4 has the shape of a hollow cylinder open at one end. From the closed end of the cylinder an extension or stub shaft 16 extends outwardly. When the brake bell 4 is shifted over the brake disc 3 onto the speed limiter 2, the extension 16 is in axial alignment with the transmission shaft 1.
The brake bell 4 is surrounded, in turn, by a housing 6 which also has the shape of a hollow cylinder open at one end. The housing 6 of the safety brake is fixedly mounted to the elevator cabin or the cable car, for example via the cap 8 of the worm or spur gear mechanism. The brake bell 4 is mounted for rotation within the housing. The mounting is effected at the open end of the brake bell 4 by a sliding ring 17 provided at the inner periphery of the housing 6 and at the closed end of the brake bell 4 by the extension 16 which extends through a central opening at the closed end of the housing 6 and is supported for rotation in said opening. The end of the extension 16 extending from the housing is suitably designed for lever engagement in that it has a tetrahedral or hexahedral periphery or is provided with radial bores.
Between the brake bell 4 and the housing 6 there are two conical spiral discs 5 one of which is mounted outside at the surface forming the closed end of the brake bell 4, while the other one is mounted inside at the bottom of the housing 6. The outer diameter of the conical spiral discs suitably corresponds to the outer diameter of the brake bell 4. FIG. 3 shows an example for a conical spiral disc which is useful for the present invention. The thickness of the conical spiral discs uniformly increases along its periphery. Between the points of minimum and maximum thickness a step 18 is formed. The conical spiral discs are mounted at the brake bell 4 and at the housing 6, respectively, with their flat sides, i.e. the sides forming no step. The conical spiral discs may be understood as a flat wedge whose two ends have been bent toward each other to thereby form a flat circular disc. The conical spiral discs may be designed as a closed ring or as a ring having a narrow gap between the points of minimum and maximum thickness. Both conical spiral discs are mutually complementary, i.e. the thickness increase of the one spiral disc corresponds to an equal thickness reduction in the other spiral disc. The direction in which the thickness of the spiral disc mounted at the brake bell 4 decreases, corresponds to the direction of rotation of the transmission shaft 1 during downward travel of the cable car or the elevator cabin. In normal operation the conical spiral discs are lying one against the other with the front faces of the step 18 abutting with each other. When the brake drum is rotated in the direction in which the transmission shaft 1 rotates during downward travel of the elevator cabin (in FIG. 3 this direction is indicated by an arrow under the assumption that the conical spiral disc shown in FIG. 3 is mounted at the brake bell 4), the brake drum 4 in FIG. 1 is urged toward the left hand side, i.e. away from the bottom of the housing 6 and towards the brake disc 3. The planar inner side of the brake bell 4 is provided with a brake lining 19 and the axial spacing between the brake lining 19 and the brake disc 3 is less than the height of the step 18 and preferably less than half the height of step 18. For safety reasons it is preferred that said axial distance corresponds to one fourth of the height of step 18. The height of the step 18 is understood to be the difference between the maximum and the minimum thickness of a conical spiral disc 5. As a consequence, the brake bell 4 can rotate by not more than one full rotation (in preferred embodiments half or a quarter rotation) and the brake bell 4 halted after a complete or a quarter rotation brakes the brake disc 3, and thus the elevator via the transmission shaft 1 and the gear engaging the rack.
Hereafter the mode of operation of the described safety brake will be explained. When a predetermined speed of downward travel is exceeded due to failure of the driving unit or breaking of the lift cable, and if thereby the speed of rotation of the transmission shaft 1 becomes so high that the force active at the centrifugal weights 13 exceeds the force of the tension springs 14, the centrifugal weights 13 will be urged radially outwardly and away from the transmission shaft 1. The centrifugal weights 13 which perform at the same time the function of brake jaws then engage the inner periphery of the brake bell 4 and set it in rotation. Due to the action of the conical spiral disc 5, the rotary motion of the brake bell shifts the latter towards the brake disc 3. The brake bell 4, on account of the engaging brake linings 15 of the centrifugal weights 13, in turn shifts the axially shiftable speed limiter 2 against the force of the cup springs 20. After a relatively minor rotation the brake bell 4 comes to a standstill because the axial space between the brake lining 19 on the inner side of the brake bell and the brake disk 3 becomes too small for further rotation. Owing to their conicity, the spiral discs 5 shift the brake bell 4 not only towards the brake disc 3 but simultaneously urge the brake bell 4 against the brake disc 3. The brake disc 3 is rapidly decelerated by the brake bell 4 which has come to a standstill so that the elevator cabin or the cable car comes to a stop.
As soon as the speed of travel drops below the predetermined speed level, the brake linings 15 disengage from the brake bell 4 and the speed limiter is urged back into its inoperative position by the cup springs 20.
When the cabin or the cable car is to be set in motion again the brake bell must first be unlocked by means of a lever which must engage the end of the extension 16. The rotary motion required for unlocking the brake bell is contrary to the path travelled by the brake bell during braking action. The safety brake may also be unlocked by opposite direction of travel.
Furthermore, means are provided which prevent accidental rotation of the brake bell 4 toward the brake disc 3. This means may consist of a catch resembling a snap lock which may be unlocked by the exertion of a relatively minor force. The catch may consist of an adjusting screw 9 inserted into a threaded bore in the housing 6 and urging, via a helical spring 21, a ball 22 into a flat frusto-conical recess 23 in brake bell 4. Suitably a plurality of such catch means are spaced equidistantly around the periphery of the housing 6.
The brake linings 15 and 19 are commercial plastic brake linings.
The sliding ring 17 should preferably be made of bronze. All the other parts may be made of steel.
FIGS. 4, 5 and 6 show an embodiment of the safety brake in which the braking force is adjustable by means of a stop screw 25 which engages a slot 24 in the planar outer side of the brake bell 4. FIG. 4 additionally shows a safety switch mechanism 26.
The stop screw 25 is screwed into a threaded bore in the bottom of the housing 6 and extends somewhat into the interior of the housing 6. The stop screw 25 engages a slot 24 provided in the planar outer side of the brake bell 4 in the inner region not covered by the conical spiral disc 5. The slot 24 curves in a circular arc through a predetermined angle. The engagement of stop screw 25 and slot 24 limits the rotary motion of the brake bell 4, thus limiting the maximum axial displacement of the brake bell 4. Since the braking force depends on the amount of axial displacement of the brake bell 4, this simultaneously limits the braking force. The braking force may be varied by a change of the length or of the arc measure of the slot 24.
In the embodiment shown in FIGS. 4 and 6 the conical spiral discs 5 are not separate parts but are made integral with the brake bell 4 and the top of the housing 6, respectively. The slot 24 generally does not extend through the bottom of the brake bell 4.
It is sufficient when the slot 24 is deep enough to ensure safe engagement between stop screw 25 and slot 24.
As shown in FIGS. 4 and 5, in this embodiment the brake disc 3 is assembled from a plurality of parts such that the brake lining 19, which in this embodiment is fastened to the brake disc rather than to the bottom of the brake bell 4, uniformly engages the bottom of the brake bell 4. The brake disc 3 consists of a clutch disc 30 with axial extension on which an annular brake lining 19. The brake lining support 31 is urged away from the clutch disc 30 by a spring, e.g., a cup spring 32. By suitable means, e.g., screws 33, the maximum distance of the brake lining support 31 from the clutch disc 30 is determined. The screws 33 are fastened in the brake lining support 31 and extend through bores in the clutch disc 30 so as to be shiftable in said bores.
The cup spring 32 is biased and produces the force which urges the brake lining support 31 against the brake bell 4 so that the resulting braking moment depends on the biasing and the characteristic of the cup spring 32. In addition, and as mentioned before, the braking moment also depends on the arc measure of the slot 24 or the amount of axial displacement of the brake bell 4 which is equal to the movement of the cup spring 32 plus the distance of the planar inside of the brake bell 4 from the brake disc 3 or the brake lining support 31 in inoperative position.
The cup spring 32 additionally ensures that the safety brake holds the elevator after the braking operation so that the elevator cannot intermittently slide or jolt downward due to minor canting of the brake bell 4 relative to the transmission shaft 1 or due to an eccentricity.
The bolt 34 transmits the rotary motion of the clutch disc 30 to the brake lining support 31. FIG. 4 shows two bolts 34. The number of bolts should be selected such that they are able to transmit to the clutch disc 30, the torque resulting from braking. The bolts 34 are mounted in blind bores around the periphery of the extension of the clutch disc 30 and engage longitudinal grooves on the inside of the brake lining support 31. The clutch disc 30 is screwed to the butt of the transmission shaft 1 and transmits the braking force to the latter by way of a follower key 7.
The embodiment of the brake disc 3 illustrated in FIGS. 4 and 5 ensures smooth response of the safety brake under the action of the adjusted braking force.
The safety switch mechanism 26 may consist of a cam 27 by which a limit switch 29 is actuated by way of a roller tappet 28 such as to interrupt current flow to the elevator or cableway motor. The cam 27 is secured to the extension 16 of the brake bell 4 extending from the housing 6 so that it rotates together with the brake bell 4. The limit switch 29 and the cam 27 are designed such that upon actuation of the safety brake, i.e., upon rotation of the brake bell corresponding to the arc measure of the slot 24, the limit switch 29 interrupts the flow of current to the drive motor.
Otherwise the construction and the function of the embodiment shown in FIGS. 4 to 6 is the same as in the embodiment of FIGS. 1 to 3.
Disengagement of the safety brake may be effected by travel in opposite direction thereby the brake bell 4 wedged against the brake lining is given an angular momentum which returns it to its initial position, said angular momentum being sufficient to completely return the brake bell to its basic position where the ball 22 snaps into the recess 23, after the brake bell 4 has come free from the brake lining 19. The axial shifting of the brake bell 4 away from the brake disc 3 is effected by the momentum produced by the cup spring 32. As soon as the basic position of the safety brake is reached, the flow of current to the drive motor is simultaneously re-established by the safety circuit mechanism 26.
Between the cam 27 and the top of the housing 6 a compression spring 35 may be provided which urges the brake bell away from the brake disc 3, i.e., which slightly urges the two conical spiral discs against each other and stabilizes the brake bell 4 in its inoperative position. As the safety brake is unlocked by travel in the opposite direction the steps 18 in the conical spiral 5 clash against each other at high speed and throw the brake bell 4 out of the position again that it is supposed to reach by the cooperation of the helical compression spring 21, the ball 22, and the recess 23. The compression spring 35 attenuates the impact of steps 18 against each other and thus stabilize the brake bell 4. The impact effect, however, occurs only at high speeds of the transmission shaft 1. If the transmission shaft has a speed of about 500 rpm at normal speed of travel of an elevator, the impact between the steps 18 is so insignificant that a compression spring 35 is not required. However, at higher speeds of 1000 rpm or more, for example, it is advisable to provide the compression spring 35 in order to be able to hold the safety brake in this position even after complete disengagement. Of course, the compression spring 35 must not be so strong that it resists the axial displacement of the brake bell 4 as the safety brake is set in operation, thus counteracting the effect of the cup spring 32.
In the embodiment of FIGS. 4 to 6 only a single slot 24 and a single stop screw 25 are provided. In the planar outer side of the brake bell 4 also a plurality of slots may be provided which may be spaced the same or different distances from the longitudinal axis of the safety brake. For each slot 24 a threaded bore for a stop screw 25 cooperating with the slot is provided in the bottom of the housing 6. If the various slots have various arc measures, i.e., if they have different length, the angle of rotation of the brake bell 4 will vary depending on the threaded bore into which the step screw 25 is screwed. The slots 24 need not be provided in the planar outside of the brake bell 4, they may also be provided on the cylindrical outer face of the brake bell 4.
All the parts of the safety brake are protected against corrosion by suitable methods, preferably by copper plating, subsequent application of a cadmium coating by electroplating, electrodeposition from cyanide-containing cadmium salt solutions, by means of cadmium anodes, or by vacuum vapor coating and finally chromatizing (DIN 50 902). The cadmium coating simultaneously reduces friction within the sliding fit for the bell, between the spiral discs and between the clutch plate and the brake lining support. The safety brake is suited to decelerate transmission shafts operating at very high speeds up to 10,000 revolutions per minute or more, as well as shafts rotating at speeds as low as 3 rpm. Preferably the worm or spur gear mechanism to which the transmission shaft is connected is designed such that the transmission shaft rotates at a speed between 300 and 1500 rpm at normal speed of travel of the elevator cabin or the cable car. At speeds below 300 rpm the trigger speed of the speed limiter cannot be precisely adjusted. At higher speeds, however, the safety brake is capable of responding to the trigger speed with a precision of ±1.25%. The safety brake is not susceptible to shock, and there is no risk that, for example, a strong impact will trigger the safety brake although the triggering speed of the transmission shaft 1 is not reached. The safety brake is quick to respond and the so-called dead time (time interval until the full braking force is reached) is less than 0.1 second.
In case part of the safety brake fails to operate, the speed limiter 2 alone will prevent elevator free fall descent down because the speed of the transmission shaft cannot substantially exceed the triggering speed, i.e., the speed at which the centrifugal weights 13 overcome the force of the tension springs 14 by virtue of the centrifugal force, owing to the speed limiter 2. | A safety brake is provided for elevators, aerial cableways and the like which prevents unchecked downward travel of the cable car or the elevator cabin in case the lifting or drive cable breaks, or the transmission gear mechanism or the drive motor fails. | 5 |
INTRODUCTION AND BACKGROUND
An oscilloscope is a wonderful tool for discovering how analog electrical signals behave with the passage of time. Particularly so for signals that we classify as ‘rapid,’ by which we mean that the variation in the signal is too fast for strip chart recorders and data loggers. Thus, we tend to think of recorders and loggers as tools for ‘steady state’ signals whose values may be expected to change as required by external conditions, but not for most signals that have ‘waveforms.’ Indeed, the principle excellence of oscillographic techniques is that they allow us to ‘see’ events whose time scales are enumerated in milliseconds, microseconds, or, nanoseconds. Thus it is that analog oscilloscopes have selectable horizontal ‘sweep speeds’ calibrated in terms of time/division for a graticule on the CRT's faceplate.
Often, what was required from early oscilloscopes was information about the amplitude or shape of a truly cyclic signal, such as produced by an oscillator, or received from an antenna or microphone, and then amplified. The two and three inch round CRTs (Cathode Ray Tubes) of early ‘scopes were thought large enough to adequately reveal such information for one to, say, five, cycles of such signal behavior. By and large, it was thought sufficient for one instance of a signal's cycle to represent the others, and unique or unusual sequences of disparate events that were too long to fit onto the viewing area of the CRT as individually recognizable events were problematic: the sweep speed needs to be at least as fast as required to resolve the shortest event into a recognizable portion of the trace, while the length needed for a trace is determined by the separation between events in the sequence, but the CRT's size limits the length of that trace. It sometimes happened that the sweep speed that produced a trace that encompassed all the events of interest was slow enough that events in the trace were crowded together to the extent that the events could not be distinguished from one another. CRTs of five inch diameter (and various rectangular sizes) later came into widespread use, and while that was a welcome development (the traces weren't so tiny, anymore), it scarcely solved the crowding problem described above.
The community of ‘scope manufacturers was first obliged to provide an X5 and an X10 control that amplified the sweep voltage applied to the horizontal deflection plates, resulting in most of the trace being off screen. The horizontal position control determined what portion was on screen, and allowed the operator to ‘pan’ along the whole trace, provided it was recurrent, and stable, etc. This allowed an expanded view of events that were too crowded to be distinguished at the normal ‘X1’ setting. But if a ‘scope had to emulate a strip chart recorder for an extended high speed event that occurred just once or infrequently (studies of nuclear explosions come to mind), a moving film camera was fitted to the CRT and the ‘scope’s internal sweep was disabled.
Later, when triggered sweeps became common, the notion of delayed sweep allowed a more elegant solution than simple horizontal magnification (which nevertheless remained on the front panels of most ‘scopes). With delayed sweep a trigger initiates a variably selectable delay afterwhich the sweep is performed to create a trace. Panning is now accomplished by varying the calibrated delay.
As digital computation and digital control mechanisms became more pervasive the notion that one cycle of a signal was as good as any other became less applicable, and ‘scope users in these new digital applications became creative in how to make the best use of the techniques just described to create the needed traces for sequences of disparate events. It was thus a welcome development when the DSO (Digital Sampling Oscilloscope) arrived with its memory.
The fact that a DSO has memory gives it at least two distinct advantages over its analog predecessor. The first of these is related to bandwidth. It turns out that to get all the components in the vertical path of an analog ‘scope to perform at high bandwidths is a significant engineering challenge. DC coupled amplifiers that will produce a hundred or more volts peak to peak at several gigahertz at a CRT's vertical deflection plates are not practical, not to mention that the writing rate for a normal CRT does not go that high. Even before the DSO, the highest frequency analog ‘scopes were sampling analog oscilloscopes (as opposed to ‘real time’ analog oscilloscopes) that relied upon regularly spaced (analog!) samples taken upon a repetitive waveform to recreate on the CRT an analog image of the input waveform. These analog samples (say, the charge on a tiny capacitance acquired during a very brief duration), when considered in sequence, formed a ‘slow moving’ analog voltage replica of the (‘fast moving’) applied input voltage. What the DSO does is take the sample and digitize it, and then store it in an Acquisition Memory operated as if it were a circular buffer. (The DSO might take the samples consecutively within a segment of an applied signal and at a very high rate for ‘real time’ operation or for ‘single shot’ operation, or it might let locations sampled at a slower rate drift across repeated cycles of the input signal for ‘repetitive sampling,’ also called ‘equivalent time’ operation.) It is then evident that once the digitized values are stored, they can be ‘played back’ at a convenient rate from a Frame Buffer using low cost raster scan techniques that are not affected by the possible high frequency (say, 20 GHz or more) nature of the applied input signal. The underlying technical issue here is that it is far easier to design and build high speed samplers and ADCs (Analog to Digital Converters) and fashion a high speed path into memory (say, by interleaving many banks of memory) than it is to design and build the equivalent actual analog signal path (amplifiers and CRT).
The second distinct advantage of the DSO over its analog parent arises because of the persistence of memory. Whereas the analog ‘scope was forced to “view the signal end-on, process it in real time and get rid the fleeting result” right away, the DSO “views the signal end-on but creates a ‘side view’ of its activity over a segment of time that is ‘permanent’” and that can be leisurely, as it were, processed, viewed and otherwise given a suitable disposition.
The notion that the signal's waveform is represented by a collection of digitized values in a memory allows a powerful extension of the notion of triggering. Whereas the analog ‘scope could only unblank the beam and start the sweep subsequent to the occurrence of a trigger, the DSO can allow the operator to decide where the trigger event is to be relative to the start and end of the Acquisition Record. So, for example, if the creation of the Acquisition Record is continued until it is about to overwrite in the (circular) Acquisition Memory the location corresponding to (or most nearly corresponding to) the time when the trigger event occurred, then the Acquisition Record will produce a trace of activity occurring subsequent to the trigger, just as for analog ‘scopes. But if the creation of the Acquisition Record is stopped immediately upon the occurrence of the trigger event, then what the Acquisition Record contains is the activity that lead up to the trigger (so called ‘negative time’). This can be an invaluable feature that simply isn't possible with the old analog architecture, and we may speculate that this, in conjunction with the bandwidth issue, is what accounts for the decline in popularity of the ‘laboratory grade’ analog oscilloscope in favor of the modem DSO. If the creation of the Acquisition Record is continued for, say, half its length, then we have captured activity both before and after the triggering event.
Now let the Acquisition Record be substantial in size, perhaps large enough that it is apparently very many times wider than the Frame Buffer. A Frame Buffer might have, say, just one or two thousand addressable locations, because the physical display device has just that many horizontal pixel locations. But if the Acquisition Record has several million (or several tens of millions) of addressable locations, then there arises the issue of how to decide what image is to be stored in the Frame Buffer.
The operator may decide to ‘zoom out’ and let the end points of the Frame Buffer correspond to the start and end of the Acquisition Record. (Recall that the Acquisition Memory is managed as though it were a circular buffer, so those starting and ending locations in the resulting Acquisition Record are generally nearly adjacent, and located ‘anywhere along the circle,’ as it were.) The resulting displayed trace is, of necessity, severely compressed along the horizontal (time) dimension, and some clever rendering techniques are often required to create a useful image that is not downright deceptive and that correctly conveys some general sense of what signal activity is actually going on.
On the other hand, the operator may decide to view just a segment of the total Acquisition Record, and at a time scale selected from among predetermined choices. That is, within certain limits, the operator can both zoom and pan along the horizontal axis. This kind of operation has become (after the eventual emergence of user friendly controls to support it) the distinguishing hallmark of the DSO: those stuck with older analog equipment could only view with envy the measurements that their more newly equipped brethren could perform.
With this kind of flexibility comes some inevitable complexity. In this case, we can have what amounts to ‘an entire strip chart's worth of data’ but we still have just a tiny screen to view it on, and various techniques have emerged to help locate, and navigate back and forth between, separate events of interest in the ‘whole trace.’ The aggravation and chances for error associated with present navigation techniques are bound to become exacerbated with time, as DSOs with hundreds of megabytes of memory, and even memories in the gigabyte range, are poised to enter the marketplace. This situation will become one where a very long and detailed trace of a signal's waveform can be represented by the Acquisition Record (say, ten or one hundred times what is presently on the market). Besides simply panning along the trace with a manual control, there are configurable automatic tools to discover the existence of potential events of interest. However discovered, the locations in the Acquisition Record of such events of interest can be somehow marked (as with Bookmarks described in U.S. Pat. No. 6,958,754 B2, by Alexander & Oldfield) or their locations otherwise remembered with indexes that point to their locations. Alexander and Oldfield even provide a mechanism to go from one bookmark to any other.
The bookmark technique of Alexander and Oldfield requires the operator to manually establish a bookmark to represent an event of interest, and while it allows the association of a name and comment with a bookmark, the underlying indexing scheme is one based on the order in which the bookmarks are defined (which might be arbitrary), rather than the natural order of succession of the bookmarked events in the trace. So, when visiting bookmarks, and going from one to another, it is entirely up to the operator to ensure that his visits match the order of the succession of events (or of any other ordering), if that is his intent, as there is nothing inherent in the bookmark concept to support an ordering other than that with which the bookmarks were defined (within which ordering the notions of ‘NEXT’ and ‘PREVIOUS’ are indirectly available).
In some circumstances there are likely to be too many instances (say, thirty, fifty, a hundred?) of such events of interest to easily keep track of. What is needed is a way to easily and quickly navigate between (visit, and revisit) such a large number of events. This is particularly so in the case where the events to be visited are found by an automatic discovery mechanism (e.g., an automated measurement subsystem is asked to find everywhere that the rise time is greater than some amount, or wherever a transition in a selected direction does not achieve a minimum threshold). In such cases, the operator is asking the ‘scope to find such locations, say, using automated measurement techniques set out and described (among other places) in U.S. patent application Ser. No. <unknown> filed 31 May 2006 and entitled COMPOSITE TRIGGER FOR A DIGITAL SAMPLING OSCILLOSCOPE. So, let's say that the ‘scope found fifty-seven events in a really long trace that met some criteria that piques our interest. The automated measurement subsystem can scan the Acquisition Record to detect satisfactions of selected criteria, and even though it might tell us the number of such events, their minimums, maximum and averages, etc., it does not ‘create a trail of bookmarks,’ as it were. It is still up to the operator to manually direct the ‘scope to display the trace segment for each of the events that met the criteria. We should like to do the next step: Quickly and easily view the fifty-seven events in the order they occurred, or, perhaps instead in the order of their severity; all the better to determine if any of them are worthy of continued interest and increased scrutiny. How to do it?
SIMPLIFIED DESCRIPTION
A solution to the problem of visiting discovered events in the trace of a DSO in the order of their occurrence is to equip the DSO with sets of event navigation controls (F, N, P & L and B, NB, NW & W) for displaying events discovered by an automatic measurement in a selected order. In a TIME Mode the controls operate to display the earliest or first (F) of those events, display the next (N) event after the one currently displayed, display the previous (P) event before the one currently displayed, and, display the last (L) event. In a SEVERITY Mode the controls operate to display the best (B) of those events, display the next best (NB) event relative to the one currently displayed, display the next worst (NW) event before the one currently displayed, and, display the worst (W) event. The notions of best and worst arise when a measured parameter, such as rise time, can be construed as a Figure Of Merit, and then ordered according to value.
Prior to operation in one of these modes the operator informs an automatic measurement subsystem of the criteria that defines an event of interest. Subsequent to the ‘scope having made the measurements (a report typically appears, saying there were so many instances discovered, etc.) the operator may conjure the event navigation controls (if they are not already present). The sets of navigation controls may be a mode control menu accompanied by four stylized arrow shaped buttons within a GUI (Graphical User Interface) that are clicked on by an operator using a mouse. One set of arrow shaped button can serve for both modes, as their behaviors are similar. Alternatively, there can be no mode menu, but two different sets of four arrow shaped buttons, one set for each mode. As will become clear, navigation operations within the different modes may be intermixed without ambiguity, and it is merely a choice as to whether to implement a mode selector and one set of four operations, or, no mode selection and two sets of four operations (four buttons twice is eight buttons), with each set of operations associated with a different mode.
In the TIME Mode, if none of the controls has previously been invoked for the present Acquisition Record, the F, N and P behave the same: an effective F. Once there has been an effective or an actual F, N behaves as expected, and once there has been an N or an L, P behaves as expected. L always goes to the last event, even if that should also be the only (and therefore also the first) event. Navigation to discovered events subsequent to the automatic measurement that discovers those events can be based on one of two strategies:
(I) The automated measure subsystem scans the Acquisition Record only once. An Event Location Table (i.e., a list containing their locations in the Acquisition Record and associated display production parameters) can be maintained and this list is traversed as F, N, P and L are issued by the operator. The display production parameters retrieved from the list are passed to the display subsystem. (II) The automatic measurement subsystem itself can be passed the navigation commands and it then:
(I) Unconditionally does an F or an L and passes to the display subsystem the appropriate segment of the Acquisition Record. (ii) Remembers what it did last, so it knows what event is currently displayed; and (iii) For N and P, re-inspects the Acquisition Record from the location of the event currently displayed to locate and pass to the display subsystem the appropriate segment of the Acquisition Record.
The latter method (II) has the advantage that, while some ‘extra’ activity can be needed to perform each step in a traverse, the operator is now able to edit the automatic search criteria to refine (within some reasonable limitations) what events are presented, and do so incrementally without having to begin the whole process over again, and without having to again ‘work his way into’ an interesting spot in the trace from an initial F or L.
Similar remarks obtain for operation in the SEVERITY Mode.
When the operator places the ‘scope in RUN it will operate with some (initial) horizontal scale and position selected by the operator. After the ‘scope has acquired a trace and has been STOP'ed, and the operator has performed an automated measurement, he can then use the aforementioned navigation controls to navigate to an event discovered by the automatic measurement subsystem. This navigation process will, similar to the ‘AUTO-SCALE’ feature found on many ‘scopes, select (and then use) suggested best display parameters for viewing the event. The operator might, however, choose to change the horizontal scale and position to better view the event or trace segments surrounding it. However, if he should then again place the ‘scope in RUN, the initial horizontal scale and position values will then be reinstated. (Of course, once the ‘scope is again running, they can be changed, just as they always could.)
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a screen shot of one implementation of a GUI for selectable navigation to automatically discovered events within the acquisition record of a digital sampling oscilloscope;
FIG. 2 is a simplified flowchart depicting aspects of a first manner of internal operation within the digital sampling oscilloscope of FIG. 1 during selectable navigation to automatically discovered events within an acquisition record; and
FIG. 3 is a simplified flowchart depicting aspects of a first manner of internal operation within the digital sampling oscilloscope of FIG. 1 during selectable navigation to automatically discovered events within an acquisition record.
DETAILED DESCRIPTION
Refer now to FIG. 1 , wherein is shown a screen shot 1 of a DSO that incorporates selected navigation to discovered events within its Acquisition Record. The DSO may be any of the DSO8XXX, MSO8XXX, or 548XX series of Digital Sampling Oscilloscopes from Agilent Technologies, Inc. In particular, a window 2 contains a portion 3 of a trace that has been navigated to in response to conditions discovered by an Automatic Measurement Subsystem. The relative position of the displayed trace segment 3 within the overall captured trace is indicated by a highlighted portion within a Memory bar 16 . Such indication is itself conventional, and occurs for whatever trace segment is displayed, no matter how that segment is selected or arrived at. Furthermore, the details of how the Automatic Measurement Subsystem was instructed to look for certain measurable features or events in the Acquisition Record are conventional, and have been largely omitted for the sake of brevity. What we can see is that within the selected tab NAVIGATION ( 11 ) there is a collection of indicia ( 17 , 18 , 19 and 20 ) that cooperates with the legend of drop down menu 6 and SETUP LIMIT TEST box 12 to place a period measurement in effect, with a MAX LIMIT ( 18 ) of 402.000 ps. We further see that for the NAVIGATION MODE a radio button 4 has been pressed, to select a TIME mode. In the TIME Mode the events discovered by the Automatic Measurement Subsystem are accessible according to their order of occurrence in the overall trace. We presume also that one of the navigation buttons 7 , 8 , 9 or 10 has subsequently been clicked upon to instruct the system to find some particular ( 7 :F-first, 8 :P-previous, 9 :N-next or 10 :L-last) instance of discovered event. Legend 20 indicates that there are a total of seven failed measurements, and legend 19 indicates that the third of these is what is shown by the trace segment 3 in window 2 . Shaped indicator 13 (the solid rectangle) and cursor markers 15 A-B in the display cooperate in showing what portion of the displayed trace segment 3 caused the automatic period measurement criterion to be satisfied (i.e., to become the third failed/discovered measurement). Legend 17 indicates that the reason the third discovered event is a failed measurement is because the automatically measured period at that location in the trace is 455.300 ps, which exceeds the limit of 402.000 ps. Indicator 14 is presumably associated with another automatic measurement (perhaps fall time) that has been defined (using the MEASUREMENT tab instead of the NAVIGATION tab) but which is not currently being navigated upon. Indicator 13 and cursor marker 15 A are coincident along the time axis, since indicators of its shape (rectangle) have been (elsewhere) declared to be associated with period limit measurements on channel one, which happens also to be what we are navigating upon.
Another radio button 5 sets a SEVERITY Mode in which the discovered events are accessible according to a Figure Of Merit associated with the selected measurement (e.g., a period measurement for some cycle exceeded a limit by more than other cycles did). In the SEVERITY Mode the four arrow buttons 7 , 8 , 9 and 10 would respectively correspond to the operations B-best, NB-next best, NW-next worst and W-worst.
In the TIME Mode, if none of the controls has previously been invoked for the present Acquisition Record, the F, N and P behave the same: an effective F. Once there has been an effective or an actual F, N behaves as expected, and once there has been an N or an L, P behaves as expected. L always goes to the last event, even if that should also be the only (and therefore also the first) event.
In the SEVERITY Mode, if none of the controls has previously been invoked for the present Acquisition Record, the B and NB behave the same: an effective B. Likewise, and initial NW and W behave as a W. Once there has been an effective or an actual B, NB behaves as expected, and once there has been an effective or actual W, NW behaves as expected. W always goes to the worst event, even if that should also be the only (and therefore also the best) event, or if all events are the same.
While we have not, for the sake of brevity, shown an actual sequence of screen shots that corresponds to it, the reader will nevertheless appreciate that each time one of the buttons 7 - 10 is clicked on the system will decide if a different trace segment is to be displayed (as well as put onto the NAVIGATION tab 11 the corresponding descriptive indicia ( 13 , 15 A/B, 19 ) for that displayed segment).
Now refer to FIG. 2 . It is a simplified flowchart 21 that describes a first strategy for implementing the navigation described in connection with FIG. 1 . In this first strategy the Automated Measurement Subsystem scans the Acquisition Record only once. An Event Location Table 25 (i.e., a list containing their locations in the Acquisition Record and associated display production parameters) can be maintained and this list is traversed as the commands F/B, N/NB, P/NW and L/W ( 7 - 10 , 31 - 33 ) are issued by the operator. The display production parameters retrieved from the Event Location Table are passed to the display subsystem.
This first manner of operation is illustrated by the flowchart 21 as follows. At step 22 the ‘scope is RUN'ing and a acquires a digitized version of a waveform in an Acquisition Memory. Presumably, at some time the ‘scope is triggered and the ’ scope becomes STOP'ed. Qualifier 23 represents the possibility that other types of operation might ensue (one of which might be the specification of automatic measurements, although that could have also been accomplished much earlier).
In any event, once the Automatic Measurement Subsystem is active, step 24 is looking for parameters of interest in the Acquisition Record, reporting them (indicia 13 , 15 A/B, 17 - 20 of FIG. 1 ) and building an Event Location Table 25 that places the discovered events in some order according to an index ( 26 ), and associates with that index the START POSITION ( 27 ) and the END POSITION ( 28 ) to be used in displaying that discovered event as that indexed segment. It will be noted that the START POSITION ( 27 ) and END POSITION ( 28 ) correspond respectively to cursor markers 15 A and 15 B. Step 24 begins with the phrase ‘DEFINE AND LOOK FOR . . . ”. By this is meant that if the definition is not yet made, or if a different definition is desired, such definition can be performed (or performed again). If a new definition is made, then the Event Location Table 25 is built anew. On the other hand, a satisfactory definition may already be in effect, in which case step 24 amounts to “LOOK FOR . . . ”.
A note is in order concerning the index 26 . We have shown it as an integer that starts at one and counts up. If the TIME Mode is in effect, then an index value of one could represent ‘first’ discovered event and an index of two the next event (the second one), and so on, with the n th entry corresponding to the last discovered event. Likewise, if the SEVERITY Mode were in effect, then an index of one could represent the best, and two the (first) next best, three the next (second) next best, and so on. Implicit in this, but not explicitly shown (it would appear to be an implementation detail) is that if the operator “pulls the rug out from under the table 25 ” by switching from one Mode to the other, the Event Location Table 25 would have to be re-constructed. On the other hand, this annoyance can be avoided by maintaining two indexes from the start—one for the TIME Mode and one for the SEVERITY mode. For the sake of brevity, we have not shown such an arrangement, but it will certainly be readily appreciated.
In any event, once the Event Location Table 25 is created subsequent to an investigation of the Acquisition Record according to the definition in use, qualifier 29 leads (assuming no other actions intervene) to step 33 , where the system indexes into the Event Location Table according to one of the commands 31 - 33 (and, of course taking into account the Mode in effect). Then the display parameters are set to an appropriate time scale (i.e., taking into account the difference between START POSITION 27 and END POSITION 28 ) and time reference position (the average of values 27 and 28 ) according to what is indexed in the table, and the discovered event that has just been navigated to is then displayed (e.g., 3 in FIG. 1 ).
FIG. 3 is a simplified flowchart 34 that describes a second strategy for implementing the navigation described in connection with FIG. 1 . In this second strategy the Automated Measurement Subsystem scans the Acquisition Record once for each navigation command. No Event Location Table is maintained, and instead the Acquisition Record itself is traversed as the commands F/B, N/NB, P/NW and L/W ( 7 - 10 , 31 - 33 ) are issued by the operator. The display production parameters are produced as before, and are passed to the display subsystem.
This second manner of operation is illustrated by the flowchart 34 as follows. Step 22 and Qualifier 23 are as they were for FIG. 2 . Once the Automatic Measurement Subsystem is active, step 35 is to look, according to the issued commands ( 31 - 33 ) and the Mode in effect, for parameters of interest in the Acquisition Record, report them (indicia 13 , 15 A/B, 17 - 20 of FIG. 1 ) and having also determined the display production parameters, pass them to the Display Subsystem (which, of course, displays the discovered event just navigated to). | Events discovered by an automatic measurement subsystem in the trace of a DSO are visited using a set of event navigation controls. In a TIME Mode the controls operate to display the first of those events, display the next event after the one currently displayed, display the previous event before the one currently displayed, and, display the last event. In a SEVERITY Mode the controls operate to display the best of those events, display the next best event relative to the one currently displayed, display the next worst event before the one currently displayed, and, display the worst event. The sets of navigation controls may be a mode control menu accompanied by four stylized arrow shaped buttons within a GUI that are clicked on by an operator using a mouse. One set of arrow shaped button can serve both modes, or different sets of buttons can serve each respective mode. | 6 |
This invention relates to a multi step reaction, analysis and dosing system and is applicable to sequential, stepwise and analysis and the exact and reproducible metering and dosing of the smallest quantities of substances in the range of <1μl. Preferred applications of the invention are the sequence analysis of proteins and peptides, and DNA-sequencing in biomedicine.
BACKGROUND
As described by Jungblut et al. in Elektrophoresis 15, 1994, pages 685 to 707, it is possible to diagnose diseases in their early stages of development, if one can successfully identify, on two-dimensional gels, those proteins which are changed because of the disease. This can be achieved if these protein variations manifest themselves in strong protein spots on the gels. The protein spots can be blotted on suitable chemically inert membranes and the blots can be sequenced in a sequencer. Alternatively, the proteins can be extracted from the gels for further analysis.
The protein and peptide sequencer is an automate for the determination of the amino acid sequence of a polypeptide chain by the stepwise Edman degradation (Edman, P. and Begg, G. 1967, Eur. J. Biochem. 1, 80-91) of the amino acids from the amino-terminal end. Under alkaline conditions, the N-terminal amino group is coupled with a coupling reagent, e.g. phenylisothiocyanante (PITC) under formation of the phenylthiocarbamoyl peptide derivative. After removal of the excess reagent, the base and other by-products, the first amino acid is cleaved off the polypeptide chain by treatment with anbydraus, strong acid (e.g. trifluoroacetic acid) and this first, N-terminal amino acid is released as a 2-anilino-thiazolinone amino acid derivative which is extracted from the rest of the polypeptide chain by organic solvents. It is transferred on-line into the converter (Wittmann-Liebold, B. Graffunder, H. Kohls, H. 1976 Anal. Biochem. 75, 621-633) where the isomerization takes place under formation of the more stable phenylhydantoin derivative of the amino acid (PTH-amino acid). The PTH-amino acids are identified by on-line HPLC separation and UV detection (Ashman, K. and Wittmann-Liebold, B. 1985, FEBS-Letters 190, 129-132). The following amino acid of the polypeptide chain, the second residue, is determined by subjecting the resulting polypeptide chain to a second round of Edman degradation and in further repeats of the degradation cycle the successive amino acid residues are determined.
By the degradation one obtains the amino-terminal (N-terminal) sequence of the first 10-100 amino acid residues. This sequence has to be compared with the already known sequences of proteins in protein databases and can therefore be definitely identified, because every protein has its specific sequence of the amino acids.
By this identification of the protein one achieves a detailed information on the processes, which are altered in the metabolic pathway and cause the disease. The conclusion is that the reason for the disease can be realized on the molecular level. Where the varied or modified proteins of the disease appear in exceedingly low concentrations, it has not been possible to characterize them clearly until now. Therefore, a more sensitive approach for the determination of the amino acid sequence of the altered proteins is desired which can only be achieved by a drastic miniaturization of the chemical processes in the automate which leads to a detailed protein analysis.
The Edman degradation requests fast changes of different aggressive, delicate and costly sequencer-grade reagents and solvents. It demands temperatures up to 60° C. and the absolute exclusion of oxygen at all parts of the reaction. In order to avoid contamination and the formation of large amounts of by-products, reagent and solvent volumes must be kept as small as possible. This becomes even more essential if only scarce amounts of polypeptides are available, e.g. in the low picomole to femtomole range (corresponding to 10 -12 to 10 -15 mol of sample).
Similarly, the invention can be employed to direct other processes, such as DNA sequencing, amino acid analysis, protein quantification, environmental research and analysis and peptide synthesis within the automate. Characteristic for all these reactions are that they require
i.) washes in order to remove salts or other impurities of the biomolecules;
ii.) reactions with organic compounds in order to obtain derivatives suitable for quantitative determination;
iii.) removal of excess reagents and buffers; and
iv.) identification and quantification of the derivatives. Typically, aggressive chemicals, organic solvents and higher temperatures are necessary to drive the reactions to completeness. Identification by on-line detection in the appropriate detector system, e.g. UV-, chemical detector or fluorescence detector is mandatory if small sample quantities have to be determined.
Automates designed for DNA sequencing, biochemical or biomedical analysis, and for peptide synthesis also require the delivery of aggressive chemicals and organic solvents which have to be delivered by means of appropriate, non-corrosive dosage valve systems into an appropriate reaction chamber. Hence, also in these automates similar valve- and reactor systems as designed for protein sequencers are provided.
The typical components of all known sequencers are
i) dosing valves;
ii) reactors;
iii) convertors/collectors; and
iv) detection systems, which in the existing analysis and dosing system are arranged in separate units combined by outer connection lines, e.g., teflon or steel tubings. Some progress in the arrangement of the valves was achieved by the P40 14 602, which describes a dosing system with numerous pneumatically governed valves, whereas the valves are arranged in a circular mode on a carrier of ringform.
Disadvantageous of all the known technical solutions is, that within and in-between the separate units exist long transportation distances. The units are, e.g., connected by PTFE tubes, which are extremely permeable to oxygen. This fact and the large number of connecting devices results in the penetration of oxygen. This affects the process in several places and the identification by the formation of additional derivatives; and the coupling of the reagent to the next amino acid may be directly blocked. Moreover, the yields of the cleaved amino acids are drastically reduced due to partial destruction.
Another important disadvantage, i.e. limiting factor of the existing systems, is that the smallest dosable quantity of chemicals is approximately 5 μl. If a very small quantity of the sample is applied, the protein which is to be analyzed is washed out rapidly. The sequence can no more unequivocally be identified. Therefore, at present, the minimum amount of ca. 20 pmol protein is necessary, to determine the sequence unambiguously.
SUMMARY OF THE INVENTION
The object of the invention is the construction of a reliable, easy-maintenance analysis and dosing system for long term use.
The analysis system designed serves for multi-purpose analysis of biomolecules, e.g.,
i) sequencing of the amino acids in polypeptides;
ii) quantitative determination of amino acid composition in polypeptides;
iii) sequencing of nucleotides in DNA or RNA;
iv) quantification of polypeptides or polynucleotides or other biomolecules (e.g. carbohydrates). The analysis system also serves applications in environmental analysis and research such as quantitative or qualitative detection of trace elements or toxic molecules in water. The layout of depressions, dosage values, reaction chamber(s) and converter(s)/collector(s) within a wafer based construction serves as units for the derivatization and analysis of these biomolecules within the wafer. By this means, exclusion of oxidants, oxygen and other contaminants of the atmosphere is possible, and the individual parts within the wafer unit connected by short cavities/channels within the wafer construction. Exceedingly small amounts of liquids can be delivered, in e.g. nano-liter amounts to perform reactions on minute samples, in the low femto- to attomole range.
The different components within the wafer-based construction, e.g., the delivery valve system(s), reactor(s), converter/collector, on-line-capillary for the separation detection/quantification, are connected by channels that can be combined in different ways by operating the appropriate valves depending on the chemical reaction performed. The design within the wafer is made in a manner that allows performance of different reactions, degradations, and derivatizations as well as separation processes, mixing, extracting or such leading to a multi-purpose-multifunctional device.
The sample, dissolved for analysis, may be introduced via the delivery valve system, or alternatively, by inserting it applied onto an appropriate solid or membrane support, into the reactor device within the wafer. Accordingly, the device described below can be applied for analysis, sequencing or derivatization or biomolecules, and is not limited to one of these reactions/purposes. When used for the derivatization and quantification or biomolecules, detection by ion-selective methods, UV-absorption, dye or fluorescence detection or chemical detection may be employed.
The invention described enables the exact and reproducible dosage as well as the analysis of the smallest amounts of substances and short connection distances in-between the components. It also guarantees the nearly complete exclusion of contaminants and eliminates penetration of oxygen and oxidants. Over all, the production is easy with low costs.
A further object of the invention is to define a process for the production of analysis and dosage systems, which is based on the latest technologies and materials developed for microelectronics.
A special advantage of the invention is, that using the present analysis and dosing system, the primary structure of proteins can be determined in femtomol to attomole amounts. This is achieved by arranging the essential elements and valves on a chip or wafer, consisting of a one- or multilayered substrate and a one- or multilayered cover. The substrate and/or the cover have depressions/grooves in order to build cavities and/or more depressions for the co-operation of the units.
As the substrates consist of semiconducting material such as silicon, or ceramic material, aluminumoxide or glass that may be equipped or covered with a chemically inert layer, the application of most modern microelectronic technologies within the production process of the analysis and dosing system is possible. Factually it sets up an integrated circuit for the inlets and outlets and the connecting lines for the transport of the chemicals, gases and samples as well as for the reactor, converter and detection system. This is achieved by arranging the essential components, valves and at least partly the related lines on a chip which consists of a one- or multilayer substrate with a cover. Through microelectronic structuring processes, depressions are located in the substrate and/or the cover, which are totally or partially converted, by joining substrate and cover, into cavities. Depressions or grooves which are not covered because of partial covering are closed by additional construction elements.
The influence of oxygen, oxidants or contaminants is minimized by the exclusion of discrete connecting lines and the application of airtight adhesives or suitable connection technologies for the fixing of construction elements.
The operation of the valves, which consists of piezoelectric elements and/or are built by pressurized membranes and/or actuators, is dead-volume free so that all chemicals are completely separated from each other and it is guaranteed that no cross contamination or the formation of salt at the reaction of an acid with a reagent/dye takes place. The smallest dosable amount of liquid is defined by the minimal distance between two valves and the geometry of the channel between the valves.
It is also possible, that the valves are built in a multilayer arrangement or consist of polysilicon elements, respectively, the operating of the valves is done by volume-variable material.
The invention shall be described in more detail with the following application examples in the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 A schematic plan view of a dosing system arranged on the substrate without cover;
FIG. 1a An alternative arrangement for the function of a dosing channel, shown without cover;
FIG. 2 A cross sectional view of FIG. 1 with a cover, section A--A;
FIG. 3 A reactor chamber arranged on a chip;
FIG. 4 A complete arrangement of essential constructing elements of a sequencer on a chip/wafer; and
FIG. 5A Shows a detailed construction of a dead-volume free membrane valve in the opened position;
FIG. 5B Shows a detailed construction of a dead-volume free membrane valve in the closed position;
FIG. 6A Shows a cross-sectional view of a membrane valve; and
FIG. 6B Shows a cross-sectional view of a further embodiment of a membrane valve.
DETAILED DESCRIPTION
In FIGS. 1 and 2 are shown a section of an analysis and dosing system. On the chip 1 are arranged delivery channels 4 and a depression 4a (here a dosing chamber for the exact volumetric metering of a reagent) for the co-operation with reactor 6a, and valves V2 to V5. In the present example, chip 1 consists of a substrate 2 and a cover 3 made from silicon.
Depressions 4 and 4a are structured in the substrate 2 with laser facilities. They are converted into cavities by joining substrate 2 and cover 3. In order to mount the reactor 6a on the substrate, the cover above the depression 4a is interrupted as shown in FIG. 3. The reactor 6a is glued with an airtight (non-permeable) adhesive on the substrate 2. The operation of the valves in the present example is realized by channel interruption and by a cover of a nonpermeable membrane. This membrane can be lifted by pressure variation and thereby the line is opened for flow.
The operation precess per FIG. 1 is:
By opening valve V1, nitrogen pressure is applied on a liquid bottle with a reagent 17 closed tightly to the outside. Subsequently, the valves V2 and V3 are switched into the open position and liquid flows through depression 4, which co-operates with cover 3 to build up cavities 5. By closing the valves V2 and V3 at the same time an exact metered liquid volume is locked within the cavity. Now valves V4 (nitrogen supply), V5 (outlet to the reactor dosing channel) and V7 (inlet to the reaction chamber 6a) are opened. Cleaning of the line is achieved by delivering nitrogen or solvent through the valves V6 and V8. Several of these dosing units allow the delivery of different reagents one after the other to the reaction chamber 6a.
In the arrangement shown in FIG. 1A, the dosing and delivery of chemicals is made as described in the following:
The chemicals to be delivered are transported through line/channel B. By opening valves V2 and V3, the chemicals flow through line E to recoil C. By closing both valves V2 and V3, an exact metered liquid volume is locked in the channel E between both valves, wherein the channel might have several geometric designs, for example semi-circular, as well as different enlargements of the cross-section of the channel can occur. By opening valves V1 and V4, the enclosed amount of liquid can be transported to outlet D by applying an inert gas overpressure. This might be set up as a single dosing unit as it is shown in FIG. 1A for the construction version "channel/membrane valve." It also may occur, that it is assigned for more than one inlet or outlet line. Depending upon the arrangement, different or equal volumes of dosing are achieved for the different liquids applied.
The construction of a reaction chamber 6a is represented in FIG. 3. In the (multi-layered) substrate 2 is laid depression 4a, for taking up solid samples or samples applied to solid supports, as well as inlet and outlet 4. On the substrate 2 is bonded a housing 7 for the lid 8, which might be opened in order to apply solid samples. It is also possible to apply another substrate fixing connection type. The air- or vacuum-tight closure is guaranteed by suitable adaption of faying surface 9 or a sealing 10.
FIG. 4 represents a possible arrangement fitted for the function as a protein sequencer unit. On the chip 1 are arranged the valves V1 to Vm as well as the reactor 6a, detector 6b, convertor 6c, and injection valve 6d. The connection between the construction elements results by depressions 4 which are transformed into cavities 5. On chip 1 are arranged different sensors (not shown) which control the transport of the substances, the temperature in reactor 6a and converter 6c as well as further parameters of the process. The measured values are sent to the governing devices, which control actuators or heating elements (not shown in FIG. 4).
A sequence analysis of a protein is done as follows:
The lines L1, L2, L30, and L22 are connected to an inert gas supply. The applied pressure is regulated by throttle valves (not shown). The lines L3 to L8 and L26 to L29 are connected to the solvent and reagents reservoir bottles. The lines L11, L13, L18, L19, L23 and L25 lead to a waste bottle. The sample is applied into reactor chamber 6a, which is closed airtight thereafter. Successively, the chemicals and solvents applied for the Edman degradation are delivered from the bottles (not shown) via lines L3 to L8, and valves V3 to V8, V12 to the reaction chamber 6a under opening of exit valve V19. The amount of chemicals is limited by time control of the dosing valves V3 to V8 or, the dosing technique as described above is applied. This means the cavity in between valves e.g. V8 and V11 is filled with a reagent until the outlet of line L11 is reached. A sensor which is also arranged on chip 1 is set up at the outlet line of valve V11 so that the delivery valves are closed automatically. Afterwards, the liquid is delivered into the reaction chamber 6a by opening the valves V 1 and V12. After the coupling reaction, the cleavage reaction takes place in the reactor and the N-terminal amino acid is cleaved off and extracted by solvents and transferred into the conversion unit. There it is derivatized by further doses of chemicals, e.g. delivered from line L27 via valve 27 to convertor 6c. Then, by applying inert gas and/or heat and/or vacuum, the amino acid derivative is dried and subsequently dissolved in the mobile phase of the detection system. The dosage of chemicals on the conversion side is performed analogous to the dosage of chemicals at the reaction side. While derivatizing one amino acid in the converter, the next N-terminal amino acid is coupled with the reagent and cleaved off the remaining polypeptide chain in the reactor chamber 6a. The derivatized amino acids are transported within line L21 to the injection system 6d--of a HPLC system or a capillary electrophoresis system.
The identification of the sample is done, e.g. by determining the retention time in a micro-bore HPLC column or alternatively, in a capillary HPLC-column or electrophoresis capillary, which is attached to the lines L31 and L32.
For the application of DNA sequencing, a slightly changed setup to FIG. 4 (not shown) is used. Four reaction chambers are arranged on the wafer. Aliquots of the DNA sample are delivered to the reaction chambers and the sample is immobilized on a suitable carrier material. Subsequently, a marker is coupled to the DNA and then the DNA is cleaved with four special reagents parallel in the four reaction chambers. Afterwards, the DNA fragments are transported to the detection system, e.g. four parallel capillary electrophoresis systems.
Another preferred application of the described system for analysis and dosing is environmental analysis and research. Another slightly changed setup to FIG. 4 (not shown) is used for the parallel determination of different solved ions in a sample, e.g. from the waste water treatment. Therefore, aliquots of the sample are delivered to different reaction chambers. Subsequently, reagents, which perform a calorimetric reaction proportional to the concentration are delivered from the reagents reservoir bottles via the lines and valves into the reaction chambers. After the reactions take place, the samples are delivered to a curvette which is arranged on the wafer. The concentration is measured by measuring the optical density of the sample.
The FIGS. 5A and 5B represent a detailed construction of a dead-volume free membrane valves on the basis of chips. They show the valves in a cross sectional view in the positions opened (FIG. 5A) and closed (FIG. 5B).
The valves operate as follows:
In the substrate 2 are structured depressions (channels) 4. By use of membrane 11, the depressions are closed air-tight. In the cover 3 at defined positions there are excisions (cut outs). They are connected with a tube 13 to a pneumatic governing valve (not shown). By switching the governing valves, an overpressure or vacuum is applied onto the membrane 11. If an overpressure is applied to membrane 11, the valve is closed dead-volume free (FIG. 5B). In case of sucking up the membrane by vacuum, the liquid can flow from the inlet line through the now existing space into the outlit line. By switching the governing valve again, overpressure is applied to membrane 11 which closes the valve. The reagent's inlet line is closed and the liquid in the delivery line is transported by an inert gas overpressure applied to the line. As a result, the delivery of the liquid out of the cavity into the outlet line takes place.
FIG. 6a shows the cross-sectional view of a membrane valve, where the membrane is moved by an actuator, e.g. a piezoelectric element or a magnetic plunger.
FIG. 6b represents the cross-sectional view of a membrane valve where the membrane is made by a multilayer arrangement. The movement of the membrane is done by, e.g. governed poly-silicon elements or thermal-extensing elements.
It will be understood that the above descriptions are made by way of illustration, and that the invention may take other forms within the spirit of structures and methods described herein. Variations and modifications will occur to those skilled in the art, and all such variations and modifications are considered to be part of the invention, as defined in the claims. | This invention describes a new analysis and dosing system and a method to manufacture such devices based on the latest microelectronic and micromachining working methods. On chip or wafer 1 which consists of the one- or multilayer substrate 2 and one- or multilayer cover 3, are arranged the essential construction components as reactor 6a, detector 6b, converter/collector 6c, injection valve 6d, micropumps, sensors, and valves V1 to V30, of the system, and the connection(s) to a detecting/metering device. The substrate 2 and/or the cover 3 show depressions 4 to build cavities and the co-operation of the elements 6a . . . 6n. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division of our prior, copending application Ser. No. 877,132 filed Feb. 13, 1978, U.S. Pat. No. 4,151,352, which in turn was a division of application Ser. No. 784,885 filed Apr. 5, 1977 and issued Apr. 4, 1978 as U.S. Pat. No. 4,082,912, which in turn was a continuation-in-part of our prior, copending application Ser. No. 701,443 filed June 30, 1976 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The cephalosporins of the present invention in general possess the usual attributes of such compounds and are particularly useful in the treatment of bacterial infections.
2. Description of the Prior Art
The cephalosporins are a well-known group of semisynthetic antibacterial agents made originally, for example, by acylation of the 7-amino group of the nucleus 7-aminocephalosporanic acid (7-ACA) and later by similar acylation of nuclei derived therefrom, as by modification of its substituent at the 3-position. Various reviews have appeared in the scientific literature (e.g. Cephalosporins and Penicillins - Chemistry and Biology, edited by Edwin H. Flynn, Academic Press, New York, 1972, and particularly pages 554-569) and in the patent literature, e.g. as in U.S. Pat. Nos. 3,687,948; 3,741,965; 3,743,644; 3,759,904; 3,759,905; 3,766,175; 3,766,906; 3,769,281; 3,796,801; 3,799,923; 3,812,116; 3,813,388; 3,814,754 and 3,814,755 (all U.S. Class 260-243C).
Issued patents on 3-thiolated cephalosporins in which the 7-substituent is
(a) α-Amino-α-phenylacetamido include U.S. Pat. Nos. 3,641,021; 3,734,907; 3,687,948; 3,741,965; 3,757,015; 3,743,644, Japan No. 71/24400 (Farmdoc 46374S), Belgium No. 776,222 (Farmdoc 38983T; U.K. No. 1,328,340 which includes various substituents on the benzene ring), Belgium No. 772,592 (Farmdoc 19696T; U.S. Pat. Nos. 3,687,948, 3,734,907 and 3,757,012), West Germany No. 2,202,274 (Farmdoc 50428T) corresponding to U.S. Pat. No. 3,759,904, Netherlands No. 7205644 (Farmdoc 76309T; U.S. Pat. No. 3,757,014); and
(b) o-, m- or p-aminoethoxyphenylacetamido as Netherlands No. 72/13968 (Farmdoc 2474OU) corresponding to U.S. Pat. No. 3,759,905 and
(c) o-aminomethylphenylacetamido as U.S. Pat. Nos. 3,766,176 and 3,766,175 (which also review the older patent literature concerning substituted 7-phenylacetamidocephalosporanic acids) and
(d) N-(phenylacetimidoyl)aminoacetamido as U.S. Pat. No. 3,692,779; and
(e) α-amino-α-(1,4-cyclohexadienyl)acetamido as in Belgium No. 776,222 (Farmdoc 38983T; U.K. No. 1,328,340).
Additional similar disclosures are found in U.S. Pat. No. 3,692,779 (Belgium No. 771,189; Farmdoc 12819T), Japan No. 72/05550 (Farmdoc 12921T), Japan No. 72/05551 (Farmdoc 12922T), U.S. Pat. No. 3,719,673 (Belgium No. 759,570; Farmdoc 39819S), Belgium No. 793,311 (Farmdoc 39702U) and Belgium No. 793,191 (Farmdoc 39684U).
Issued disclosures of 3-thiolated cephalosporins in which the 7-substituent is 7-mandelamido (7-α-hydroxyphenylacetamido) are found, for example, in U.S. Pat. No. 3,641,021, France No. 73.10112, U.S. Pat. No. 3,796,801, Great Britain No. 1,328,340 (Farmdoc 38983T), U.S. Pat. No. 3,701,775, Japan No. 48-44293 (Farmdoc 55334U) and in Hoover et al., J. Med. Chem. 17(1), 34-41 (1974) and Wick et al., Antimicrobial Ag. Chemo., 1(3), 221-234 (1972).
U.S. Pat. No. 3,819,623 (and, for example, also U.K. No. 1,295,841 and West Germany No. 1,953,861) discloses specifically and with working details the preparation of 2-mercapto-1,3,4-thiadiazole-5-acetic acid and its conversion to 7-(1H-tetrazol-1-yl-acetamido)-3-(5-carboxymethyl-1,3,4-thiadiazol-2-ylthiomethyl)-3-cephem-4-carboxylic acid which is also disclosed in West Germany Offenlegungsschrift No. 2,262,262.
U.S. Pat. Nos. 3,766,175 and 3,898,217 disclose a compound of the formula ##STR1## wherein R is ##STR2## or a nontoxic, pharmaceutically acceptable salt thereof, and
A compound of the formula ##STR3## wherein
R is --H or lower alkyl;
R 1 is --H, (lower)alkanoyloxy, ##STR4## n is an integer from 4-7, inclusive; and the pharmaceutically acceptable addition salts thereof, respectively.
U.S. Pat. Nos. 3,883,520 and 3,931,160 and Farmdoc Abstract 22850W make reference to 3-heterocyclicthiomethyl cephalosporins containing a number of substituents (including carboxyl) on the numerous heterocycles included but these references are completely general in nature and include no physical constants, yields, methods of synthesis or the like and do not even name any such compound containing a carboxyl substituent.
U.S. Pat. No. 3,928,336 provides a review of much of the older cephalosporin art.
U.S. Pat. Nos. 3,907,786 and 3,946,000 disclose cephalosporins containing various fused ring bicyclic thiols.
Farmdoc abstract 18330X discloses compounds of the formula ##STR5## (where R 1 =acyl or H; R 3 =H or methoxy; n=1-9).
SUMMARY OF THE INVENTION
The present invention provides compounds having the structure: ##STR6## (often written herein as ##STR7## wherein n is one or two and R 1 is acyl or hydrogen and R 2 is hydrogen or the group having the formula ##STR8## wherein, when W represents hydrogen, Z represents (lower)alkanoyl, benzoyl, naphthoyl, furoyl, thenoyl, nitrobenzoyl, methylbenzoyl, halobenzoyl, phenylbenzoyl, N-phthalimido, N-succinimido, N-saccharino, N-(lower)alkylcarbamoyl, (lower)alkoxy, (lower)-alkylthio, phenoxy, carbalkoxy, carbobenzoxy, carbamoyl, benzyloxy, chlorobenzyloxy, carbophenoxy, carbo-tert.-butoxy or (lower)alkylsulfonyl, and when W represents carbalkoxy, Z represents carbalkoxy and, when W represents phenyl, Z represents benzoyl or cyano or wherein W and Z taken together represent 2-oxocycloalkyl containing 4 to 8 carbon atoms inclusive. In the preferred embodiments of this invention R 2 is hydrogen, pivaloyloxymethyl, acetoxymethyl, methoxymethyl, acetonyl, phenacyl, p-nitrobenzyl, β,β,β-trichloroethyl, 3-phthalidyl or 5-indanyl.
As set forth below in more detail the present invention also provides salts of these acids. The stereochemistry of the bicyclic nucleus is that found in Cephalosporin C.
Acyl (R 1 ) comprises the groups having the structures: ##STR9## wherein R is hydrogen, hydroxy or methoxy and R' is hydrogen or methyl.
A preferred embodiment of the present invention consists of the compounds of Formula I wherein R 1 has the structure ##STR10##
Another preferred embodiment of the present invention consists of the compounds of Formula I wherein R 1 has the structure ##STR11##
The present invention also provides the process for the production of the antibacterial agents having the structure ##STR12## wherein n is one or two and R 1 is acyl as defined above which comprises reacting a compound of the formula ##STR13## wherein n is one or two or a salt or easily hydrolyzed ester or Schiff base as with benzaldehyde or salicylaldehyde thereof (including, but not limited to, those of U.S. Pat. No. 3,284,451 and U.K. No. 1,229,453 and any of the silyl esters described in U.S. Pat. No. 3,249,622 for use with 6-aminopenicillanic acid and used in Great Britain No. 1,073,530 and particularly the pivaloyloxymethyl, acetoxymethyl, methoxymethyl, acetonyl, phenacyl, p-nitrobenzyl, β,β,β-trichloroethyl, 3-phthalidyl and 5-indanyl esters) thereof with an organic monocarboxylic acid chloride or a functional equivalent thereof as an acylating agent.
Such functional equivalents include the corresponding acid anhydrides, including mixed anhydrides and particularly the mixed anhydrides prepared from stronger acids such as the lower aliphatic monoesters of carbonic acid, or alkyl and aryl sulfonic acids and of more hindered acids such as diphenylacetic acid. In addition, an acid azide or an active ester or thioester (e.g. with p-nitrophenyl, 2,4-dinitrophenol, thiophenol, thioacetic acid) may be used or the free acid itself may be coupled with compound II after first reacting said free acid with N,N'-dimethylchloroformiminium chloride [cf. Great Britain 1,008,170 and Novak and Weichet, Experientia XXI, 6, 360 (1965)] or by the use of enzymes or of an N,N'-carbonyldiimidazole or an N,N'-carbonylditriazole [cf. South African patent specification 63/2684] or a carbodiimide reagent [especially N,N'-dicyclohexylcarbodiimide. N,N'-diisopropylcarbodiimide or N-cyclohexyl-N'-(2-morpholinoethyl)carbodiimide; cf. Sheehan and Hess, J. Amer. Chem. Soc., 77, 1967 (1955)], or of alkylylamine reagent [cf. R. Buijle and H. G. Viehe, Angew. Chem. International Edition 3, 582, (1964)] or of an isoxazolium salt reagent [cf. R. B. Woodward, R. A. Olofson and H. Mayer, J. Amer. Chem. Soc., 83, 1010 (1961)], or of a ketenimine reagent [cf. C. L. Stevens and M. F. Munk, J. Amer. Chem. Soc., 80, 4065 (1958)] or of hexachlorocyclotriphosphatriazine or hexabromocyclotriphosphatriazine (U.S. Pat. No. 3,651,050) or of diphenylphosphoryl azide [DPPA; J. Amer. Chem. Soc., 94, 6203-6205 (1972)] or of diethylphosphoryl cyanide [DEPC; Tetrahedron Letters No. 18, pp. 1595-1598 (1973)] or of diphenyl phosphite [Tetrahedron Letters No. 49, pp. 5047-5050 (1972)]. Another equivalent of the acid chloride is a corresponding azolide, i.e., an amide of the corresponding acid whose amide nitrogen is a member of a quasiaromatic five membered ring containing at least two nitrogen atoms, i.e., imidazole, pyrazole, the triazoles, benzimidazole, benzotriazole and their substituted derivatives. As an example of the general method for the preparation of an azolide, N,N'-carbonyldiimidazole is reacted with a carboxylic acid in equimolar proportions at room temperature in tetrahydrofuran, chloroform, dimethylformamide or a similar inert solvent to form the carboxylic acid imidazolide in practically quantitative yield with liberation of carbon dioxide and one mole of imidazole. Dicarboxylic acids yield diimidazolide. The by-product, imidazole, precipitates and may be separated and the imidazolide isolated, but this is not essential. The methods for carrying out these reactions to produce a cephalosporin and the methods used to isolate the cephalosporin so produced are well known in the art.
Mention was made above of the use of enzymes to couple the free acid with compound II. Included in the scope of such processes are the use of an ester, e.g. the methyl ester, of that free acid with enzymes provided by various microorganisms, e.g. those described by T. Takahashi et al., J. Amer. Chem. Soc., 94(11), 4035-4037 (1972) and by T. Nara et al., J. Antibiotics (Japan) 24(5), 321-323 (1971) and in U.S. 3,682,777.
For the coupling of the organic carboxylic acid as described above which compound II (or a salt or preferably an easily hydrolyzed ester of Schiff base, as with benzaldehyde, thereof) it is also convenient and efficient to utilize as the coupling agent phosphonitrilic chloride trimer (J. Org. Chem., 33(7), 2979-81, 1968) or N-ethoxy-1,2-dihydroquinoline (EEDQ) as described in J. Amer. Chem. Soc., 90, 823-824 and 1652-1653 (1968) and U.S. Pat. No. 3,455,929. The reaction is preferably carried out at 30°-35° C. in benzene, ethanol or tetrahydrofuran using about equimolar quantities of all three reagents followed by conventional isolation and removal by conventional methods of any blocking groups present.
An additional process of the present invention comprises the preparation of the compounds of the present invention by the displacement of the 3-acetoxy group of a 7-acylaminocephalosporanic acid (prepared by substituting 7-aminocephalosporanic acid for the 3-thiolated-7-aminocephalosporanic acids in the acylation procedures described herein and elsewhere reported) with a thiol HSR 3 having the formula ##STR14## wherein n is one or two and then removing the protecting group if any is present, as on the aminomethyl or methylaminomethyl group or on the carboxyl group or both. The displacement of such a 3-acetoxy group with such a thiol may be accomplished in solution as in water or aqueous acetone at a temperature of at least room temperature and preferably within the range of about 50° to 100° C. in the presence of a mild base such as sodium bicarbonate, e.g. preferably near neutrality such as at about pH 6. An excess of the thiol is preferably employed. The reaction product is isolated by careful acidification of the reaction mixture followed by extraction with a water-immiscible organic solvent. As noted above, the preparation of many other 7-acylamidocephalosporanic acids is described in the patent and scientific literature, e.g. in U.S. Class 260-243C.
When the organic carboxylic acid contains a functional group such as amino or methylamino it is often desirable to first block (or protect) said group, then carry out the coupling reaction and finally subject the resulting compound to chemical removal of the protecting group, that is, subjecting the resulting compound to elimination reaction of the protecting group.
The salts of the compounds of this invention include the nontoxic carboxylic acid salts thereof, including nontoxic metallic salts such as sodium, potassium, calcium and aluminum, the ammonium salt and substituted ammonium salts, e.g. salts of such nontoxic amines as trialkylamines including triethylamine, procaine, dibenzylamine, N-benzyl-beta-phenethylamine, 1-ephenamine, N,N'-dibenzylethylenediamine, dehydroabietylamine, N,N'-bis-dehydroabietylethylenediamine, N-(lower)-alkylpiperidine, e.g. N-ethylpiperidine, and other amines which have been used to form salts with benzylpenicillin; and the nontoxic acid addition salts thereof (i.e., the amine salts) including the mineral acid addition salts such as the hydrochloride, hydrobromide, hydroiodide, sulfate, sulfamate and phosphate and the organic acid addition salts such as the maleate, acetate, citrate, oxalate, succinate, benzoate, tartrate, fumarate, malate, mandelate, ascorbate and the like.
Also included in this invention are the compounds (used as either intermediates or metabolic precursors) in which the amino group is "blocked" by substituents such as 2-iodoethoxycarbonyl (U.K. No. 1,349,673), t-butoxycarbonyl, carbobenzyloxy, formyl, o-nitrophenylsulfenyl, β,β,β-trichloroethoxycarbonyl, 4-oxo-2-pentenyl-2, 1-carbomethoxy-1-propenyl-2- and the like. Particularly included in such blocking groups are the ketones (especially acetone) and aldehydes (especially formaldehyde and acetaldehyde) disclosed, for example, in U.S. Pat. Nos. 3,198,804 and 3,347,851 and the β-ketoesters and β-diketones disclosed, for example, in U.S. Pat. No. 3,325,479 and the β-ketoamides disclosed in Japan No. 71/24714 (Farmdoc 47,321S).
The preferred esters of the cephalosporins of the present invention are the pivaloyloxymethyl, acetoxymethyl, methoxymethyl, acetonyl and phenacyl esters. All are useful intermediates in the production of the cephalosporin having a free carboxyl group.
As indicated above, these five esters of 7-aminocephalosporanic acid are each prepared by known methods. One excellent procedure is that of U.S. Pat. No. 3,284,451 in which sodium cephalothin is esterified by reaction with the corresponding active chloro or bromo compound (e.g. phenacyl bromide, chloroacetone, chloromethyl ether, pivaloyloxymethyl chloride [also called chloromethyl pivalate], acetoxymethyl chloride) and then the thienylacetic acid sidechain is removed enzymatically as in the same patent or chemically as in U.S. Pat. No. 3,575,970 and in Journal of Antibiotics, XXIV (11), 767-773 (1971). In another good method the triethylamine salt of 7-aminocephalosporanic acid is reacted directly with the active halogen compound, as in United Kingdom No. 1,229,453.
These esters of 7-aminocephalosporanic acid are then reacted with the nucleophile HSR 3 in the same manner as is illustrated herein for 7-aminocephalosporanic acid itself. The 3-thiolated ester of 7-aminocephalosporanic acid is then coupled with the organic carboxylic acid R'-OH as before. Before or after removal of any blocking group, e.g. on an amino group in the 7-sidechain, the ester of the cephalosporin so obtained is, if not used per se, converted to its free acid, including its zwitterion (and, if desired, any salt) by removal of the esterifying group, as by aqueous or enzymatic hydrolysis (as with human or animal serum) or acidic or alkaline hydrolysis or by treatment with sodium thiophenoxide as taught in U.S. Pat. No. 3,284,451 and, in the penicillin series, by Sheehan et al., J. Org. Chem. 29(7), 2006-2008 (1964).
In another alternative synthesis, the 3-thiolated 7-aminocephalosporanic acid is prepared as described herein and then acylated at the 7-amino group and finally esterified, as by reaction of the appropriate alcohol with the acid chloride prepared, for example, by reaction of the final cephalosporin with thionyl chloride or by other essentially acidic esterification procedures.
In the treatment of bacterial infections in man, the compounds of this invention are administered parenterally in an amount of from about 5 to 200 mg./kg./day and preferably about 5 to 20 mg./kg./day in divided dosage, e.g. three to four times a day. They are administered in dosage units containing, for example, 125, 250 or 500 mg. of active ingredient with suitable physiologically acceptable carriers or excepients. The dosage units are in the form of liquid preparations such as solutions or suspensions.
The other reagents used to prepare the compounds of the present invention are synthesized either as described in the art (e.g. as in the patents and publications noted above) or by strictly analogous procedures. For convenience and purposes of illustration, however, there are given below some specific examples of such syntheses, e.g. to prepare carboxylic acids containing a free amino group which is "blocked" with tert.-butoxycarbonyl.
2-(tert.-Butoxycarbonylaminomethyl)-1,4-cyclohexadienylacetic acid
A solution of 16.5 g. (0.1 mole) of o-aminomethylphenylacetic acid in 1.5 l of liquid ammonia (which had been treated with 50 mg. of Li to remove a trace of moisture) was slowly diluted with 500 ml. of dry t-BuOH. To the solution was added in small portions 3.4 g. (0.5 atom) of Li over a period of 4 hours and the mixture was stirred for 16 hours at room temperature removing the liquid ammonia in a hood and finally evaporated to dryness below 40° C. The residue was dissolved in 500 ml. of water and the solution was chromatographed on a column of IR-120 (H + , 700 ml.) resin and eluted with 1% NH 4 OH solution. Ninhydrin positive fractions of the eluate were combined and evaporated to dryness. The residue was washed with four 50 ml. portions of hot acetone and recrystallized from 500 ml. of ethanol-water (1:1) to give 11.2 g. (67%) of colorless needles, o-( 2-aminomethyl-1,4-cyclohexadienyl)acetic acid. M.p. 183° C.
IR: ν max nuj 1630, 1520, 1380, 1356 cm -1 .
NMR: δD 2 O+K 2 CO 3 2.72 ##STR15## 3.01 (2H, s, CH 2 CO), 3.20 (2H, s, CH 2 -N), 5.78 (2H, s, H >C═).
Anal. Calcd. for C 9 H 13 NO 2 : C, 64.65; H, 7.84; N, 8.38. Found: C, 64.77; H, 8.06; N, 8.44.
Improved Procedure for the Preparation of α-(2-aminomethyl-1,4-cyclohexadienyl)-acetic acid ##STR16##
The procedure used by Welch, Dolfini and Giarrusso in U.S. Pat. No. 3,720,665 (Example 1) to make D-2-amino-2-(1,4-cyclohexadienyl)acetic acid was adapted. A solution of 830 ml. of distilled liquid ammonia was dried with 40 mg. of lithium under an argon atmosphere. To this stirred solution was added 11.0 g. (0.07 mole) of 2-aminomethylphenylacetic acid and 340 ml. of tert. butyl alcohol. A total of 1.6 g. (0.225 mole) of lithium was added to the vigorously stirred solution over a period of 2 hours. The grey mixture was then treated with 35 g. (0.215 mole) of triethylamine (TEA) hydrochloride and stirred overnight at room temperature for 18 hours. The tert. butyl alcohol was removed at 40° (15 mm.) to yield a white residue which was dried in vacuo over P 2 O 5 overnight. The solid was dissolved in 30 ml. of 1:1 methanol-water and added with stirring to 3.5 l. of 1:1 chloroform-acetone at 5°. The mixture was stirred for 20 min. and the amino acid, α-(2-aminomethyl-1,4-cyclohexadienyl)acetic acid, was collected and dried for 16 hours in vacuo over P 2 O 5 to yield 6.3 g. (58%) of white crystals, m.p. 190° decomp. The IR and NMR spectra were consistent for the structure.
A solution of 19.31 g. (0.135 m) of tert.butoxycarbonylazide in 152 ml. of tetrahydrofuran (THF) was added to a stirred solution of 14.89 g. (0.09 m) of 2-aminomethyl-1,4-cyclohexadienylacetic acid and 7.20 g. (0.18 m) of sodium hydroxide in 281 ml. of water. The solution was stirred for 18 hr. at 25° and then filtered thru diatomaceous earth (Super-cel). The THF was removed at 40° (15 mm) and the residual solution was washed with ether (2×175 ml.) and acidified with 6 N hydrochloric acid (HCl). The mixture was stirred in an ice-bath and the precipitate was collected and dried for 18 hr. in vacuo over P 2 O 5 at 25° to yield 17.3 g. (72.6%) of 2-(tert.-butoxycarbonylaminomethyl)-1,4-cyclohexadienylacetic acid as a white powder. The IR and NMR spectra were consistent for the structure.
Preparation of 3-Aminomethyl-2-thiophene Acetic Acid ##STR17##
(A) Thiophene-3-carboxaldehyde Dimethyl Acetal (2a)
A mixture of thiophene-3-carboxaldehyde.sup.(1) (322 g., 2.9 moles), trimethoxymethane (636 g., 6 moles) and IR-120 resin (H + , 6 g.) in methanol (200 ml.) was refluxed over a period of 4 hours. The resin was removed and the filtrate was evaporated under reduced pressure to give a colorless oil which was distilled under reduced pressure. Yield 423 g. (94%), b.p. 90°-95° C. 13 mmHg.
ir: ν max liq 3150, 1045, 1025 cm -1
nmr: δ ppm neat 3.21 (6H, s, OCH 3 ), 5.43 ##STR18## 7.0-7.4 (3H, m, thiophene-H)
B. 2-Formylthiophene-3-carboxaldehyde Dimethylacetal (3a)
To a stirred solution of 2a (423 g., 2.68 moles) in anhydrous ether (1 L) was added dropwise in 1 hour a freshly prepared solution of n-butyllithium (27 moles) in ether keeping a gentle reflux under dry N 2 . Reflux being continued for 0.5 hour, a solution of DMF (dimethylformamide) (432 g., 6 moles) in anhydrous ether (0.8 L) was added dropwise to the mixture over a period of 0.75 hour with vigorous stirring. After the complete addition the mixture was stirred overnight, poured onto crushed ice (1 Kg.) with stirring and allowed to rise to room temperature. The organic layer was separated and the water layer was saturated with NaCl and extracted thoroughly with ether (2×200 ml.). The ether extracts were combined, dried over MgSO 4 and concentrated. The residue was distilled under reduced pressure and the pale yellow oil was collected at 100°-125° C., 0.7 mmHg. Yield, 277 g. (56%).
ir: ν max liq 3110, 1660, 1100 cm -1 .
nmr: δ ppm neat 3.40 (6H, s, OCH 3 ), 5.86 ##STR19## 7.27 (1H, d, J=6Hz, thiophene-Hβ), 7.81 (1 H, d-d, J=1.5 and 6Hz, thiophene-Hα), 10.34 (1H, d, J=1.5 Hz, --CHO).
(C) 1-Methylsulfinyl-1-methylthio-2-(3-carboxaldehyde-ethyleneacetal-2-thienyl)ethylene (4b)
Preparation of 4b was carried out according to the procedure similar to that reported by K. Ogura et al. 4 ). Triton B (40% in methanol, 2 ml. in THF (tetrahydrofuran) (5 ml.) was added to a solution of methyl methylthiomethyl sulfoxide 2 ) (2.5 g., 20 m. moles) and 2-formyl-3-thiophenecarboxaldehyde ethylene acetal 3 ) (3b). The mixture was refluxed for about one hour and concentrated under reduced pressure.
ir: ν max liq 3110, 1600 cm 31 1.
nmr: δ ppm CDCl .sbsp.3 2.42 (3H, s, S--CH 3 ), 2.78 (3H, s, SO--CH 3 ), 4.15 (4H, m, CH 2 CH 2 --), 6.12 ##STR20## 7.34 (1H, d, J=4.5Hz, thiophene-Hβ), 7.40 (1H, d, J=4.5Hz, thiophene-Hα), 8.28 (1H, s, --CH=).
The semicarbazone of 4 was prepared by a usual manner and crystallized from ethanol-DMF. M.p. 212°-213° C.
Anal. Calcd. for C 10 H 13 N 3 O 2 S 2 : C, 39.58; H, 4.32; N, 13.85; S, 31.70. Found: C, 39.46; H, 4.24; N, 14.05; S, 31.63.
(D) 1-Methylsulfinyl-1-methylthio-2-(3-carboxaldehyde dimethylacetal-2-thienyl)ethylene (4a)
The compound 4a was prepared by the procedure similar to that for 4b. Triton B (40% in methanol, 50 ml) was added to a solution of methyl methylthiomethylsulfoxide (72 g., 0.58 mole) and 3a (108 g, 0.58 mole) in THF (300 ml) and the mixture was refluxed for 4 hours. Separation by column chromatography with silica gel (400 g) eluting with chloroform (5 L) gave 130.5 g (78%) of 4a as a pale yellow oil.
ir: ν max liq 3100, 1580, 1100, 1050 -1 .
nmr: δ ppm CCl .sbsp.4 2.42 (3H, s, S--CH 3 ), 2.70 (3H, s, SO--CH 3 ), 3.34 (6H, s, OCH 3 ), 5.56 ##STR21## 7.20 (1H, d, J=6Hz, thiophene-Hβ), 7.40 (1H, d, J=6Hz, thiophene-Hα), 8.12 (1H, s, --CH═).
(E) Ethyl 3-formyl-2-thienylacetate 4 ) (5)
Dry hydrogen chloride (33 g) was absorbed in anhydrous ethanol (500 ml). To this solution 4a (130 g, 0.45 mole) was added and the mixture heated under reflux for 5 mins. The reaction mixture was diluted with water and evaporated under reduced pressure. The residue was extracted with benzene (2×100 ml) and the benzene extracts were combined, washed with water (50 ml), dried over MgSO 4 and evaporated to dryness. The oily residue was column-chromotographed on silica gel (400 g) eluting with chloroform (5 L). Fractions containing the desired product were combined and concentrated. The residual oil (60 g) was distilled under reduced pressure to afford 23 g (23%) of 5, boiling at 120°-126° C./1 mmHg.
ir: ν max liq 3110, 1730, 1670 cm -1 .
nmr: δ ppm CDCl 3 1.30 (3H, t, J=6Hz, --CH 2 CH 3 ), 4.25 (2H, q, J=6Hz, --CH 2 CH 3 ), 4.26 (2H, s, --CH 2 CO), 7.25 (1H, d, J=5Hz, thiophene-Hβ), 7.48 (1H, d, J=5Hz, thiophene-Hα), 10.15 (1H, s, CHO).
The analytical sample of 5 was submitted as the 2,4-dinitrophenylhydrazone which was crystallized from chloroform. M.p. 178°-179° C.
ir: ν max nujol 1720, 1610, 1570 cm -1 .
Anal. Calcd. for C 15 H 14 N 4 O 6 S: C, 47.62; H, 3.73; N, 14.81; S, 8.47. Found: C, 47.33; H, 3.47; N, 14.77; S, 8.68.
According to the similar procedure 2.2 g (7.6 m moles) of the ethylene acetal 4b was treated with 1.1 g of dry hydrogen chloride in 800 ml of anhydrous ethanol to afford 5 which was purified by column chromatography on silica gel (30 g). Elution with chloroform gave 663 mg (44%) of 5 as a pale yellow oil.
(F) Ethyl 3-formyl-2-thienylacetate oxime (6)
Sodium carbonate (1.7 g, 16 m mole) was added to a solution of the aldehyde 5, (3.14 g, 16 m mole) and hydroxylamine hydrochloride (2.2 g, 32 m mole) in 50% aq. ethanol (40 ml) at 5° C. with stirring. The reaction mixture was warmed up to room temperature. After 2.5 hrs., the reaction mixture was concentrated under reduced pressure. The residue was extracted with benzene (3×50 ml). The benzene extracts were washed with water (10 ml), dried over MgSO 4 , and evaporated under reduced pressure. Separation by column chromatography on silica gel (60 g) gave 2.7 g (80%) of colorless oil 6.
ir: ν max liq 3400, 1730, 1620 cm -1 .
nmr: δ ppm Aceton-d .sbsp.6 1.23 (3H, t, J=7.5Hz, --CH 2 CH 3 ), 4.01 (2H, s, --CH 2 CO), 4.14 (2H, q, J=7.5Hz, --CH 2 CH 3 ), 7.31 (2H, s, thiophene-H), 8.26 (1H, s, --CH=N), 10.15 (1H, s, NOH, disappeared by addition of D 2 O).
(G) The δ-lactam of 3-aminomethyl-2-thienylacetic acid (7)
Method A: Catalytic reduction
A mixture of the oxime 6 (2.65 g, 12.4 m moles), 10% palladium on charcoal, dry hydrogen chloride (1.4 g, 37.2 m moles) in anhydrous ethanol (68 ml) was hydrogenated overnight under atmospheric pressure at room temperature. The catalyst was exchanged twice and the reaction was carried out over a period of 3 days. The catalyst was removed and the filtrate was concentrated under reduced pressure. To the residue was added water (10 ml) and the mixture washed with ethyl acetate (2×10 ml). The aqueous layer was adjusted to pH 9 with sodium carbonate, saturated with sodium chloride, and extracted with ethyl acetate (3×20 ml). The ethyl acetate extracts were dried over MgSO 4 , treated with charcoal, and evaporated under reduced pressure. Recrystallization from ethyl acetate gave 417 mg (22%) of colorless needles 7 melting at 194°-195° C.
ir: ν max KBr 3200, 1650, 1480 cm -1 .
nmr: δ ppm DMSO-d .sbsp.6 3.53 (2H, t, J=3 Hz, --CH 2 CO--), 4.36 (2H, d-t, J=3, 1.5 Hz, changed to a triplet by addition of D 2 O, J=3 Hz, CH 2 N), 6.95 (1H, d, J=4.5 Hz, thiophene-Hβ), 7.45 (1H, d, J=4.5 Hz, thiophene-Hα), 8.0 (1H, m, disappeared by addition of D 2 O, NH).
Anal. Calcd. for C 7 H 7 NOS: C, 54.88; H, 4.61; N, 9.14; S, 20.93. Found: C, 55.04; H, 4.45; N, 9.13; S, 20.50.
Method B: Zn-dust reduction
To a solution of the oxime 6 (18.3 g, 86 m moles) in acetic acid (200 ml), zinc dust (17 g, 258 m moles) was added portionwise over a period of 1 hr. at 40°-50° C. with vigorous stirring. The reaction mixture was stirred overnight at room temperature and heated at 60° C. for 4 hours. The contents were filtered and the filtrate was concentrated under reduced pressure. To the residual oil was added water (100 ml) and the mixture washed with ether (2×50 ml). The aqueous solution was layered with ethyl acetate (100 ml) and adjusted to pH 10 with sodium carbonate. The precipitate was filtered off. The filtrate was extracted with ethyl acetate. The ethyl acetate extracts were washed with water (10 ml), dried over MgSO 4 , and evaporated under reduced pressure. The residual solid was triturated with benzene. Crystallization from ethyl acetate gave 2.7 g (21%) of the lactam 7 which was identical to Method A in the IR and the NMR spectra.
H. 3-Aminomethyl-2-thienylacetic acid (8)
A mixture of the lactam 7 (2.88 g, 18.8 m moles) and 6 N hydrochloric acid (50 ml) was heated under reflux for 3 hrs. The reaction mixture was concentrated under reduced pressure. To the residue was added water (20 ml) and the mixture treated with charcoal and evaporated under reduced pressure. The trituration of the residue with THF gave the amino acid 8 hydrochloride (3.72 g, 95%; m.p. 171°-172° C.; ir (KBr) cm -1 : 3450, 3000, 1700, 1200; nmr (D 2 O)ppm: 4.80 (2H, s, --CH 2 CO), 4.27 (2H, s, CH 2 --N), 7.26 (1H, d, J=6 Hz, thiophene-Hβ), 7.53 (1H, d, J=6 Hz, thiophene-Hα). The hydrochloride (3.71 g, 17.9 m moles) was dissolved in water (10 ml) chromatographed on a column of IR-120 (H, 30 ml) and developed successively with water (100 ml) and 5 N-NH 4 OH (2 L). The ammonia eluate was evaporated to dryness. The residue was crystallized from aqueous acetone to give 3.0 g (98%) of 8, m.p. 223°-225° C.
ir: ν max KBr 3000, 1620, 1520 cm -1 .
nmr:δ ppm D .sbsp.2 O-Na .sbsp.2 CO .sbsp.3 3.20 (2H, s, --CH 2 CO), 4.13 (2H, s, CH 2 N), 7.04 (1H, d, J=6 Hz, thiophene-Hβ), 7.30 (1H, d, J=6 Hz, thiophene-Hα).
Anal. Calcd. for C 7 H 9 NO 9 S: C, 49.10; H, 5.30; N, 8.18; S, 18.73. Found: C, 48.53: h, 5.22; N, 7.98; S, 18.97.
I. 3-t-Butoxycarbonylaminomethyl-2-thienylacetic acid (9)
A mixture of 3-aminomethyl-2-thienylacetic acid 8 (3.1 g, 18 m. moles) and triethylamine (8 g. 80 m moles) in 50% aqueous acetone (80 ml) was added dropwise t-butoxycarbonyl azide (5.7 g, 40 m moles) over a period of 20 mins. at 0° C. with vigorous stirring. The reaction mixture was stirred overnight at room temperature and concentrated under reduced pressure. The concentrate was washed with ether (2×20 ml), adjusted to pH 2 with conc. HCl and extracted with ethyl acetate (2×50 ml). The ethyl acetate extracts were washed with saturated aqueous sodium chloride, dried over MgSO 4 , treated with charcoal and evaporated under reduced pressure. The residue was triturated with n-hexane and crystallized from n-hexane and benzene to give 4.5 g (92%) of colorless needles 9, melting at 62°-63° C.
ir: ν max nujol 3350, 1700 cm -1 .
nmr: δ ppm CDCl .sbsp.3 1.43 (9H, s, BOC-H), 3.27 (2H, s, CH 2 CO), 4.16 (2H, d, J=6 Hz, CH 2 --N, a singlet when D 2 O was added), 5.00 (1H, br, --NH--, disappeared by addition of D 2 O), 6.30 (1H, broad s, --COOH, disappeared by addition of D 2 O), 6.86 (1H, d, J=6 Hz, thiophene-Hβ), 7.06 (1H, d, J=6 Hz, thiophene-Hα).
Anal. Calcd. for C 12 H 17 NO 4 S: C, 52.89; H, 6.29; N, 5.14; S, 11.77. Found: C, 53.30; H, 6.39; N, 5.13; S, 11.72.
Preparation of 2-N-Methylaminomethyl-4-methoxy-(and 4-hydroxy-)phenylacetic Acids ##STR22##
2-N-Tosylaminomethyl-4-hydroxyphenylacetic Acid (2)
To a solution of 14.56 g. (0.08 mol.) of 2-aminomethyl-4-hydroxyphenylacetic acid (1) (U.S. Pat. No. 3,823,141) and 13 g. (0.32 mol.) of sodium hydroxide in 200 ml. of water was added dropwise with stirring at 65°-70° C. a solution of 18.5 g. (0.097 mol.) of p-toluenesulfonyl chloride in 50 ml. of dry ether and the mixture was kept at the same temperature for one hour. The mixture being cooled, the aqueous layer was separated, washed with ether (2×50 ml.), acidified with 6 N HCl and extracted with 400 ml. of ethyl acetate. The extract was washed with water and a saturated aqueous NaCl solution, dried with Na 2 SO 4 and treated with active carbon (1 g.). The filtrate was concentrated to dryness and the residue was crystallized from ethyl acetate to give 11.0 g. (40.5%) of 2 melting at 212°-215° C.
ir: ν max KBr 3240, 1700, 1380, 1330, 1150 cm -1
uv: λ max 1%K .sbsp.2 CO .sbsp.3 230 nm (ε: 7,750)
nmr: δ ppm DMSO-d .sbsp.6 2.47 (3H, s, Ar--CH 3 ), 3.60 (2H, s, CH 2 CO), 3.93 (2H, d, J=6.0 Hz, CH 2 N), 6.6-8.2 (7H, m, phenyl-H).
2-(N-Methyl-N-tosylamino)methyl-4-methoxyphenylacetic Acid (3)
A mixture of 11 g. (0.033 mol.) of 2, 10.3 ml. (0.17 mol.) of methyl iodide and 9.2 g. (0.24 mol.) of sodium hydroxide in 100 ml. of water was heated at 80°-90° C. for 45 minutes in a sealed tube with occasional shaking. The mixture was washed with ethyl acetate (30 ml.) and the water layer was acidifed with 6 N HCl and extracted with ethyl acetate (3×30 ml.). The combined extracts were washed with water (30 ml.) and a saturated aqueous NaCl solution (30 ml.) treated with active carbon (1 g.) and dried over Na 2 SO 4 . The filtrate was evaporated to dryness and the residue was crystallized from benzene to give 8 g. (66.5%) of the N,O-dimethyl derivative 3 melting at 146°-150° C.
ir: ν max KBr 1690, 1500, 1340, 1280, 1150 cm -1 .
uv: λ max EtOH 229 nm (ε: 20500), 278 nm (ε: 2400).
nmr: δ ppm DMSO-d .sbsp.6 2.52 (3H, s, N--CH 3 ), 2.47 (3H, s, Ar--CH 3 ), 3.67 (2H, s, CH 2 CO), 3.74 (3H, s, OCH 3 ), 4.10 (2H, s, CH 2 N), 6.7-7.8 (7H, m, Ar-H), 11.5 (1H, br-s, COOH).
Anal. Calc'd. for C 18 H 21 NO 5 S: C, 59.49; H, 5.82; N, 3.84; S, 8.82. Found: C, 59.48; H, 5.68; N, 3.37; S, 9.22.
2-N-Methylaminomethyl-4-methoxyphenylacetic Acid (4a)
To a solution of liquid ammonia (300 ml.) was added 9.4 g. (0.026 mol.) of 3 at -50° C. and the mixture was stirred until a clear solution was obtained at the same temperature. To the solution was added 3.3 g. (0.14 g. atom) of Na in small pieces at -40° C. and the mixture was stirred for 2 hours. Ammonia was evaporated and the residue was dissolved in 100 ml. of water carefully. To the solution was added 100 ml. of Amberlite IR-C 50 (ammonium type) and the mixture was stirred for 30 minutes to room temperature. The resin was removed and the filtrate was treated with barium acetate until no more precipitate was observed. The precipitate was filtered off and the filtrate was chromatographed with a column of IR-120 ion-exchange resin (H + , 100 ml.) by eluting with 5-10% ammonia. The eluate (2 L) containing the desired product was evaporated to dryness below 50° C. and the residue was triturated with acetone to give 4.4 g. (81%) of 4a, m.p. 225°-227° C.
ir: ν max KBr 1590, 1380, 1260, 1035 cm -1 .
nmr: δ ppm D .sbsp.2 O 2.77 (3H, s, N--CH 3 ), 3.6 (2H, s, CH 2 CO), 3.87 (3H, s, OCH 3 ), 4.18 (2H, s, CH 2 N), 6.8-7.4 (3H, m, phenyl-H).
2-N-Methylaminomethyl-4-hydroxyphenylacetic Acid (4b)
A mixture of 2.9 g. (0.014 mol.) of 4a in 30 ml. of 48% hydrobromic acid was refluxed for 5 hours and the solution was evaporated to dryness. The residue was dissolved in 50 ml. of water. The solution was chromatographed on a column of Amberlite IR-120 (H + , 50 ml.) eluting with 5-10% ammonia. The eluate was collected in 250 ml. fractions. Fractions containing the product were combined and evaporated to dryness below 50° C. The residue was triturated with acetone to give 1.3 g. (48.5%) of 4b, which was crystallized from 80% ethanol. M.p. 218°-221° C.
ir: ν max KBr 2000-3400, 1610, 1540, 1460, 1380, 1270 cm -1 .
uv: λ max 1%K .sbsp.2 CO .sbsp.3 243 nm (ε: 4700), 297 nm (λ: 1350).
nmr: δ ppm D .sbsp.2 O+NaOH 2.64 (3H, s, N--CH 3 ), 3.47 (2H, s, CH 2 CO), 3.94 (2H, s, N--CH 2 ), 6.5-7.2 (3H, m, phenyl-H).
Anal. Calc'd. for C 10 H 13 NO 3 : C, 61.53; H, 6.71; N, 7.17. Found: C, 61.44; H, 6.81; N, 7.20.
2-N-t-Butoxycarbonyl-N-methylaminomethyl-4-methoxyphenylacetic Acid (5, R=CH 3 )
A mixture of 1.05 g. (5 m.mol.) of 4a, 1.43 g. (6 m.mol.) of t-butyl 4,6-dimethylpyrimidin-2-ylthiolcarbonate and 1.4 ml. of triethylamine in 40 ml. of 50% THF was stirred at room temperature for 20 hours. Most of the THF was evaporated and the resulting aqueous solution (ca. 20 ml.) was washed with ether. The water layer was acidified with 6N HCl and extracted with ether (3×10 ml.). The ethereal extracts were washed with water (10 ml.) and a saturated aqueous NaCl solution (10 ml.), treated with a small amount of active carbon and dried over Na 2 SO 4 . The filtrate was evaporated to dryness to give 1.0 g. (77.5%) of 5 (R=CH 3 ) as an oil.
nmr: δ ppm CDCl .sbsp.3 1.47 (9H, s, BOC-H), 2.77 (3H, s, N--CH 3 ), 3.60 (2H, s, CH 2 CO), 3.79 (3H, s, O--CH 3 ), 4.49 (2H, s, CH 2 N), 6.1-7.3 (3H, m, phenyl-H).
2-N-t-Butoxycarbonyl-N-methylaminomethyl-4-hydroxyphenylacetic Acid (5, R=H)
A mixture of 1 g. (4.78 m.mol.) of 4b, 1.5 g. (6.3 m.mol.) of t-butyl 4,6-dimethylpyrimidin-2-ylthiolcarbonate and 2.1 ml. of triethylamine in 50 ml. of 50% aqueous THF solution was stirred at room temperature for 20 hours. The mixture was concentrated to 20 ml. under reduced pressure. The concentrate was washed with ether (10 ml.), acidified with 6N HCl and extracted with ethyl acetate (2×100 ml.). The combined extracts were washed with water (30 ml.) and a saturated aqueous NaCl solution (2×30 ml.), treated with a small amount of active carbon and dried over anhydrous Na 2 SO 4 . The filtrate was evaporated to dryness to give 1.3 g. (92%) of 5 (R=H) as an oil.
ir: ν max liq 3000-3600, 1670, 1260, 1150 cm -1 .
nmr: δ ppm CDCl .sbsp.3 1.44 (9H, s, C(CH 3 ) 3 ), 2.73 (3H, s, N--CH 3 ), 3.54 (2H, s, CH 2 CO), 4.38 (2H, s, CH 2 N), 6.5-7.3 (3H, m, phenyl-H).
Preparation of Ortho-N-methylaminomethyl-phenylacetic Acid ##STR23##
o-(p-Toluenesulfonylaminomethyl)phenylacetic Acid (2)
To a stirred solution of o-aminomethylphenylacetic acid hydrochloride (7.50 g., 37 m.mol.) and sodium hydroxide (4.74 g., 118 m.mol.) in water (100 ml.) was added p-toluenesulfonyl chloride (7.64 g., 40 m.mol.) in portions at 60° C. The mixture was stirred for 1 hour at the same temperature and acidified with hydrochloric acid. The mixture was extracted with ethyl acetate (4×50 ml.). The combined extracts were washed with water, treated with a small amount of carbon and dried. The solvent was evaporated under reduced pressure and the residue crystallized from ethyl acetate to afford 2 as colorless prisms. Yield, 9.84 g. (84%). M.p. 155°-156° C.
ir: ν max nuj 3300, 1705, 1335, 1170 cm -1 .
nmr: δ ppm DMSO-d .sbsp.6 2.38 (3H, s, CH 3 ), 3.65 (2H, s, CH 2 CO), 3.97 (2H, d, J=5 Hz, CH 2 N), 7.1-8.2 (9H, m, phenyl-H & NH).
Anal. Calc'd. for C 16 H 17 NO 4 S: C, 60.17; H, 5.37; N, 4.39; S, 10.10. Found: C, 60.11, 60.15; H, 5.43, 5.40; N, 4.28, 4.30; S, 9.72, 9.80.
o-(N-p-Toluenesulfonyl-N-methylaminomethyl)phenylacetic Acid (3)
A mixture of 2 (9.0 g., 28 m.mol.) sodium hydroxide (6.0 g.) and methyl iodide (6 ml.) in water (60 ml.) was heated in a sealed tube for 30 minutes at 70° C. After cooling, the reaction mixture was acidified with hydrochloric acid to separate pale yellow precipitate which was crystallized from ethyl acetate-n-hexane to give colorless prisms, 3. Yield, 8.5 g. (91%). M.p. 162°-163° C.
ir: ν max KBr 2700-2300, 1700, 1600, 1345, 1200, 925 cm -1 .
nmr: δ ppm D .sbsp.2 O+KOH 2.37 (3H, s, CH 3 ), 2.49 (3H, s, CH 3 ), 3.80 (2H, s, CH 2 CO), 4.18 (2H, s, CH 2 N), 7.0-8.0 (8H, m, phenyl-H).
Anal. Calc'd. for C 17 H 19 NO 2 : C, 61.24; H, 5.74; N, 4.20; S, 9.61. Found: C, 61.31, 61.36; H, 5.73, 5.71; N, 4.51, 4.29; S, 9.63, 9.55.
N-Methylaminomethylphenylacetic Acid (4)
Method A (using hydrobromic acid)--A mixture of 28.6 g. (0.086 mol.) of 3 and 20 g. (0.213 mol.) of phenol in 260 ml. of 48% hydrobromic acid was refluxed for 30 minutes. The mixture was cooled, diluted with the same volume of water and washed with ethyl acetate (2×50 ml.). The aqueous layer was evaporated to dryness in diminished pressure to give an oil which was chromatographed on a column of Amberlite IR-120 (H + form, 200 ml.) eluting with 5% ammonium hydroxide solution. The eluate (2.5 l.) was collected and evaporated to dryness under reduced pressure. The residue was triturated with acetone and crystallized from ethanol to afford 6.7 g. (43.5%) of 4 as colorless needles, melting at 168°-170° C. (dec.).
Method B (using metallic sodium in liquid ammonia)--To a mixture of 3 (35 g., 0.105 mol.) in liquid ammonia (1000 ml.) was added 13.3 g. (0.578 atom) of sodium in small pieces under vigorous stirring over a period of 2 hours. The ammonia was evaporated with stirring on a water-bath in a well-ventilated hood and finally under reduced pressure to remove it completely. The residue was dissolved in ice water (400 ml.) and the solution was stirred with ion-exchange resin IRC-50 (H + form, 400 ml.) for 0.5 hour at room temperature. The resin was filtered off and to the filtrate was added an aqueous 1 M solution of barium acetate until no more precipitate was formed (ca 50 ml. of the barium acetate solution was required). The mixture was filtered and the filtrate was chromatographed on a column of IR-120 (H + form, 400 ml.) as in Method A to give 13.6 g. (72%) of 4.
o-(N-methyl-N-t-butoxycarbonylaminomethyl)phenylacetic Acid (5)
t-Butyl 4,6-dimethylpyrimidin-2-ylthiolcarbonate (11 g., 0.048 mol.) was added in one portion to a mixture of 4 (7.2 g., 0.04 mol.) and 1,1,3,3-tetramethylguanidine (6.9 g., 0.06 mol.) in 50% aqueous THF and the mixture was stirred overnight at room temperature. The THF being evaporated under reduced pressure, the aqueous solution was acidified to pH 2 with dil. hydrochloric acid and extracted with ethyl acetate (2×20 ml.). The combined extracts were washed with water, treated with a small amount of active carbon and evaporated under diminished pressure. The residue was triturated with hexane and crystallized from n-hexane-ether to afford 9.2 g. (83%) of 5 as colorless prisms. M.p. 96°-98° C.
ir: ν max KBr 1730, 1630, 1430, 1830, 1250 cm -1 .
nmr: δ ppm CDCl .sbsp.3 1.49 (9H, s, t-butyl), 2.78 (3H, s, N--CH 3 ), 3.72 (2H, s, CH 2 CO), 4.25 (2H, s, CH 2 N), 7.28 (4H, s, phenyl), 9.83 (1H, s, --COOH).
Anal. Calc'd. for C 15 H 21 NO 4 : C, 64.50; H, 7.58; N, 5.01. Found: C, 64.69; H, 7.66; N, 4.89.
Preparation of 3-N-methylaminomethyl-2-thienylacetic Acid ##STR24##
3-Aminomethyl-2-thienylacetic Acid δ-lactam (2)
Glacial acetic acid (140 ml.) was added dropwise with stirring to a mixture of 2-ethoxycarbonylmethylthiophene-3-carboxaldehyde oxime (1) (41 g., 0.19 mole) and zinc dust (65.4 g., 1 mole) in methanol, and the mixture was stirred under reflux for 4 hours. The mixture was cooled and insolubles were removed by filtration and washed with methanol (3×50 ml.). The filtrate was combined with the washings and evaporated in vacuo to dryness, the residue being extracted with methanol (5×100 ml.). The methanol extracts were combined and evaporated under reduced pressure. To the residue was added water (50 ml.) and the mixture was adjusted to pH 10 with Na 2 CO 3 and extracted with chloroform (3×100 ml.). The combined chloroform extracts were washed with water (10 ml.), dried over MgSO 4 , and evaporated under reduced pressure. The residual oil (30 g.) was triturated with hot benzene (150 ml.). The colorless needles were collected by filtration and recrystallized from ethyl acetate to give the lactam 2 (7.7 g., 26%), melting at 195°-196° C.
UV: λ max MeOH 232 nm (ε, 6500)
Anal. Calc'd. for C 7 H 7 NOS: C, 54.88; H, 4.61; N, 9.14; S, 20.93. Found: C, 55.04; H, 4.45; N, 9.13; S, 20.50.
3-N-Methylaminomethyl-2-thienylacetic Acid δ-lactam (3)
To a suspension of sodium hydride (50% in paraffin, 1.82 g., 38 m.moles) in absolute benzene (500 ml.) was added the lactam 2 (4.85 g., 32 m.moles) with stirring under nitrogen atmosphere and the mixtures was refluxed for 2 hours. Methyl iodide (22.7 g., 160 m.moles) was added in one portion at room temperature and the mixture was again refluxed for 2 hours. ice-water (50 g.) was added to the mixture and organic layer was separated. The aqueous layer was extracted successively with benzene (2×50 ml.) and chloroform (50 ml.). The extracts were combined and dried on MgSO 4 . The solvent was evaporated under reduced pressure. To the residue was added a hot mixture of benzene-n-hexane (1:1, 100 ml.) to recover 2 as needles (2.02 g., 42%). The filtrate was evaporated and the residue was crystallized from benzene-n-hexane to afford colorless plates 3. Yield: 2.7 g. (51%). M.p. 98°-100° C.
ir: ν max nujol 1620 cm -1 .
nmr: δ max CHCl .sbsp.3 3.15 (3H, s, N--CH 3 ), 3.72 (2H, t, J=3 Hz, CH 2 CO), 4.53 (2H, t, J=3 Hz, --CH 2 --N), 6.87 (1H, d, J=4.5 Hz, thiophene-Hβ), 7.30 (1H, d, J=4.5 Hz, thiophene-Hα.
uv: λ max MeOH 232 nm (ε, 6700)
Anal. Calc'd. for C 8 H 9 NOS: C, 57.46; H, 5.42; N, 8.38; S, 19.17. Found: C, 57.56; H, 5.26; N, 8.31; S, 19.13.
3-(N-Methylaminomethyl)-2-thienylacetic Acid (4)
A mixture of the lactam 3 (3.5 g., 21 m.moles) and 6 N HCl (100 ml.) was heated under reflux for 12 hours. The mixture was treated with carbon and concentrated to dryness under reduced pressure. The residual oil was dissolved in water (10 ml.) and chromatographed on a column of IR-120 (H + , 50 ml.). The column was eluted with water (200 ml.) and 5 N, NH 4 OH (3 L.). The amino acid 4 (3.0 g., 77%) was isolated by evaporation of the ammonia eluates followed by crystallization from aqueous acetone. M.p. 181°-182° C.
ir: ν max KBr 1570, 1360 cm -1 .
nmr: δ ppm D .sbsp.2 O 2.21 (3H, s, N--CH 3 ), 3.80 (2H, s, CH 2 CO), 4.20 (2H, s, CH 2 --N), 7.19 (1H, d, J=6 Hz, thiophene-Hβ), 7.46 (1H, d, J=6 Hz, thiophene-Hα).
uv: λ max H .sbsp.2 O 237 nm (ε, 7600)
Anal. Calc'd. for C 8 H 11 NO 2 S: C, 51.87; H, 5.99; N, 7.56; S, 17.31. Found: C, 51.67; H, 6.50; N, 7.28; S, 16.69.
3-(N-t-butoxycarbonyl-N-methylaminomethyl)-2-thienylacetic Acid (5)
To a mixture of 3-N-methylaminomethyl-2-thienylacetic acid 4 (2.7 g., 14.6 m.moles) and triethylamine (6 g., 60 m.moles) in 50% aqueous acetone (60 ml.) was added dropwise t-butoxycarbonyl azide (4.2 g., 29.2 m.moles) over a period of 20 minutes at 0° C. with vigorous stirring. The reaction mixture was stirred overnight at room temperature and concentrated under reduced pressure. The concentrate was washed with ether (2×20 ml.), adjusted to pH 2 with concentrated HCl and extracted with ethyl acetate (2×50 ml.). The ethyl acetate extracts were washed with a saturated aqueous NaCl solution, dried on MgSO 4 , treated with charcoal and evaporated under reduced pressure. The residue was triturated with n-hexane and crystallized from n-hexane-benzene to give 3.68 g. (88%) of colorless needles 5 melting at 82°-83° C.
ir: ν max nujol 1730, 1640 cm -1 .
nmr: δ ppm CDCl .sbsp.3 1.47 (9H, s, BOC-H), 2.78 (3H, s, N--CH 3 ), 3.87 (2H, s, CH 2 --CO), 4.48 (2H, s, CH 2 --N), 6.91 (1H, d, J=6 Hz, thiophene-Hβ), 7.20 (1H, d, J=6 Hz, thiophene-Hα), 10.63 (1H, s, CO 2 H, disappeared by addition of D 2 O).
Anal. Calc'd. for C 13 H 19 NO 4 S: C, 54.72; H, 6.71; N, 4.91; S, 11.24. Found: C, 54.91; H, 6.85; N, 4.92; S, 11.19.
The use of an "en-amine" blocking group with a prospective 7-side chain containing a free amino group prior to acylation of a nucleus such as II herein is well known as from U.S. Pat. Nos. 3,223,141, 3,813,390; 3,813,391; 3,823,141 and Belgium Pat. No. 773,773.
Sodium 2-[N-(1-carbethoxypropen-2-yl)aminomethyl]-1,4-cyclohexadienyl acetate (4)
To a stirred solution of 460 mg. (0.02 g. atom) of metallic sodium in 100 ml. of absolute EtOH was added 3.34 g. (0.02 mole) of 2-aminomethyl-1,4-cyclohexadienylacetic acid and 3.1 g. (0.024 mole of ethyl acetoacetate and the mixture was heated to reflux for 4 hours with stirring. The hot reaction mixture was filtered and the filtrate was allowed to keep cold overnight to give 2.0 g. of colorless needles 4 melting at 264° C. The additional product (3.3 g.) was obtained by concentration of the mother liquid. The total yield was 5.3 g. (88%).
IR: ν max nuj 3300, 1635, 1600, 1570, 1300, 1275, 1170, 1090 cm -1 .
NMR: δ ppm D .sbsp.2 O 1.23 (3H, t, 7 Hz, CH 2 CH 3 ), 1.96 & 2.25 (3H, s, C═C--CH 3 , cis & trans), 2.70 ##STR25## 3.04 (2H, s, CH 2 CO), 3.66 & 3.95 (2H, s, CH 2 --N, cis & trans), 4.07 (2H, q, 7 Hz, CH 2 CH 3 ), 4.45 & 4.56 ##STR26##
Anal. Calcd. for C 15 H 20 NO 4 Na: C, 59.79; H, 6.69; N, 4.64. Found: c, 59.69; H, 6.76; N, 4.75.
2-t-Butoxycarbonylaminomethyl-4-hydroxyphenylacetic acid is prepared, for example, according to U.S. Pat. No. 3,823,141.
o-(N-methylaminomethyl)phenylacetic acid δ-lactam ##STR27##
Sodium hydride (57% in paraffin, 4.3 g.; 0.11 mol.) was washed with dry n-hexane and suspended in dry benzene (100 ml.). To the suspension was added a solution of o-aminomethylphenylacetic acid δ-lactam (U.S. Pat. No. 3,796,716) (14.7 g., 0.1 mol.) in dry benzene or xylene (200 ml.) with stirring under a nitrogen atmosphere. The mixture was refluxed for one hour and cooled to room temperature. To the mixture was added methyl iodide (18 ml.) in one portion and the mixture was refluxed again for 1.5 hours. The reaction mixture was cooled to room temperature and poured into ice-water (100 ml.). The aqueous layer was separated from the organic layer and extracted with CHCl 3 (2×50 ml.). The extracts were combined with the organic layer and dried on MgSO 4 . The solvent was removed and the oily residue was distilled in vacuo to afford 14.9g. (92%) of o-(N-methylaminomethyl)phenylacetic acid δ-lactam, boiling at 130°-135° C./2 mmHg., m.p. 35°- 37° C.
ir: ν max KBr 3300, 1620, 1490 cm -1 .
nmr: δ ppm CDCl .sbsp.3 3.12 (3H, s), 3.59 (2H, t, J=1.5 Hz), 4.48 (2H, t, J=1.5 Hz), 7.21 (4H, br-s).
Anal. Calc'd. for C 10 H 11 NO.1/4H 2 O: C, 72.49; H, 6.84; N, 8.45. Found: C, 72.78, 72.70; H, 6.76, 6.81; N, 8.49, 8.51.
o-N-Methylaminomethylphenylacetic acid ##STR28##
A mixture of the above-produced o-(N-methylaminomethyl)phenylacetic acid δ-lactam (5.0 g., 0.031 mol) and conc hydrochloric acid (500 ml.) was refluxed for 40 hours. The mixture as evaporated under reduced pressure, and the residual oil was dissolved in water (20 ml.) and treated with a small amount of active carbon. The filtrate was washed with benzene (50 ml.) and evaporated to dryness. The residual oil was crystallized by trituration with THF (or acetone) to give colorless needles of o-N-methylaminomethylphenylacetic acid hydrochloride (4.5 g., 67%). Anal. Calc'd. for C 10 H 13 NO 2 .HCl: C, 55.69; H, 6.54; N, b 6.49; Cl, 16.44. Found: C, 55.65, 55.74; H, 6.62, 6.60; N, 6.53, 6.53; Cl, 16.36.
Some unreacted starting material was recovered from the benzene layer and the THF washings (1.2 g., 24%, b.p. 140°-143° C./2 mmHg).
An aqueous solution of o-N-methylaminomethylphenylacetic acid hydrochloride (5 g.) was column chromatographed with IR-120 ion-exchange resin (H + , 70 ml.) and eluted with 3 N NH 4 OH (2 l) to afford 3.9 g. (93%) of o-N-methylaminomethylphenylacetic acid as needles.
ir: ν max KBr 1650, 1470 cm -1 .
The following examples are given in illustration of, but not in limitation of, the present invention. All temperatures are in degrees Centigrade. 7-Aminocephalosporanic acid is abbreviated as 7-ACA; -ACA- represents the moiety having the structure ##STR29## and thus 7-ACA can be represented as ##STR30## Methyl isobutyl ketone is represented as MIBK. "Skellysolve B" is a petroleum ether fraction of B.P. 60°-68° C. consisting essentially of n-hexane.
LA-1 resin is a mixture of secondary amines wherein each secondary amine has the formula ##STR31## wherein each of R 1 , R 2 and R 3 is a monovalent aliphatic hydrocarbon radical and wherein R 1 , R 2 and R 3 contain in the aggregate from eleven to fourteen carbon atoms. This particular mixture of secondary amines, which is sometimes referred to in these examples as "Liquid Amine Mixture No. II," is a clear amber liquid having the following physical characteristics: viscosity at 25° C. of 70 cpd., specific gravity at 20° C. of 0.826; refractive index at 25° C. of 1.4554; distillation range at 10 mm., up to 170° C.--0.5%. 170°-220° C.--3%, 220°-230° C.--90% and above 230° C.--6.5%.
IR-120 is also called Amberlite IR-120 and is a strong cation exchange resin containing sulfonic acid radicals. Amberlite IR-120 is a commercially available cation exchange resin of the polystyrene sulfonic acid type; it is thus a nuclear sulfonated polystyrene resin cross-lined with divinyl benzene obtained by the procedure given by Kunin, Ion Exchange Resins, 2nd. Edition (1958), John Wiley and Sons, Inc. Therein see pages 84 and 87 for example.
Amberlite IRC-50 is a commercially available cation exchange resin of the carboxylic type; it is a copolymer of methacrylic acid and divinylbenzene.
Dicyclohexylcarbodiimide is abbreviated as DCC, tetrahydrofuran as THF, thin layer chromatography as TLC, p-toluenesulfonyl as Ts and methanol as MeOH.
When the following instrumental readings are given, for infrared nu if used is written ν, for ultraviolet lambda is written as λ, with molar absorptivity as epsilon (ε) and for nuclear magnetic resonance (nmr) delta is written as δ and tau as τ (δ=10-τ).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Synthesis (Schemes 1, 2 and 3)
The 3-side chain thiol, 2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiol (3), was prepared by N-ethoxycarbonylmethylation of 6-chloro-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-one (1) with sodium hydride and ethyl chloroacetate in DMF (dimethylformamide) and subsequent thiolation with sodium hydrosulfide (Scheme 1). Condensation of 7-ACA (7-aminocephalosporanic acid) with 3 carried out by refluxing in phosphate buffer (pH 7) to give the 3-substituted-thio 7-ACA (4), which was coupled with an appropriate N-BOC-protected amino acid by the active ester method using 2,4-dinitrophenol (DNP). The resulting N-BOC-protected cephalosporins 7 and 11 were deblocked with TFA (trifluoroacetic acid) and converted to the monosodium salt with N sodium hydroxide (Schemes 2 and 3).
Scheme 1. Preparation of 7-Amino-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid ##STR32##
Scheme 2. Preparation of 7-[(o-Aminomethylphenyl)acetamido]-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acids ##STR33##
Scheme 3. Preparation of 7-(3-Aminomethyl-2-thienylacetamido)-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acids ##STR34##
6-Chloro-2,3-dihydro-2-ethoxycarbonylmethyl-s-triazolo[4,3-b]pyridazin-3-one (2)
To a solution of 6-chloro-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-one [P. Francavilla and F. Lauria, J. Het. Chem., 8, 415 (1971)] (1, 1.00 g., 5.9 m.mole) in dry DMF (30 ml.) was added sodium hydride (50% in paraffin, 0.3 g., 6.3 m.mole) under stirring with formation of yellow crystals. To the mixture was added ethyl chloroacetate (1.4 ml., 13 m.mole) and the mixture was heated at 90° C. for 8 hours with stirring. After cooling, the reaction mixture was poured into water (50 ml.) and extracted with toluene (5×40 ml.). The organic extracts were combined, dried over anhydrous sodium sulfate and evaporated at reduced pressure. The residue was crystallized with benzene-n-hexane to give yellow needles of 2 (1.16 g., 77%), m.p. 114°-115° C. (lit. 110° C.).
ir: ν max KBr 1735, 1710 cm -1 .
uv: λ max EtOH 231 nm (ε, 26000)
nmr: δ ppm CDCl .sbsp.3 7.58 (1H, d, J=10 Hz, pyridazine-H), 6.98 (1H d, J=10 Hz, pyridazine-H), 4.80 (2H, s, -CH 2 CO), 4.27 (2H, q, J=7.5 Hz, CH 2 CH 3 ), 1.29 (3H, t, J=7.5 Hz, CH 2 CH 3 ).
Anal. Calc'd. for C 9 H 9 N 4 O 3 Cl: C, 42.12; H, 3.53; N, 21,83; Cl, 13.81. Found: C, 41.54, 41.46; H, 3.22, 3.49; N, 21.51, 21.53; Cl, 13.88, 13.99.
2-Carboxymethyl-2,3-dihydro-6-mercapto-s-triazolo[4,3-b]pyridazin-3-one (3)
To a solution of 6-chloro-2,3-dihydro-2-ethoxycarbonylmethyl-s-triazolo[4,3-b]pyridazin-3-one (2, 30 g., 0.12 mole) in ethanol (900 ml.) was added NaSH.2H 2 O (70% pure, 45.9 g., 0.36 mole) and the mixture was refluxed for 0.5 hour. The reaction mixture was evaporated at reduced pressure. The residue was dissolved in water (200 ml.) and concentrated HCl was added to the solution to adjust to pH 2. The precipitate (3) was collected by filtration and washed with water. Yield 18.3 g. (69%).
ir: ν max KBr 2900, 2450, 1750, 1660 cm -1 .
uv: λ max 1%NaHCO .sbsp.3 aq . 260 nm (ε, 19500), 313 nm (ε, 7000)
nmr: δ ppm DMSO-d .sbsp.6 7.88 (1H, d, J=10 Hz, pyridazine-H), 7.45 (1H, d, J=10 Hz, pyridazine-H), 4.72 (2H, s, CH 2 CO).
Anal. Calc'd. for C 7 H 6 N 4 O 3 S: C, 37.17; H, 2.67; N, 24.77; S, 14.17. Found: C, 37.35, 37.23; H, 2.26, 2.28; N, 23.58, 23.69; S, 14.32.
7-Amino-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (4)
To a suspension of 7-aminocephalosporanic acid (8.79 g., 32.2 m.mole) in 0.1 M phosphate buffer (pH 7, 149 ml.) were added NaHCO 3 (8.14 g., 97.0 m.mole) and the thiol 3 (7.30 g., 32.2 m.mole) with stirring. The mixture was heated at 80° C. for 0.5 hour under N 2 stream. The mixture was treated with active carbon and adjusted to pH 3 with concentrated HCl. The resulting precipitate was collected by filtration and washed with water to give 7.59 g. (54%) of 4.
ir: ν max KBr 1800, 1720, 1600, 1540, 1470 cm -1 .
uv: λ max Buffer (pH 7) 252 nm (ε, 19500), 298 nm (ε, 8400).
nmr: δ ppm D .sbsp.2 O+K .sbsp.2 CO .sbsp.3 7.56 (1H, d, J=9 Hz, pyridazine-H), 7.05 (1H, d, J=9 Hz, pyridazine-H), 5.45 (1H, d, J=5 Hz, 6-H), 5.05 (1H, d, 5 Hz, 7-H), 4.43 (1H, d, J=14 Hz, 3-CH 2 ), 4.04 (1H, d, J=14 Hz, 3-CH 2 ), 3.88 (1H, d, J=18 Hz, 2-H), 3.45 (1H, d, J=18 Hz, 2-H).
EXAMPLE 1
Preparation of BB-S469 ##STR35##
2,4-Dinitrophenyl o-(N-butoxycarbonylaminomethyl)phenylacetate (6a)
To a mixture of o-(N-butoxycarbonylaminomethyl)phenylacetic acid (5a, 13 g., 49 m.mole) and 2,4-dinitrophenol (9.02 g., 49 m.mole) in dry ethyl acetate (123 ml.) was added dicyclohexylcarbodiimide (DCC) (10.1 g., 49 m.mole) under water cooling (5°-15° C.), and the mixture was stirred for 30 minutes at the same temperature and then for 40 minutes at room temperature. The resulting precipitate was filtered off and the filtrate was evaporated to give 23.9 g. of the active ester 6a, which was used in the next acylation reaction without further purification.
ir: ν max KBr 1775, 1700, 1600, 1530 cm -1 .
7-[o-(N-Butoxycarbonylaminomethyl)phenylacetamido]-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (7a)
To a cold (0° C.) mixture of 4 (4.38 g., 10 m.mole), Et 3 N (4.5 ml., 30 m.mole), CH 3 CN (20 ml.) and water (20 ml.) was added a solution of 2,4-dinitrophenyl o-(N-butoxycarbonylaminomethyl)phenylacetate (6a, 4.79 g.) in THF (tetrahydrofuran) (20 ml.). After stirring at room temperature overnight, THF and CH 3 CN in the reaction mixture were removed at reduced pressure and the resulting aqueous solution was adjusted to pH 2 with dilute HCl and extracted with ethyl acetate (10×30 ml.). The organic extracts were dried over sodium sulfate and evaporated. The residue was chromatographed on a column of silica gel (60 g.) and eluted with CHCl 3 and 3% MeOH-CHCl 3 successively to give 2.40 g. (37%) of 7a, mp. >161° C. (dec.).
ir: ν max KBr 1780, 1720 cm -1 .
uv: λ max pH 7 Buffer 252 nm (ε, 19800), 298 nm (ε, 8900).
nmr: δ ppm DMSO+D .sbsp.2 O 7.67 (1H, d, J=9.0 Hz, pyridazine-H), 7.10 (4H, s, phenyl-H), 7.05 (1H, d, J=9.0 Hz, pyridazine-H), 5.66 (1H, d, J=4.5 Hz, 7-H), 5.07 (1H, d, J=4.5 Hz, 6-H), 4.71 (2H, s, N-CH 2 -CO), 4.4-4.0 (4H, m, 3-CH 2 & CH 2 -N), 3.8-3.5 (4H, m, 2-H & CH 2 CO), 1.42 (9H, s, t-Butyl-H).
Anal. Calc'd. for C 28 H 31 N 7 O 7 S 2 .2H 2 O: C, 49.62; H, 5.20; N, 14.46; S, 9.46. Found: C, 49.97, 49.95; H, 4.79, 4.62; N, 14.00, 13.84; S, 9.37, 9.32.
BB-S469; 7-[(o-(Aminomethylphenyl)acetamido]-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (8a)
Trifluoroacetic acid (3.4 ml.) was added to 7a (2.33 g.) at 0° C. and the mixture stirred for 15 minutes at room temperature. To the mixture was added dry ether (100 ml.), and the precipitate was collected by filtration and washed with dry ether (2×50 ml.). The solid was dissolved in a mixture of CH 3 CN (100 ml.) and water (14 ml.) and the solution was adjusted to pH 4-5 with concentrated NH 4 OH to afford a precipitate which was collected by filtration and washed with CH 3 CN (2×50 ml.) to give 1.75 g. (82%) of 8a as the ammonium salt. M.p. >160° C. (dec.).
ir: ν max KBr 1765, 1710, 1640, 1590 cm -1 .
uv: λ max pH 7 Buffer 252 nm (ε, 23900), 298 nm (ε, 10900).
Anal. Calc'd. for C 24 H 22 N 7 O 7 S 2 .NH 4 + .H 2 O: C, 46.51; H, 3.96; N, 18.08; S, 10.35. Found: C, 46.52, 46.26; H, 4.15, 4.19; N, 17.60, 17.48; S, 10.89, 10.41.
Preparation of BB-S469 Monosodium Salt
To a suspension of 8a (1.58 g.) in 50% acetone-water (30 ml.) was added a 10% solution to adjust the pH to 7.7. An additional amount of acetone was added and the precipitate was collected by filtration and washed with acetone to give 1.38 g. (87%) of monosodium salt of 8a, m.p. >170° C. (dec.).
ir: ν max KBr 1765, 1710, 1640, 1600, 1540, 1485 cm -1 .
uv: λ max pH 7 Buffer 252 nm (ε, 20600), 298 nm (ε, 9200).
nmr: δ ppm D .sbsp.2 O+K .sbsp.2 CO .sbsp.3 7.52 (1H, d, J=9 Hz, pyridazine-H), 7.27 (4H, s, phenyl-H), 7.03 (1H, d, J=9 Hz, pyridazine-H), 5.62 (1H, d, J=4.5 Hz, 7-H), 5.07 (1H, d, J=4.5 Hz, 6-H).
Anal. Calc'd. for C 24 H 22 N 7 O 7 S 2 Na.2H 2 O: C, 44.79; H, 4.07; N, 15.23; S, 9.96. Found: C, 44.44, 44.95; h, 3.68, 3.90; N, 16.50, 16.67; S, 10.38, 10.45.
EXAMPLE 2
Preparation of BB-S472 ##STR36##
7-(3-N-t-Butoxycarbonyl-N-methylaminomethyl-2-thienylacetamido)-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid. (11b)
A mixture of the BOC-protected amino acid (10b, 513 mg., 1.8 m.mole), 2.4-dinitrophenol (400 mg., 2.16 m.mole) and DCC (445 mg., 2.16 m.mole) in THF (5 ml.) was stirred at room temperature for 12 hours. The precipitated urea was removed and the filtrate was added to a mixture of 7-amino-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic acid (4, 800 mg., 1.8 m.mole) and triethylamine (0.76 ml., 5.4 m.mole) in water (5 ml.) at 0° C. with stirring. Stirring was continued until active ester had disappeared on tlc (silica gel plate; Rf 0.95; solvent system, CHCl 3 :MeOH=3:1). The reaction mixture was diluted with water (20 ml.), layered with AcOEt (50 ml.) and adjusted to pH 2 with concentrated HCl at 5° C. The organic layer was separated and aqueous layer was extracted with AcOEt (3×50 ml.). The AcOEt extracts were combined, washed with sat. aq. NaCl, dried over MgSO 4 and concentrated under reduced pressure. The residual oil (1.9 g.) was chromatographed on silica gel (40 g.). The column was eluted successively with CHCl 3 (400 ml.), 3% MeOH-CHCl 3 (100 ml.) and 10% MeOH-CHCl 3 while monitoring with tlc (silica gel plate, solvent system MeOH:CHCl 3 =1:2, detected with I 2 ). From the CHCl 3 eluate was recovered a mixture of 2,4-DNP and the BOC-protected amino acid 9 and 3% MeOH-CHCl 3 eluate 50 mg. of 9. The desired product (11b) (Rf 0.4, solvent system CHCl 3 :MeOH=3:1) was obtained by evaporation of the eluate with 10% MeOH--CHCl 3 . Yield 490 mg. (39%). M.p. 215°-220° C.
ir: ν max KBr 3400, 1780, 1720, 1680, 1550 cm -1 .
uv: λ max pH 7 Buffer 245 nm (ε, 23000), 260 nm (ε, 18000), 300 nm (ε, 7900).
nmr: δ ppm DMSO-d .sbsp.6 1.42 (9H, s, BOC--H), 2.75 (3H, s, N--CH 3 ), 3.80 ##STR37## 4.72 (2H, s, BOC-N-CH 2 ), 5.10 (1H, d, J=4.5 Hz, 6-H), 5.70 (1H, d-d, J=4.5 & 10.5 Hz, changed to a doublet J=4.5 by addition of D 2 O, 7-H), 6.85 (1H, d, J=4.5 Hz, thiophene Hβ), 7.19 (1H, d, J=9 Hz, pyridazine H), 7.34 (1H, d, J=4.5 thiophene Hα), 7.72 (1H, d, J=9 Hz, pyridazine-H), 9.11 (1H, d, J=10.5 Hz, disappeared by addition of D 2 O, NH).
Anal. Calc'd. for C 28 H 31 N 7 O 9 S 3 .H 2 O: C, 46.46; H, 4.60; N, 13.55; S, 13.29. Found: C, 46.67; H, 4.71; N, 12.79; S, 12.81.
BB-S472; 7-(3-Methylaminomethyl-2-thienylacetamido)-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (12b)
Trifluoroacetic acid (0.4 ml.) was added to 11b (400 mg., 0.57 m.mole) at 0° C. and the mixture was stirred at room temperature for 15 minutes. To the reaction mixture was added anhydrous ether (10 ml.) to separate a precipitate which was collected by filtration, washed with anhydrous ether (2×10 ml.) and suspended in acetonitrile (10 ml.). The suspension was adjusted to pH 4 with concentrated NH 4 OH and stirred for 10 minutes. The solid was collected by filtration, washed with acetonitrile (2×5 ml.) and dried at 60° C./1 mmHg for 7 hours to afford 310 mg. (90%) of 12b melting at 188°-191° C. (dec.).
ir: ν max KBr 3400, 1770, 1720, 1680, 1550 cm -1 .
uv: λ max pH 7 Buffer 245 nm (ε, 22400), 260 nm (ε, 18700), 300 nm (ε, 8600).
Anal. Calc'd. for C 23 H 23 N 7 O 7 S 3 .3H 2 O: C, 41.87; H, 4.43; N, 14.86; S, 14.58. Found: C, 42.03; H, 3.59; N, 14.79; S, 14.35.
Preparation of BB-S472 Monosodium Salt
To a suspension of 12b (230 mg., 0.38 m.mole) in 0.5 ml. of deionized water was added N NaOH to adjust to pH 8.9. Acetone (15 ml.) was added to the solution. The precipitate was collected by filtration, washed with acetone (2×50 ml), and dried at 60° C./1 mmHg for 7 hours to afford 170 mg. (71%) of monosodium salt of BB-S472, m.p. ≦210° C. (dec.).
ir: ν max KBr 3400, 1765, 1710, 1680, 1600 cm -1 .
uv: λ max pH 7 Buffer 245 nm (ε, 21800), 260 nm (ε, 18500), 300 nm (ε, 7800).
nmr: δ ppm D .sbsp.2 O 2.72 (3H, s, N--CH 3 ), 3.45 (1H, d, J=18 Hz, 2--H), 3.75 (1H, d, J=18 Hz, 2--H), 3.95 ##STR38## 4.57 (2H, s, N--CH 2 ), 5.00 (1H, d, J=4.5 Hz, 6--H), 5.53 (1H, d, J=4.5 Hz, 7--H), 6.97 (1H, d, J=9 Hz, pyridazine--H), 7.03 (1H, d, J=4.5 Hz, thiophene--Hβ), 7.34 (1H, d, J=4.5 Hz, thiophene--Hα), 7.48 (1H, d, J=9 Hz, pyridazine--H).
Anal. Calc'd. for C 23 H 22 N 7 O 7 S 3 Na.1/2H 2 O: C, 43.40; H, 3.64; N, 15.40; S, 15.11. Found: C, 43.26; H, 4.08; N, 14.18; S, 13.91.
EXAMPLE 3
Preparation of BB-S478 ##STR39##
7-[2-(N-t-Butoxycarbonyl-N-methylaminomethyl)-4-hydroxyphenylacetamido]-3-(2-carboxymethyl-2,3-dihydro-s-triazolo-[4,5-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (7c)
A mixture of 2-N-t-butoxycarbonyl-N-methylaminomethyl-4-hydroxyphenylacetic acid (5c), (708 mg., 2.4 m.mole), 2,4-dinitrophenol (478 mg., 2.6 m.mole) and DCC (536 mg., 2.6 m.mole) in dry THF (20 ml.) was stirred at room temperature for 2 hours. The precipitated urea was removed by filtration. The filtrate was added to a solution of 7-amino-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,5-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic acid (4) (876 mg., 2 m.mole) in 20 ml. of water containing triethylamine (0.84 ml., 6 m.mole) and the mixture was stirred at room temperature for 18 hours. After concentrating to 20 ml. the aqueous solution was washed with ether, acidified with 6N HCl and extracted with 200 ml. of ethyl acetate. The extract was filtered to remove insolubles, washed with water and a saturated aqueous NaCl solution and dried. The solution was evaporated to dryness and the oily residue was chromatographed on a silica gel (Wakogel C-200, 25 g.) eluting with chloroform and 3% of chloroform-methanol. The fractions containing the desired product (monitored by tlc; Rf 0.3; solvent system, CHCl 3 :MeOH=2:1) were collected and evaporated to dryness. The oily residue was triturated with ether-n-hexane to give 630 mg. (44%) of the product 7c melting at 200°-210° C. (slow dec.).
ir: ν max KBr 1780, 1720, 1660, 1400, 1240, 1150 cm -1 .
uv: λ max pH 7 Buffer 252 nm (ε, 13000), 300 nm (ε, 5400).
nmr: δ ppm DMSO-d .sbsp.6 1.39 (9H, s, C--CH 3 ), 2.73 (3H, s, N--CH 3 ), 3.3-3.9 (4H, m, CH 2 CO & 2--H), 4.35 (4H, m, CH 2 N & 3--H), 4.48 (2H, s, NCH 2 CO), 5.03 (1H, d, 4.5 Hz, 6--H), 5.61 (1H, d-d, 8 & 4.5 Hz, 7--H), 6.4-7.2 (3H, m, phenyl--H), 6.98 (1H, d, 10 Hz, pyridazine--H), 7.61 (1H, d, 10 Hz, pyridazine--H), 8.87 (1H, d, 8 Hz, NH).
Anal. Calc'd for C 30 H 33 N 7 O 10 S 2 : C, 50.34; H, 4.65; N, 13.70; S, 8.96. Found: C, 50.98; H, 5.36; N, 11.88; S, 7.60.
BB-S478; 7-(2-N-Methylaminomethyl-4-hydroxyphenylacetamido)-3-(2-N-carboxymethyl-2,3-dihydro-s-triazolo[4,5-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (8c)
A mixture of 7c (570 mg., 0.8 m.mole) and trifluoroacetic acid (1.5 ml.) was stirred at 10° C. for 30 minutes and the mixture was diluted with ether (50 ml.) to separate the trifluoroacetate of 8c which was collected by filtration and then dissolved in a mixture of 10 ml. of acetonitrile and 5 ml. of water and then filtered. The filtrate was adjusted to pH 6 with concentrated ammonium hydroxide and the mixture was diluted with acetonitrile (100 ml.). The resulting precipitate was collected by filtration, washed with acetonitrile and dried in vacuo over P 2 O 5 to give 370 mg. (75%) of 8c, melting at 215°-220° C. (dec.).
ir: ν max KBr 1770, 1710, 1600, 1380, 1350 cm -1 .
uv: λ max pH 7 Buffer 252 nm (ε, 19000), 300 nm (ε, 9100).
nmr: δ ppm D .sbsp.2 O+K .sbsp.2 CO .sbsp.3 2.75 (3H, s, N--CH 3 ), 2.9-3.3 (4H, m, CH 2 CO & 2--H), 4.0-4.3 (4H, m, CH 2 N & 3--H), 4.57 (2H, s, NCH 2 CO), 4.81 (1H, d, 4.5 Hz, 6--H), 5.53 (1H, d, 4.5 Hz, 7--H), 6.6-7.5 (5H, m, phenyl--H & pyridazin--H).
Anal. Calc'd. for C 25 H 25 N 7 O 8 S 2 .5/2H 2 O: C, 45.45; H, 4.58; N, 14.84; S, 9.71. Found: C, 45.69; H, 4.21; N, 15.03; S, 9.46.
Preparation of Monosodium Salt of BB-S478
To a suspension of 8c (308 mg., 0.5 m.mole) in water (2 ml.) was added 0.3-0.4 ml. of N NaOH and the mixture was stirred at room temperature; the pH of the resulting solution was 9.2. Acetone (20 ml.) was slowly added to the solution. The resulting precipitate was collected by filtration, washed with acetone (10 ml.) and dried in vacuo over P 2 O 5 to give 290 mg. (91%) of the monosodium salt of BB-S478, melting at 230°-235° C. (dec.).
ir: ν max KBr 1770, 1700, 1600, 1390, 1350 cm -1 .
uv: λ max pH 7 Buffer 250 nm (ε, 18000), 300 nm (ε, 8400).
Anal. Calc'd. for C 25 H 24 N 7 O 8 S 2 Na.5/2H 2 O: C, 43.98; H, 4.28; N, 14.36; S, 9.39. Found: C, 43.96; H, 4.14; N, 13.51; S, 9.34.
EXAMPLE 4
Preparation of BB-S479 ##STR40##
7-[o-(N-Butoxycarbonyl-N-methylaminomethyl)phenylacetamido]-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (7b)
To a cold (0° C.) mixture of 4 (5.4 g., 12 m.mole), Et 3 N (5.5 ml.), CH 3 CN (25 ml.) and water (25 ml.) was added a solution of 2,4-dinitrophenyl o-(N-butoxycarbonyl-N-methylaminomethyl)phenylacetate (6b) in THF [prepared from o-(N-butoxycarbonyl-N-methylaminomethyl)phenylacetic acid (5b) (3.48 g., 13.5 m.mole), 2,4-dinitrophenol (2.49 g., 13.5 m.mole) and DCC (2.79 g., 13.5 m.mole) in dry THF (37 ml.)]. The mixture was stirred at room temperature overnight. THF and CH 3 CN were removed from the reaction mixture by evaporation under reduced pressure and the resulting aqueous solution was washed with ether (3×30 ml.), adjusted to pH 2-3 with dilute HCl and extracted with ethyl acetate (4×30 ml). The organic extracts were combined, dried over sodium sulfate and evaporated. The residue was chromatographed on a column of SiO 2 (100 g.). After washing with CHCl 3 , the column was eluted with 3% MeOH in CHCl 3 to afford a desired fraction containing 7b. Yield 3.8 g. (45%). m.p.>200° C. (dec.).
ir: ν max KBr 1780, 1720, 1680 cm -1 .
uv: λ max pH 7 Buffer 250 nm (ε, 18800), 297 nm (ε, 8400).
nmr: δ ppm DMSO+D 2 O 7.62 (1H, d, J=10.5 Hz, pyridazine--H), 7.14 (4H, s, phenyl--H), 6.98 (1H, d, J=10.5 Hz, pyridazine--H), 5.61 (1H, d, J=4.5 Hz, 7--H), 5.03 (1H, d, J=4.5 Hz, 6--H), 4.67 (2H, s, N--CH 2 ), 4.42 (2H, s, CH 2 --N), 4.4-4.0 (2H, m, 3--CH 2 ), 3.8-3.4 (4H, m, 2--H & CH 2 --CO), 2.72 (3H, s, N--CH 3 ), 1.38 (9H, s, BOC--H).
Anal. Calc'd for C 30 H 33 N 7 O 9 S 2 .5/2H 2 O: C, 48.38; H, 5.14; N, 13.16; S, 8.61. Found: C, 48.25, 48.23; H, 4.52, 4.46; N, 12.93, 12.86; S, 8.68.
BB-S479; 7-[o-(Methylaminomethyl)phenylacetamido]-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (8b)
Trifluoroacetic acid (7 ml.) was added to the t-BOC-derivative 7b (3.8 g., 5.5 m.mole) at 0° C., and the mixture was stirred for 20 minutes at room temperature. Dry ether (100 ml.) was added to the mixture. The resulting precipitate was collected by filtration and washed with dry ether (3×100 ml.). The precipitate was dissolved in a mixture of CH 3 CN (120 ml.) and water (18 ml.) and the solution was adjusted to pH 5-6 with concentrated NH 4 OH to give an oily precipitate which was triturated with CH 3 CN to form solid material. The product 8b was collected by filtration, washed with CH 3 CN and dried. Yield 2.55 g. (77%).
ir: ν max KBr 1770, 1710, 1600, 1550 cm -1 .
Preparation of Monosodium Salt of BB-S479
To a solution of BB-S479 (8b) (2.54 g., 4.3 m.mole) in water (25 ml.), N NaOH (ca. 3 ml.) was added under cooling (the pH of the solution was 10). A large amount of acetone was added to the solution and the precipitate was collected by filtration and washed with acetone to give 1.94 g. (84%) of monosodium salt of BB-S479. M.p. >200° C. (dec.).
ir: ν max Kbr 1770, 1710, 1600, 1550 cm -1 .
uv: λ max pH 7 Buffer 250 nm (ε, 19400), 297 nm (ε, 8700).
Anal. Calc'd for C 25 H 24 N 7 O 7 S 2 Na.1/2H 2 O: C, 47.61; H, 4.00; N, 15.55; S, 10.17. Found: C, 47.43, 47.43; H, 4.67, 4.68; N, 15.97, 15.70; S, 9.25, 9.84.
EXAMPLE 5
Preparation of BB-S482 ##STR41##
7-(3-N-t-Butoxycarbonylaminomethyl-2-thienylacetamido)-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (11a)
A mixture of the BOC-protected amino acid (9, 410 mg., 1.56 m.mole), 2,4-dinitrophenol (313 mg., 1.7 m.mole) and DCC (353 mg., 1.7 m.mole) in THF (5 ml.) was stirred at room temperature for 12 hours. The precipitated urea was removed and the filtrate was added to a mixture of 7-amino-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]-pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic acid (4, 683 mg., 1.56 m.mole) and triethylamine (0.62 ml., 4.68 m.mole) in water (5 ml.) at 0° C. with stirring. Stirring was continued at room temperature until the active ester disappeared on tlc (silica gel plate; Rf 0.95; solvent system, CHCl 3 :MeOH=3:1). The reaction mixture was diluted with water (20 ml.), layered with AcOEt (50 ml.) and adjusted to pH 2 with concentrated HCl at 5° C. The organic layer was separated and the aqueous layer was extracted with AcOEt (3× 50 ml.). The AcOEt (ethyl acetate) extracts were combined, washed with saturated aqueous NaCl, dried over MgSO 4 and concentrated under reduced pressure. The residual oil (1.8 g.) was chromatographed on silica gel (40 g.). The column was eluted successively with CHCl 3 (400 ml.) and 3% MeOH--CHCl 3 (500 ml.). The eluate was monitored with tlc (silica gel plate, solvent system CHCl 3 :MeOH=2:1, detected with I 2 ). The desired product 11a (Rf 0.2) was obtained by evaporation of the MeOH--CHCl 3 eluate. Yield 450 mg. (42%), melting at 155°-160° C.
ir: ν max KBr 3300, 1775, 1720, 1680 cm -1 .
uv: λ max pH 7 Buffer 245 nm (ε, 23900), 260 nm (ε, 19200), 300 nm (ε, 8700).
nmr: δ ppm DMSO-d 6 1.39 (9H, s, BOC-H), 3.76 ##STR42## 4.05 (2H, d, J=6 Hz, changed to a singlet by addition of D 2 O, BOCNH--CH 2 ), 4.20 (2H, m, 3-CH 2 ), 4.69 (2H, s, N--CH 2 CO 2 ), 5.06 (1H, d, J=4.5 Hz, 6--H), 5.62 (1H, d-d, J=4.5 & 9 Hz, changed to a doublet J=4.5 Hz by addition of D 2 O, 7--H), 6.83 (1H, d, J=4.5 Hz, thiophene--Hβ), 7.00 (1H, m, disappeared by addition of D 2 O, NHBOC), 7.04 (1H, d, J=9 Hz, pyridazine--H), 7.12 (1H, d, J=4.5 Hz, thiophene-Hα), 7.65 (1H, d, J=9 Hz, pyridazine-H), 8.97 (1H, d, J=9 Hz, disappeared by addition of D 2 O, 7--NH).
Anal. Calc'd. for C 27 H 29 N 7 O 9 S 3 : C, 46.88; H, 4.23; N, 14.17; S, 13.90. Found: C, 46.42; H, 4.37; N, 13.49; S, 13.61.
BB-S 483; 7-(3-Aminomethyl-2-thienylacetamido)-3-(2-carboxymethyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (12a)
Trifluoroacetic acid (0.4 ml.) was added to 11a (410 mg., 0.59 m.mole) at 0° C. and the mixture was stirred at room temperature for 15 minutes. To the reaction mixture was added anhydrous ether (10 ml.) to separate a precipitate which was collected by filtration, washed with anhydrous ether (2×10 ml.) and suspended in acetonitrile (10 ml). The suspension was adjusted to pH 4 with concentrated NH 4 OH and stirred for 10 minutes. The precipitate was collected by filtration, washed with acetonitrile (2×5 ml.) and dried at 60° C./1 mmHg for 7 hours to afford 310 mg. (88%) of 12a, melting at above 200° C. (slow dec.).
ir: ν max KBr 3400, 3150, 1760, 1700, 1680, 1600 cm -1 .
uv: λ max pH 7 Buffer 245 nm (ε, 17100), 260 nm (ε, 14100), 300 nm (ε, 6500).
Anal. Calc'd for C 22 H 21 N 7 O 7 S 3 .3H 2 O: C, 40.90; H, 4.21; N, 15.17; S, 14.89. Found: C, 40.39; H, 3.62; N, 15.87; S, 14.35.
Preparation of Monosodium Salt of BB-S483
To a suspension of 12a (280 mg., 0.47 m.mole) in 0.5 ml. of deionized water was added N NaOH to adjust to pH 9.5 and insoluble material was collected by filtration. Acetone (15 ml.) was added to the filtrate to separate the precipitate which was collected by filtration, washed with acetone (2×5 ml.) and dried at 70° C./1 mmHg for 7 hours to afford 220 mg. (76%) of monosodium salt of 12a. M.p. >210° C. (slow dec.). ir: ν max KBr 3400, 3250, 1760, 1710, 1650, 1600, 1550 cm -1 .
uv: ε max pH 7 Buffer 245 nm (ε, 19900), 260 nm (ε, 16400), 300 nm (ε, 6900).
nmr: δ ppm D 2 O 3.60 (2H, m, 2--H), 3.91 (2H, s, CH 2 CO), 4.12 (2H, s, CH 2 --NH 2 ), 4.20 (2H, m, 3--CH 2 ), 4.55 (2H, s, N--CH 2 CO), 4.95 (1H, d, J=4.5 Hz, 6--H), 5.50 (1H, d, J=4.5 Hz 7--H), 6.94 (1H, d, J=9 Hz, pyridazine--H), 6.99 (1H, d, J=4.5 Hz, thiophene--Hβ), 7.28 (1H, d, J=4.5 Hz, thiophene--Hα), 7.32 (1H, d, J=9 Hz, pyridazine--H).
Anal. Calc'd. for C 22 H 20 N 7 O 7 S 3 Na.1/2CH 3 COCH 3 : C, 43.92; H, 3.61; N, 15.26; S, 14.97. Found: C, 43.48; H, 4.56; N, 15.28; S, 13.91.
Solubility
All of the monosodium salts in this series showed more than 10% solubility in water.
Nephrotoxicity
A preliminary nephrotoxicity study was carried out by administration of the test compound to a group of two rabbits at 100 mg./kg. intravenously. The results obtained with BB-S469 and BB-S479 indicated that they might have little nephrotoxic potential.
In vitro Activity (Table 1)
The MIC's were determined by the serial dilution method using Mueller-Hinton agar against 51 gram-positive and 96 gram-negative bacteria. The 147 test organisms were classified into 16 groups according to the genera and the types of antibiotic resistance, 5 groups for gram-positive and 11 for gram-negative bacteria. In Table 1 is shown the in vitro activity in terms of geometric mean of MIC's. BB-S472 and BB-S479 showed better overall activity than their non-N-methylated analogs, BB-S483 and BB-S469, respectively. BB-S479 was superior to BB-S472 in some species of gram-negative bacteria. Comparing with cefamandole, BB-S479 was more active against most of the test organisms except against Providencia species and Staphylococci.
TABLE 1__________________________________________________________________________In vitro Activity Against 147 Test Organisms Geometric Mean MIC* (mcg./ml.) No. of BB-S469 BB-S472 BB-S478 BB-S479 BB-S483 Cefam-Test Organism Strains (Ex. 1) (Ex. 2) (Ex. 3) (Ex. 4) (Ex. 5) andole BL-S786**__________________________________________________________________________S. aureus (sensitive) 4 0.4 0.4 0.4 0.3 0.3 0.1 1.3S. aureus penicil-linase+) 13 1.2 0.9 1.0 0.9 1.1 0.4 3.0S. aureus(Methicillin-R) 15 30 58 50 35 48 2.4 48S. pyogenes 10 0.05 0.05 0.04 0.04 0.08 0.04 0.2D. pneumoniae 9 0.03 0.05 0.03 0.04 0.04 0.2 0.08E. coli (sensitive) 13 0.3 0.2 0.2 0.2 0.3 0.3 0.4E. coli(Penicillinase +) 7 11 15 10 2.6 21 5.7 9.3Enterobacter(sensitive) 3 1.0 1.3 0.8 0.5 1.3 1.0 1.3Enterobacter(Cephalosporinase +) 7 4.7 3.2 2.6 2.1 5.2 4.7 7.7Proteus (indole-) 6 0.6 0.3 0.4 0.5 0.7 0.6 0.9Proteus (indole +) 14 0.5 0.3 0.3 0.2 0.4 0.5 0.7 Proteus (indole +,cephalosporinase +) 5 11 8.3 7.3 4.8 17 3.6 29Providencia sp. 5 4.2 4.8 4.8 4.2 2.1 0.7 1.4Klebsiella sp. 12 0.9 0.8 0.6 0.6 1.1 2.4 0.8S. marcescens 16 130 200 40 35 81 34 180Miscellaneous (Sal-monella, Shigella,Citrobacter) 8 0.7 0.4 0.3 0.4 0.9 0.3 0.7__________________________________________________________________________ *Mueller-Hinton Agar (inoculum size: 10.sup.4 dilution) MIC cutoff: 200 mcg./ml. **BLS786 is sodium 7(2-aminomethylphenylacetamido)-3-(1-carboxymethyltetrazol-5-ylthiomethyl-3-cephem-4-carboxylate
EXAMPLE 6
Substitution in the procedure of Example 3 for the 2-N-t-butoxycarbonyl-N-methylaminomethyl-4-hydroxyphenylacetic acid used therein of an equimolar weight of 2-N-t-butoxycarbonylaminomethyl-4-hydroxyphenylacetic acid and of 2-N-t-butoxycarbonylaminomethyl-4-methoxyphenylacetic acid and of 2-N-t-butoxycarbonyl-N-methylaminomethyl-4-methoxyphenylacetic acid, respectively, produces the compounds having the structures ##STR43##
EXAMPLE 7
Preparation of BB-S493 ##STR44##
7-[(2-N-t-Butoxycarbonylaminomethyl-1,4-cyclohexadienyl)-acetamido]-3-(2-N-carboxymethyl-s-triazolo[4,5-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (2)
A mixture of 2-N-t-butoxycarbonylaminomethyl-1,4-cyclohexadienylacetic acid (l, 640 mg., 2.4 m.mole), 2,4-dinitrophenol (422 mg., 2.4 m.mole) and DCC (494 mg., 2.4 m.mole) in 10 ml. of dry THF was stirred for 1.5 hours at room temperature. The precipitated urea was removed by filtration. The filtrate was added in one portion to a solution of 7-amino-3-(2-N-carboxymethyl-s-triazol[4,5-b]-pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic acid in 10 ml. of water containing triethylamine (0.56 ml., 4 m.mole) and the mixture was stirred at room temperature for 3 hours. The reaction mixture was concentrated to 10 ml. under reduced pressure, washed with ether (3×10 ml.), acidified with 6 N hydrochloric acid and extracted with ethyl acetate (5×10 ml.). The combined extracts were washed with a saturated saline solution and dried with anhydrous Na 2 SO 4 . The solvent was evaporated and the residue was chromatographed on silica gel (Wako-gel C-200, 30 g.) eluting with chloroform-methanol (0-50%). The fractions containing the desired product were collected. The solvent was removed and the residue was triturated with ether-n-hexane to give 410 mg. (30%) of the product 2. M.p. 110° C. (decomp.).
ir: ν max KBr 1780, 1730, 1610, 1530, 1250, 1160 cm -1 .
uv: λ max Buff (pH 7) 252 nm (ε, 19000), 300 nm (ε, 8600, sh).
Anal. Calc'd. for C 29 H 33 N 7 O 9 S 2 .2H 2 O: C, 48.12; H, 5.15; N, 13.54; S, 8.86. Found: C, 48.07; H, 4.64; N, 12.70; S, 8.39.
BB-S493; 7-[(2-Aminomethyl-1,4-cyclohexadienyl)acetamido]3-(2-N-carboxymethyl-s-triazolo[4,5-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic Acid (3)
The N-BOC-protected cephalosporin 2 (350 mg., 0.51 m.mole) was treated with trifluoroacetic acid (TFA) (1 ml.) for 30 minutes at room temperature. To the mixture was added ether (50 ml.) to give the TFA salt of 3, which was collected by filtration and then dissolved in a mixture of acetronitrile (5 ml.) and water (2 ml.). The solution was treated with a small amount of active carbon, adjusted to pH 6 with concentrated ammonium hydroxide. The precipitate was collected, washed with acetonitrile (5 ml.) and dried in vacuo to afford 235 mg. (78%) of 3. M.p. 220°-230° C. (decomp.).
ir: ν max KBr 1770, 1740, 1710, 1650, 1600, 1550 cm -1 .
uv: λ max Buff (pH 7) 252 nm (ε, 20000), 300 nm (ε, 9000, sh).
Anal. Calc'd. for C 24 H 25 N 7 O 7 S 2 .H 2 O: C, 47.60; H, 4.49; N, 16.19; S, 10.59. Found: C, 47.77; H, 4.06; N, 16.49; S, 10.64.
______________________________________In vitro Antibacterial Activity of BB-S493 Compared withBB-S479 and Cefamandole (Determined by Steers' Agar Dilu-tion Method on Mueller-Hinton Agar Plate) MIC (mcg./ml.)Organism BB-S493 BB-S479 Cefamandole______________________________________S. aureus Smith A9537 0.4 0.4 0.1S. aureus A9497 0.2 0.1 0.05S. aureus BX-1633 A9606 0.4 0.4 0.2St. faecalis A9536 100 100 50E. coli NIHJ 0.1 0.05 0.025E. coli ATCC 8739 0.2 0.05 0.05E. coli Juhl A15119 0.2 0.1 0.4E. coli BX-1373 0.4 0.2 0.4E. coli A15810 0.2 0.1 0.2E. coli A9660 0.1 0.05 0.1E. coli A15147 6.3 3.1 3.1Kl. pneumoniae A9678 0.4 0.4 1.6Kl. pneumoniae A9977 0.2 0.1 0.4Kl. pneumoniae A15130 0.2 0.1 0.4Kl. pneumoniae A9867 0.2 0.1 0.8Pr. vulgaris A9436 0.4 0.1 0.2Pr. vulgaris A9699 6.3 0.8 25Pr. mirabilis A9554 0.2 0.1 0.8Pr. mirabilis A9900 0.2 0.1 0.8Pr. morganii A9553 >100 >100 >100Pr. morganii A20031 0.4 0.1 0.8Pr. rettgeri A15167 0.1 0.1 0.1Ps. aerugionsa A9930 >100 >100 >100Ps. aeruginosa A9843 >100 >100 >100Shig dysenteriae 0.05 0.025 0.2Shig. flexneri A9684 25 12.5 3.1Shig. sonnei A9516 0.05 0.025 0.05Serr. marcescens A20019 100 25 50Enterob. cloacae A9656 6.3 1.6 3.1Sal. enteritidis A9531 0.1 0.05 0.1Sal. typhosa A9498 0.1 0.05 0.1B. anthracis A9504 0.0125 0.025 0.2______________________________________
__________________________________________________________________________In vivo Activity of BB-S479 and Related Compounds (Mice, sc) (PD.sub.50 (mgm./kg.)Organism BB-S469 BB-S472 BB-S478 BB-S479 BB-S483 BB-S493 Cefamandole BL-S786__________________________________________________________________________S. aureus Smith 0.19 0.12 0.08 0.16 0.34 0.29 0.93 0.53 0.16 0.12 0.74 0.55 0.29 0.2 0.6 0.94 0.2 0.8 0.46 0.8 0.6E. coli Juhl 0.19 0.19 0.08 0.19 0.15 0.27 0.95 0.43 0.24 0.15 1.7 0.55 0.15 0.12 1.8 0.46 2.2 0.39 0.8__________________________________________________________________________
Additional Starting Materials
6-Chloro-2-(2-cyanoethyl)-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on
To a solution of 6-chloro-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on [P. Francabilla and F. Lauria, J. Het. Chem. 8, 415 (1971)] (17 g., 0.1 mole) in dry DMF (300 ml.) was added potassium tert.-butoxide (0.5 g., 4.5 m.moles) with stirring. Acrylonitrile (6.6 g., 0.2 mole) in dry DMF (10 ml.) was added to the mixture. The mixture was stirred at 100°-110° C. for 24 hours, then poured into water (700 ml.) and extracted with ethyl acetate (5×400 ml.). The organic extracts were combined, dried over Na 2 SO 4 and evaporated. The residue was crystallized from ethyl acetate to give light yellow needles of 6-chloro-2-(2-cyanoethyl)-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on (2.5 g., 11%). M.p. 166°-168° C.
ir: ν max KBr 2230, 1720, 1550, 1500 cm -1 .
uv: λ max dioxane 373 nm (ε2000).
nmr: δ ppm DMSO-d .sbsp.6 3.03 (2H, t, J=6.0 Hz, CH 2 ), 4.21 (2H, t, J=6.0 Hz, CH 2 ), 7.23 (1H, d, J=10.0 Hz, pyridazine--H), 7.93 (1H, d, J=10.0 Hz, pyridazine--H).
Anal. Calc'd. for C 8 H 6 N 5 OCl: C, 42.97; H, 2.70; N, 31.32; Cl, 15.86. Found: C, 42.73, 42.56; H, 2.57, 2.50; N, 31.36, 31.68; Cl, 15.96, 15.81.
2-(2-Carboxyethyl)-6-chloro-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on
A solution of 6-chloro-2-(2-cyanoethyl)-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3on (724 mg.) in 6N-HCl (15 ml.) was refluxed for 6 hours. The reaction mixture was extracted with ethyl acetate (10×20 ml.). The combined extracts were washed with saturated aqueous sodium chloride (50 ml.), dried over Na 2 SO 4 and evaporated to give light yellow, solid 2-(2-carboxyethyl)-6-chloro-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on (567 mg., 72%). M.p.>170° C. (sublimation).
ir: ν max KBr 3400-2400, 1730, 1710, 1540 cm -1 .
uv: λ max dioxane 377 nm (ε1500).
nmr: δ ppm D .sbsp.2 O+NaHCO .sbsp.3 2.70 (2H, t, J=7.0 Hz, CH 2 ), 4.24 (2H, t, J=7.0 Hz, CH 2 ), 7.17 (1H, d, J=10.0 Hz, pyridazine--H), 7.70 (1H, d, J=10.0 Hz, pyridazine--H).
Anal. Calc'd. for C 8 H 7 N 4 O 3 Cl: C, 39.60; H, 2.91; N, 23.09; Cl, 14.61. Found: C, 39.62, 39.48; H, 2.97, 2.67; N, 23.05, 22.70; Cl. 13.93, 14.12.
2-(2-Carboxyethyl)-2,3-dihydro-6-mercapto-s-triazolo[4,3b]pyridazin-3-on
A mixture of 2-(2-carboxyethyl)-6-chloro-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on (567 mg., 2.34 m.moles) and 70% sodium hydrosulfide dihydrate (924 mg., 7.02 m.mole) in water (10 ml.) was stirred at room temperature for two hours. The reaction mixture was adjusted successively to pH 1 with c. HCl, to pH 10 with NaOH and then to pH 1 with c. HCl. The resulting precipitate of 2-(carboxyethyl)-2,3-dihydro-6-mercapto-s-triazolo[4,3-b]pyridazin-3-on was collected by filtration and washed with water. Yield: 418 mg. (74%). M.p. 174°-176° C.
ir: ν max KBr 3600-2600, 2440, 1730, 1720 (sh) cm -1 .
uv: ε max pH 7 buffer 262 nm (ε17000), 318 nm (ε6600).
nmr: δ ppm DMSO-d .sbsp.6 2.73 (2H, t, J=7.0 Hz, CH 2 ), 4.07 (2H, t, J=7.0 Hz, CH 2 ), 7.30 (1H, d, J=10.0 Hz. pyridazine-H), 7.74 (1H, d, J=10.0 Hz, pyridazine--H).
Anal. Calc'd. for C 8 H 8 N 4 O 3 S: C, 40.00; H, 3.36; N, 23.32; S, 13.35. Found: C, 39.08, 39.06; H, 3.12, 3.20; N, 22.65, 22.70; S, 14.23, 14.29.
7-Amino-3-[2-(2-carboxyethyl)-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl]-3-cephem-4-carboxylic Acid.
A mixture of 7-ACA (405 mg., 1.49 m.moles), the thiol 2-(2-carboxyethyl)-2,3-dihydro-6-mercapto-s-triazolo[4,3-b]pyridazin-3-on (357 mg., 1.49 m.moles) and NaHCO 3 (375 mg., 4.47 m.moles) in 0.1 M phosphate buffer (pH 7, 8 ml.) was stirred at 80° C. for 30 minutes. The reaction mixture was cooled and filtered to remove insolubles. The filtrate was adjusted to pH 1-2 with c. HCl. The resulting precipitate, 7-amino-3-[2-(2-carboxyethyl)-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl]-3-cephem-4-carboxylic acid, was collected by filtration and washed with water. Yield: 519 mg. (77%).
ir: ν max KBr 3600-2200, 1800, 1725, 1620, 1550, 1480 cm -1 .
uv: λ max pH 7 buffer 253 nm (ε20000), 298 nm (ε10000).
nmr: δ ppm D .sbsp.2 O+K .sbsp.2 CO .sbsp.3 2.20 (2H, t, J=7.0 Hz, CH 2 ), 3.40 (1H, d, J=17.5 Hz, 2--H), 3.85 (1H, d, J=17.5 Hz, 2--H), 4.00-4.50 (4H, m, 3-CH 2 and N-CH 2 -), 5.01 (1H, d, J=4.0 Hz, 6-H), 5.40 (1H, d, J=4.0 Hz, 7-H), 6.94 (1H, d, J=10.0 Hz, pyridazine-H), 7.44 (1H, d, J=10.0 Hz, pyridazine--H).
Anal. Calc'd. for C 16 H 16 N 6 O 6 S 2 .3/2H 2 O: C, 40.09; H, 3.99; N, 17.52; S, 13.37. Found: C, 40.06, 40.12; H, 3.33, 3.34; N, 16.96, 16.98; S, 13.87, 13.98.
7-ACA refers to 7-aminocephalosporanic acid and DMF to dimethylformamide.
EXAMPLE 8
7-[o-(N-Butoxycarbonyl-N-methylaminomethyl)phenylacetamido]-3-[2-(2-carboxyethyl)-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl]-3-cephem-4-carboxylic acid
To a mixture of 7-amino-3-[2-(2-carboxyethyl)-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl]-3-cephem-4-carboxylic acid (452 mg., 1 m.mole) and triethylamine (0.46 ml., 3.3 m.mole) in 50% aqueous acetonitrile (4 ml.) was added a THF solution (3 ml.) of 2,4-dinitrophenyl o-(N-t-butoxycarbonyl-N-methylaminomethyl)phenylacetate prepared from o-(N-t-butoxycarbonyl-N-methylaminomethyl)phenylacetic acid (283 mg., 1.1 m.mole), 2,4-dinitrophenol (202 mg., 1.1 m.mole) and DCC (227 mg., 1.1 m.mole). The mixture was stirred at room temperature overnight and concentrated under reduced pressure to remove the organic solvents. The aqueous concentrate was washed with ether (3×20 ml.), acidified with c.HCl to pH 1-2 and extracted with ethyl acetate (5×20 ml.). The combined extracts were dried with anhydrous Na 2 SO 4 and evaporated to dryness. The residue was chromatographed on a column of silica gel (Wako gel, C-200, 10 g.) by eluting with a mixture of MeOH-CHCl 3 (MeOH: 0 to 3%). The combined eluates which contained the desired product were evaporated to give 359 mg. (50%) of the title compound. M.p.>150° C. (dec.).
ir: ν max KBr 3600-2400, 1780, 1720, 1680, 1550, 1490 cm -1 .
uv: λ max pH 7 Buffer 253 nm (ε19800), 298 nm (ε9400).
nmr: δ ppm DMSO-d .sbsp.6 1.37 (9H, s, t-Bu-H), 2.70 (3H, s, N-CH 3 ), 2.70 (2H, t, J=7.0 Hz, --CH 2 --), 3.2-4.5 (10H, m), 5.01 (1H, d, J=5 Hz, 6-H), 5.60 (1H, d-d, J=5 & 8 Hz, the 8 Hz coupling disappeared by addition of D 2 O, 7--H), 6.93 (1H, d, J=10 Hz, pyridazine--H). 7.58 (1H, d, J=10 Hz, pyridazine--H).
Anal. Calcd. for C 31 H 35 N 7 O 9 S 2 .5/2H 2 O: C, 49.08; H, 5.31; N, 12.92; S, 8.45. Found: C, 49.32; 49.36; H, 4.70, 4,63; N, 12.52, 12.53; S, 8.44, 8.43.
BB-S 525; 7-[o-(N-Methylaminomethyl)phenylacetamido]-3-[2-(2-carboxyethyl)-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl]-3-cephem-4-carboxylic acid
A mixture of trifluoroacetic acid (1 ml.) and the BOC-protected cephalosporin prepared above (302 mg., 0.42 m.mole) was allowed to stand at room temperature for 15 min. and then diluted with ether (10 ml.). The resulting precipitate was collected by filtration and washed with dry ether (2×10 ml.) to afford 263 mg. of solid which was dissolved in a mixture of water (6 ml.) and acetonitrile (3 ml.). The stirred solution was adjusted at pH 4 with 1 N-NaOH (0.36 ml.) and diluted with acetonitrile (100 ml.) to give the precipitate (187 mg.), which was suspended in water (4 ml.) and adjusted at pH 9 with sodium hydroxide (1 N, 0.3 ml.). The solution was treated with a small amount of active carbon and freeze-dried to leave the monosodium salt of BB-S 525. Yield 106 mg. (39%). M.p.>180° C. (dec.).
ir: ν max KBr 3600-2400, 1770, 1710, 1600, 1490, 1400 cm -1 .
uv: λ max pH 7 Buffer 253 nm (ε19800), 298 nm (ε8800).
nmr: δ max D .sbsp.2 O 2.70 (2H, m, --CH 2 --), 2.75 (3H, s, N-CH 3 ), 4.4-3.4 (10H, m), 4.92 (1H, d, J=4.0 Hz, 6-H), 5.55 (1H, d, J=4.0 Hz, 7--H), 6.93 (1H, d, J=9.5 Hz, pyridazine--H), 7.28 (4H, s, Ph--H), 7.40 (1H, d, J=9.5 Hz, pyridazine--H).
Anal. Calcd. for C 26 H 26 N 7 O 7 S 2 .Na.3H 2 O: C, 45.28; H, 4.68; N, 14.22; S, 9.30. Found: C, 45.34, 44.84; H, 4.01, 3.85; N, 14.14, 14.08; S, 9.76.
______________________________________In vitro antibacterial activity of BB-S 525 compared withBB-S 479 and cefamandole (determined by Steers' agar dilutionmethod on Mueller-Hinton agar plate) MIC (mcg./ml)Organism BB-S 525 BB-S 479 Cefamandole______________________________________S. aureus Smith 0.4 0.4 0.2S. aureus 0.2 0.2 0.05S. aureus BX-1633 0.8 0.8 0.2St. faecalis >100 >100 100E. coli NIHJ 0.2 0.1 0.1E. coli ATCC 8739 6.3 3.1 6.3E. coli Juhl 0.4 0.2 0.4E. coli BX-1373 0.4 0.2 0.2E. coli 0.2 0.1 0.1E. coli 0.2 0.05 0.05E. coli 6.3 3.1 1.6Kl. pneumoniae 1.6 0.8 3.1Kl. pneumoniae 0.2 0.1 0.2Kl. pneumoniae 0.2 0.2 0.8Kl. pnuemoniae 0.2 0.2 0.8Pr. vulgaris 0.2 0.2 0.2Pr. vulgaris 3.1 0.8 50Pr. mirabilis 0.4 0.1 0.4Pr. mirabilis 0.2 0.1 0.2Pr. morganii >100 >100 3.1Pr. morganii 0.2 0.2 0.8Pr. rettgeri 0.8 0.8 0.1Ps. aeruginosa >100 > 100 >100Ps. aeruginosa >100 >100 >100Shig. dysenteriae 0.1 0.1 0.1Shig. flexneri 12.5 12.5 3.1Shig. sonnei 0.1 0.1 0.2Serr. marcescens 25 12.5 50Enterob. cloacae 3.1 3.1 1.6Sal. enteritidis 0.2 0.1 0.1Sal. typhosa 0.2 0.1 0.1B. anthracis 0.2 0.2 0.05______________________________________
EXAMPLE 9
Substitution in the procedure of Example 8 for the 2-N-t-butoxycarbonyl-N-methylaminomethyl-4-hydroxyphenylacetic acid used therein of an equimolar weight of 2-N-t-butoxycarbonylaminomethyl-4-hydroxyphenylacetic acid and of 2-N-t-butoxycarbonylaminomethyl-4-methoxyphenylacetic acid and of 2-N-t-butoxycarbonyl-N-methylaminomethyl-4-methoxyphenylacetic acid, respectively, produces the compounds having the stuctures ##STR45##
There is also provided by the present invention a compound having the formula ##STR46## wherein A represents ##STR47## wherein R" is hydrogen, hydroxy or methoxy; R' is hydrogen or methyl; n is one or two and M is ##STR48## n is 0 to 4; R is hydrogen, alkyl having 1 to 8 carbon atoms, cycloalkyl of 3 to 6 carbon atoms, phenyl, C 1 -C 4 phenalkyl, pyridyl, thienyl, or pyrrolyl; R 1 is hydrogen, methyl or ethyl; R 2 and R 3 are each hydrogen, alkyl having 1 to 6 carbon atoms, phenyl, pyridyl, or thienyl; R 4 and R 5 are each hydrogen or alkyl of 1 to 4 carbon atoms; R 6 is alkyl having 1 to 4 carbon atoms, phenyl, phenalkyl having 1 to 4 carbon atoms, pyridyl, thiadiazolyl, amino or C 1 -C 4 alkylamino; X is NH or oxygen; and each phenyl group is unsubstituted or substituted with one or two substituents selected from the group consisting of alkyl having 1 to 6 carbon atoms, alkoxy having 1 to 4 carbon atoms, hydroxy, amino, NHR 1 , N(R 1 ) 2 , nitro, fluoro, chloro, bromo or carboxy, or a nontoxic, pharmaceutically acceptable salt thereof.
There is also provided by the present invention a compound having the formula ##STR49## wherein A represents ##STR50## wherein R" is hydrogen, hydroxy or methoxy; R 1 is hydrogen or methyl; n is one or two and M is selected from the group consisting of ##STR51## wherein R 5 is a hydrogen atom, a methyl or an ethyl group; X 2 is --O--, --NH--; R 6 is a basic group such as alkyl or aralkyl substituted with substituted or unsubstituted NH 2 , such as alkyl-NHCH 3 , aralkyl-NHCH 3 , ##STR52## R 7 is an alkyl group such as a methyl, ethyl, propyl, isopropyl, butyl, isobutyl, pentyl or 2-ethyl-hexyl group; a cycloalkyl group such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl or cycloheptyl; an aryl group such as phenyl or naphthyl; an aralkyl group such as benzyl or naphthylmethyl; a heterocyclic group and wherein the alkyl, cycloalkyl, aryl, aralkyl and heterocyclic groups may be substituted with one or more groups selected from the class consisting of amino groups, substituted amino groups such as methylamino, diethylamino or acetamido groups, the halogen groups such as fluorine, chlorine or bromine, nitro groups, alkoxy groups such as methoxy, ethoxy, propyloxy, isopropyloxy, butoxy or isobutoxy; or a nontoxic, pharmaceutically acceptable salt thereof.
There is also provided by the present invention a compound having the formula ##STR53## wherein A represents ##STR54## wherein R" is hydrogen, hydroxy or methoxy; R' is hydrogen or methyl; n is one or two and M is ##STR55## wherein Y is alkyl of one to six carbon atoms, phenyl, benzyl, alkoxy of one to six carbon atoms, or benzyloxy; Z is alkyl of one to six carbon atoms, phenylbenzyl, alkoxy of one to six carbon atoms, cyclopentyl, cyclohexyl and phenyl, or Y+Z taken together are a 3-benzoxazolidine ring; or a nontoxic, pharmaceutically acceptable salt thereof.
Also included within the present invention are pharmaceutical compositions comprising a mixture of an antibacterially effective amount of a compound of the present invention and a semisynthetic penicillin or another cephalosporin or a cephamycin or a β-lactamase inhibitor or an aminoglycoside antibiotic.
There is further provided by the present invention a pharmaceutical composition comprising an antibacterially effective amount of a compound having the formula ##STR56## wherein A represents ##STR57## wherein R" is hydrogen, hydroxy or methoxy; R' is hydrogen or methyl; n is one or two and M is hydrogen, pivaloyloxymethyl, acetoxymethyl, melthoxymethyl, acetonyl, phenacyl, p-nitrobenzyl, βββ-trichloroethyl, 3-phthalidyl or 5-indanyl and preferably is hydrogen or a nontoxic, pharmaceutically acceptable salt thereof.
There is further provided by the present invention a method of treating bacterial infections comprising administering by injection to an infected warm-blooded animal, including man, an effective but nontoxic dose of 250-1000 mgm. of a compound having the formula ##STR58## wherein A represents ##STR59## wherein R" is hydrogen, hydroxy or methoxy; R' is hydrogen or methyl; n is one or two and M is hydrogen, pivaloyloxymethyl, acetoxymethyl, methoxymethyl, acetonyl, phenacyl, p-nitrobenzyl, βββ-trichloroethyl, 3-phthalidyl or 5-indanyl or a nontoxic, pharmaceutically acceptable salt thereof.
There is also provided by the present invention a method for combatting Shig. dysenteriae infections which comprises administering to a warm-blooded mammal infected with a Shig. dysenteriae infection an amount effective for treating said Shig. dysenteriae infection of a composition comprising a compound having the formula ##STR60## wherein A represents ##STR61## wherein R" is hydrogen, hydroxy or methoxy; R' is hydrogen or methyl; n is one or two and M is hydrogen, pivaloyloxymethyl, acetoxymethyl, methoxymethyl, acetonyl, phenacyl, p-nitrobenzyl, βββ-trichloroethyl, 3-phthalidyl or 5-indanyl and preferably is hydrogen or a nontoxic, pharmaceutically acceptable salt thereof.
There is also provided by the present invention a method for combatting B. anthracis infections which comprises administering to a warm-blooded mammal infected with a B. anthracis infection an amount effective for treating said B. anthracis infection of a conposition comprising a compound having the formula ##STR62## wherein A represents ##STR63## wherein R" is hydrogen, hydroxy or methoxy; R' is hydrogen or methyl; n is one or two and M is hydrogen, pivaloyloxymethyl, acetoxymethyl, methoxymethyl, acetonyl, phenacyl, p-nitrobenzyl, βββ-trichloroethyl, 3-phthalidyl or 5-indanyl and preferably is hydrogen or a nontoxic, pharmaceutically acceptable salt thereof. | Certain 7-acylamido-3-(2-carboxyalkyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic acids and their salts and easily hydrolyzed esters of the 4-carboxyl group were synthesized and found to be potent antibacterial agents which exhibited good aqueous solubility. A preferred embodiment was 7-[o-(methylaminomethyl)phenylacetamido]-3-(2-carboxyalkyl-2,3-dihydro-s-triazolo[4,3-b]pyridazin-3-on-6-ylthiomethyl)-3-cephem-4-carboxylic acid. | 2 |
FIELD OF THE INVENTION
This invention relates to surgical apparatus in general, and more particularly to surgical apparatus of the sort used to repair fractures in delicate bones.
BACKGROUND OF THE INVENTION
When a human bone has been fractured, the fractured portions must be properly aligned with one another so as to allow for proper healing. Sometimes proper alignment can be achieved without artificial assistance. At other times it may be necessary to stabilize the bone about the point of the fracture with special surgical apparatus. In situations where the fractured bone is fairly large, e.g. a femur, a tibia, a fibula, etc., such stabilization can be effected through a wide variety of surgical apparatus, e.g. pins, plates, etc. However, where the fractured bone is fairly small and delicate, e.g. a metacarpal, a phalanx, a metatarsal, etc., the choice of surgical apparatus is substantially more restricted. In general, a small and delicate bone can be stabilized about the point of the fracture only by wiring together the fractured portions of the bone with very fine, flexible steel wire. In such interosseous wiring, the surgeon typically first drills one or more holes through the bone on each side of the fracture line, and then threads the wire in and out of the holes and across the fracture line so as to effectively tie the fractured portions of the bone together in healing position.
Unfortunately, in the case of small bones, the surgical holes and interosseous wire must be sized as fine as possible. This presents something of a problem, inasmuch as it can be time-consuming and tiring to thread a flexible steel wire through the tiny surgical holes, a procedure roughly analagous to threading a needle. This is particularly true under the difficult operating constraints frequently imposed by the fracture site.
OBJECTS OF THE INVENTION
Accordingly, the principal object of the present invention is to provide a novel interosseous wiring system which facilitates the deployment of interosseous wire about a fracture site.
Another object of the invention is to provide a novel interosseous wiring system which is simple to use, inexpensive to manufacture, and effective in operation.
SUMMARY OF THE INVENTION
These and other objects of the invention are addressed by a novel interosseous wiring system which comprises an interosseous wire and a threading tool. The interosseous wire of the present invention is an ordinary interosseous wire, except that it has an enlargement formed on its leading end. The threading tool comprises a shaft having a side recess near its front tip, and a canal extending axially between the side recess and the tool's front tip. The recess is sized so as to be slightly larger than the enlargement formed on the leading end of the wire, and the canal is sized so as to be slightly wider than the width of the wire, yet substantially narrower than the width of the enlargement formed on the leading end of the wire, in order that the wire can be attached to the threading tool by positioning the wire's enlargement in the tool's recess and extending the trailing end of the wire out through the tool's canal and away from the tool's front tip, and then gently pulling on the trailing end of the wire in a direction away from the threading tool so that tension keeps the enlargement properly seated in the recess and the wire thereby attached to the tool.
When it is desired to use the novel interosseous wiring system to thread an interosseous wire through a hole from a first side of a bone to a second side of the same bone, i.e., as part of an interosseous wiring procedure intended to repair a fracture in the bone, the threading tool is passed through the hole from the second side of the bone to the first side, so that the threading tool's front tip thereafter resides on the first side of the bone while a trailing portion of the threading tool resides on the second side of the bone. Then the leading end of the wire is attached to the front tip of the threading tool in the manner previously described, i.e., by positioning the wire's enlargement in the tool's side recess and threading the trailing end of the wire out through the tool's canal, and then gently pulling on the trailing end of the wire in a direction away from the threading tool so that tension keeps the enlargement properly seated in the recess and the wire thereby attached to the tool. Next the tool is withdrawn back through the bone, carrying the leading end of the wire with it, until the front tip of the tool (and the leading end of the wire) emerge from the hole on the second side of the bone. Then the interosseous wire is disengaged from the threading tool by relaxing the tension on the wire and dismounting the wire's enlargement from the tool's recess.
BRIEF DESCRIPTION OF THE DRAWINGS
Still other objects and features of the present invention will be more fully disclosed or rendered obvious in the following detailed description of the preferred embodiment of the invention, which is to be considered together with the accompanying drawings wherein like figures refer to like parts and further wherein:
FIG. 1 is a top plan view of the threading tool;
FIG. 2 is an enlarged fragmentary top plan view showing the front tip of the threading tool engaging the leading end of the interosseous wire, wherein the wire is shown in phantom;
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is a front end view in elevation showing the front tip of the threading tool;
FIG. 5 is a top plan view showing the threading tool about to be withdrawn back through a bone; and
FIGS. 6 and 7 are top plan views showing various ways in which the interosseous wire may be deployed about a fracture in a bone.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Looking first at FIGS. 1-4, the preferred embodiment of the present invention comprises an interosseous wire 5 and a threading tool 10. Wire 5 is a wire of the sort typically used in interosseous wiring procedures, e.g. it is a flexible stainless steel wire approximately 0.38 mm in diameter, except that it has an enlargement 15 formed on its leading end. Preferably, the enlargement 15 is in the shape of a spherical ball formed integral with the leading end of the wire, and is sized so as to be substantially wider in diameter than wire 5, e.g. enlargement 15 is approximately 0.81 mm in diameter. Enlargement 15 is preferably formed on the leading end of wire 5 simply by melting and beading the end of the wire by high temperature melting.
Threading tool 10 comprises a stiff metal shaft 20 and a handle 25. Shaft 20 is circular in cross-section and is sized so as to be somewhat wider in diameter than the diameter of the wire's enlargement 15, e.g. shaft 20 is approximately 0.89 mm in diameter. Shaft 20 has a side recess 30 located adjacent its front tip 35. Recess 30 is cylindrical in shape. The diameter and depth of recess 30 both slightly exceed the diameter of the wire's enlargement 15, e.g. they are both 0.84 mm in dimension, in order that recess 30 can accommodate the wire's enlargement 15 without the enlargement protruding out of recess 30.
Threading tool 10 also has a canal or groove 40 extending axially between recess 30 and the tool's front tip 35. Preferably, canal 40 has a U-shaped cross-section as shown in FIG. 4. Canal 40 is sized so as to have a width slightly greater than the diameter of wire 5, e.g. 0.40 mm, and a depth slightly greater than the radius of the wire's enlargement 15, e.g. 0.43 mm, in order that canal 40 can accommodate the trailing end of wire 5 when the wire's enlargement 15 is seated in the tool's recess 30. It is to be appreciated that canal 40 is sized so that it has a width substantially smaller than the diameter of the wire's enlargement 15, so as to prevent the enlargement from passing out of recess 30 through canal 40. It is also to be appreciated that on account of the foregoing construction, wire 5 can be attached to threading tool 10 by positioning the wire's enlargement 15 in the threading tool's side recess 30 and extending the trailing end of wire 5 out through the tool's canal 40 and away from the tool's front tip, and then gently pulling on the trailing end of wire 5 in a direction away from the threading tool so that tension keeps the wire's enlargement 15 properly seated in recess 30 and the wire thereby attached to the tool.
Looking next at FIG. 5, the interosseous wiring system is adapted to be utilized as follows. When it is desired to pass wire 5 from a first side 45 to a second side 50 of a bone 55, e.g. as part of an interosseous wiring procedure intended to repair a fracture 60, a hole 65 is first drilled through the bone. Hole 65 is sized so as to be slightly larger in diameter than the diameter of the threading tool's shaft 20, e.g. hole 65 is 1.10 mm in diameter. Then the threading tool's front tip 35 is passed through hole 65, from the bone's second side 50 to its first side 45, so that the tool's front tip 35 thereafter resides on the first side of the bone while a trailing portion of the tool's shaft resides on the second side of the bone. Next wire 5 is attached to the threading tool in the manner previously described, i.e., by positioning the wire's enlargement 15 in the threading tool's recess 30 and passing the trailing end of the wire out through the tool's canal 40, and then gently pulling on the free end of the wire so as to put the wire into tension and thereby maintain the wire's enlargement properly seated in the tool's recess. Then the tool is withdrawn back through bone 55, carrying the leading end of wire 5 with it, until the tool's front tip 35 (and the leading end of wire 5) resides on the second side 50 of the bone. Wire 5 is then released from the threading tool by first relaxing the tension placed on the trailing end of the wire, and then dismounting the wire's enlargement 15 from the tool's side recess 30 and the wire's body from the tool's canal 40. It will, of course, be appreciated that it will generally be easiest to position the wire's enlargement 15 in the threading tool's recess 30 and the wire's body in the tool's canal 40 when the threading tool is oriented so that its recess 30 and canal 40 are located at the "top" of the shaft, i.e., in the position shown in FIGS. 2-5, whereby gravity will assist loading of the wire into recess 30 and canal 40.
It is to be appreciated that the desired interosseous wiring of a fractured bone can be accomplished simply by repeating the foregoing procedure as required. Thus, for example, if it should be desired to create a so-called "tension band" with interosseous wiring (FIG. 6), a pair of parallel holes 67 and 70 are first drilled into bone 75 on opposite sides of a fracture 80, so that each hole connects a first side 85 of the bone with a second side 90 of the bone. Then the leading tip of the threading tool is passed through hole 67 from the bone's second side 90 to its first side 85, where it is attached to the leading end of wire 5 in the manner previously described. Next the tool is withdrawn back through hole 67, carrying the leading end of the wire with it, until the tool's front tip 35 (and the leading end of wire 5) resides on the second side 90 of the bone. Then the wire is released from the threading tool in the manner previously described. Next the front tip of the threading tool is passed through hole 70 from the bone's first side 85 to its second side 90, where it is once again attached to the leading end of the wire in the manner previously described. Then the threading tool is withdrawn back through hole 70, carrying the leading end of the wire with it, until the tool's front tip 35 (and the leading end of wire 5) resides on the first side 85 of the bone. Then the interosseous wire is released from the threading tool in the manner previously described. The threaded wire can then be secured under tension so as to form the so-called "tension band" about the fracture.
Alternatively, if it is desired to utilize the interosseous wiring system to form a so-called "figure eight fixation" (FIG. 7), a pair of parallel holes 95 and 100 are first drilled through bone 105 on either side of fracture 110, so that each hole connects a first side 112 of the bone with a second side 113 of the bone. Then wire 5 is threaded through hole 95 (from side 112 to side 113) with threading tool 10 in the manner previously described. Next the wire is drawn diagonally across the exterior of bone 105 so that its lead end is returned to first side 112 of the bone. Then the wire is threaded through hole 100 with threading tool 10 in the manner previously described. Next the wire is drawn diagonally across the exterior of bone 105 so that its lead end is returned to first side 112 of the bone. Finally, the threaded wire is secured under tension, so as to form the so-called "figure eight fixation" about the fracture.
MODIFICATION OF THE PREFERRED EMBODIMENT
It is, of course, possible to modify the preferred embodiment described and illustrated above without departing from the scope of the present invention.
Thus, for example, the shape of enlargement 15 formed on the leading end of wire 5 and the shape of recess 30 formed on the side of shaft 20 could be modified from the shapes previously described, e.g. enlargement 15 could be formed in the shape of a cylinder rather than in the shape of a sphere (and recess 30 left unaltered), or enlargement 15 could be formed in the shape of a square cube and the threading tool's side recess 30 could be formed in the corresponding shape of a square hole, or enlargement 15 could be formed in the shape of a rod set perpendicular to wire 5 (i.e., so as to form a "T") and recess 30 could be formed in the shape of a slot set perpendicular to canal 40 (i.e., so as to form a corresponding "T").
Alternately, the various dimensions of wire 5, enlargement 15, shaft 20, recess 30, canal 40, etc. could be varied somewhat from the dimensions provided above.
These and other changes of their type will be obvious to persons skilled in the art, and are considered to be within the scope of the present invention. | An interosseous wiring system comprising a wire having an enlargement formed on the leading end thereof and a threading tool, said threading tool having means for attaching said enlargement to the front tip of said tool, in order that said wire may be threaded through a hole by passing the front tip of said tool through said hole, attaching the wire to said tool, and thereinafter withdrawing said front tip of said tool back through said hole, thereby carrying the leading end of said wire back through said hole. | 0 |
ORIGIN OF THE INVENTION
The invention described herein was jointly made in the performance of work under NASA Contract NAS1-18584 and an employee of the United States Government. In accordance with 35 U.S.C. 202, the contractor elected not to retain title.
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention relates generally to material testing and more particularly to a sensor for detecting crack lengths.
2. Discussion of the Related Art
Structural defects such as flaws and cracks are formed in materials during the manufacturing process or during subsequent loading. These cracks propagate due to applied loads and can result in catastrophic failure. Two of the broad objectives of improved design methodology are to select tough materials that resist crack formation and crack propagation and to monitor the growth of the crack so that repair or replacement can be accomplished at appropriate intervals. Monitoring may be accomplished by actual measurement or by employing appropriate models.
Techniques for the detection and measurement of cracks depend upon several factors such as the nature of the material, crack size, crack location and the nature of the loading, i.e., static or dynamic loading. Visual inspection, either naked or aided by dye penetrant or magnetic particles; reduction in stiffness; increase in damping; x-ray radiography; holographic interferometry; ultrasonics; acoustic emission; eddy current; potential drop and resonant frequency measurements are some of the methods which have been developed for assessing the crack damage in components and structures. For applications where cracks are well defined and are present on the surface of the component or structure, special gages have been developed. These gages are bondable and give an electrical signal as the output. A crack detection coating, consisting of an epoxy base layer matrix containing micro-capsules filled with an electrically conductive emulsion and a top layer of silver conductive paint, has been marketed under the name "CDC-2" by B.L.H. Electronics of Waltham, Mass. A crack in the base structure propagates into the epoxy layer, rupturing the micro-capsules and causing conduction between the metallic structure and the conducting paint. Various crack detection gages and crack propagation gages incorporating thin metallic filaments are also commercially available from the Micro-Measurements Division of the Measurements Group, Inc. of Raleigh, N.C. A crack in the base structure, on which the gages are bonded, ruptures the gage filaments, resulting in an increase in the total resistance. In a variation of this concept, the crack propagation gage is deposited on the specimen by a silkscreen process using a silver-epoxy resin mixture.
The output from gages that consist of filaments or strands is discontinuous and the resolution depends upon the number of lines per unit length. To overcome this limitation, a bondable foil gage that produces a continuous DC output voltage proportional to the crack length through an indirect potential drop measurement technique has been developed and marketed by the Hartrun Corporation of St. Augustine, Fla. under the name "Krak-gage". The gage, of course, has to be used with the accompanying instrumentation. In the DC potential drop method, a constant direct current is passed through the specimen if it is conducting or through a thin conducting gage bonded to the specimen. The process is usually monitored by measuring the potential difference between two probes placed on either side of the crack. The technique requires that the calibration relationship between crack length and measured potential be determined either by experimental or theoretical means.
Thus, the bondable filamentary gages that do not require special instrumentation do not give a continuous output and the bondable foil gage that gives a continuous output requires special instrumentation. The direct bonding of nonmetallic resistor elements, in the form of a carbon coating, to a structure on which the strain has to be measured, is attributed to A. Bloch as early as 1935. Later this concept was utilized in fabricating gages, with a resistance varying between 15KΩ and 35KΩ, which could be bonded to a structure for strain measurement. More recently, several types of conducting particle impregnated polymers have been investigated for possible applications as fatigue damage indicators, strain gages and overload indicators, as indicated in the Dally et al reference discussed below.
OBJECTS OF THE INVENTION
It is accordingly an object of the present invention to improve current methods and devices for measuring the length of surface cracks in a material.
It is another object of the present invention to determine crack length in a continuous manner.
It is a further object of the present invention to accomplish the foregoing objects with a bondable gage.
It is another object of the present invention to accomplish the foregoing objects with simple instrumentation.
Additional objects and advantages of the present invention are apparent from the drawings and specification which follows.
SUMMARY OF THE INVENTION
The foregoing and additional objects are obtained by a crack length sensor according to the present invention. The crack length sensor is fabricated in a rectangular or other geometrical form from a conductive powder impregnated polymer material. The long edges of the sensor are silver painted on both sides and the sensor is then bonded to a test specimen via an adhesive having sufficient thickness to also serve as an insulator. A lead wire is connected to each of the two outwardly facing silver painted edges. The resistance across the sensor changes as a function of the crack length in the specimen.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1(a) is a top view of a crack length sensor mounted on an uncracked specimen;
FIG. 1(b) is a side view of the embodiment of FIG. 1(a);
FIG. 2 is a graph showing the resistance change as a function of strain for a carbon-polymer sensor;
FIG. 3 is a top view of a crack length calibration sensor;
FIG. 4 is a graph of resistance change percent versus crack length change percent for L=25 mm;
FIG. 5(a) is a physical model and FIG. 5(b) is a complex electrical model of a particle filled polymer for strain conditions;
FIG. 6 is a simplified electrical model of a carbon-powder impregnated polymer sensor used for determining crack length;
FIG. 7 graphs predicted and actual resistance change percent as a function of length change percent;
FIGS. 8(a) and 8(b) are top views of a specimen with and without a crack length gage bonded thereto; and
FIG. 9 is a graph of the crack length sensor resistance versus load.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention originated from an attempt to employ carbon powder impregnated polymeric sensors to measure the normal strains in the adhesive layer of a bonded joint. Although this particular application dealt with the measurement of strains, the potential application of conductive polymers in crack length measurement was recognized and explored. Initially, carbon flakes were dispersed in an epoxy matrix and cast in molds to fabricate gages. While such mixtures exhibited satisfactory conducting properties, they could not be fabricated in very small thicknesses suitable for bonding. Therefore, it was decided to fabricate the gage with a commercially available, carbon powder impregnated PVC sheet material sold by the Mitech Corporation under the tradename Magnex AP-900. While sheets of many thicknesses are available, the smallest available thickness of approximately 0.25 mm was selected. This material exhibited a surface resistivity of approximately 10 4 ohm/cm 2 . The sensor may have any suitable geometrical shape. In addition, any suitable conducting powder such as carbon, silver, nickel, iron, etc. may be impregnated in any suitable polymer substrate.
To understand the behavior of the gage material, its strain-sensitivity was measured. Referring to FIG. 1(a), a 25 mm×12 mm sensor 12, cut from a larger sheet of carbon powder-polymer material, was bonded on a 200 mm×25 mm×3 mm aluminum specimen 10. These dimensions are by way of example only and are not intended to limit the scope of the present invention in any way. The edges perpendicular to the specimen longitudinal axis were silver painted with paint 14 and lead wires 16 were attached with the silver paint. FIG. 1(b) shows a strain gage 18 mounted on the opposite face of the specimen 10 with the gage longitudinal axis aligned with the specimen longitudinal axis. The specimen 10 was subjected to a gradually increasing tensile load along the longitudinal axis, as indicated by the arrows P, and the electrical resistance of the sensor 12 and the response of strain gage 18 were recorded. The change in electrical resistance, as a fraction of the initial resistance, is shown in FIG. 2 as a function of the strain for three identical tests. It is seen that the repeatability of the test is good and that the response is almost linear, except for some nonlinearity at low strains. The average gage factor for the sensor material is approximately 0.6.
Further tests were conducted to study the response of the sensor material to breaks in the carbon chains. Referring to FIG. 3, in a first series of tests a slit 20 of gradually increasing length ΔL was introduced in rectangular calibration sensors 12 and the electrical resistance was measured with an appropriate resistance measuring device schematically represented by element 21, such as a digital ohm-meter. The calibrations were all 25 mm wide and the long edges were silvered on both faces. Short electrical wires 16 were attached to each sensor at the end with silver paint. The continuous length L of the sensor was varied from 25 mm to 150 mm, in steps of 25 mm. For each length, at least two sensors were tested. The initial resistance R of the sensors was measured and was in the range of 1-10KΩ.
The slit 20 was cut in each sensor by a jig-saw parallel to the silvered edges and both the length ΔL of the slit and the resulting electric resistance were measured. The slit, approximately 0.8 mm in width, was lengthened in small steps over the entire length L of each sensor. The slit length ΔL and the resistance were measured after each step. The fractional change in resistance, ΔR/R, was plotted as a function of the ratio of the slit length to the sensor length, ΔL/L, for each sensor. The results for three identical, 25 mm long sensors are shown in FIG. 4. The repeatability of the experimental results is seen to be very good, indicating that the concept of utilizing measured changes in electrical resistance to indicate corresponding length of a geometrical discontinuity such as a slit or crack is feasible.
An attempt was made to predict the change in resistance due to the slit. To accomplish this, the sensor had to be represented by an electrical model. A relatively complex electrical model is discussed in "Conductive Polymers as Fatigue Damage Indicators," by J. W. Dally and G. A. Panizza in Experimental Mechanics, Vol. 12(3), pp. 124-9, 1972, and is represented in FIGS. 5(a) and 5(b). The article discusses a graphite-epoxy composite in detail for use as a fatigue damage indicator. The electrical model is applicable to a carbon impregnated polymer. Modifying this two-dimensional model, each carbon particle C is represented by a fixed resistor for its own internal resistance and a variable resister for each point of contact with an adjacent carbon particle. This complex model was simplified for the current investigation because resistance changes due to geometrical discontinuity, and not due to strain, were being measured. The simplified model, shown in FIG. 6, considers all the chains formed by the carbon particles to be arranged in parallel. The effective or equivalent resistance R for the simple model is: ##EQU1## where R 1 =R 2 =R 3 =. . . =R N =R c = resistance of each carbon particle-chain between the silvered edges and N=total number of chains. When n chains are cut, the fractional change in resistance can be shown to be: ##EQU2## If the chains are assumed to be uniformly distributed, the above equation can be rewritten as: ##EQU3## where ΔL=length of cut or discontinuity and L=length of the edges parallel to the cut. A graphical representation of the above equation is shown in FIG. 7. In this figure, the test results for the sensors with gage lengths of 25 mm, 50 mm, and 125 mm are also shown, as continuous lines. All the sensors had the same width of 25 mm. It is seen that the predicted and measured responses show the same trend and, in general, the measured response approaches the predicted response as the gage length is increased. The dotted curve shows the response of a 50 mm long gage in which short wires were attached at one end with silver paint but the long edges were not silvered; a schematic of this sensor is shown next to the dotted curve. It is clear from FIG. 7 that silvering the opposite edges parallel to the slits has the effect of greatly emphasizing the carbon chains between these edges. Considering the simplicity of the electrical model used for the prediction and the variability due to the nature of the test material, the results were considered very encouraging.
In a second series of tests, sensors 12 cut from the carbon powder dispersed polyvinyl chloride sheet were bonded to aluminum compact tension specimens 10, as shown in FIG. 8(b). The objective of this series of tests was to show that the resistance changes measured for the sensors 12 could be interpreted in terms of crack lengths in the aluminum specimen 10 on which the sensors were bonded. A basic requirement for this calibration was that a crack in the aluminum should extend into the sensor through a bonding adhesive. The faithfulness of this extension depends upon several factors such as the properties of the adhesive, the mechanical properties of the sensor and the loading rate. If the conditions are not optimal, the crack in the sensor can either lead or lag behind the crack in the speciment. In many practical situations, crack length measurements are made under fatigue or impact loading conditions.
In experiments of this type, the crack length in the specimen should be independently measured or controlled. In this test, the crack length in the aluminum specimens was sought to be controlled by machining a groove 22 ahead of a slit 20a in the specimen 10 to reduce the specimen thickness and by drilling a hole 24 at the end of the groove 22, as shown in FIG. 8(a). This procedure was also influenced by the decision to apply static or quasi-static loads, indicated by arrows P, rather than fatigue loads. A possible consequence of this procedure was crack acceleration as the induced crack approached the hole 24.
Three different values of the groove length L were used: 25 mm, 50 mm, and 75 mm. For each length, several specimens were tested. On each specimen, a sensor 12 of approximately 25 mm width and 89 mm length was bonded on the face opposite to the groove 22, with one sensor edge overlapping the slit 20. A room temeprature curing, two-component epoxy cement 26, as shown in FIG. 1(a), was employed for the bonding of sensor 12 to the specimen 10. The adhesive thickness employed exceeded the minimum amount needed for the bonding in order to ensure electrical insulation. The long edges of the sensor were silvered on both faces before bonding and lead wires 16 were attached to the sensor by silver paint 14 after bonding. A short slit of 0.8 mm width was cut in the grooved region of the aluminum specimen and in the overlapping sensor edge to serve as a starter crack. Then the load P was applied via holes 30 in specimen 10 until a crack extended to groove hole 24. At each stage, the sensor resistance was measured via an ohm-meter. A typical sensor response is shown in FIG. 9 for a speciment with L=50 mm.
As shown in FIG. 9, the crack gage exhibited an intial resistance of about 6.6KΩ when bonded to an aluminum specimen with a grooved length L of 50 mm. In the intial stages of loading, the resistance increased steadily but by very small amounts due to the strain-sensitivity of the gage. At a load of approximately 1000N, the crack propagated and extended to the hole, resulting in a jump in gage resistance, ΔR, of about 8.3KΩ. Further loading resulted in steady but small increments of resistance. The fractional abrupt change in resistance was interpreted, with the help of a gage calibration curve as shown in FIG. 7, as a crack extension length of 45.7 mm. Typical results from this series of tests are summarized in Table 1.
TABLE 1______________________________________Crack Extension Test Results Actual Crack Measured crackL (mm) Extension (mm) extension (mm)______________________________________25 22.0 21.7 22.0 20.6 22.0 23.950 47.0 45.7 47.0 52.6 47.0 46.575 72.0 73.9 72.0 76.5 72.0 74.7______________________________________
It is interesting to note in Table 1 that for all three specimens with L=75 mm, the measurements indicate an overshooting of the crack in the crack gage. This could have been the result of crack acceleration. For the specimens with L=25 mm and L=50 mm, only one of the three specimens showed this behavior.
Thus, the feasibility of using carbon powder impregnated polymeric gages for measuring surface crack extensions in components and structures is shown. The gages are inexpensive and do not require special instrumentation. The results are repeatable and the reported results indicate a maximum error of about 12 percent. The accuracy can be expected to be better with thinner gages and thinner adhesive layers; the matrix for the carbon powder should also be sufficiently brittle. The gage sensitivity can also be improved by optimizing the shape of the gage.
Many improvements, modifications and substitutions will be apparent to the skilled artisan without departing from the spirit and scope of the present invention as described herein and defined in the following claims. | A crack length sensor is fabricated in a rectangular or other geometrical form from a conductive powder impregnated polymer material. The long edges of the sensor are silver painted on both sides and the sensor is then bonded to a test specimen via an adhesive having sufficient thickness to also serve as an insulator. A lead wire is connected to each of the two outwardly facing silver painted edges. The resistance across the sensor changes continuously as a function of the crack length in the specimen and sensor. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a portable water purifying and filtering unit in which the dirty and possibly contaminated water is forced by simple manual pressure through the unit as it is needed for use.
2. Description of the Prior Art
Prior art devices for water filtering are known which are of the bag type usable for removing impurities from a given quantity of liquid. Generally these bags are hung at a stationary position and the untreated water is allowed to seep by gravity flow through a intermediate filter and into a lower part of the bag from which it is taken into other vessels for use. This type of filter is shown in U.S. Pat. No. 3,224,586 issued on Dec. 21, 1965 to K. L. Wade for "Bag Assemblage". Another gravity type of water filter is shown in U.S. Pat. No. 3,536,197 issued to Samuel L. Ward on Oct. 27, 1970 for "Liquid Treating Apparatus". Much of the prior art development has been concerned with relatively high volume filtration. The present invention on the other hand is directed towards provision of a highly efficient low volume filter that is itself portable and easily carried by the user as he moves about. It is particularly designed for use by outdoorsmen, backpackers, and the like.
SUMMARY OF THE INVENTION
The present invention has the object of overcoming filtration problems with portable filters that satisfy the need for producing potable water to be carried and used in the field. It has the further object of incorporating in one filter device a convenient receptacle for carrying a radio transmitter or the like to provide a finder signal in the event the device is needed in a survival environment. Alternately, the receptacle can be used for storing matches, lighters, or other compact emergency materials that might be essential for survival in the field.
The present invention has as its components several light and flexible elements that resist damage even with rough usage and keep the essential elements for survival at hand. A mounting arrangement is provided for shoulder mounting to leave the hands free.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described with reference to the accompanying specification and the drawings in which like numerals are used to identify like parts as they appear throughout the different views and in which:
FIG. 1 is a perspective external view with parts broken away showing the filter;
FIG. 2 is a sectional view of the device showing its internal parts;
FIG. 3 is a view with parts broken away showing an alternate embodiment to be used as a mouthpiece.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1 and 2 the unit 10 includes a flexible outer bag 12 having a removable, separate, rigid central portion 13 which is clamped in place by an external clamp or strap 15 that contains the intermediate filter 14 as well as a central receptacle 16 with snap cover 16a for holding radio transmitter, matches, or other essential survival materials. The shoulder strap 18 is connected as shown to permit ready portability of the device. The upper end of the container is closed by a cap 20 that is clamped in place by strap 43 and removable when necessary.
FIG. 2 shows the detail of the two chambers into which the unit 10 is generally divided. At the upper lefthand end there is a chamber 22, while at the lower righthand end there is a second chamber 24. The chamber 22 is preferably embodied as a bag 22a with an upper Velcro opening 38 in which the untreated water and chemicals are placed. The bag 22a is placed in the chamber 22 through a top opening 44 in the bag 12. The bag 22 chemically treats the water and also filters it as the water passes through the bag 22a by gravity and squeezing. The opening 44 is normally clamped shut about the cap 20 by the clamp 43 as best shown in FIG. 1. The opening 44 preferably has incorporated in it an elastic band designed to stretch open and receive the bag 22 in its full and distended condition. The rigid center portion 13 includes the central receptacle 16 referred to in connection with FIG. 1. Two separate filter elements are included which include a lower fine filter element 25 and an upper charcoal filled element 26. Incorporated in the lower filter 25 is a one-way check valve 28 which permits flow of the liquid in the direction indicated by arrow. An ascending tube 32 communicates between the outlet of element 26 and the upper end of the cap 20. It will also be seen that the chamber 22a has an opening at its upper end indicated by the numeral 36 that is used to receive dirty and possibly contaminated water. Preferably, and for convenience the upper end of the bag 22a is opened by the Velcro fastener 38. The fine filter 25 preferably includes a fine silt and bacterial filter element. The filter element used in the final filter stage 26 is a silver-anodized charcoal purifying element. All of the parts of the filter unit within the bag 12 are flexible with the exception of the rigid central portion 13 which consists of element 14 and the enclosed receptacle 16 which is removable and separate from bag 12. The bag 12 and the lower chamber 24 are preferably lined with a silver metallic material. It will be seen that the uncovering of opening 44 at the top of the bag 12 is through removal of the upper clamp or strap 43.
FIG. 3 shows an alternate embodiment of the filter cap which includes an upper drinking cup 40 in which the tube 32 carrying the filtered water upwardly terminates. The upper cup thus replaced the cap 20 of FIG. 1. It is held in place by the strap 43. A snap cap 41 can be used over the cup 40 if desired. With this arrangement, it is possible for the user to filter small amounts of the water at a time and to drink it straight from the cup without requiring any drinking vessel.
METHOD OF OPERATION
The unit 10 is first filled by insertion of the bag 22a filled with the water to be purified through the opening 44 of the bag 12. The upper chamber 22 is then compressed by manual squeezing to force the water through the filter 25 and outwardly through the check valve 28 into the lower chamber 24. In the last step, the lower bag or chamber 24 is manually squeezed and the purified water is forced outwardly through the charcoal filled element 26 and up through the tube 32 where it can be poured into an external vessel. If the embodiment of FIG. 3 is used, it can be forced upwardly through the tube 32 into the available drinking cup 40 for immediate use. As shown in FIGS. 1 and 2, the central receptacle 16 for storing emergency materials preferably has a sliding cover 16a so that it can be opened and closed to a water tight condition without affecting the other elements in the filter. The external strap 15a is shown that encircles the unit 10 at its midsection. The upper strap 43 is shown at the upper end of the unit to which is attached to the upper end of the carrying strap 18. The other end of the carrying strap 18 can be attached by sewing or other means to the bottom of the bag 12.
It will thus be seen that I have provided by my invention a novel and improved survival and filter system that operates even in a hostile environment in a simple and reliable fashion. It is both portable and simple to operate. | A water purifying system unit that is portable, fabricated of durable parts and makes provision for storage of basic survival needs in addition to water. A double chamber unit with bag and filter with separating filter and storage compartment provides three stage filtration of water. An appropriate mouthpiece makes drinking directly from the unit possible. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a National Stage entry under 35 U.S.C. §371 of International Application PCT/US2005/01427 filed on Jan. 14, 2005. International Application PCT/US2005/01427 claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application Ser. No. 60/536,631, filed Jan. 15, 2004. The entire contents of each of the above applications are incorporated herein by reference.
STATEMENT OF GOVERNMENT RIGHTS
[0002] The United States Government has a paid-up license in the present invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of Award No. N00014-03-1-0758 awarded by Office of Naval Research.
BACKGROUND
[0003] A. Field of the Invention
[0004] The present invention relates generally to optical couplers, and, more particularly to an optical coupler for coupling an optical fiber into a silicon-on-insulator (SOI) waveguide.
[0005] B. Description of the Related Art
[0006] Silicon-on-insulator (SOI) is one of the more recent and promising integrated optics technologies because it allows the use of conventional microelectronics patterning and fabrication techniques and it offers a high index contrast for strong light confinement in small dimensions. This enables the miniaturization of functional integrated optical devices and the ability to monolithically integrate electronic and optical circuits. For nanometer SOI integrated optics, one of the key issues is efficient light coupling into SOI waveguides. Following the conventional methods for coupling into polymer waveguides, four main approaches are taken to couple light into SOI waveguides: transverse coupling, grating coupling, prism coupling, and vertical tapering.
[0007] Transverse coupling, including end-fire coupling and end-butt coupling, has been a coupling efficiency approximately proportional to the mode dimension ratio. However, the mode size of a single mode SOI waveguide is often on the order of hundreds of nanometers due to higher refractive index contrast. As a result, very low efficiency occurs for transverse coupling.
[0008] Grating coupling is not well-suited for optical integrated circuits (OIC) due to difficulty in mode matching, sensitivity to wavelengths, complexity of design and fabrication. One solution to these problems includes a 90 degree grating coupler designed and fabricated from an optical fiber to wide waveguide. Two-dimensional simulations show that up to a 74% coupling efficiency between a single-mode optical fiber and a 240-nm-thick GaAs—AlO x waveguide may be achieved, however, the coupling efficiency was measured to be only 19%. Another proposed solution includes a fiber-waveguide coupler composed of two one to three millimeter-long gratings and four layers. A 95% coupling efficiency can be achieved with this, however, the structure is difficult to fabricate.
[0009] Thus, there is a need in the art for an optical coupler for coupling an optical fiber to a SOI waveguide that overcomes the problems of the related art.
SUMMARY
[0010] The present invention solves the problems of the related art by providing an optical coupler for coupling an optical fiber into a silicon-on-insulator (SOI) waveguide efficiently and economically.
[0011] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] 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:
[0013] FIG. 1 is a schematic cross-sectional view of an optical coupler in accordance with an embodiment of the present invention;
[0014] FIG. 2 is a graph showing a finite-different time-domain (FDTD) simulation result for the optical coupler shown in FIG. 1 ;
[0015] FIG. 3 ( a ) is schematic cross-sectional view of a polishing mechanism for fabricating the optical coupler shown in FIG. 1 ;
[0016] FIG. 3 ( b ) is a scanning electron microscope (SEM) picture of an optical coupler of the present invention fabricated by direct polishing;
[0017] FIG. 3 ( c ) is an illustration of a grayscale-lithographed optical coupler of the present invention;
[0018] FIG. 4 is a picture of an epoxy-bonding machine for bonding the optical coupler of the present invention to an optical fiber and a waveguide;
[0019] FIGS. 5 ( a ) is a picture showing the coupling results of a light coupled into a waveguide (side view);
[0020] FIG. 5 ( b ) is a picture showing the coupling results of a light coupled into a waveguide (front view); and
[0021] FIG. 5 ( c ) is a picture showing the spectrum response of the optical coupler of the present invention, wherein the solid line is an expected curve, the dashed line is an experimental fitting, and the diamond dots with bars are experimental data with standard deviation.
DETAILED DESCRIPTION
[0022] The following detailed description of the invention refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims and equivalents thereof. The present invention is broadly drawn to an optical coupler that incorporates the advantages of the prism couplers and tapered waveguides, yet more easily integrates into the planar manufacturing process.
[0023] A slab waveguide consists of three layers: the cladding, guiding and substrate layers, which have refractive indices n c , n g , and n s , respectively. The imposition of an electromagnetic boundary condition leads to two physical conditions: (1) total internal reflection in the guiding layer; and (2) a phase matching condition in each layer, which results in a set of discrete modes and their corresponding mode angles. With the optical coupler of present invention (shown generally as reference numeral 10 in FIG. 1 ), guided waves can be introduced with the appropriate mode angle and thereby achieve high coupling efficiency, as shown in FIG. 1 .
[0024] Optical coupler 10 may be made from a variety of materials, but is preferably constructed of silicon. As shown in FIG. 1 , optical coupler includes a tapered top portion 12 connecting together first and second top planar portions 14 , 16 , and a base portion 18 connecting together with first and second top planar portions 14 , 16 with side portions 20 . The intersection of base portion 18 and one side portion forms a termination point T.
[0025] Optical coupler 10 looks like a vertically tapered waveguide, in which direct polishing or gray scale lithography may be used to create a smooth slope on a double polished silicon wafer with a desired slope angle α. For example, slope angle α may be 16.1° for 260 nanometer (nm) SOI waveguide. When a laser or light beam 104 from an optical fiber 101 is incident upon optical coupler 10 at a parallel or almost parallel angle to an SOI waveguide 100 , light beam 104 is bent to the termination point T of optical coupler 10 by total internal reflection. The slope is designed with such a slope angle α that the incident angle at point T is equal to the waveguide mode angle ΘM. As such, light beam 104 produces a very strong evanescent electromagnetic field in a narrow region below the coupler base and light beam 104 can thus tunnel through the low-index gap (tunnel layer 102 ) between optical coupler 10 and SOI waveguide 100 , and become launched into SOI waveguide 100 . According to the geometrical relations, slope angle a satisfies the following equation (1):
α=(90°−Θ M )/2, (1)
and the termination point satisfies the following equation (2):
L=H /tan2α. (2)
When the slope is lengthened, the tolerance of the slope angle α and termination point T will increase because there is a larger range for adjusting the incident position.
[0026] For optical tunneling, the prism coupling theory may be used as a reference. For traditional polymer waveguides, whose cladding and guiding layers are realized using two different polymers, n g =n c +Δn , where Δn is often quite small. As a result, the mode angle Θ M (to the normal) is large. For this reason, it has become widely accepted that the refractive index of the coupler, n p >n g >max(n c ,n s ) is required for mode matching. However, in the case of high index contrast waveguides this condition is not as restrictive since the mode angle of the waveguide is much smaller. In particular, high efficiency coupling using the same index, notably that of silicon, can be achieved. To demonstrate this, silicon couplers were fabricated to couple light into a 260 nm SOI slab waveguides. The refractive indices of the cladding layer, air (n c =1.00), and the guiding layer, silicon (n g =3.48), have a very large difference. Consequently, the mode angle (Θ TE =58.1° for 1550 nm TE and Θ TM =40.7° for TM light) is quite small. Therefore, to match the modes, a higher refractive index of the coupler than of the guiding layer is not necessary.
[0027] In the coupler, two coupling effects are in competition, namely, tunneling into the waveguide and leaking back into the coupler. The output beam results from the integration of tunneling minus leakage over all feed-in points. As a result, there exists a condition of optimal coupling. It has been shown that the optimal coupling is equivalent to matching the spatial amplitude distribution of the input beam to the leakage field of the coupler, and theoretically that 81% coupling efficiency for a uniform tunnel layer and 96% for a linearly tapered tunnel layer can be achieved between a flint glass prism and a polymer waveguide.
[0028] The optical coupler of the present invention optimizes the coupling parameters using the plane-wave method: the incident angle, the tunnel layer thickness, and the beam size. With the optical coupler of the present invention, an optimal coupling efficiency of 77% occurs for an air tunnel layer of 160 nm and a beam size 20.4 micrometers (μm) when working at λ=1550 nm (TE mode). Applying these parameters, the optical coupler of the present invention was validated using computational electromagnetic simulations based on the finite-difference time-domain (FDTD) method. FIG. 2 illustrates the simulation result for TE mode light coupled into the 260 nm SOI slab waveguide. A windowed TE light with λ=1550 nm source is incident on the silicon coupler. The slope is designed to satisfy the mode angle of the slab waveguide. This result can be applied to larger couplers when shifting the incident point only if the slope is straight and long. Similarly, there is a set of optimal parameters for the TM mode. However, due to the large difference in mode angles, the optical coupler cannot couple both TE and TM modes into the waveguide simultaneously. For this reason, coupling for the TE mode is demonstrated. For TM mode coupling, similar results should occur for the optical coupler except that the slope angle of the optical coupler changes to 24.7°.
[0029] To experimentally demonstrate this technique, a coupler was fabricated using a direct polishing method. To do this, a polishing stage was constructed with a tilt angle of 16.1°, as shown in FIG. 3 ( a ). Next a carefully cleaved silicon wafer slab (350 μm thick) was selected, the cleavage side was polished, and the polished slab was glued on the sample stage. After coarse polishing using a 1.0 μm grid size diamond lapping film up to about two-thirds of the wafer thickness, fine polishing using a 0.1 μm film, and followed by final polishing using a 0.05 μm film, the silicon slab was cleaved using a diamond saw and then the incident surface was polished. FIG. 3 ( b ) shows the SEM picture of the coupler fabricated using this method.
[0030] An alternate method for fabricating the coupler is based on grayscale lithography and inductively coupled plasma (ICP) etching. In this case, the coupler is designed as shown in FIG. 3 ( c ), a continuous-tone grayscale mask is prepared using high-energy-beam-sensitive (HEBS) glass. After lithography, ICP etching, and lift-off, a grayscale-lithographed coupler is complete. This method has the advantage that no polishing is needed and smaller couplers can be fabricated.
[0031] Two setups were built to test the optical of the present invention. One setup is used for coupling evaluation, and the other setup is used for device bonding. Principally, the second setup is a rotational version of the first setup, except that extra components are added for bonding. Three factors affect the coupling efficiency for the optical coupler: the incident angle, the tunnel layer thickness, and the beam size. In both setups, these factors can be adjusted until the coupling efficiency is optimized. FIG. 4 shows only the second test setup since the second setup is more complex. In the setup of FIG. 4 , a polarization-maintaining pigtailed fiber of a 1550 nm laser diode is clamped on a three-dimensional (3D) translation stage. This stage is installed on a vertical rotation stage to modify the incident angle. The sample (SOI waveguide) is mounted on the sample stage, consisting of a 3D translation stage, a rotational stage, and goniometers, by which the sample position and the waveguide orientation can be adjusted. In addition, a soldering iron hole is provided under the sample stage for thermo-cured epoxy bonding. The optical coupler is affixed to a pneumatic plunger head, which is pushing from the top and can control the tunnel layer thickness by adjusting the pressure between the coupler and the sample. A microscope objective and an infrared camera are used to observe the out coupling.
[0032] In the experiment, the 1550 nm TE light from a fiber is coupled into a 10 μm wide waveguide (on 260-nm-thick SOI) through a lateral taper, as shown in FIG. 5 ( a ). High light density for out-coupling is observed on the end of the waveguide, as shown in FIG. 5 ( b ). In order to evaluate the coupling efficiency, a long, narrow SOI slab instead of the lateral-tapered waveguide is used in the experiments to exclude the propagation loss due to the roughness of the waveguide sidewalls. The input power from the fiber, and output power from the slab are measured using a near IR power meter (for example, a LaserMate-Q™ powermeter available from Coherent, Inc.). The ratio between output and input is calculated to be 14.2%. Excluding the reflection on the incident surface of the coupler (30%), the loss in the silicon (−2 dB/cm), as well as the reflection on the output facet of the waveguide (30%), the coupling efficiency is estimated to be 46% for the SOI slab.
[0033] In optical communication applications, the transmission bandwidth is a key factor. In order to assess the spectral response of the optical coupler, a tunable laser (Agilent 8164A) is utilized as a light source in the experiment. The laser has a tuning range from 1510 nm to 1640 nm and tuning resolution as small as 0.01 nm. While maintaining a constant input power and incident angle, and scanning the wavelength over the tuning range, an output power is measured at every 10 nm of wavelength change, and the measurement is repeated five times at each wavelength to decrease random error. The spectral response of the coupler is shown in FIG. 5 ( c ), in which the expected curve (solid line) is calculated by keeping the optimal parameters for 1550 nm-TE coupling but shifting the wavelength. The comparison of the fitting curve (dashed line) with expected curve shows a good match of the coupling tendencies. The results also show that the coupling efficiency changes quite slowly as a function of wavelength. The experimental response changes even slower than the expected result because propagation and scattering worsen the directivity of the light beam. Although the optimal response wavelength is 1550 nm, the coupler can work over a range of 1510 nm-1590 nm.
[0034] For optoelectronic integration, the optical fiber, optical coupler, and waveguide were bonded together with an epoxy-bonding machine, as shown in FIG. 4 . Using this setup, the alignment between the optical fiber and the optical coupler can be adjusted. Once the maximum coupling is achieved, an epoxy (e.g., Epotek™ 353ND epoxy) is dispensed. After being heated to 120° C. for about two minutes, the epoxy is cured. In the end, an integrated coupler is formed and the pneumatic plunger can be detached. Under appropriate conditions, the loss introduced in the bonding process can be as low as −0.45 dB (10%). In addition, we found that Dynasolve™ 165 can be used to remove cured epoxy in the case of misalignment.
[0035] The optical coupler of the present invention provides many advantages over the related art. For example, the optical coupler incorporates the advantages of tapered waveguides and prism couplers. The optical coupler satisfies the requirement of parallel incidence, which makes it well-suited for the planar integration of optoelectronic devices. The optical coupler also shows flexibility in applications, simplicity in fabrication, reliability in alignment, high efficiency, and broadband transmission. In addition, the optical coupler may be used for coupling into other dielectric waveguides since the incident angle on the coupler base can be set in the range of about zero to 90° when designing a slope angle of about 45° to zero; and the material of the optical coupler may be altered to other high refractive and low loss materials, e.g. GaAs, based upon ease of fabrication. Thus, the optical coupler of the present invention provides a general solution for coupling into semiconductor waveguides and integration of planar optoelectronic devices.
[0036] It will be apparent to those skilled in the art that various modifications and variations can be made in the optical of the present invention and in construction of the optical coupler without departing from the scope or spirit of the invention. Examples of which have been previously provided.
[0037] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims. | An optical coupler for parallel coupling from a single mode optical fiber, or fiber ribbon, into a silicon-on-insulator (SOI) waveguide for integration with silicon optoelectronic circuits. The optical coupler incorporates the advantages of the vertically tapered waveguides and prism couplers, yet offers the flexibility of planar integration. The optical coupler may be fabricated using wafer polishing technology or grayscale photolithography. The optical coupler can be packaged using epoxy bonding to form a fiber-waveguide parallel coupler or connector. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/283,105 filed Oct. 27, 2011, which is a continuation of U.S. patent application Ser. No. 12/783,863 filed May 20, 2010, which issued as U.S. Pat. No. 8,068,497 on Nov. 29, 2011, which is a continuation of U.S. patent application Ser. No. 10/434,615 filed May 9, 2003, which issued as U.S. Pat. No. 7,724,749 on May 25, 2010, which claims the benefit of U.S. Provisional Application Ser. No. 60/379,829 filed May 10, 2002, the contents of which are hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of wireless communications. More specifically, the present invention relates to a system and method for prioritizing the retransmission of protocol data units (PDUs) to assist radio link control (RLC) layer retransmission.
BACKGROUND
[0003] In third generation (3G) cellular systems for Frequency Division Duplex (FDD) and Time Division Duplex (TDD), there are retransmission mechanisms in the Acknowledgement Mode of the Radio Link Control (RLC) layer to achieve high reliability of end-to-end data transmissions. The RLC layer is a peer entity in both the Radio Network Controller (RNC) and the User Equipment (UE).
[0004] A block diagram of a UMTS Terrestrial Radio Access Network (UTRAN) MAC-hs layer architecture is illustrated in FIG. 1 , and a block diagram of the user equipment (UE) MAC-hs architecture is shown in FIG. 2 . The architecture shown in FIGS. 1 and 2 is described in detail co-pending U.S. patent application Ser. No. 10/270,822 filed on Oct. 15, 2002 which is assigned to the present assignee. The UTRAN MAC-hs 30 shown in FIG. 1 comprises a transport format resource indicator (TFRI) selector 31 , a scheduling and prioritization entity 32 , a plurality of Hybrid Automatic Repeat (H-ARQ) processors 33 a, 33 b, a flow controller 34 and a priority class and transmission sequence number (TSN) setting entity 35 .
[0005] The UE MAC-hs 40 comprises an H-ARQ processor 41 . As will be explained with reference to both FIGS. 1 and 2 , the H-ARQ processors 33 a, 33 b in the UTRAN MAC-hs 30 and the H-ARQ processor 41 in the UE MAC-hs 40 work together to process blocks of data.
[0006] The H-ARQ processors 33 a, 33 b in the UTRAN MAC-hs 30 handle all of the tasks that are required for the H-ARQ process to generate transmissions and retransmissions for any transmission that is in error. The H-ARQ processor 41 in the UE MAC-hs 40 is responsible for generating an acknowledgement (ACK) to indicate a successful transmission, and for generating a negative acknowledgement (NACK) to indicate a failed transmission. The H-ARQ processors 33 a, 33 b and 41 process sequential data streams for each user data flow.
[0007] As will be described in further detail hereinafter, blocks of data received on each user data flow are assigned to H-ARQ processors 33 a, 33 b. Each H-ARQ processor 33 a, 33 b initiates a transmission, and in the case of an error, the H-ARQ processor 41 requests a retransmission. On subsequent transmissions, the modulation and coding rate may be changed in order to ensure a successful transmission. The data block to be retransmitted and any new transmissions to the UE are provided by the scheduling and prioritization entity 32 to the H-ARQ entities 33 a, 33 b.
[0008] The scheduling and prioritization entity 32 functions as radio resource manager and determines transmission latency in order to support the required QoS. Based on the outputs of the H-ARQ processors 33 a, 33 b and the priority of a new data block being transmitted, the scheduling and prioritization entity 32 forwards the data block to the TFRI selector 31 .
[0009] The TFRI selector 31 , coupled to the scheduling and prioritization entity 32 , receives the data block to be transmitted and selects an appropriate dynamic transport format for the data block to be transmitted. With respect to H-ARQ transmissions and retransmissions, the TFRI selector 31 determines modulation and coding.
[0010] It is highly desirable for the retransmitted data blocks to arrive at the RLC entity of the receiving side (i.e., the UE) as soon as possible for several reasons. First, the missed data block will prevent subsequent data blocks from being forwarded to higher layers, due to the requirement of in-sequence delivery. Second, the buffer of the UE needs to be sized large enough to accommodate the latency of retransmissions while still maintaining effective data rates. The longer the latency is, the larger the UE buffer size has to be to allow for the UE to buffer both the data blocks that are held up and continuous data receptions until the correct sequence data block is forwarded to higher layers. The larger buffer size results in increased hardware costs for UEs. This is very undesirable.
[0011] Referring to FIG. 3 , a simplified flow diagram of the data flow between a Node B (shown at the bottom of FIG. 3 ) and a UE (shown at the top of FIG. 3 ) is shown. PDUs from higher level processing are scheduled and may be multiplexed into one data block. A data block can only contain PDUs of higher layers of the same priority. A unique TSN is assigned to each data block by the scheduler. The higher layers may provide a plurality of streams of different priorities of PDUs, each priority having a sequence of TSNs. The scheduler then dispatches the data blocks to the plurality of H-ARQ processors P 1 B -P 5 B . Each H-ARQ processor P 1 B -P 5 B is responsible for processing a single data block at a time. For example, as shown in FIG. 3 , the Priority 1 PDUs comprise a sequence illustrated as B 1 1 -B 1 N . Likewise, the Priority 2 PDUs are sequenced from B 2 1 -B 2 N and the Priority 3 PDUs are sequenced from B 3 1 -B 3 N . These PDUs are scheduled (and may be multiplexed) and affixed a TSN by the common scheduler. For purposes of describing the invention, it is assumed that one PDU equals one data block. After a data block is scheduled to be processed by a particular processor P 1 B -P 5 B , each data block is associated with a processor identifier, which identifies the processor P 1 B -P 5 B that processes the data block.
[0012] The data blocks are then input into the scheduled Node B H-ARQ processors P 1 B -P 5 B which receive and process each data block. Each Node B H-ARQ processor P 1 B -P 5 B corresponds to an H-ARQ processor P 1 UE -P 5 UE within the UE. Accordingly, the first H-ARQ processor P 1 B in the Node B communicates with the first H-ARQ processor P 1 UE in the UE. Likewise, the second H-ARQ processor P 2 B in the Node B communicates with the second H-ARQ processor P 2 UE in the UE, and so on for the remaining H-ARQ processors P 3 B -P 5 B in the Node B and their counterpart H-ARQ processors P 3 UE -P 5 UE respectively within the UE. The H-ARQ processes are timely multiplexed onto the air interface and there is only one transmission of an H-ARQ on the air interface at one time.
[0013] For example, taking the first pair of communicating H-ARQ processors P 1 B and P 1 UE , the H-ARQ processor P 1 B processes a data block, for example B 1 1 , and forwards it for multiplexing and transmitting it over the air interface. When this data block B 1 1 is received by the first H-ARQ processor P 1 UE , the processor P 1 UE determines whether or not it was received without error. If the data block B 1 1 was received without error, the first H-ARQ processor P 1 UE transmits an ACK to indicate to the transmitting H-ARQ processor P 1 B that it has been successfully received. On the contrary, if there is an error in the received data block B 1 1 , the receiving H-ARQ processor P 1 UE transmits a NACK to the transmitting H-ARQ processor P 1 B . This process continues until the transmitting processor P 1 B receives an ACK for the data block B 1 1 . Once an ACK is received, that processor P 1 B is “released” for processing another data block. The scheduler will assign the processor P 1 B another data block if available, and can choose to retransmit or start a new transmission at any time.
[0014] Once the receiving H-ARQ processors P 1 UE -P 5 UE process each data block, they are forwarded to the reordering buffers R 1 , R 2 , R 3 based on their priority; one reordering buffer for each priority level of data. For example, Priority 1 data blocks B 1 1 -B 1 N will be received and reordered in the Priority 1 reordering buffer R 1 ; Priority 2 data blocks B 2 1 -B 2 N will be received and reordered in the Priority 2 reordering buffer R 2 ; and the Priority 3 data blocks B 3 1 -B 3 N will be received and reordered by the Priority 3 reordering buffer R 3 .
[0015] Due to the pre-processing of the data blocks by the receiving H-ARQ processors P 1 UE -P 5 UE and the ACK/NACK acknowledgement procedure, the data blocks are often received in an order that is not sequential with respect to their TSNs. The reordering buffers R 1 -R 3 receive the out-of-sequence data blocks and attempt to reorder the data blocks in a sequential manner prior to forwarding onto the RLC layer. For example, the Priority 1 reordering buffer R 1 receives and reorders the first four Priority 1 data blocks B 1 1 -B 1 4 . As the data blocks are received and reordered, they will be passed to the RLC layer.
[0016] On the receiving side, the UE MAC-hs, (which has been graphically illustrated as MAC-hs control), reads the H-ARQ processor ID, whether it is sent on a control channel such as the HS-SCCH or whether the data block has been tagged, to determine which H-ARQ processor P 1 UE -P 5 UE has been used. If the UE receives another data block to be processed by the same H-ARQ processor P 1 UE -P 5 UE , the UE knows that that particular H-ARQ processor P 1 UE -P 5 UE has been released regardless of whether or not the previous data block processed by that H-ARQ processor P 1 UE -P 5 UE has been successfully received or not.
[0017] FIG. 4 is an example of a prior art system including an RNC, a Node B, a UE and their associated buffers. This example assumes that the UE is the receiving entity and the Node B is the transmitting entity. In this prior art system, a PDU with SN=3 is not received successfully by the UE. Therefore, the RLC in the UE requests its peer RLC layer in the RNC for a retransmission. Meanwhile, the PDUs with SNs=6-9 are buffered in the Node B, and PDUs with SNs=4 and 5 are buffered in the UE. It should be noted that although FIG. 4 shows only several PDUs being buffered, in reality many more PDUs (such as 100 or more) and PDUs from other RLC entities may be buffered.
[0018] As shown in FIG. 5 , if a retransmission of the PDU with SN=3 is required, it must wait at the end of the queue in the Node B buffer, and will be transmitted only after the PDUs with SNs=6-9 are transmitted. The PDUs in the UE cannot be forwarded to the upper layers until all PDUs are received in sequence.
[0019] In this case, the PDU with SN=3 stalls the forwarding of subsequent PDUs to higher layers, (i.e. SNs=4-9), assuming all the PDUs are transmitted successfully. Again, it should be noted that this example only reflects 11 PDUs, whereas in normal operation hundreds of PDUs maybe scheduled in advance of retransmitted data PDUs, which further aggravates transmission latency and data buffering issues.
[0020] It would be desirable to have a system and method whereby the retransmitted data can avoid the delays due to congestion in the transmission buffers.
SUMMARY
[0021] The present invention is a system and method for transferring data in a wireless communication system. A plurality of data blocks are received and temporarily stored in a first memory. The plurality of data blocks are then transmitted. A determination is then made as to whether each of the transmitted data blocks was received successfully or needs to be retransmitted because the data block was not received successfully. Each of the transmitted data blocks that needs to be retransmitted is marked and stored in a second memory having a higher priority than the first memory. The marked data blocks stored in the second memory are transmitted before transmitting data blocks stored in the first memory.
[0022] Each marked data block may include a common channel priority indicator (CmCH-Pi). The CmCH-Pi of the marked data block is read and used to determine which of a plurality of memories to place the marked data block in based on the CmCH-Pi.
[0023] In accordance with one preferred embodiment of the present invention, a wireless communication system for transferring data includes a UE, a Node B in communication with the UE and a radio network controller (RNC) in communication with the Node B and the UE. The RNC transmits a plurality of data blocks to the UE via the Node B. The UE sends a status report to the RNC. The report indicates whether each of the transmitted data blocks was received successfully by the UE or needs to be retransmitted because the data block was not received successfully by the UE. The RNC marks each of the data blocks that needs to be retransmitted and sends the marked data blocks to the Node B. The Node B receives, temporarily stores and prioritizes transmission of the marked data blocks over other data blocks previously received and stored in Node B. The Node B transmits the marked data blocks to the UE before the other data blocks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] A more detailed understanding of the invention may be had from the following description, given by way of example and to be understood in conjunction with the accompanying drawings wherein:
[0025] FIG. 1 is a UTRAN MAC-hs.
[0026] FIG. 2 is a prior art UE MAC-hs.
[0027] FIG. 3 is a block diagram of the data flow between a Node B and a UE.
[0028] FIG. 4 is a diagram of the RLC layer exhibiting a missed PDU transmission.
[0029] FIG. 5 is a diagram of retransmission by the RLC layer of the missed PDU transmission.
[0030] FIG. 6 is a signal diagram of a method of prioritizing retransmissions in accordance with the present invention.
[0031] FIG. 7 is a block diagram of the data flow between a Node B and a UE, whereby retransmissions are assigned to a higher priority queue.
[0032] FIG. 8 is a block diagram of the data flow of a DSCH transmission scheduling PDUs with CmCH-Pi indications.
[0033] FIGS. 9 and 10 are diagrams of retransmission by the RLC layer of a missed PDU transmission in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] The preferred embodiments will be described with reference to the drawing figures where like numerals represent like elements throughout.
[0035] In describing the present invention, reference may be made to the terminology “buffer” and “memory.” It is intended that these terms are equivalent, and are used to indicate a plurality of data blocks or PDUs in a successive queue.
[0036] In order to reduce the latency of an RLC layer retransmission, the present invention prioritizes a retransmission of a PDU over a subsequent PDU in the buffer of an intermediate node, such as a Node B for example.
[0037] In the downlink direction (data transmissions from serving RNC (SRNC) to UE), one source of the latency of the retransmissions is generated in applications that buffer in the UTRAN outside of the SRNC. For example, buffering for an application could occur in the Controlling RNC (CRNC) or in the Node B. In several applications, the RNC RLC sends the PDU to the MAC-d in the RNC which creates an MAC-d PDU which is sent to the CRNC and then Node B (note that in the case that a UE has not moved out of the cell coverage of the SRNC, the CRNC will be the same RNC, and therefore, any messages sent are internal. When the UE has moved out of cell coverage of the SRNC and the new CRNC is known as the Drift RNC (DRNC). For simplification, in both cases this RNC will be referred to as a CRNC).
[0038] Since the MAC-d PDU contains exactly 1 RLC PDU (plus other potential MAC information), a MAC-d PDU can be considered equivalent to a RLC PDU. Although, discussion of PDUs in the CRNC or the Node B in the present application refers to MAC-d PDUs (not RLC PDUs), they can be considered equivalent for the purpose of the present invention and the term PDU will be used hereinafter to refer to both.
[0039] To allow for continuous data flow, the PDUs from the RNC RLC are usually queued in buffers of the CRNC or Node B for a while, before they are transmitted to the UE and thus the peer RLC. As will be described in detail hereinafter, the presently inventive method of retransmitting data at a higher priority bypasses the buffering/queuing of data in the UTRAN.
[0040] One embodiment of the present invention is the RLC retransmissions from the Radio Network Controller (RNC) to the User Equipment (UE) of a system employing High Speed Downlink Packet Access (HSDPA). A method 100 for reducing the latency of retransmissions in accordance with the present invention is depicted in FIG. 6 . FIG. 6 shows the communications between an RNC 102 , a Node B 104 and a UE 106 .
[0041] The RLC layer in the UE 106 generates a Status Report PDU (step 108 ) which indicates the status of received, (i.e., successfully transmitted), or missing PDUs, (i.e., unsuccessfully transmitted). This status report PDU is transmitted (step 110 ) to the RNC 102 . Once the RLC layer in the RNC 102 receives the Status Report PDU from its peer entity in the UE 106 , the RNC 102 prepares the retransmission of the missed PDU (step 112 ).
[0042] The present invention implements a method to enable the Node B to distinguish the retransmitted PDU from other PDUs. In a first embodiment, the RNC 102 marks the retransmitted PDU by using a field of bits on its Frame Protocol (FP) overheads. The retransmitted PDU includes a CmCH-Pi which is updated (or increased) every time the PDU is sent (step 114 ) from the RNC 102 to the Node B 104 . This permits the Node B 104 to track the number of times the PDU is sent and, therefore, identify the proper queue in which to place the PDU. Preferably, the CmCH-Pi is typically set and updated at the RNC 102 . However, this function may also be performed at the Node B 104 . The Node B 104 reads the CmCH-Pi and determines the proper priority queue for the PDU (steps 116 ). The Node B 104 transmission scheduler services the higher priority queues in advance of lower priority queues. The Node B 104 places the PDU to be retransmitted in a buffer having a higher priority than it originally had when the PDU was originally transmitted as a result of the setting of the CmCH-Pi by the RNC 102 .
[0043] The PDU is then retransmitted (step 118 ) in a buffer (i.e., memory) having a higher priority than the priority of the original transmission. Other transmissions for this UE may be buffered in Node B 104 lower priority transmission queue at the time of the PDU retransmission. The setting of the increased CmCH-Pi for retransmitted PDUs results in transmission scheduling in advance of other PDUs previously received and buffered in Node B 104 .
[0044] Referring to FIG. 7 , retransmissions are assigned to a higher priority queue so that they supercede transmission of other data blocks which originate from the same “original” transmission buffer. Once the receiving H-ARQ processors P 1 UE -P 5 UE process each data block, they are forwarded to the reordering buffers R 1 , R 2 , R 3 based on their priority; one reordering buffer for each priority level of data. For example, reordering buffer R 2 reorders data blocks B 2 1 , B 2 2 and B 2 4 . Reordering buffer R 3 reorders data blocks B 3 3 , B 3 4 and B 3 6 . A data block (“X”) is missing between the data blocks B 2 2 and B 2 4 . An additional data block (“X”) is missing between the data blocks B 3 4 and B 3 6 . Thus, expected data blocks B 2 3 and B 3 5 are not received, e.g., due to a NACK message being misinterpreted as being an ACK message.
[0045] The missing data blocks are then retransmitted. Normally, the data block B 2 3 would have been placed in the Priority 2 transmission buffer. However, since the data block B 2 3 was missed and had to be retransmitted, the data block B 2 3 is placed in a higher priority transmission buffer, (in this case the Priority 1 transmission buffer), and thus is sent earlier than if it were placed in the Priority 2 or 3 transmission buffers. Likewise, the data block B 3 5 would have normally been placed in the Priority 3 transmission buffer. However, since the data block B 3 5 was missed and had to be retransmitted, the data block B 3 5 is placed in either the Priority 1 or Priority 2 transmission buffer so that it is transmitted earlier than if it had been placed in the Priority 3 transmission buffer.
[0046] Upon reception of PDUs in the Node B, the CmCH-PI is used to determine the priority queue B 1 n-B 3 n. The scheduler services the higher priority queues first and assign transmissions to transmitting H-ARQ processors P 1 B -P 5 B , Upon successful transmission to the UE, the receiving H-ARQ processors P 1 UE -P 5 UE forward the retransmitted PDUs to the RLC layer.
[0047] This procedure may also be applied for a DSCH system, except that the intermediate node is the CRNC instead of the Node B. Referring to FIG. 8 , PDUs 805 with CmCH-Pi indications are given priority by a prioritization entity 810 and are scheduled for transmission by the MAC-sh in the CRNC. The MAC-sh maintains multiple priority queues 815 A, 815 B, and a DSCH transmission scheduler 820 determines which PDU 805 is to be transmitted based on the priority of that data. Therefore, by setting increased CmCH-Pi for DSCH retransmissions, these transmissions will be serviced in advance of other data for the UE. This is similar to the HS-DSCH case where the Node B MAC-hs entity schedules transmissions.
[0048] Referring to FIG. 9 , a system is shown in accordance with the present invention implementing the prioritization method of FIG. 6 . After the RLC layer in the UE transmits a status report PDU to the RLC layer in the RNC indicating that the PDU with SN=3 has not been successfully received, the RNC sends a retransmission of the PDU with SN=3. The PDU will be prioritized over other PDUs in the buffer of the intermediate node by placement within a higher priority buffer. It should be noted that although only 11 PDUs are shown, in actuality, there may be hundreds of queued PDUs.
[0049] The benefits of the present invention can be seen with reference to FIG. 10 , which depicts the result of the prioritization function in the receiving buffer. The retransmitted PDU with SN=3 arrives at the receiving buffer, and the in-sequence PDUs with SN=3 to 5 can be forwarded to the higher layer much more quickly than the prior art scenario depicted in FIG. 5 .
[0050] While the present invention has been described in terms of the preferred embodiment, other variations which are within the scope of the invention as outlined in the claims below will be apparent to those skilled in the art. | Managing the transmission and retransmission of radio link control (RLC) data protocol data units (PDUs) is disclosed. An indication is received that an RLC data PDU was not successfully received by a receiving device. The RLC data PDU, that was not successfully received, is retransmitted, and prioritized over non-retransmitted RLC data PDUs. A number of times that the RLC data PDU was retransmitted is determined. | 7 |
RELATED INVENTIONS
[0001] Under 35 U.S.C § 121, this application claims the benefit of prior co-pending U.S. patent application Ser. No. 10/097,089, A Process and System for Treating Waste from the Production of Energetics, by Cha et al., filed Mar. 14, 2002, incorporated herein by reference.
STATEMENT OF GOVERNMENT INTEREST
[0002] The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND
[0003] Carbon sorption is the conventional method for treating munitions manufacturing waste containing explosive compounds such as 2,4,6 trinitrotoluene (TNT), trimethylenetrinitronitramine (RDX), and tetramethylenetetranitramine (HMX). The liquid form of this waste is termed “pinkwater.” Typically using granulated activated carbon (GAC) filters, the waste is passed through the GAC with the explosive constituents removed by sorbing onto the carbon. This method is non-destructive, i.e., the sorbed molecules of contaminant remain intact chemically. Thus, the process generates spent contaminant-laden GAC filters that require further treatment, to include regeneration of the carbon filter for re-use or safe disposal at the end of the filter's useful life. The U. S. military and its contractors generate substantial amounts of spent GAC from pinkwater treatment and would save considerable resources by replacing the GAC filtration process with a process that actually destroys or neutralizes energetic contaminants.
[0004] Thus, it is a given that conventional sorbing processes have several disadvantages that are immutable. Further, direct oxidation by chemical or biological processes is not as efficient as sequential reduction/oxidation processes due to the relatively oxidized nature of energetics.
[0005] It is known to use the Fenton reaction for oxidizing hydrocarbons to their constituents. Typically, the oxidizing agent used in the reaction is hydrogen peroxide, H 2 O 2 . Mixed with a metallic salt, H 2 O 2 produces a free radical that breaks the bonds of a hydrocarbon molecule in an exothermic reaction. This results in a low-free-energy state generally associated with the production of carbon dioxide (CO 2 ) and water.
[0006] Elemental iron (Fe 0 ) oxidizes to Fe +2 in the presence of oxygen. This removes most of the oxygen from the solution and contributes to the solution attaining an anaerobic state.
[0007] Zero-valent iron has been used in permeable reactive barriers (PRBs), an emerging technology that has been applied in recent years to remediate groundwater contaminated with a wide range of pollutants. Permeable Reactive Barrier Technologies for Contaminant Remediation, EPA/600/R-98/125, U. S. EPA, September 1998; Field Applications of In Situ Remediation Technologies: Permeable Reactive Barriers, EPA/542/R-99/002, U.S. EPA, June 1999. Iron is a strong reducing agent (E o =−0.44V) and can reduce relatively oxidized pollutants, including chlorinated solvents, metals, nitrates, and radionuclides. U.S. EPA (September 1998).
[0008] Researchers have shown that iron can reduce TNT, RDX, and HMX at high rates. Hundal, L. S., et al., Removal of TNT and RDX from Water and Soil Using Iron Metal, Environmental Pollution, 97: 55-64, 1997. Further, the Fenton reaction is an established process applied to treat a wide variety of pollutants in hazardous wastes, wastewater, and groundwater. Eckenfelder, W. W., The Role of Chemical Oxidation in Waste Treatment Processes, Proceedings of the First International Symposium on Chemical Oxidation, Technomic Publishing Co., Inc., Lancaster, Pa., pp. 1-10, 1992; Huang, C. P. et al., Advanced Chemical Oxidation: Its Present Role and Potential Future in Hazardous Waste Treatment, Waste Management, 16: 361-377, 1993.
[0009] The well-known Fenton reaction has been used in a number of recent patents dealing with environmental remediation. For example, for in-situ subterranean treatment of contaminated ground water or soil, the following employ the Fenton reaction as at least a part of their process: U.S. Pat. No. 6,206,098, In situ Water and Soil Remediation Method and System, to Cooper et al., Mar. 27, 2001 using a catalyst prior to injection of an oxidizer to initiate the Fenton reaction; U.S. Pat. No. 5,967,230, In situ Water and Soil Remediation Method and System, to Cooper et al., Oct. 19, 1999; and U.S. Pat. No. 5,611,642, Remediation Apparatus and Method for Organic Contamination in Soil and Groundwater, to Wilson, Mar. 18, 1997, describing a subterranean system for implementing the Fenton reaction.
[0010] U.S. Pat. No. 5,789,649, Method for Remediating Contaminated Soils, to Batchelor, et al., Aug. 4, 1998, describes the use of zero-valent iron and a catalytic metal to degrade chlorinated compound contaminated soil. U.S. Pat. Nos. 5,611,936, 5,616,253, Apr. 1, 1997; and U.S. Pat. No. 5,759,389, Jun. 2, 1998, all entitled Dechlorination of TCE with Palladized Iron, all to Fernando, et al., describe a method to de-chlorinate TCE with elemental iron having a palladium coating.
[0011] Zero-valent iron is used for at least part of the remediation process in establishing subterranean permeable reactive barriers as described in U.S. Pat. No. 5,733,067, Method and System for Bioremediation of Contaminated Soil Using Inoculated Support Spheres, to Hunt, et al., Mar. 31, 1998; U.S. Pat. No., 5,833,388, Nov. 10, 1998, and U.S. Pat. No. 5,975,800, Nov. 2, 1999, both entitled Method for Directing Groundwater Flow and Treating Groundwater In Situ, both to Edwards and Dick; U.S. Pat. No. 5,857,810, In Situ Chemical Barrier and Method of Making, to Cantrell and Kaplan Jan. 12, 1999; and U.S. Pat. No. 6,207,114, Reactive Material Placement Technique for Groundwater Treatment, to Quinn, et al., Mar. 27, 2001.
[0012] Zero-valent iron powder has been used for in-situ decontamination of halocarbons and metals more noble than iron as described in U.S. Pat. No. 5,975,798, In Situ Decontamination of Subsurface Waste Using Distributed Iron Powder, to Liskowitz et al., Nov. 2, 1999. U.S. Pat. No. 6,132,623, Immobilization of Inorganic Arsenic Species Using Iron, to Nikolaidis, et al., Oct. 17, 2000, describes the use of zero-valent iron to immobilize inorganic arsenic species. U.S. Pat. No. 5,783,088, Method of Removing Oxidized Contaminants from Water, to Amonette, et al., Jul. 21, 1998, describes treatment of oxidized contaminants using a layered aluminosilicate incorporating Fe (II). U.S. Pat. No. 5,538,636, Process for Chemically Oxidizing Highly Concentrated Waste Waters, to Gnann et al., Jul. 23, 1996, uses the Fenton reaction together with electrolysis and multiple steps of neutralization to purify wastewater and address problems associated with the sludge resulting therefrom.
SUMMARY
[0013] The process provided by a preferred embodiment of the present invention transforms the energetic compounds in waste associated with munitions production and de-commissioning. It eliminates the need for subsequent treatment or re-generation with attendant concerns of possible secondary contamination. The process involves at least one pre-filtration and two sequential reduction and oxidation reactions and a post-reaction neutralization process to break down energetics to innocuous end products such as carbon dioxide, water, and environmentally benign products precipitated in a sludge.
[0014] The two-step treatment process combines two known treatment technologies: zero-valent metal reduction and Fenton oxidation. It also provides a final “polishing” step in which the acid pH of the mixture resulting from the Fenton reaction is neutralized and sediment settled out of the aqueous mixture.
[0015] It capitalizes on the advantages of each of the individual reduction and oxidation reactions and the resulting synergism of their serial combination. The neutralization post-treatment step enables re-use of the water by-product and stabilizes any resulting precipitated sludge.
[0016] The system uses a pre-filter containing filter media and a zero-valent metal, a first vessel for conducting the Fenton oxidation, and a second vessel for pH-neutralizing the treated waste and allowing it to settle prior to drawing off water for re-use and pumping any resultant sludge for further disposition. The system is designed to handle those highly oxidized waste streams that would not ordinarily lend themselves to Fenton oxidation, such as those containing energetics, in particular TNT, RDX, HMX, and combinations thereof.
[0017] The pre-filter system may use natural material as filter media such as sand or diatomaceous earth or manmade material such as polystyrene particles. Although elemental iron (Fe 0 ) is the most cost-effective and efficient to use, metals such as tin, aluminum, zinc, magnesium, nickel, palladium, platinum, and combinations thereof may be used with the filter media. Upon reaction of the elemental iron with the waste stream, at least part of it is converted to the ferrous ion (Fe +2 ) and combined with the filtered and now initially treated waste stream. The iron and sand may be incorporated in a replaceable vented cartridge, the venting providing for safely dumping accumulating gases, such as hydrogen.
[0018] The system may also use a mix control module to facilitate automated control of the mix within the Fenton oxidation reactor and the settling tank. The mix control module monitors and controls the pH of each of the reactor and the settling tank as well as the amount of the oxidizer, typically hydrogen peroxide (H 2 O 2 ), and metal ion, typically the ferrous ion Fe +2 , in the Fenton reactor. A preferred reactor would be of the continuous stirred tank reactor (CSTR) type. Alternatively, the Fenton reactor could be a tank provided with an impeller mixer.
[0019] For the settlement tank, pH is neutralized to within the range of 6.0-8.0 by adding a base, such as NaOH, and suspended solids are permitted to settle, forming sludge. A sludge pump is provided for emptying the settling tank periodically as needed.
[0020] In a preferred embodiment, the Fenton reactor is positioned lower than the zero-valent reactor thus enabling gravity feed of the filtered and reduced waste stream from the zero-valent reactor to the Fenton reactor. Likewise the settling tank is positioned lower than the Fenton reactor thus enabling gravity feeding of the contents of the Fenton reactor to the settling tank. The integrated use of a preferred embodiment of the present invention in the processing line of a manufacturing plant is envisioned.
[0021] A method for filtering and deoxygenating a waste stream containing suspended and colloidal highly oxidized solids comprises:
physically filtering the waste stream while establishing a reducing environment via use of zero-valent metal as part of the filtering; subjecting the filtered waste stream to zero-valent metal reduction in a zero-valent metal column reactor; subjecting the product resultant from the zero-valent column to a Fenton oxidation reaction in a Fenton reactor; and pH-neutralizing the output of the Fenton reactor in a sedimentation tank.
[0026] The process permits reclaiming most of the aqueous portion of a waste stream's constituents and renders any sludge benign and suitable for possible re-use or safe disposal. The process further provides for automated monitoring and control of both the Fenton reactor and the settling tank.
[0027] Advantages of a preferred embodiment of the present invention include:
uses low-cost scrap metal as the zero-valent metal, typically scrap iron; filters and treats both liquids, such as pinkwater and solids, such as the constituents of TNT, RDX and HMX; provides for venting Hydrogen gas at the top of the zero-valent reactor; provides a pH monitoring and control system to optimize the Fenton reaction; treats energetic compounds in a controlled reactor; eliminates the need for GAC and concomitant regeneration and solid waste disposal; presents a small footprint when compared to conventional waste processors; suitable for use as a mobile system, to include trailer-mounting; eliminates a complex environmental monitoring system needed for both the process and resultant products (sludge, CO 2 , and clean water); achieves lower overall system capital and maintenance costs; achieves lower cost of final by-product disposal; monitors the process easier and at less cost; and requires a low skill level for system operation.
[0041] Compared to presently used methods, a preferred embodiment of the present invention replaces traditional GAC filtration while reducing the need for subsequent processing and regeneration of the GAC.
BRIEF DESCRIPTION OF DRAWINGS
[0042] FIG. 1 is a schematic of a system for accomplishing a method of the invention, presenting the sequential zero-valent metal reduction and Fenton oxidation process.
[0043] FIG. 2 is a graph presenting TNT reduction with zero-valent iron.
[0044] FIG. 3 is a graph presenting RDX reduction with zero-valent iron.
[0045] FIG. 4 is a graph presenting HMX reduction with zero-valent iron.
[0046] FIG. 5 presents the relationship for estimated concentrations of TNT vs. zero-valent metal column reactor length at various flow rates using the design equation in which the rate constant, k, is 0.0285 s −1 , the column inside diameter (ID) is 2.5 cm, and the porosity is 0.66.
[0047] FIG. 6 presents the relationship for estimated concentrations of RDX vs. zero-valent metal column reactor length at various flow rates using the design equation in which the rate constant, k, is 0.0185 s −1 , the column ID is 2.5 cm, and the porosity is 0.66.
DETAILED DESCRIPTION
[0048] Select embodiments of the present invention incorporate pre-filtration and a reduction and an oxidation reaction process seriatim. Pre-filtration employs filter media, such as fine sand, to filter solids. A zero-valent metal column reactor de-oxygenates the waste stream in a first process. The first process involves the use of a metal having an inherent reducing potential, typically elemental iron (Fe 0 ) available as scrap iron, while the second process facilitates the well-known Fenton reaction. The pre-filtration and first process may be accomplished in the same vessel. To enable re-use of any aqueous portion of the waste stream, a final “polishing” step may be employed to neutralize the effluent resultant from the second process (Fenton reaction).
[0049] A schematic diagram of a preferred embodiment of the present invention is illustrated in FIG. 1 . A waste stream containing energetics is provided via a pump 101 . The first treatment uses a pre-filter 102 A and a zero-valent metal column reactor 102 B. A pre-filter 102 A containing sand and zero-valent metal filters solids, such as particles of TNT, RDX, HMX, nitroglycerin (NG), and “de-oxygenates” the aqueous portion of the waste stream through a chemical reducing reaction facilitated by the zero-valent metal in the pre-filter 102 A and the zero-valent column reactor 102 B. The ratio of sand to metal is maintained at a level sufficient to treat the expected waste stream, with a typical value of 85% sand to 15% elemental iron. Next, the product from the pre-filter 102 A, i.e., filtered water containing energetic compounds, is reduced in the zero-valent column reactor 102 B. Both the pre-filter 102 A and the zero-valent metal column reactor 102 B are vented to prevent accumulation of hydrogen gas by providing a breather 109 at the top of the zero-valent column reactor 102 B.
[0050] The Fenton reaction reactor 103 uses iron released from a zero-valent column reactor 102 B as Fe +2 , together with injected hydrogen peroxide 105 , H 2 O 2 , to complete the remediation of the pinkwater and associated solid wastes. To optimize the reaction, provision is made for injection of an acid 111 , typically sulfuric acid, to maintain a sufficiently low pH of 2.0-3.0. Normally, the amount of Fe +2 generated in the zero-valent column reactor 102 B will be sufficient to carry the Fenton reaction. Should this not be the case, the same injection system used to provide the acid 111 may be used to supplement the Fenton reaction with additional metal. An impeller mixer 110 is provided in the Fenton reaction tank 103 to insure complete mixing and subsequent transformation of the energetic intermediates.
[0051] A settling tank 106 into which a strong base 107 , such as sodium hydroxide (NaOH), is mixed is provided to both neutralize the resultant product and to separate the aqueous part from the solids. This tank 106 is also monitored via a controller 104 to maintain optimum pH. The solids are removed as a benign sludge by a sludge pump 108 while the aqueous portion 112 is re-cycled as needed.
[0052] Scrap iron is an industrial waste material that is readily available and relatively inexpensive. A sand and iron pre-filter 102 A, with an inherently long service life, facilitates a passive process that requires little maintenance or regeneration, requiring only a pump 101 to draw the waste stream into it. Degradation of zero-valent iron does not generate toxic by-products. The reduction products of the energetics may be of concern, however. The subsequent Fenton oxidation process, fully oxidizing the reduction products to benign constituents such as CO2, water, and benign inorganic compounds, breaks down these products.
[0053] It may be difficult for Fenton's reagent alone to oxidize energetics due to their highly oxidized nature. This is addressed uniquely in select embodiments of the present invention by using a combination of a pre-filter 102 A and a zero-valent metal column reactor 102 B to reduce the explosives to products that are much more amenable to processing using the Fenton reaction. Yet another advantage of a preferred embodiment of the present invention is the use of the Fe +2 (a degradation by-product of the pre-treatment process) in the subsequent Fenton reactor 103 , thereby reducing the need for supplying commercial ferrous additives.
[0054] Selective embodiments of a process using this innovative treatment system specifically remove and “mineralize” TNT and heterocyclic nitramines (RDX and HMX) from pinkwater.
[0055] The U.S. Army Engineer Research and Development Center (ERDC) in cooperation with the University of Delaware conducted bench scale tests on the processes of the instant invention. Refer to FIGS. 2-4 for results of TNT, RDX and HMX reduction experiments conducted on bench scale reactors using these commonly available materials: sand and scrap iron in a pre-filter 102 A, scrap iron in a zero-valent column reactor 102 B, hydrogen peroxide and sulfuric acid added to a first vessel comprising the Fenton reactor 103 , and sodium hydroxide to base-neutralize the resultant acidic waste stream in a second vessel. The majority of TNT ( FIG. 2 ) in solution was removed within 30 minutes. Similarly, RDX ( FIG. 3 ) and HMX ( FIG. 4 ) in solution were completely removed within 30 minutes.
[0056] Refer to FIGS. 5 and 6 . Preliminary experiments using a glass column of 2.5 cm diameter filled with scrap iron rapidly reduced TNT ( FIG. 5 ) and RDX ( FIG. 6 ). Results from the column study show that the concentrations of TNT and RDX in column effluent can be predicted using the advection-dispersion-reaction equation:
∂ C A ∂ t = D L ∂ 2 C A ∂ x 2 - u ∂ C A ∂ x - kC A ( 1 )
where C a is the concentration of the contaminant in the aqueous phase; t is time; D L is the longitudinal dispersion coefficient, x is the coordinate in the flow direction; μ is mean interstitial water velocity and k is a constant selected for a class of contaminants.
[0057] To evaluate whether the metal pre-treatment in the pre-filter and zero-valent metal column reactor 102 B will enhance the subsequent Fenton oxidation process, experiments were carried out to study mineralization of the reduction products of the explosive compounds by Fenton's reagent (H 2 O 2 and Fe ′2 ). A five-fold increase was observed in mineralization of TNT due to Fe(0) pre-treatment. In another study, H 2 O 2 (40 mM) was added to effluent from a zero-valent column reactor 102 B, which received a wastewater containing TNT and RDX. No TNT or RDX was detected in the effluent, indicating that TNT and RDX were completely reduced to TAT and the ring cleavage products of RDX, respectively. Subsequent H 2 O 2 addition mineralized 50% of TAT and greater than 95% of RDX reduction products within 100 minutes.
[0058] Refer to FIG. 1 . A pump 101 provides the waste to a system 100 for accomplishing a process representing a preferred embodiment of the present invention. The system 100 uses a unit 102 that incorporates a pre-filter 102 A containing filter media and zero-valent metal for filtration of solids and de-oxygenation of the wastewater stream and a zero-valent metal column reactor 102 B to reduce the highly oxidized state of the energetics in the waste stream; a Fenton reaction vessel 103 to which a strong oxidizer, typically hydrogen peroxide, is added to mineralize the metal-treated energetics in the waste stream; a mix control system 104 ; a supply 105 of oxidizer; a neutralization and sedimentation tank 106 ; and a source 107 of a strong base. The waste stream may be fed to the Fenton reaction vessel 103 via gravity feed. Likewise, the clean water from the neutralization and sedimentation tank 106 may be gravity fed to a holding tank, or the like. A sludge pump 108 is an option for removing sediment from the neutralization and sedimentation tank 106 for further disposal.
EXAMPLE
[0059] A pump 101 supplies a waste stream, e.g., pinkwater, to the bottom of a pre-filter 102 A containing a mixture of sand and zero-valent iron in a ratio of 15:85. The iron de-oxygenates the pinkwater as the iron transforms from Fe 0 to Fe +2 , and the sand filters colloidal and suspended particles from the pinkwater. The pre-filter 102 A may be provided in the form of a disposable cartridge, or be an adapted sand filter available from swimming pool supply companies.
[0060] As the pinkwater flows upwards through the zero-valent metal column reactor 102 B, the energetics contained therein are reduced quickly by the zero-valent iron. For example, TNT is reduced to triaminotoluene (TAT) and RDX and HMX are reduced to ring-cleavage products. The effluent, which carries the reduction products and corrosion by-products, such as the ferrous ion (Fe +2 ), then exits from the top of the column 102 B and flows to the Fenton reaction vessel 103 by gravity. A gas vent 109 is located at the top of the column 102 B to release any hydrogen gas generated from the anaerobic reduction process.
[0061] The Fenton oxidation process takes place in a Fenton reaction vessel 103 that in one configuration is a completely stirred tank reactor (CSTR) 103 that uses an externally powered mixing paddle 110 . To the CSTR 103 , a hydrogen peroxide solution is added continually to produce “Fenton's reagent” (i.e., hydrogen peroxide (H 2 O 2 ) plus Fe +2 ). In the presence of Fe +2 , hydrogen peroxide decomposes to form the hydroxyl radical (OH − ), a very strong oxidizing agent, with E o =+2.33V, that quickly oxidizes the reduction products of the energetics to stable end products such as carbon dioxide, water, and a nitrate. For the Fenton reaction to occur optimally, the pH in the CSTR 103 is maintained within a range of 2.0-3.0 using a mix control system 104 (e.g., pH meter, recorder, and automated controller) to add the necessary pH reducer, such as a sulfuric acid solution (H 2 SO 4 ), from an acid source 111 . The contents of the CSTR 103 are continuously stirred with one or more mixing paddles 110 , such as those used with impeller mixers. Under normal operation, addition of iron to the CSTR 103 is not required. However, should the need arise, iron, as a ferrous ion (Fe +2 ), may be injected in the same manner as the acid.
[0062] The treated effluent from the CSTR 103 flows into a neutralization and sedimentation tank 106 by gravity, where it is pH-neutralized by adding a base, such as sodium hydroxide (NaOH), from a supply tank 107 or other source. By bringing the pH to a neutral value in the range of 6.0-8.0, a sludge containing a ferric hydroxide is formed from precipitation of the ferric ion. The sludge is collected and removed at the bottom of the neutralization and sedimentation tank 106 via a sludge pump 108 . The treated water 112 exits the top of the neutralization and sedimentation tank 106 and may be re-used.
[0063] Although a preferred embodiment of the present invention focuses on pinkwater treatment, any waste containing energetic compounds (explosives, propellants, and other pyrotechnic compounds) may be treated efficiently by this method. For example, waste generated from demilitarization activities; air scrubber fluids or solutions containing energetic compounds; clean-up site lagoon water containing energetic compounds; and ground water contaminated with energetics that is pumped to the surface for treatment.
[0064] Although specific functions for this system and method have been described, other functions using the described apparatus and method are not excluded from falling within the ambit of the claims herein.
[0065] The abstract is provided to comply with the rules requiring an abstract, which will allow a searcher to quickly ascertain the subject matter of the technical disclosure of any patent issued from this 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). Any advantages and benefits described may not apply to all embodiments of the invention. | A waste stream is treated in a pre-filter having media, preferably sand, connected below a zero-valent metal column reactor incorporating a metal with reducing potential, preferably elemental iron (Fe 0 ); the combination preferably configured as a single unit. The waste stream is pumped through the pre-filter to trap solids and deoxygenate it, then enters the reactor and is subjected to a reducing process. Most of the Fe 0 is transformed to the ferrous ion (Fe +2 ), mixed with the reduced product, and fed to a continuous stirred tank reactor (CSTR) in which Fenton oxidation occurs. The output is then sent to a sedimentation tank and pH-neutralized using a strong base such as sodium hydroxide (NaOH). The aqueous portion is drawn off and the sludge pumped from the sedimentation tank. The system is monitored and controlled to optimize required additives, while monitoring of pressure drop across the pre-filter and column reactor establishes replacement requirements. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation from U.S. patent application Ser. No. 14/191,591, filed on Feb. 27, 2014, and entitled METHOD AND APPARATUS OF APPLYING CALL SUPPRESSION MEASURES TO RESTRICT PHONE CALLS, which is a continuation from U.S. patent application Ser. No. 13/329,812, filed on Dec. 19, 2011, now issued U.S. Pat. No. 8,681,967, and entitled METHOD AND APPARATUS OF APPLYING CALL SUPPRESSION MEASURES TO RESTRICT PHONE CALLS, each of which is incorporated by reference herein in their entirety.
TECHNICAL FIELD OF THE INVENTION
This invention relates to a method and apparatus of restricting undesired phone calls to an end user, and in particular, to providing a phone system that automatically applies rules and regulations to a telephone network to regulate the times, frequency and/or source of telephone calls to the end user.
BACKGROUND OF THE INVENTION
Users may be called by business organizations at any time on their home phone, mobile phone or even their office telephone. Generally, the calls received by any individual user may be from a business or organization that the user has no desire to contact. The calls may be soliciting services or charities of which the user is not interested in participating or offering money to support.
Various state and Federal government laws, rules and regulations offer users privacy from unwanted calls. However, those laws may be difficult to enforce and violations may be even more difficult to report. Current phone systems are not equipped with options to automatically apply state and Federal rules with regard to limits on the hours, days and times that solicitations are made to the user. Business organization may have no desire to violate the terms of these government rules and regulations. However, keeping track of the dates, times and localities being called on any given day may be difficult.
SUMMARY OF THE INVENTION
One embodiment of the present invention may include a method of determining whether to perform telephone call blocking. The method may include initiating a telephone call from a call server, determining whether the call is a solicitation call, and determining the area code of the call and performing a lookup operation of the area code in a call suppression database. The method may also provide retrieving at least one call block entry for a current day from the call suppression database, and comparing the area code to the at least one call block entry for the current day to determine whether the call should be blocked.
Another example embodiment of the present invention may include an apparatus configured to determine whether to perform telephone call blocking. The apparatus may include a transmitter configured to transmit a telephone call. The apparatus may also include a processor configured to determine whether the call is a solicitation call, determine the area code of the call and perform a lookup operation of the area code in a call suppression database, and retrieve at least one call block entry for a current day from the call suppression database. The processor is also configured to compare the area code to the at least one call block entry for the current day to determine whether the call should be blocked.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an example call suppression communication system according to example embodiments of the present invention.
FIGS. 2A and 2B illustrate example call suppression graphical user interfaces according to example embodiments of the present invention.
FIGS. 3A and 3B illustrate yet another example call suppression graphical user interface according to example embodiments of the present invention.
FIGS. 3C and 3D illustrate an editable date suppression graphical user interface according to example embodiments of the present invention.
FIGS. 3E and 3F illustrate another editable date suppression graphical user interface according to example embodiments of the present invention
FIG. 4 illustrates a flow diagram of an example method according to example embodiments of the present invention.
FIG. 5 illustrates another flow diagram of an example method according to example embodiments of the present invention.
FIG. 6 illustrates an example graphical user interface of a call regulation system according to example embodiments of the present invention.
FIG. 7 illustrates a database logic diagram illustrating the logical relationships between the various entities.
FIG. 8 illustrates a network entity that may include memory, software code and other computer processing hardware, according to example embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of a method, apparatus, and system, as represented in the attached figures, is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention.
The features, structures, or characteristics of the invention described throughout this specification may be combined in any suitable manner in one or more embodiments. For example, the usage of the phrases “example embodiments”, “some embodiments”, or other similar language, throughout this specification refers to the fact that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the present invention. Thus, appearances of the phrases “example embodiments”, “in some embodiments”, “in other embodiments”, or other similar language, throughout this specification do not necessarily all refer to the same group of embodiments, and the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
In addition, while the term “message” has been used in the description of embodiments of the present invention, the invention may be applied to many types of network data, such as packet, frame, datagram, etc. For purposes of this invention, the term “message” also includes packet, frame, datagram, and any equivalents thereof. Furthermore, while certain types of messages and signaling are depicted in exemplary embodiments of the invention, the invention is not limited to a certain type of message, and the invention is not limited to a certain type of signaling.
FIG. 1 illustrates a telephone communication regulation system according to example embodiments of the present invention. Referring to FIG. 1 , the telephone communication system may be regulated on the side of the business organization 102 to provide an automated call dialing regulator based on local, state and/or federal regulations. The regulations may be stored in a telephony regulation database 104 . In this example, the business organization 102 includes a telephony server used to provide dialing features for the telemarketers 108 to dial-out to the end users (private residences 110 A, 110 B and 110 C). The telemarketers 108 are also in communication with a text messaging engine server 103 which communicates over a public land mobile network (PLMN) 105 . A regulation database 104 provides a record of the various different regulations corresponding to the various different demographics. A regulation service 107 provides an engine to communicate those regulations to the call and text message initiation platforms 106 and 103 , respectively.
The regulations of each of the three respective private residences 110 A, 110 B and 110 C may be based on Federal, state and local government laws and regulations. As may be observed from FIG. 1A , each of the three example private residences are located in different states across the United States. Each of the private residences is located in a geographically unique area that may be identified by a zip code, area code, postal code, etc., each of which may be used by the telephony regulation database 104 to distinguish certain regulations from one another. For example, the telephony regulation database may organize regulations by state, zip code and/or area code. Such regulations may be regularly updated and downloaded to the database 104 for cross-referencing by the telephony server 106 when attempting to dial a particular user located in a particular geographical area.
Phone calls originated from the telephony server 106 may be automatically selected from a spreadsheet of end users' telephone numbers. Once the call is dialed, the call in progress may be handed over to a telemarketer 108 automatically via a call distribution scheme handled by the telephony server 106 . The call may be routed to the public switched telephone network (PSTN) 108 , which routes the call to its intended destination. The business organization 102 may be responsible for regulating its own phone calling procedures and may require a call regulation system to be adapted to its internal calling infrastructure. Alternatively, the call dialing may be performed with the assistance of a third party calling service that matches individual end users or call destinations to the geographical regulations that are enacted within the end users' locations.
The regulation service 107 may provide regulation information to the calling and text messaging platforms. For instance, the regulation service 107 may be utilized by the telephony server 106 and/or text messaging server 103 , which are responsible for sending notifications to the intended recipients. For example, the regulation service 107 may provide a list of zones that are eligible for a regulation to be applied, a list of zone types. (Federal, State, Area Code, etc.), a list of channels (delivery methods) that are eligible for a regulation block to be applied, a listing of all active one time regulation blocks for a given date and time, a listing of all active reoccurring regulation blocks for a given date and time, a listing of active one time regulation blocks that are currently in effect based on the start and end times for the regulation, adjusted for the local time zone and broken down by area code, the most granular zone type available, a listing of active reoccurring regulation blocks that are currently in effect, adjusted for the local time zone and broken down by area code, the most granular zone type available. Any regulations with an ‘allowed window’ are not included. Other features of the regulation service 107 may allow the deactivation of existing one time and reoccurring regulations, a way to create a new one time block or reoccurring regulation blocks for a given zone and channel, and a way to log notifications that have been blocked due to the existence of a specific one time or reoccurring regulation.
FIG. 2A illustrates an example graphical user interface (GUI) application used to initiate a call suppression procedure, according to example embodiments. Referring to FIG. 2A , a window 200 provides a user with a view of the basic call suppression setup for a statewide selection procedure. For example, certain states with stringent regulations that are not cohesive to the business organizations interests or communication procedures may be selected in a state exclusion window 202 . Other states that are desirable for call solicitation purposes may be included in a state inclusion window 204 . A particular date 206 may be added as day that calls will be suppressed or not allowed for any of the selected states. A note section 208 may provide a place to comment about the suppression date, and a result section 210 may summarize the actions performed by the call administrator setting up the call regulation system.
FIG. 2B illustrates another example graphical user interface (GUI) application used to initiate a call suppression procedure, according to example embodiments. Referring to FIG. 2B , a window 220 provides a user with another view of the basic call suppression setup for a statewide selection procedure. A particular day(s) of the week 222 may be selected as a day that receives reoccurring call suppression. Similar to FIG. 2A , the excluded states 226 and included states 224 may be setup manually by the administrator. A day of the week suppression menu 228 may offer an easy way to select the day(s) of the week that calls should be suppressed. In addition an hourly schedule 230 may be setup to provide a time-frame during which calls may be processed and dialed to the selected states on the allowed days. Multiple day suppressions for one or more states may be added at one time. If “allow calling hours” is unchecked, when the user selects the save button, the call suppression will be in effect the entire day from 12:00:00 AM to 11:59:59 PM.
FIG. 3A illustrates a GUI 300 used to inform the user of a call suppression conflict with a previously selected call suppression schedule, according to example embodiments. When such a scheduling conflict is presented, the user may accept the overriding new schedule or cancel and revert back to the previous call suppression schedule.
FIG. 3B illustrates a call solicitation suppression schedule 310 . The schedule may have been previously setup and modified to include additional holidays or days of the week when calls should be suppressed. In menu 310 , the user may be able to view values for existing call date suppressions. Fields, such as zone 311 , zone type 312 , date 313 , day of week 314 , status 315 , note 316 and actions 317 correspond to each call suppression entry. The zone entry 311 will display the state name and may also include the zip code and area code. The zone type 312 displays the type of zone, such as state, zip code, area code, federal zone, etc. The action column 317 will display a link to edit the record or remove the record from the list.
The user may be able to sort and filter each column except for the actions column 317 , which provides options to remove or edit the existing call suppression entry. Selecting the remove option will delete the entry from the database 104 . If a record is active, within 15 minutes of removing the record, the system will acknowledge removal of the suppression. Selecting the edit action will open the screen shown in FIGS. 3C and/or 3 D. If the status of a date suppression record is ‘complete’, the user will not be able to edit or remove the record. If the status of a date suppression record is ‘pending’, the user will not be able to edit the record.
FIGS. 3C and 3D illustrate an editable date suppression graphical user interface according to example embodiments of the present invention. Referring to FIG. 3C , date suppression menu 320 provides a particular zone which has been selected “Louisiana” corresponding to a particular date 322 that a call suppression is supposed to be enacted. In FIG. 3D , the menu 330 provides feedback 332 from the system that a call suppression schedule is already in existence for the selected zone and date. The save button on the edit date suppression menu 330 will remain inactive until a valid date and note is entered into the screen.
FIGS. 3E and 3F illustrate another editable date suppression graphical user interface according to example embodiments of the present invention. Referring to FIG. 3E , a menu option 340 provides feedback 342 that a date may be selected that is equal to or greater than today, to guide the user to select an appropriate date that may be accepted by the date suppression schedule. FIG. 3F illustrates further details of the existing call suppression entries 350 . These entries are similar to those illustrated in FIG. 3B , however, additional entries, such as start time 351 and stop time 352 may be used to create a window of time when call suppressions may be active or inactive.
FIG. 4 illustrates a flow diagram of an example method according to example embodiments of the present invention. The call suppression system of the business organization 102 may follow a particular logic or method of operation when determining whether a call should be suppressed or routed. For example, a call may be initiated at operation 402 . The call may be designated as a solicitation type of call at operation 404 . If the call is not a solicitation, it may be routed without delay at operation 418 . If the call is a solicitation, the area code of the call may be looked up at operation 406 . Next, a determination may be made as to whether a current call block is in place for today at operation 408 . In this operation, the telephony regulation database 104 may be accessed by the telephony server 106 to view the call blocks that are scheduled for the current day.
If the call block does exist, the current area code of the call will be matched against the existing call block entry at operation 420 . If the current area code of the call is part of the blocked entries, then the result will be marked as a “regulation block” at operation 422 , which flags the call as “not routed.” Alternatively, if there is no call block present for the current day, or the call block does not prevent the call from being routed, an additional regulation may be checked, such as whether the call is violating a Federal calling window regulation (e.g., no calls allowed 9 PM through 8 AM, etc.), at operation 410 . If the Federal window is being violated, the call may be marked as a “regulation block” at operation 412 . If the Federal window is not being violated, then state laws may be checked by mapping the area code of the call to the particular state at operation 414 . If a state regulation does exist, the state's calling window may be checked at operation 416 , and if it is not in violation the call may be routed at operation 418 .
FIG. 5 illustrates another flow diagram of an example method according to example embodiments of the present invention. Referring to FIG. 5 , when a call is placed, the call area code is referenced at operation 502 to determine whether a call block is active at operation 504 . If so, the current time corresponding to the area code's location is determined and that local time is used as a basis to determine whether a block is present at operation 506 . If so, the call is marked as a regulation block in the database 104 and a response message is generated based on the time, location and date referenced from the database 104 at operation 508 .
FIG. 6 illustrates an example graphical user interface of a call regulation system according to example embodiments of the present invention. Referring to FIG. 6 , the interface 600 provides support for various different compliance tools, which are accessed through a centralized interface. The interface provides a way to enables the call processing platform to block solicitation-based communications driven by continually evolving Federal and State regulations.
Through the interface 600 , compliance leaders who monitor the dynamic regulatory environments that impact business-to-consumer communications (e.g., FTC, FCC, HIPAA, and State Regulations) have the capability to initiate global and state-specific call blocking rules, including the ability to apply specific dates, recurring days, and time blocking settings for specific hours in a day.
An input interface 602 included in the top section of the user interface 600 provides the capability to select the specific states that will be included in the suppression. The central portion 604 of the user interface focuses on the specific dates or days of the week that will be evaluated for the blocked timeframe as well as notes regarding the reason for the regulation. The lower section 606 summarizes the blocks that have been added and the active call filters and regulations that are presently active.
Storage of the criteria input is housed in the regulation database. From these settings, the platform evaluates the communication delivery times based on the time zone of the message recipients to determine when calls can be placed based on the configuration settings specified by the conditions for —each regulation.
FIG. 7 illustrates a logic diagram of the database entity relationship diagram. Referring to FIG. 7 , a ‘BlockingZoneTypes’ entity is configured to store the categories under which ‘BlockingZones’ 704 can be categorized. This is generally used to denote the scope in area for which a regulation block is intended. Examples of ‘BlockingZoneType’ entries include Federal, State, Area Code, etc. ‘BlockingZones’ 704 contains all of the zones that are available to be associated with a particular regulation. Examples include Federal, Alabama, Florida, 205 , 251 , 850 , etc. ‘BlockingChannels’ 712 provides a listing of the delivery method affected by a regulation (e.g., voice calls and text messages).
‘BlockingByDates’ 702 stores regulations where the scope of the regulation is to be in effect one particular time. These regulations are associated with specific channels and zones and are in effect for the date range stored in the table. Once a regulation has been entered, it cannot be deleted or modified, only deactivated. The date and user associated with the regulation's entry is also stored.
‘BlockingByDateLogs’ 708 stores a history of voice calls that have been blocked due to a one time regulation. ‘BlockingByDOW’ 706 collects regulations where the scope of the regulation is reoccurring for a zone and channel for a specific day of the week. The ‘AllowStartTime’ and ‘AllowEndTime’ fields of 706 provide for exceptions of a daily reoccurring regulation for a portion of the day. For example, all calls to Louisiana are blocked on Sundays with the exception of the hours of 9:00 AM to 5:00 PM. Once a regulation has been entered, it cannot be deleted or modified, only deactivated. The date and user associated with the regulation's entry is also stored. The ‘BlockingByDOWLogs’ entity 714 stores a history of voice calls that have been blocked due to a reoccurring regulation.
The operations of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a computer program executed by a processor, or in a combination of the two. A computer program may be embodied on a computer readable medium, such as a storage medium. For example, a computer program may reside in random access memory (“RAM”), flash memory, read-only memory (“ROM”), erasable programmable read-only memory (“EPROM”), electrically erasable programmable read-only memory (“EEPROM”), registers, hard disk, a removable disk, a compact disk read-only memory (“CD-ROM”), or any other form of storage medium known in the art.
An exemplary storage medium may be coupled to the processor such that the processor may read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an application specific integrated circuit (“ASIC”). In the alternative, the processor and the storage medium may reside as discrete components. For example FIG. 8 illustrates an example network element 800 , which may represent any of the above-described network components of FIG. 1 .
As illustrated in FIG. 8 , a memory 810 and a processor 820 may be discrete components of the network entity 800 that are used to execute an application or set of operations. The application may be coded in software in a computer language understood by the processor 820 , and stored in a computer readable medium, such as, the memory 810 . Furthermore, a software module 830 may be another discrete entity that is part of the network entity 800 , and which contains software instructions that may be executed by the processor 820 . In addition to the above noted components of the network entity 800 , the network entity 800 may also have a transmitter and receiver pair configured to receive and transmit communication signals (not shown).
One example embodiment of the present invention may include a method of
While preferred embodiments of the present invention have been described, it is to be understood that the embodiments described are illustrative only and the scope of the invention is to be defined solely by the appended claims when considered with a full range of equivalents and modifications (e.g., protocols, hardware devices, software platforms etc.) thereto. | A determination of whether to perform telephone call blocking includes initiating a telephone call from a call server, determining whether the call is a solicitation call and determining the area code of the call and performing a lookup operation of the area code in a call suppression database. The process may also include retrieving a call block entry for a current day from the call suppression database, and comparing the area code to the call block entry for the current day to determine whether the call should be blocked. | 7 |
RELATIONSHIP TO PRIOR APPLICATION
This application is based upon and claims priority from the U.S. Provisional Patent Application number 61311873 filed Mar. 9, 2010 which is incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to an intermedullary device for the stabilization of osseous matter for the purpose of improved healing and mobility during healing.
BACKGROUND
Typically, an intramedullary nail is placed into the intramedullary cavity of physically compromised osseous material in order to maintain proper alignment of the material for optimal healing. The intramedullary nail is then secured by screws to allow support of the bone so that the patient can use the appendage during healing. Previous intramedullary nails had holes on both the distal and proximal ends for the insertion of fixtures, such as screws, that go through the intramedullary hardware and compromised osseous material. The holes that are closest to the point of nail insertion are called the “proximal” holes and those furthest away are the “distal” holes. The most commonly used system for securing an intramedullary nail uses an external guide or jig to find the proximal holes in the nail. With the assistance of the external guide or jig, the surgeon then drills through all of the tissue surrounding the bone and into the bone. For minimal damage and maximal healing, the fixture holes that are drilled into the leg and the bone must precisely align with the insertion holes in the intramedullary hardware so that the hardware can be secured with respect to the medullary canal.
Various types of external guides and jigs have been proposed to assist in the insertion of intramedullary hardware, such as shown in U.S. Pat. No. 4,733,654 A1 to Marino and U.S. Pat. No. 5,776,194 A1 to Mikol et al. Such external guides and jigs may be temporarily attached to the proximal end of the intramedullary nail to help align the bone fixtures and/or the drill to the receiving opening in the intramedullary nail. While such external guides and jigs are helpful to achieve proper alignment, their accuracy decreases they proceed from the proximal end to the distal end of the intramedullary nail. Additional solutions are needed, especially for attaching the distal end of the intramedullary nail to a distal osseous material fragment.
There are currently no effective external systems for finding the distal holes of an intramedullary nail. As mentioned above, guides for the distal hole become less reliable as distance from the proximal end of the intramedullary nail increases, particularly if any bending of the intramedullary nail has occurred. A commonly used procedure involves repeated x-raying of the patient to find the hole and then drilling through the leg into the bone. Another method for securing the distal end of the intramedullary nail is to drill the receiving opening into the intramedullary nail only after the intramedullary nail is placed into the bone, as disclosed in U.S. Pat. No. 5,057,110 A1 to Kranz et al. Bioresorbable materials, however, are not as strong as metals, leading to an intramedullary nail that is weaker than desired and has a weaker attachment than desired.
Continuing, additional problems occur with intramedullary nails using bioresorbable materials due to the healing requirements of a bone with respect to the strength and rigidity of the intramedullary nail. U.S. Pat. No. 4,756,307 A1 to Crowninshield and U.S. Pat. No. 4,338,926 A1 to Kummer et al. disclose an intramedullary nail with bioresorbable portions to weaken the nail relative to the bone over time. These intramedullary nails, however, forsake the use of a transverse bone fastener to achieve the benefit of the bioresorbable portions.
Finally, while most intramedullary nails remain in the patient's leg throughout their lifetime, the nail does occasionally need to be removed due to complications. The complications usually arise from the presence of the screws holding the nail in place. When the removal of the nail is necessary the physician must repeat the insertion procedure to find the location of the screws and drill into the leg again.
It would thus be advantageous to provide an intramedullary nail and related portions and/or components that overcomes the above-noted shortcomings.
SUMMARY OF THE INVENTION
The proposed invention solves the difficulty of the labor and time intensive process of securing an intramedullary nail within the intramedullary cavity of a bone by external screwing and drilling. The proposed invention engenders an anchoring mechanism located within the intramedullary nail to engage the cortical bone. In this way, the labor and time requirements related to securing an intramedullary nail within the intramedullary cavity are substantially reduced. Additionally, the invention achieves the advantage of reduced radiological exposure to patients and medical personnel, and reduced scarring for the patient. Use of the proposed invention is not limited to fractures of the length of the long bone, but could also be used in fractures of the ball from the rest of the long bone or for smaller bones.
Exemplary embodiments are provided, these embodiments are not to be interpreted as limitations upon the invention. In one embodiment, the bone-securing device comprises a intramedullary nail, open on both ends, having at least one or more engaging elements. The intramedullary nail may be inserted into the intramedullary cavity of a bone such that the intramedullary nail is secured within the intramedullary cavity on one or both sides of a fracture, thereby aligning the fractured bone fragments, thus allowing the promotion of healing and the formation of a new center portion from and between the splintered parts.
The invention also relates more particularly to engaging elements that are attached to the wall of intramedullary nail. The engaging elements may be attached to the intramedullary nail by, but not limited to, being cut from the material of the wall of the intramedullary nail. Attachment of the engaging elements to the nail itself allows for greater stability than prior internal anchoring devices. After the intramedullary nail is placed into the intramedullary cavity of the bone, the engaging elements are engendered to engage the surrounding cortical bone tissue. The engaging elements are preferably located at the distal end of the intramedullary nail's insertion point, but there may be a plurality of engaging elements along the length of the intramedullary nail, including at the proximal end. In some embodiments, the end of the intramedullary nail proximal to its insertion point will have openings located on its walls instead of engaging elements. These openings on the proximal end would allow for the insertion of external screws. The intramedullary nail would be compatible with an external guide to allow for the discovery of any screw holes from outside the bone.
In this invention, the engaging elements are attached to the wall of the intramedullary nail. In the preferred embodiment, the engaging elements are cut directly from the wall of the intramedullary nail so that they are integral to the intramedullary nail. In some embodiments, the materials of the intramedullary nail and that of the engaging elements are different. This may be achieved, for example, at the casting by combining the materials when the intramedullary nail is cast or they may be combined after casting, for example using a dovetail design. In the preferred embodiment, the engaging elements are curved and the tips are self-tapping to facilitate engagement with bone tissue.
The engaging elements are pushed outward by a mechanism internal to the intramedullary nail. This internal mechanism comprises a threaded flexible rod and a driver that fits within the hollow section of the intramedullary nail. The driver is located on the flexible rod and can either move along the length of the flexible rod or is secured to the flexible rod. This driver shifts position to engender the movement of the engaging elements.
In one embodiment, the internal, hollow portion of the intramedullary nail is threaded to allow for a controlled movement of the flexible rod. In this embodiment, the driver is bound to the flexible rod such that it moves upwards as the flexible rod screws upwards along the threaded portion of the intramedullary nail. The driver moves with the flexible rod longitudinally along the length of the intramedullary nail and pushes out the engaging elements as it passes through the center of the intramedullary nail.
In another embodiment, the internal flexible rod rotates in the intramedullary nail without moving longitudinally. In this embodiment, the driver is not secured in place on the rotating flexible rod, but may move along the surface of the flexible rod as the flexible rod turns. In this embodiment, the rotating flexible rod drives the driver into the space between or amongst the engaging elements. In turn, the driver pushes the engaging elements outward relative to the outer surface of the intramedullary nail. In either embodiment, the driver may remain in place between or amongst the engaging elements allowing for improved engagement properties of the engaging elements.
In another embodiment, the driver is bound to the flexible rod such that it turns with the flexible rod and is already amongst the engaging elements. The driver is shaped such that it initially allows the engaging elements to remain unengaged. Turning the flexible rod a single or partial turn engenders the driver to exert pressure on the engaging elements so that they engage the bone.
In the preferred embodiment of the invention, the distal end of the intramedullary nail is open and internally constructed to catch bone marrow as the intramedullary nail is driven into the intramedullary cavity of the bone. This internal construction involves a narrowing and curving of the inner portion of distal end such that a concave face is proffered toward any marrow entering the hollow portion of the tube. This catching of the marrow prevents the marrow from clogging any internal structures of the intramedullary nail.
In the preferred embodiment of the intramedullary nail, the intramedullary nail, the engaging elements, the flexible rod and driver(s) are independently composed of titanium alloy, cobalt chromium, stainless steel or other compounds having similar structural properties.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front and side view of possible construction of the intramedullary nail with close up of the mechanism of the preferred embodiment
FIG. 2 is a view of a possible construction of the intramedullary nail with a handheld power device inserted and the anchors extended
FIG. 3 is the internal structure of the intramedullary nail before the driver engages the anchors
FIG. 4 the internal structure of the intramedullary nail after the driver has engaged the anchors
DETAILED DESCRIPTION OF THE INVENTION
The intramedullary nail may be placed into a long bone by cutting the outer tissue, drilling into the bone and reaming out the intramedullary space to facilitate the insertion of the intramedullary nail. A guide wire may be sent into the intramedullary space, the intramedullary nail inserted onto the guide wire, and then the intramedullary nail hammered securely into the intramedullary space so that it traverses a broken or weak point in the bone.
Referring to the FIG. 1 , the intramedullary nail 100 may be bent or straight to match the structure of the intended bone. FIG. 1B is a side view of nail 100 in FIG. 1A . The nail 100 has a proximal end 102 closer to the point of insertion and a distal end 104 further from the point of insertion. The proximal end 102 may have holes 106 for the insertion of external screws (not shown) as demonstrated by FIG. 1C . The hole 106 may be circular or they may be compression holes 106 . FIG. 1D shows an example of the distal end 104 wherein anchors 108 are attached to the nail. The anchors 108 may be curved as shown in FIG. 1D . The anchors 108 are able to shift position so that the tips of the anchor extend out of the nail 100 and may engage external material. FIG. 1E shows a top view cross section of the distal end 104 with the anchors 108 partially extended out of the nail 100 . In the preferred embodiment, the anchors 108 are positioned fully within the nail 100 until an operator wishes to secure the distal end of the nail 100 within intramedullary space. As shown in FIG. 1D , the distal end 104 of the nail 100 may be open to allow a guide wire (not shown) to pass through the entire length of the nail 100 .
The anchors 108 are able to shift position so that their tips extend out of the nail 100 and engage the surrounding cortical bone. The anchors 108 in FIG. 1D have tips that are curved toward the distal end 104 , but the anchors 108 may also be attached to the nail 100 on the end of the anchor closer to the proximal end 102 of the nail 100 and the tip of the anchor 108 may be closer to the distal end 104 with the anchor 108 tip pointing toward the proximal end 102 . The anchors 108 may also be perpendicular to the nail 100 so that they would appear sideways to the position of the anchors 108 shown in FIG. 1D . The anchors 108 can take a variety of shapes.
FIG. 1F shows an example of a flexible rod 110 with a driver 112 attached. The driver 112 may be attached to the flexible rod 110 in a variety of ways. For example, the driver 112 may be secured to the flexible rod 110 so that they move in unison. In another example, the flexible rod 110 may be externally threaded and the driver 112 internally threaded such that the driver 112 can screw along the flexible rod 110 , thereby changing its position on the flexible rod 110 . Other configurations are easily produced by a person of ordinary skill in the art. The flexible rod 110 may extend completely through the driver 112 or the driver 112 may be positioned at the terminus of the flexible rod 110 . In the preferred embodiment, the flexible rod 110 is hollow to allow for the insertion of the guide wire. The driver 112 has a body 114 and a conical top 116 . The driver body 114 is structured to fit within the inside of the nail 100 , so that the driver 112 can move longitudinally through the nail 100 .
As demonstrated by FIG. 2 , in the inventive concept, the flexible rod 110 with the attached driver 112 is positioned within the nail 100 with the conical top 116 portion closer to the anchors 108 than the driver's body 114 . The driver 112 may be positioned between the anchors 108 and the proximal end 102 or the distal end 104 . In the example shown in FIG. 3 , the driver 112 is at the terminus of the flexible rod 110 between the anchors 108 and the distal end 104 . As shown in FIG. 3 , the anchors 108 are attached to the nail wall 200 and still within the nail 100 with the nail 100 pressed tightly against the intramedullary cavity wall 202 . In the inventive concept, the driver 112 moves between or amongst the anchors 108 and engendered them outward to engage the bone 202 . In the example shown in FIG. 2 , a handheld power device 204 , such as a riveting tool or similar device, may be used to pull the flexible rod 110 a particular distance toward the proximal end 102 . As shown in FIG. 3 , such an action will cause the driver 112 to move between or amongst the anchors 108 and push out the anchors 108 so that they engage the intramedullary cavity wall 202 . As reflected in FIG. 2 , so that the nail 100 is not dislodged by the force of the handheld power device 204 , the nail 100 may have a brace 206 at the top to secure the handheld power device 204 in relation to the nail 100 . The handheld power device 204 may also apply torque if the flexible rod 110 and driver 112 of FIG. 3 are externally and internally threaded, respectively. As displayed in FIG. 2 , if the handheld power device 204 applies torque, then the brace 206 would prevent the nail 100 and the handheld power device 204 from moving respective to one another.
The anchors 108 may be attached to the nail wall 200 by a living hinge. The anchor 108 may also have a space 208 for the attachment of a pin (not shown) that is secured to the nail wall 200 as shown in FIG. 3 . The anchors 108 may also be attached to the nail wall 200 by a wire ring 210 that is in communication with the nail wall 200 as shown in FIG. 4 .
After the driver 112 has been moved a particular distance by the force applied by the handheld power device 204 , the driver 112 remains between or amongst the anchors 108 to secure them in place. This creates a solid line of material through the width of the nail 100 and prevents the anchors 108 from falling back inside the nail 100 .
Once the driver is in place, it can be held in place by pressure from the anchors ( 108 ) that are wedged between the driver and the intramedullary cavity wall ( 202 ). The flexible rod ( 110 ) and driver ( 112 ) may also be kept from moving through a locking mechanism. Such a locking mechanism may include a screw that goes through the flexible rod ( 110 ) or a clamp that holds the flexible rod ( 110 ) in place.
If the nail 100 needs to be removed, the handheld power device 204 is again applied and the driver 112 moves further along the length of the nail 100 . The driver 112 then pushes on the internal ends of the anchors 108 and pushes them back against the inside nail wall 200 . This pulls the tip of the anchor 108 out of the bone 202 so that the nail 100 may be removed.
The nail 100 may be manufactured by separately producing the proximal end 102 and the distal end 104 and joining the two ends together. In one manufacturing method, slots may be cut from the tubular sheath using a mill. The driver 112 , secured to the flexible rod 110 , may be inserted and positioned in the nail 100 . Then anchors 108 , which may also be made using a mill, are inserted into the slots in the nail 100 . These anchors 108 may be secured by pins (not shown) that go through spaces 208 in the anchors 108 or by a ring 210 . If a ring 210 is used, the ring 210 may be flexible enough to allow for bending while inserting into the nail 100 , but resilient enough that it regains its shape when in position in the nail 100 .
In an alternative manufacturing process, the nail 100 may be produced by methods currently known in the art, for example casting. Before cooling, the flexible rod 110 and driver 112 are inserted into the hollow portion of the nail 100 . Also, before cooling, the nail 100 is laser etched with tabs outlining the desired structure of the anchors 108 . Then the profile of the anchors 108 is stamped into the tabs using a mandrel. This may create a living hinge for the anchors 108 . A mandrel may also be used to stamp a rib into the wall of the nail 100 . This rib would allow for the placement of a flexible ring 210 if the anchors 108 are held in place by a ring 210 . Lastly, one may manufacture the nail 100 by fabricating the dynamic portion of the nail containing the anchors 208 separately then subsequently enjoining the dynamic portion with the remainder of the nail. For example, such enjoining may be accomplished by welding, threading an end of the dynamic portion and the remainder of the nail and screwing them together thereby engendering a connection of the two portions, or other such means providing comparable structural integrity. | An intramedullary nail comprising an outer tubular sheath, a flexible rod and a driver element mobile within the sheath longitudinally with an engagement element formed out of the wall of the tubular sheath. After the nail has been inserted, distal end first, into the intramedullary cavity, the flexible rod is pulled, thereby engendering the driver element to advance the engagement element into the cortical bone, thus keeping the intramedullary nail in position within the intramedullary cavity. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
During the production of hydrocarbons, such as crude oil and/or natural gas from a subterranean reservoir, it is necessary to closely regulate and control the flow of the well effluent. The latter normally is comprised of crude oil, water and gas in varying amounts. Close regulation of the well's operation is essential, not only to preserve the flow of product, but to do so in a manner to assure that the environment is protected and that the operation does not constitute a prospective safety hazard to personnel or to equipment.
Some offshore wells, when they reach the producing stage, are operated and controlled remotely. Such wells are provided with necessary control equipment in the form of valving, pressure regulators and the like, to maintain a controlled, orderly outflow of product. The system in one embodiment, includes the use of radio transmission between the well and the land-based control center. Each well can thereby be individually monitored and controlled as needed, either by an operator or automatically.
It can be appreciated that a reliable remote control feature is highly desirable in any offshore well. This feature is particularly true where a malfunction of the well or the wellhead can result in spillage of crude oil into the surrounding waters. Also, when weather conditions are such that well equipment might be damaged as by a hurricane, a storm, or the like, it is desirable to close the well in and permit it to remain idle until the weather crisis has subsided.
Toward promoting well safety, the U.S. Government (Minerals Management Office) has established procedures for recommencing flow, or opening a well to restore production after the well has been closed down under normal circumstances or even under an emergency situation. The mandated well start-up procedure takes into account that flow control or other equipment may have been damaged to the point where permitting the well to flow, could constitute a safety hazard to the environment, to equipment and personnel, or to all three.
With these concerns in mind, the Federal Regulation presently in effect requires that when a well is to be opened after a shutdown to allow flow to recommence, the presence of an operator on the well site is mandatory. The operator's primary function is to physically restart fluid flow. This regulation assumes that by manually opening the main flow control valve at the site, the operator has checked the well equipment to assure that it is in proper condition to assure safe continuation of the producing operation.
It can be appreciated that for a large number of individual offshore wells, each of which may be remotely controlled, manual restarting at the well site can be hazardous, time consuming, and an expensive phase of a producing operation. To obviate the need for personnel at the well site, the present system provides a method and apparatus for remotely reopening the well after a shut down under controlled or emergency conditions. It further incorporates a safety feature that automatically closes down the well after a brief reopened period should it be shown to be operating in a manner that causes the well flow line pressure to stabilize either below or above a predetermined acceptable range of operating pressures.
2. Discussion of the Prior Art
A well-control system similar to the one hereinafter disclosed, is taught in U.S. Pat. No. 5,191,937, which issued in the name of Fred R. Cook, Sr. on Mar. 9, 1993. The system includes a remotely actuated well-control system, wherein well operation is initially commenced and thereafter continued flowing or alternately closed down. The determining factor in the well's operating mode is established by monitoring the pressure generated downstream of the well, which in turn hydraulically actuates control elements to achieve an operating or non-operating mode.
As hereinafter discussed, the present invention addresses the problem of well start-up through use of an improved electronic pressure monitoring facility which provides a continuous yet accurate flow of data to assure continued safe operation of the well within preferred operating parameters.
SUMMARY OF THE INVENTION
To remotely reopen or to recommence flow from a previously closed down offshore well in a safe manner, the well is presumed to be provided with a main flow line, having a flow line valve which is subject to actuation whereby production flow through the valve and the flow line or conduit is controlled. The control system embodies means for remotely actuating the main flow control valve to open position to institute a provisional flow of the production fluid. The system further embodies a timer mechanism which is preset to a brief period of approximately two minutes or fraction thereof. During this time interval, flow line pressure will presumably stabilize to a value within a range of the desired operating pressures.
If at the end of the timed interval, flow line pressure fails to stabilize at an acceptable value within the prescribed operating range, a safety mechanism will automatically discontinue further production flow into the conduit by closing the main flow control valve.
To achieve the objectives of the invention, the apparatus and novel method includes providing a remotely actuated control system which comprises basically two circuits. Both circuits are concurrently functional to selectively communicate the main flow valve actuator to the flow line conduit. A safety circuit is interposed to override or to automatically close the well if necessary when an equipment or other malfunction is detected.
One circuit includes a flow line pressure sensing means which functions to assure production of fluid flow from the well only within the prescribed range of acceptable flow line pressures. The pressure sensing means is communicated with the main flow valve's actuator to discontinue flow through said main valve in the event that the flow line pressure does not stabilize to an acceptable value.
The other circuit includes a flow initiating valve means which is actuated to open position by a remotely transmitted radio signal. Timer means associated with said flow initiating valve, maintains communication between the flow line and the main valve actuator. After a preset operating period, it automatically disconnects said other circuit, thereby releasing the main valve to close only in the event the pressure sensing means indicates the flow line pressure outside of the prescribed operating pressure range.
Stated otherwise, the invention is addressed to a well control apparatus, which is responsive to receiving a remotely transmitted, wireless signal to commence fluid flow from a subterranean reservoir with which the well is communicated. The well is further connected with a conduit having a main flow control valve which is operable between open and closed positions to regulate fluid flow through the conduit.
A pressure sensing means detects conduit instantaneous pressure, which is in turn directed to a pressure discriminating valve. The latter functions to actuate the system's main control valve, thereby to initiate fluid flow into the conduit.
The apparatus further embodies the improvement of a first comparator means which receives data to electronically generate a first signal representative of any pressure differential which exists between the conduit instantaneous pressure, and a predetermined conduit operating pressure.
Valve means communicates said pressure sensing means with the pressure discriminating valve, which in turn functions to continue or to maintain the instantaneous conduit pressure thereby to sustain fluid flow into the conduit only when the comparator generated signal indicates that the conduit instantaneous pressure falls within the range of acceptable conduit operating pressure.
It is therefore an object of the invention to provide an offshore well control system that is capable of assuring safe start-up, or reopening of a closed well through the facility of a remotely transmitted signal.
DESCRIPTION OF THE DRAWING
FIG. 1 is an environmental illustration of a well of the type contemplated.
FIG. 2 is a schematic illustration of the well's control system.
FIG. 3 is an enlarged segmentary section of one of the well's essential control features.
FIG. 4 is a block diagram of the disclosed system.
DESCRIPTION OF THE INVENTION
FIG. 1 represents an embodiment of an offshore well 10 positioned such that a casing 11 is embedded into the ocean floor 12. Casing 11 extends through the body of water 13 to a point above the surface 14. Above the latter, the well is comprised of a support structure or platform 16 having a well head 17 which includes necessary flow control valving and pressure regulating members. Casing 11 supports platform 16 as well as wellhead 17, which maintains control over the production flow.
In the standard form of wellhead, the necessary valving is provided which will direct produced fluid including crude oil, water and gas, from a subterranean reservoir to a vessel positioned nearby or to a shore position. Preferably, production from a number of satellite wells is accumulated for further processing or pipelining to a processing point.
Wellhead 17 is communicated with a flow line 18 which extends downwardly through casing 11 and into a subterranean reservoir. Flow line 18 is perforated in the usual manner to allow ingress of production fluids from the surrounding substrate and is further provided with main flow control valve 21. Said valve is positioned upstream of a conduit or line 20 and functions between opened and closed positions as dictated by a main flow valve actuator 22.
It should be noted that the disclosed control system is comprised primarily of an electro-pneumatic combination in which the well's gaseous products function as the pneumatic medium. As a practical matter, the entire control system, referred to herein as the Remote Terminal Unit (RTU) 19 is enclosed within a protective casing on platform 16.
The upper end of well 10 as noted embodies a normal form of wellhead 17 having operating components, some of which function in response to manual manipulation operation or to a radio signal, or both. The signal is received by an antenna 19a from a shore-based or mother platform-based transmitter station not shown, but which is normally spaced miles away from the controlled well.
The shore-based or mother platform control or transmitting station is comprised primarily of a transmitter or transceiver, capable of broadcasting a predetermined frequency signal a sufficient distance to reach well 10 or wells being reopened, and received by appropriate receiving equipment, including antenna 19a.
Referring to FIG. 2, at well 10 the control system is comprised of first or main control valve 21 which as noted, is positioned upstream of flow conduit 20 to regulate fluid flow from a subterranean reservoir, to wellhead 17 and thence into flowline 20. Valve 21 is operable to fully open or closed positions, being subject to adjustment by main valve actuator 22 to which it is connected.
Referring again to FIGS. 2 and 3, valve actuator 22 is communicated to a second or pressure discriminator valve 23 by line 24 though which gas, as the actuating medium is conducted. Second valve 23 in one embodiment is comprised of a generally elongated body 26 having an inlet port 27 and an outlet port 28 which define the primary, interruptable flow paths of the system.
An axial passage 29 through elongated body 26 defines a cylindrical guide for a transfer plunger or valve operator 31. Plunger 31 comprises a piston-like member adapted for sealed, sliding longitudinal movement between forward and retracted positions. Said plunger can be longitudinally adjusted from the retracted to the forward position by pneumatic pressure or alternately, by manual manipulation.
Plunger 31 further includes spaced apart peripheral seals which slideably engage the contiguous cylindrical walls of passage 29 to form a dynamic, fluid tight engagement. Annular chamber 32, communicates inlet port 27 and outlet port 28, when plunger 31 is in it's advanced position, thereby allowing fluid pressure to be transmitted from line 33 to line 24 by way of chamber 32, and thence to main valve actuator 22.
The lower end of valve body 26 is provided with an inlet port 36 for receiving pressurized fluid to urge plunger 31 into its advanced or open position. Compression spring 37 retained within valve body 26 normally urges plunger 31 into its retracted or closed position to cause discontinuance of pressure communication through annular compartment 32, and thereby, to discontinue pressure against main valve actuator 22, a sequence that permits main valve 21 to close.
Line 33 is provided with a pressure regulator 41 which is communicated by lines 42 and 46 to flow conduit 20 through a connecting valve 43 and line or pressure sensing means 44. Functionally, when valve 43 is in open position, conduit 20 will be communicated directly by way of pressure regulator 41 to second valve 23. Pressure regulator 41 functions to limit or reduce pressure from conduit 20 acting against valve 23 to a preferred operating value not exceeding about 120 psi.
Conduit 20 is provided with a tap which accommodates pressure sensing means 44 having valve 43 at the downstream end thereof, which is communicated through line 46 and 47 to a pressure transducer 51. The latter monitors and registers the pressure in conduit 20, converts it into analog form and forwards this data to an electronic analog comparator 49. Said comparator is programmed to achieve a running comparison to establish differences that occur between conduit 20 instantaneous pressure, and the acceptable range of operating pressures at which conduit 20 must operate. Comparator 49 will generate a transmissible signal, and/or alternately, a digital reading to reflect the pressure differential.
Instantaneous pressure at 20 is transmitted from valve 43 to a second pressure regulator 52 in which the pressure is reduced to about 120 psi and directed through line 38 to first supplementary solenoid valve 48. From valve 48, the pressure is further directed through line 48a which then pressurizes the plunger 31 of valve 23 sufficiently to overcome the retarding force of spring 37 thereby urging plunger 31 into the advanced position, thus communicating line 33 with line 24.
Solenoid valve 48 is normally maintained in closed position, except for a preset brief time interval, when it is opened in response to a signal to allow initial opening of valve 23 by displacement of plunger 31. Solenoid valve 48 is thus interconnected electrically with a controller 53.
A second source of pressure, which is applied to valve 23 likewise originates at conduits 20 and is reduced to approximately 40 psi in regulator 52. Said pressure is then directed through a normally closed second supplementary solenoid valve 56 by way of line 66. With valve 56 in open position, pressure will be directed through line 34 to be applied against the lower side of plunger 31, thereby supplying a sufficient force to maintain plunger 31 in its advance or displaced position, whereby to communicate line 33 with line 24.
Functionally, the holding pressure transmitted by way of solenoid valve 56 to displace plunger 31 is sufficient to maintain the plunger in its displaced condition and allow flow through 23. Said pressure, however, is bypassed around plunger 31 in its retracted position; thus, 56 is effective only after plunger 31 has been initially moved to the advanced position by the action of valve 48. Since valve 48 is subject to the action of a timer 53 to relay 67, this valve will remain open to initially displace plunger 31 thus commencing the pressure flow into line 24 for a limited period as determined by the timer, which will cause 48 to close automatically at the end of the timed period.
If during the timed period, the signal produced by the comparator 49 does not indicate a favorable operating pressure in conduit 20, the holding pressure exerted on plunger 31 by way of valve 56 will not be maintained. After the set time period has elapsed, plunger 31 will be returned by spring 37 to its retracted position, thereby terminating further fluid flow through main valve 21.
From a safety consideration, timer 58 is connected electrically to controller 53. While pulse signals are received by timer 58, relay 62 is closed allowing voltage for solenoid valve 48 and relay 61. However, at such time as a malfunction in controller 53 or in the power system causes the fluid producing operation to cease, the computer generated signal conducted to timer 58 will cause the latter to open and remove supply voltage thereby automatically closing 23 to further actuation of valve 21. The latter will assume the closed or no flow position.
This is achieved by timer 58, which receives a pulsed signal from 53 at a uniform rate. When the signal is interrupted due to a malfunction in computer 53, closing of valve 23 will take place immediately. Similarly, since pressure sensing conductor 44 will be in a continuous detecting mode, the instantaneous pressure in conduit 20 will at all times be conducted through transducer 51 to comparator 49. Therefore, during any period of operation, should a malfunction in the equipment cause either an under pressuring or overpressuring at conduit 20, this condition will be analyzed in comparator 49 and computer 53 and the appropriate signal directed to valve 56, which will revert to the closed position.
Operationally, the primary feature of the disclosed system is to facilitate the reopening of one or more offshore or even onshore wells from a control or transmitting station which is remote from the wells. For purposes of discussion, the system, it will be assumed that the occurrences of storms, hurricanes, or even ordinary maintenance or other reasons has caused one or more of the wells to be shutdown to avoid the possible damage to equipments as well as to the environment.
In essence, to reactivate a closed in well or wells, the system provides that a radio transmission to one or more of the wells, fluid flow from the well to a fluid carrying conduit 20 will be provisionally commenced. If after a brief operation period of between 30 seconds and about 3 minutes, say for example 2 minutes, the conditions in conduit 20 indicate that the fluid flow conditions have stabilized and the operating pressure is within an acceptable range of operating pressures, the provisional condition will be overwritten and the well permitted to continue flowing.
If, however, during this provisional operating period the conditions in conduit 20 indicates a pressure either above or below the acceptable operating range this is an indication of possible equipment malfunction. The well will be automatically closed down to avoid further damage to equipment or to the well's surrounding environment as a result of accidental spillage.
Normal Well Operation
To facilitate the description of the starting or the reopening of a well, it is assumed that under normal operating conditions, main flow control valve 21 will be open, valve 23 will be open to allow flow from line 33 into line 28, valve 56 will be open and valve 48 will be closed. During the normal operating period, the pressure in 20 will be conducted by conductor 44, and this pressure applied to a pressure transducer 51. The latter in turn sends a data signal to comparator 49. The comparator will now run a continuous analytical comparison between the instantaneous pressure in conduit 20 and the conduit's acceptable operating pressure operating range. A generated signal to valve 56 will keep this valve open to sustain the fluid flow operation.
To close down a well whether under ordinary or emergency conditions, requires a signal to be sent from the remote transmitting station to the controller computer 53 which in turn forwards the necessary command to valve 56 to close. Loss of pressure from valve 56 by way of vent port 63 will cause valve 23 to immediately close, which further closes valve 21, thereby terminating fluid flow into conduit 20.
Reopening A Well
For a well reopening procedure, a radio signal is sent from the remote transmitting station to RTU 19 and is received by antenna 19a at computer 53. The computer will forward an activating command to normally closed valve 48 which in response to said command will open. Residual pressure normally present in conduit 20 will be transmitted through pressure conductor 44 and valve 43, to pressure regulator 52. This pressure at about 120 psi will then be transmitted by way of line 38 and open valve 48, through line 49 to displace plunger 31 to its advanced position. Opening of the latter will cause pressure at regulator 41 to be transmitted by line 33, valve 23 and line 24 to valve actuator 22. The latter will cause main flow control valve 21 to open, thereby commencing fluid flow into conduit 20.
With the opening of valve 48 for a limited, preset timed period, the system will be activated. Valve 48 will be sustained in open position only for about 2 minutes, during which period fluid flow in conduit 20 will continue toward stabilization.
During this provisional operating period, conditions in conduit 20 may tend to be unstable and could remain so for duration as the timed period. If all the equipment, however, is in proper operating order, the conduit 20 condition will normally settle to a constant measurable pressure. During this period, pressure in conduit 20 is monitored by pressure transducer 51 and resulting data is fed to the comparator 49. The latter, which as noted, has been programmed to compare incoming fresh data will analyze the data.
Comparator 49, upon analyzing the incoming data, will generate a signal indicating either of two prevailing conditions. Under favorable conditions, and with the pressure in conduit 20 stabilized at the acceptable pressure level, controller 53 will send a command to valve 56 to remain open. At the end of the provisional two minute period, valve 48 will automatically close thereby discontinuing that segment of pressure on plunger 31 which is conducted by way of line 49.
This reduction of the plunger 31 displacing pressure will not affect its advanced position, since the pressure from valve 56 maintaining plunger 31 displaced, will sustain valve 23 in the open condition.
During this provisional period, should non-stabilized conditions in conduit 20 indicate an instantaneous pressure either above or below the accepted range of operating pressure, this data will be transmitted by conductor 44 and valve 43 to pressure transducer 51. The data, when fed to comparator 49, will cause the latter to generate a command to valve 56 causing the latter to close. The effect of this sequence of events will be that all pressure previously applied to plunger 31 by holding valve 56, and closing of valve 48, will be discontinued. Plunger 31 will be urged by spring 37 into its retracted position resulting in no pressure being transferred through said valve 23 to the valve actuator 22.
Should it be determined after an on site inspection by personnel that the disclosed well control system is not workable or defective, flow to conduit 20 can be commenced by physically opening valve 23 to its advanced position and commencing operation of controller 53. Thereafter, with the well control system normally operating, even though valve 23 has been opened manually, the system will continue to function under control at the controller 53.
As a further safety factor the system, will function to close down the entire well flowing operation in the event that computer 53 becomes inoperable due to loss of power at anytime, or for other reasons. This is achieved by way of the timer 58 which will receive a periodic pulsed signal in response to computer operation. In the event the received signal is not read by 58, the supply relay 62 will open to automatically discontinue pressure to valve 23. Plunger 31 will retract to close main flow valve 21 and consequentially the passage of further fluid into conduit 20. | System for remotely controlling the start-up of a closed-in well. A radio signal transmitted to the well actuates a main flow control valve to provisionally commence flow from the well into a conduit. During the provisional period, a comparator electronically analyzes the well's immediate operating pressure against a preferred operating parameter, and generates a signal representing the difference between the two. A generated signal further initiates such commands as will sustain well flow if the latter is within the preferred operating parameters, or after the brief provisional operating period, discontinues flow if necessary. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a device and method for shipping and dispensing precise amounts of dry particulate matter, such as fertilizer and pesticide products and such, into a liquid carrier stream.
Many useful agricultural chemicals and other such products are distributed in dry bulk form, either as powders, granules or small pellets, but are ultimately dissolved into a liquid carrier for application by spraying or irrigation equipment. Thus, a farmer will either purchase the chemicals dry, either in bags or bins, and mix them with water or other liquid carrier as needed, such as by pouring the dry chemicals and liquid carrier separately into a mixing tank, or will transport a tank to a chemical dealer who will dispense a pre-mixed solution into the tank. Unfortunately, environmental and safety regulations are typically more stringent regarding the transportation of chemicals in liquid form than in dry form.
Pneumatic systems have been developed for metering and transporting dry particulate matter in a stream of air, from a bulk storage bin to a mixing tank for subsequent mixing with a liquid. A useful example of such a system is a portable unit described in U.S. Pat. No. 5,803,673 and sold under the trade name “ACCUBIN”. The entire contents of the above-referenced patent are incorporated herein by reference as if fully set forth.
With many agricultural chemicals, prolonged exposure to high concentrations of air-borne particulates is not desirable.
SUMMARY OF THE INVENTION
The invention features a means of transporting and storing a dry particulate material, and then dispensing controlled quantities of that material directly into a stream of liquid carrier. The invention is particularly applicable for use with agricultural chemicals, such as pesticides (e.g., herbicides), fertilizers and adjuvants. By “particulate form”, we mean to include powders, granular and pelletized materials that are not suspended in a liquid medium.
According to one aspect of the invention, a device is provided for dispensing precise amounts of dry particulate matter directly into a liquid carrier stream. The device includes a bin for holding a quantity of particulate matter, a conduit for transporting a stream of liquid carrier, and a meter connected to the bin for controllably releasing a desired amount of the particulate matter from the bin into the conduit while disallowing entry of the liquid carrier to the bin. The bin, conduit and meter are all mounted upon a portable structure for transportation with particulate matter in the bin.
In the embodiment discussed in more detail below, the meter is arranged at the bottom end of the bin, such that the particulate matter is fed into the meter by gravitational force.
In some embodiments, the meter includes a multi-vaned rotor constrained to rotate within a housing, with the rotor vanes defining between them discrete pockets of known volume. These pockets preferably each have a volume of less than about 30 cubic inches (500 cubic centimeters), more preferably less than about 25 cubic inches (400 cubic centimeters), and most preferably less than about 10 cubic inches (150 cubic centimeters).
In some cases, the meter also includes an electric drive motor for driving the rotor.
In presently preferred embodiments, the device includes a controller for controlling the number of revolutions of the motor, and, thereby, the volume of particulate matter released from the bin.
For supplying electrical power to the motor, an electrical storage battery may be mounted to the portable structure. In some instances, a battery charger may be adapted to receive power from an external source to recharge the battery. The battery may also be adapted to supply electrical power to the controller.
In some embodiments, an electronic programmable controller is included. The controller is adapted to operate the meter to release a desired volume of particulate matter, in accordance with operator input. This controller is preferably mounted upon the portable structure, but in other embodiments the controller may be a separable unit, with an electrical port provided on the inductor for attaching the remote electronic controller for controllably operating the meter.
In some instances, the controller is adapted to receive an operator input representing a desired weight of matter to be released and to calculate, based upon at least this input and a stored particulate matter density value, a corresponding volume of matter to be released.
When a preset amount of matter has been released, in some cases the controller is adapted to automatically stop releasing the particulate matter, while liquid carrier continues to flow along the conduit. Under such conditions, the controller is preferably adapted to alert an operator when the preset amount of particulate matter has been released.
In some embodiments, the conduit is adapted to apply a sub-atmospheric pressure to the released particulate matter, in the presence of an operative liquid carrier flow, to motivate the released matter into the conduit. This conduit may include an eductor, for example, which effectively forms a venturi. Such an eductor is preferably constructed to dissolve the particulate matter into the carrier liquid within the eductor, or as soon as possible thereafter. Preferably, the conduit is adapted to apply a vacuum of between about 0.5 and 6 pounds per square inch (3.4 and 41 kilo-pascals) below atmospheric pressure to the released particulate matter.
In some embodiments a check valve is disposed between the conduit and the meter. The check valve is adapted to be normally closed and to open when the sub-atmospheric pressure falls below a predetermined threshold, thereby applying the sub-atmospheric pressure to the downstream side of the meter. In some cases, a pressure switch responsive to this sub-atmospheric pressure is included, for enabling operation of the meter only in the presence of a desired amount of vacuum. In such cases, the pressure switch is located between the check valve and the meter.
Preferably, the bin comprises a hopper with sides sloped at an angle of between about 45 and 60 degrees from horizontal. It is also preferred that the hopper have an internal volume of between about 5 and 200 cubic feet (0.14 and 5.7 cubic meters).
In some cases, a vibrator is structurally connected to the bin and adapted to vibrate the bin during operation to assist flow of the particulate matter into the meter.
Preferably the portable structure has a base footprint sufficiently small to fit within a 4 foot by 8 foot (1.2 meter by 2.4 meter) rectangle. For example, one preferred embodiment has a base footprint of about 42 inches by 48 inches (1.0 meter by 1.2 meters).
According to another aspect of the invention, a method of dispensing precise amounts of dry particulate matter directly into a liquid carrier stream is provided. The method includes first connecting the conduit of the device of the invention, the bin of which contains particulate matter, to a source of liquid carrier; and then motivating a flow of the liquid carrier through the conduit, thereby dispensing a desired amount of the particulate matter from the bin of the device into the flow of liquid carrier.
In some cases, the particulate matter comprises an agricultural pesticide, fertilizer or adjuvant.
The liquid carrier may comprise water or a liquid fertilizer, for instance.
In some instances, the flow of liquid carrier is directed from the conduit of the device to a receptacle.
Where the device includes an electronic controller for controlling the meter of the device, the method may further include, prior to the step of motivating, entering a value into the controller representing a desired amount of particulate matter to be released. The method may also include, prior to the step of motivating, entering a value into the controller representing the density of the particulate matter to be released.
According to another aspect of the invention, a method of distributing agricultural chemicals in particulate form, to be mixed with a liquid carrier before use, is provided. The method includes the steps of:
(1) providing multiple devices constructed according to the invention, as described above;
(2) distributing the devices, with corresponding quantities of agricultural chemicals, to individual end users for dispensing the agricultural chemicals into liquid carrier streams at remote locations; and then
(3) accepting the devices as returned from the end users, after the end users have dispensed at least some of the distributed chemicals.
In some embodiments, the method also includes, before distributing each device, filling the bin of the device with the corresponding quantity of agricultural chemical; and then, after accepting the returned devices, refilling the bins of the devices with additional agricultural chemicals.
By using an inductor constructed according to the invention, a dry chemical substance can be properly and accurately metered directly into a liquid carrier, without possibly harmful exposure to chemical dust and fumes. Additionally, transportation of pre-mixed liquid chemicals can be avoided, with the chemicals being transported all the way to their use site in dry form. Simple, automated operation at remote sites may be provided by a control system that is adapted to run on on-board batteries, with very little operator input. Other advantages and features will also be understood from the following description of embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a programmable, dry chemical inductor.
FIG. 2 shows the inductor being transported by truck.
FIGS. 3A and 3B are schematic side views of the inductor, with transparent side panels, to illustrate its internal components and structure.
FIG. 4A is a side view of the metering device, with the end caps of the meter housing transparent to show the internal rotor.
FIG. 4B is a cross-sectional view, taken along line 4 B— 4 B in FIG. 4A, with the drive motor not sectioned.
FIG. 5 is an illustration of the control panel of the inductor.
FIG. 6 is an upper level functional schematic of the controller.
FIG. 7 illustrates a method of distributing agricultural chemicals.
DETAILED DESCRIPTION OF EMBODIMENTS
Referring first to FIG. 1, a dry chemical inductor 10 is in the form of a box structure having side 12 and top 14 surfaces of sheet aluminum covering a steel frame 16 . Lifting brackets 18 at the four top corners of the frame are provided with lifting eyes 19 for hoisting the inductor by chain. Recesses 20 between the feet 22 of the frame provide clearance for fork lift tines. The feet are spaced so as to fit just inside of the lifting brackets of a lower inductor, with sufficient clearance for the lid of the lower inductor, for stable stacking. The inductor housing has an overall height “H” of 72 inches (1.83 meters), with a base footprint of about 42 by 48 inches (1.0 by 1.2 meters), the size of a standard shipping pallet, for efficient stacking on a standard flatbed truck. The height “H” of various embodiments will depend in part on the desired internal hopper volume. These dimensions provide for an internal hopper volume of 40 cubic feet (1.1 cubic meters), for example. Given the small size of the inductor, it can readily be loaded onto the bed of a standard pickup truck 24 for transportation, as illustrated in FIG. 2 . Other sizes of inductors will accommodate other hopper volumes.
Still referring to FIG. 1, the top 14 of inductor 10 has an opening which is normally covered by a removable lid 26 . The opening may be of 22.5 inches (57 centimeters) in diameter, for example, similar to the diameter of a standard drum. Lid 26 is in the form of a cover 28 and rubber gasket 30 held in place by a clamp ring 32 to form a dust-free seal to reduce the chance of operator exposure to airborne chemicals. Generally, such a seal is required by some presently existing safety, environmental and regulatory standards for shipping particulate chemicals.
As discussed further below, and shown in subsequent drawings, inductor 10 has an internal hopper containing a quantity of bulk material which is intended to be mixed with a liquid carrier for use. To dispense a desired quantity of the bulk material into a liquid carrier, the user must first hook up the carrier inlet port 34 to a liquid carrier source, such as a water pump (not shown), that is adapted to motivate a flow of liquid carrier into the inlet port of the inductor. The mixture outlet port 36 is connected to a flexible hose for directing the liquid carrier and entrained bulk material from the inductor to a desired destination, such as a spray tank or mixing tank (also not shown). In the illustrated embodiment, ports 34 and 36 are two-inch (roughly 5 centimeter) cam and groove quick-connect couplings, sized to permit a liquid carrier flow rate of at least about 350 gallons (1350 liters) per minute. A value representing the amount of bulk material to be released (the “setpoint”) is keyed into a control panel 38 , and a flow of liquid is started through the inductor. When the inductor has sensed the presence of sufficient carrier flow, it automatically meters into the flow the desired amount of bulk material, without letting the liquid carrier flow up into the internal hopper to wet any unreleased bulk material. When the desired amount of bulk material has been released into the flow of carrier liquid, inductor 10 automatically stops dispensing the bulk material and alerts the user that the setpoint has been reached. The user can then turn off the flow of carrier liquid, or let it continue to run through the inductor, such as to complete the filling of a spray tank and further dilute the mixture.
Referring to FIGS. 3A and 3B, a sealed hopper 40 is mounted within the outer structure of inductor 10 . Hopper 40 is shaped to promote gravitational feeding of bulk materials into the metering device 42 located at its lower end. We have determined that a wall slope angle “α” of between about 45 and 60 degrees will work for many particle shapes and sizes, 60 degrees being preferable for powders and other very fine particles. To assist with the flow of the bulk material into metering device 42 , an electric vibrator 44 , such as a model DC-300-24V available from Vibco, may be firmly attached to hopper 40 to vibrate the hopper and induce downward flow. Behind control panel 38 is a programmable electronic controller 46 that controls the operation of inductor 10 , including vibrator 44 and metering device 42 . Electric power is provided by a pair of 12 VDC, 17 amp-hour rechargeable batteries 48 , which provide enough power for about 4 hours of operation between charges with the vibrator running. An electrical charge port 50 is accessible from outside the inductor to recharge batteries 48 and/or power the inductor. Internal conduits hydraulically connect ports 34 and 36 through metering device 42 .
FIGS. 4A and 4B better illustrate the structural detail of metering device 42 . A ⅛ horsepower, 32 RPM, 24 VDC gearmotor 52 , such as model PR990235, available from Leeson, drives the multi-vaned rotor 54 of a bulk material transfer gate 56 , such as the airlock described in U.S. Pat. No. 5,803,673. Gate 56 has a rotationally molded polycarbonate housing 58 and end caps 60 , and an injection molded “DELRIN” rotor 54 with eight integrally molded vanes 62 that define, in cooperation with housing 58 and end caps 60 , eight discrete pockets 64 that transport bulk material from upper opening 66 , open to the hopper ( 40 , FIG. 3A) to a conical vacuum chamber 68 defined within housing 58 below the rotor. The rotor is supported on integrally molded axial projections 100 protruding from each end of the rotor through corresponding holes in end caps 60 . An aluminum motor shaft receiver 102 , of hexagonal outer shape, is insert molded into one of projections 100 , and defines a keyed central hole for receiving the motor shaft which drives the rotor. PTFE-encapsulated neoprene O-rings 104 provide for dynamic sealing between rotor 54 and end caps 60 during operation. A running clearance of about 0.005 inch (0.13 millimeter) is provided axially between the rotor and each end cap, and radially between the rotor and housing 58 . We have found that this clearance results in acceptably low leakage about the vanes for most intended bulk materials and at operating vacuum pressures. At the highest point of their rotation, vanes 62 of rotor 54 extend above the upper flange 106 of the gate (i.e., into the hopper) a distance “d” of about 1.0 inch (25 millimeters), helping to avoid “bridging” of packable bulk materials just above the gate. In this embodiment, rotor 54 has an overall diameter of about 7 inches (18 centimeters) and a length of about 7 inches (18 centimeters).
All of pockets 64 are of similar volume. In this embodiment, each pocket 64 has a volume of about 25.92 cubic inches (425 cubic centimeters), which is effectively the “resolution” of the dispensing system. Of course, gates 56 defining discrete pockets of other shapes and volumes are considered within the scope of this invention. For example, pocket volumes as low as 3 cubic inches (50 cubic centimeters) provide even finer resolution. Ideally, each pocket is completely and sequentially filled with bulk material from opening 66 , and completely empties into vacuum chamber 68 . To help ensure complete pocket filling and emptying, motor 52 may be adapted to impart a vibration to gate 56 . For embodiments having a separate vibrator ( 44 , FIG. 3 A), the gate may be structurally coupled to the vibrator to enhance pocket filling. Rotor positional feedback to the controller is provided by rare earth magnets 69 embedded in the vanes of the rotor, which are sensed by a hall effect sensor 71 in the housing end cap adjacent the motor. Alternatively, motors 52 with built-in positional feedback systems may be employed. As rotor 54 rotates, pulses from hall effect sensor 71 inform the controller of the passage of each vane, and therefore of the emptying of each pocket. The controller monitors these pulses until it has determined that the desired number of pockets of material, as determined from operator input and known pocket volume, have been dispensed. Once the controller stops applying power to motor 52 , friction and internal damping generally cause the motor to coast only a few degrees before coming to a stop, providing for an accuracy of +/−1 pocket or better in the total amount released. Better accuracies may be provided by equipping the motor with braking means (not shown) to positively stop rotation of the rotor at a desired vane increment.
The inner side walls of vacuum chamber 68 are sloped at an angle “β” of about 76 degrees above horizontal, to aid in directing released bulk material downward into the inlet of a vacuum check valve 70 . We prefer an angle β of at least 70 degrees to overcome the tendency of some materials to adhere to the inner walls of housing 58 which, alternatively, may be of die-cast aluminum with an anodized PTFE inner surface.
Check valve 70 is attached, by air-tight connections, to both gate housing 68 and eductor 72 . Valve 70 contains a wafer 74 which is urged against a seat, toward gate 56 , by a preload extension spring 76 , thereby blocking flow between the gate and eductor. When a predetermined carrier flow rate through eductor 72 has been reached or exceeded, flowing from inlet 78 to outlet 80 , a reduction in absolute pressure is achieved below wafer 74 . When the vacuum below wafer 74 is sufficient, wafer 74 moves away from its seat and transmits this vacuum to chamber 68 . It is preferred that gate 56 not be operated to dispense materials before a vacuum pressure has been established in chamber 68 . In other words, it is preferable that a threshold flow rate through eductor 72 be established before motor 52 begins to rotate rotor 54 . To that end, a pressure switch 82 is responsive to vacuum pressure within chamber 68 and signals the controller when the pressure in chamber 68 is below a predetermined threshold. The controller does not activate motor 52 until such a signal is received, thus preventing material release until a sufficient flow rate of carrier liquid has opened check valve 70 . This also helps to reduce the amount of contamination of bulk material in the hopper if the system were operated with a failed, open check valve. Should the flow of carrier liquid suddenly stop, check valve 70 will automatically and rapidly close, thus preventing any substantial flow of carrier liquid up into chamber 68 . At the same time, switch 82 will detect the loss of vacuum and the controller will stop energizing motor 52 . Of course, insubstantial amounts of carrier vapor or droplets will occasionally pass through check valve 70 and enter chamber 68 , such as when flow through eductor 72 is abruptly stopped. Of this minor amount of leakage, a small amount of vapor may be vented through gate 56 and up into the hopper. Importantly, however, the combination of check valve 70 and gate 56 avoids any significant amount of carrier liquid, any amount which would cause detrimental contamination, packing or dissolution, to enter the hopper. Commercially available eductors 72 are available as models 2083-X from Mazzei (high flow, low vacuum), and “2-inch ELL” from Penberthy (low flow, high vacuum). For more controlled air flow through vacuum chamber 68 , such as to help keep released materials flowing through check valve 70 , a vacuum check valve (not shown) may be installed through the side wall of housing 58 , below gate 56 , to let in a controlled flow of air and regulate vacuum pressure.
Referring to FIG. 5, control panel 38 has a digital display 84 for displaying textual information, and a keypad 86 for operator input. Besides a typical 10 number keys and a decimal key, keypad 84 includes a “START/STOP” key 88 , an “ON/OFF” key 90 , an “ENTER” key 92 and a “RESET” key 94 . “ON/OFF” key 90 controls system power, as its name implies. After entering a setpoint, the operator pushes the “START/STOP” key 88 to begin automatic release of the material. During operation, pushing the “START/STOP” key 88 pauses the release of material and initiates an audible alarm and appropriate visual display indicating that release has been interrupted. “ENTER” key 92 is used for entering user input, such as data and passwords, and “RESET” key 94 is for acknowledging and resetting alarms or clearing keyed values. In addition, there are four additional functions performed by pushing various keys in combination with key “7”, sub-labelled “FUNCTION”. Holding key “7” while pushing key “1”, for example, displays the calibration factor (CF) for three seconds. This calibration factor represents the density of the bulk material, in pounds per pocket. Holding key “7” while pushing key “3”, displays current battery voltage (VDC). Holding key “7” while pushing either the “RESET” or “ENTER” keys will either raise or lower, respectively, the contrast of display 84 . If desired, a coaxial controller cable input jack 120 (FIG. 1) may be provided for operation of the inductor from a pendant controller or keypad.
Three password levels are provided for various function authorizations. A typical user will be provided with a first level password which enables the entry of setpoints and very basic system operation. A second level password allows the user to change inventory parameters, calibration factors, or perform self-calibration. For self-calibration, the user will direct the system to dispense a given amount (e.g., weight) of material. The user then weighs the dispensed material with appropriate weighing means (not shown) and enters the weight of the material actually dispensed. The controller then adjusts its calibration factor accordingly. An example of changing inventory parameters is changing a value representing the total amount of bulk material presently contained within the hopper. For example, when filling the inductor with bulk material, a dealer may enter into the controller the total weight of material supplied. During operation, the controller continuously subtracts from this value the weight of material dispensed. When the controller determines that all of the material originally supplied has been dispensed (i.e., when the total weight register reads “0”), any further dispensing of material by the end user is disallowed. This safeguard is particularly important for enabling the dealer to reliably track the overall amount of material dispensed through the inductor, for example. A third level password authorizes more advanced adjustments, such as changing the motor speed, timer values or alarm points.
Referring to FIG. 6, a programmable microprocessor 96 is programmed to perform all data manipulations in controller 46 . CPU 96 receives input from the vacuum sensor or switch 82 (FIG. 4 B), the vane-sensing hall effect sensor 71 (FIG. 4 B), keypad 86 and, in some embodiments, a serial port (e.g., port 120 in FIG. 1 ). Based upon these inputs, CPU 96 drives motor drive circuitry 97 to pulse-width modulate high side power to gate motor 52 (FIG. 4B) to drive the gate rotor and dispense product. At the same time, CPU 96 triggers a power switch 98 to turn on the vibrator, if so equipped. A 5V voltage regulator 99 steps battery voltage down to power the electronic controller components. Display 84 is a two row, 16 character per row, backlit LCD display via which the controller communicates visually with the operator. In addition, a buzzer 101 gives an audible alarm when triggered by the CPU.
In FIG. 7, a method of distributing agricultural chemicals in particulate form includes distributing devices described herein, with quantities of agricultural chemicals, to individual end users 150 for dispensing the agricultural chemicals into liquid carrier streams at remote locations, and then accepting the devices as returned from the end users, after the end users have dispensed some of the distributed chemicals.
Other embodiments are also within the scope of the invention, although not illustrated in the drawings. For example, much smaller inductors may be produced for home gardening and landscaping applications, which are filled with dry chemicals at garden supply stores and then rented to homeowners or lawn care specialists. Such inductors may be attached to garden hoses for automatically dispensing selected rates of chemical into a monitored flow of water through the inductor. After use, the inductor may be returned to the dealer for cleaning and reuse, without the customer having ever been exposed to dry chemicals or had to either mix or transport liquid chemicals. Furthermore, inductors may be equipped with multiple, separate hoppers and metering devices, which may all feed a common eductor for instance, with a more sophisticated controller programmed to enable the operator to select chemical mix ratios, such as for customized fertilization. Such an inductor may be particularly useful to lawn care specialists, transported to each work site on the back of their equipment truck. Other embodiments will also be found to fall within the scope of the following claims. | A device and method for dispensing precise amounts of dry particulate matter, such as agricultural chemicals, directly into a liquid carrier stream, such as a flow of water, and a method of employing such a device to distribute chemicals. The device includes a bin for holding a quantity of particulate matter, a conduit for transporting a stream of liquid carrier, and a meter at the bottom of the bin for controllably releasing a desired amount of the particulate matter from the bin into the conduit while disallowing entry of the liquid carrier to the bin. The bin, conduit and meter are all mounted upon a portable structure for transportation with particulate matter in the bin. The meter includes a multi-vaned rotor turned by a controlled motor, and defines discrete pockets of known volume. The operator simply connects the device to a flow of water and keys into the controller an amount of material to be released. The rotor releases the material into a chamber under vacuum pressure generated by a venturi, through a check valve, and into an eductor. Agricultural chemicals may be advantageously distributed to end users in particulate form, to be mixed with a liquid carrier at the work site, without possibly harmful exposure to chemical dust and fumes. | 1 |
FIELD OF THE INVENTION
The present invention relates to a mechanism for attaching an implement such as a snowplow onto a vehicle while allowing some free motion of the implement in service.
BACKGROUND OF THE INVENTION
Float mechanisms are employed for mounting material-moving implements such as loader buckets and snowplows onto vehicles. The float mechanism allows a limited degree of free motion of the implement, allowing it to accommodate uneven terrain surfaces. Preferably, the float mechanism is designed to attach to an instant transfer connector on the vehicle to allow the implement, with the float mechanism attached thereto, to be readily removed for transportation, use on a different vehicle, or to free the vehicle for other uses. One such float mechanism is taught in U.S. Publication 2008/0028643.
While the float mechanism taught in the '643 publication offers a significant improvement over earlier implement mounting structures, it has been found to suffer from limited stability under some operating conditions. When mounted to a wheeled vehicle having relatively low-pressure tires, it has been found the bouncing of such vehicles over relatively uneven surfaces results in an undesirable degree of pitching of the implement due to the free play in the float mechanism.
SUMMARY
The present invention is for a float mechanism for attaching a material-moving implement such as is taught in the U.S. Pat. No. 7,360,327 to an instant transfer connector on a vehicle. One such instant transfer connector is available from Caterpillar Inc. The float mechanism allows the material-moving implement a limited degree of free motion relative to the instant transfer connector on the vehicle to accommodate irregularities in the surface over which the vehicle and the material-moving equipment travel.
The float mechanism has a mounting frame which has a pair of substantially vertical supports affixed at a set separation configured to slidably and lockably engage the instant transfer connector which is attached to the vehicle. A fixed frame is attached to the material-moving implement, and may be formed as an integral part of the implement.
A pivot bracket is pivotally attached with respect to one of the frames about a pivot bracket axis and is slidably connected with respect to the other of the frames so as to accommodate a limited degree of translational motion sliding along a nominally vertical axis. The pivot bracket serves to maintain the motion of the fixed frame relative to the mounting frame within the nominally vertical plane while allowing limited translation between the frames, and thereby prevents unintended pitching of the material-moving implement.
The slidable connection of the pivot bracket to one of the frames can be provided by a pair of guides that are fixed to either the pivot bracket or the frame, in combination with a pair of sleeves that are affixed to the other of these elements. Stops on the guides can be employed to limit the translational motion between these elements.
In some applications, it can also be beneficial to limit the rotational motion between the fixed frame and the mounting frame. This motion could be limited by one or more stops affixed to one of the frames or to the pivot bracket. However, to reduce the bending moments on the pivot bracket resulting from loads due to the scraping action of the material-moving implement, it is preferred to limit the rotation by a mechanism that is substantially spaced apart from the pivot bracket which, in addition to limiting the rotation of the frames, also serves to guide the motion along a path that maintains the two frames in parallel relationship. This action can be provided by one or more slots in one of the frames, and one or more corresponding stabilizing elements on the other of the frames, configured to slidably engage the slot(s), thereby providing limited motion in a plane that is substantially normal to the pivot bracket axis.
In one embodiment, a horizontally-extending transfer bar affixed to either the mounting frame or the fixed frame slidably engages one or more substantially vertical slots in the other frame. Providing a pair of substantially vertical slots that are spaced apart will tend to balance the forces to reduce wear and reduce the likelihood of binding.
When one or more slots in combination with one or more stabilizing elements are employed to limit rotational motion between the fixed frame and the mounting frame, movable blocks can be employed to deactivate the float mechanism and prevent free movement. These blocks can be positioned to block a portion of the slot(s) to prevent movement of the stabilizing element(s) therein. Preventing free movement can be particularly advantageous when the float mechanism is employed with a loading bucket during loading operations, to prevent any motion that could result from uneven loading.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a partially-exploded isometric view showing a float mechanism that forms one embodiment of the present invention, the float mechanism serving to support a material-moving implement. The float mechanism has a fixed frame that is affixed to the implement and a mounting frame that has a pair of vertical members configured to attach to an instant transfer connector of a vehicle (not shown). The fixed frame has a centrally-positioned cross-brace with a pivot shaft affixed thereto. A pivot bracket is pivotably attached to the pivot shaft so as to rotate with respect to the fixed frame about a pivot bracket axis. The pivot bracket in turn has a pair of guides that are slidably engaged by sleeves on the mounting frame. The guides extend along a plane that is normal to the pivot bracket axis; in service, the guides are positioned so as to generally extend vertically. The guides pass through top and bottom plates that limit the translation of the sleeves thereon. The rotation of the pivot bracket with respect to the fixed frame can be limited by a bracket stop protrusion that extends from the top plate so as to engage the cross brace of the fixed frame to limit rotation of the pivot bracket.
FIG. 2 is an exploded view showing further details of how the pivot bracket shown in FIG. 1 is connected to the remaining structures. The pivot bracket has a bracket passage therethrough configured to slidably engage the pivot shaft, and a retaining collar is provided that attaches to the pivot shaft to trap the pivot bracket thereon. To engage the pivot bracket with the mounting frame, the guides are provided by a pair of guide pins that slide into guide passages in the top and bottom plates of the pivot bracket. The guide pins are inserted into the passages while the sleeves of the mounting frame are positioned between the top and bottom plates with sleeve passages aligned with the guide passages. When the guide pins are installed, the sleeves are trapped on the guide pins between the top and bottom plates.
FIG. 3 is an isometric view showing the pivot bracket shown in FIGS. 1 and 2 when connected to the fixed frame and the mounting frame.
FIG. 4 is an isometric view that illustrates another float mechanism of the present invention; this embodiment provides greater stability for the implement attached to the fixed frame. In this float mechanism, pivoting of the fixed frame relative to the mounting frame is further limited by a pair of substantially vertical slots that are slidably engaged by a transfer bar that serves as a stabilizing element as well as reducing bending moments on the pivot bracket. As illustrated, the transfer bar is affixed to the fixed frame, spaced apart vertically from the pivot shaft, and the slots are provided on the mounting frame. The slots are formed by slot plates affixed to the mounting frame in combination with closure plates that attach to the slot plates to close the remaining side of the slots. The use of a pair of slots to engage the transfer bar provides an effective three-point support for the implement to increase stability and reduce bending moments on the pivot shaft.
FIG. 5 is an isometric view of the embodiment shown in FIG. 4 when partially exploded to show further details of the structure associated with the vertical slots, including extendable blocks that can be positioned to immobilize the transfer bar in the slots to provide a rigid connection between the mounting frame and the fixed frame.
FIG. 6 is an isometric view illustrating an embodiment similar to that shown in FIGS. 4 and 5 , but where two vertical slots are provided on the fixed frame and engage a transfer bar attached to the mounting frame.
FIGS. 7 and 8 are isometric views showing an embodiment having a fixed frame that is provided with a pair of horizontal guide slots, each of which is slidably engaged by a vertically-extending transfer post affixed to the mounting frame. FIG. 7 shows the float mechanism partly exploded.
FIG. 8 is an isometric view showing the float mechanism shown in FIG. 7 when assembled and where relative motion between the frame members can be prevented by locking pins that engage both a mounting frame and at least one of the bars that define the horizontal guide slots.
FIG. 9 is a partially-exploded isometric view showing an embodiment similar to that shown in FIGS. 4 and 5 , but where the pivot bracket is provided with sleeves that slidably engage guides provided on the mounting frame.
FIG. 10 is a partially-exploded isometric view showing an embodiment similar to that shown in FIG. 9 , but where the pivot bracket engages a pivot shaft on the mounting frame, and has sleeves that slidably engage guides mounted to the fixed frame.
DETAILED DESCRIPTION
FIGS. 1-3 illustrate a float mechanism 10 that is designed for supporting a material moving implement such as a snowplow 12 to allow the snowplow 12 to move freely to traverse uneven ground surfaces while being supported on a vehicle (not shown). The float mechanism 10 has a fixed frame 14 that is affixed to the snowplow 12 , and can be made an integral part thereof. The float mechanism 10 also has a mounting frame 16 that is connected to the fixed frame 14 by a pivot bracket 18 . The mounting frame 16 in turn has a pair of substantially vertical supports 20 that are configured to releasably engage a conventional instant transfer connector on the vehicle, such as the instant transfer provided by Caterpillar Inc.
The fixed frame 14 has a pivot shaft 22 that extends along a pivot axis 24 . The pivot axis 24 is substantially horizontal when the float mechanism is in service, and extends in the direction of travel of the vehicle. In the float mechanism 10 , the pivot shaft 22 is mounted to a centrally-located cross-brace 26 that is affixed to the remainder of the fixed frame 14 . The pivot bracket 18 has a bracket passage 28 therethrough, which is lined with an appropriate weight-bearing low-friction bracket bushing 30 that slidably engages the pivot shaft 22 on the fixed frame 14 . The bracket bushing 30 can be a conventional grooved metal bushing. The pivot shaft 22 has a length sufficient that it extends beyond the bracket passage 28 . As shown in FIG. 2 , a pivot shaft passage 32 is provided through the pivot shaft 22 to accommodate a pivot shaft bolt 34 . A retaining collar 36 is configured to slidably engage the portion of the pivot shaft 22 that extends beyond the bracket passage 28 , and has a collar passage 38 into which the pivot shaft bolt 34 can be threadably secured. When the pivot bracket 18 and the retaining collar 36 are slidably engaged on the pivot shaft 22 , the collar passage 38 is aligned with the pivot shaft passage 32 and the pivot shaft bolt 34 can be inserted into the aligned passages ( 32 , 38 ) to retain the retaining collar 36 on the pivot shaft 22 with the pivot bracket 18 trapped between the retaining collar 36 and the fixed frame 14 , as shown in the assembled view of FIG. 3 . Preferably, bracket washers 40 of a durable, low-friction material such as nylon are interposed between the pivot bracket 18 and the fixed frame 14 , and between the pivot bracket 18 and the retaining collar 36 (as best shown in the exploded view of FIG. 2 ).
The pivot bracket 18 in turn is connected to the mounting frame 16 by a slide mechanism 42 that allows limited translation between the pivot bracket 18 and the mounting frame 16 , this motion being limited to translation in a plane that is normal to the pivot axis 24 . As shown in FIG. 2 , the pivot bracket 18 is provided with a top plate 44 and a bottom plate 46 , each having a pair of guide passages 48 into which guide pins 50 can be inserted. The guide passages 48 are centered on guide axes 52 which reside in a plane that is normal to the pivot axis 24 ; typically, the guide axes 52 are substantially vertical.
The mounting frame 16 has a pair of sleeves 54 , each having a sleeve passage 56 that is sized to slidably engage one of the guide pins 50 . When the sleeves 54 are placed between the top plate 44 and the bottom plate 46 with the sleeve passages 56 aligned with the guide passages 48 , the guide pins 50 can be inserted into the aligned passages ( 48 , 56 ) and secured to the pivot bracket 18 by guide pin bolts 58 that each pass through a bracket pin passage 60 on the pivot bracket 18 and a guide pin passage 62 through one of the guide pins 50 . The sleeve passages 56 are preferably lined with sleeve bushings 64 of a durable, low friction material such as nylon.
When the fixed frame 14 , the mounting frame 16 , and the pivot bracket 18 are so connected, the snowplow 12 is free to rotate about the pivot axis 24 to accommodate changing angles of road surfaces over which the snowplow 12 is operated. Additionally, the slidable engagement between the pivot bracket 18 and the mounting frame 16 allows the snowplow 12 a limited degree of vertical translation along the guide axes 52 to allow the snowplow 12 to ride over small obstructions.
While the position of the snowplow 12 is typically limited by the ground surface to be traversed, it is frequently desirable to limit the rotation of the snowplow 12 to maintain it in a generally horizontal position when lifted from the ground. The rotation of the snowplow 12 can be limited by means for limiting the rotation between the fixed frame 14 and the mounting frame 16 . One example of such means, shown in FIGS. 1-3 , is to provide a stop protrusion 66 affixed to the pivot bracket 18 and positioned to engage the cross-brace 26 of the fixed frame 14 when the fixed frame 14 rotates relative to the pivot bracket 18 by a predetermined angle.
While the float mechanism 10 can provide more stable support to the snowplow 12 than earlier float mechanisms, it relies solely on the connections of the pivot bracket 18 to maintain the motion of the fixed frame relative to the mounting frame constrained within a plane. This places great requirements for structural integrity on the pivot bracket, and makes it highly susceptible to wear. These disadvantages can be reduced by employing means for limiting the rotation between the fixed frame and the mounting frame that also aid in limiting the motion between these elements to motion within a plane.
FIGS. 4 and 5 illustrate a float mechanism 100 , which provides greater stability for an implement 102 attached to a fixed frame 104 compared to the float mechanism 10 discussed above. Again, a pivot bracket 106 is rotatably mounted to a pivot shaft 108 on the fixed frame 104 , and is connected and to a mounting frame 110 by a slide mechanism 112 . However, the float mechanism 100 differs in the means for limiting rotation between the fixed frame 104 and the mounting frame 110 that are employed.
In the float mechanism 100 , the pivot shaft 108 is located in a lower region 114 of the fixed frame 104 ; this position of the pivot shaft 108 will tend to reduce the moment of torques on the pivot bracket 106 resulting from forces transmitted by the implement 102 when in operation. Rotation of the fixed frame 104 relative to the mounting frame 110 is limited by a transfer bar 116 that is slidably restrained by engagement with a pair of guide slots 118 . The use of a pair of guide slots 118 to engage the transfer bar 116 provides an effective three-point support for the implement 102 to further reduce bending moments on the pivot shaft 108 and the pivot bracket 106 , as well as increasing the stability of the implement 102 when in motion.
The transfer bar 116 in this embodiment is affixed to the fixed frame 104 so as to extend substantially horizontally, and is spaced apart vertically from the pivot shaft 108 so as to be located in an upper region 120 of the fixed frame 104 . The guide slots 118 are provided on the mounting frame 110 , and extend substantially vertically, extending parallel to the direction of motion provided by the slide mechanism 112 . The guide slots 118 are each formed by a slot plate 122 affixed to the mounting frame 110 , in combination with a closure plate 124 that attaches to the slot plate 122 to close the remaining side of the guide slot 118 . The slot plate 122 and the closure plate 124 are each provided with a replaceable bearing surface ( 126 , 128 ) of a durable, low-friction material such as nylon. The transfer bar 116 has a pair of opposed bar vertical sides 130 , and when the closure plate 124 is attached to the slot plate 122 with the transfer bar 116 interposed therebetween, the bearing surfaces ( 126 , 128 ) are positioned against the bar vertical sides 130 to limit the motion of the transfer bar 116 relative to the guide slot 118 to motion within a nominally vertical plane. Each of the closure plates 124 can be attached to its associated the slot plate 122 by bolts 132 that are inserted through aligned passages ( 134 , 136 ) in the closure plate 124 and the slot plate 122 .
Rotation of the fixed frame 104 with respect to the mounting frame 110 is limited by the motion of the transfer bar 116 in the guide slots 118 . Each of the slot plates 122 has a slot upper plate 138 that defines an upper end of the guide slot 118 , while a lower end of the guide slot 118 is defined by a blocking plate 140 that slidably engages a block mounting bracket 142 affixed to the slot plate 122 . Both the slot upper plate 138 and the blocking plate 140 are preferably provided with resilient pads 144 for respectively engaging a bar upper surface 146 and a bar lower surface 148 of the transfer bar 116 to limit its movement with respect to the guide slot 118 . As the fixed frame 104 rotates with respect to the mounting frame 110 about a pivot axis 150 defined by the pivot shaft 108 , at some point the bar upper surface 146 or the bar lower surface 148 will engage one of the resilient pads 144 , this engagement serving to block further rotation in that direction.
When the blocking plates 140 that form the lower ends of the guide slots 118 are movably mounted to the mounting frame 110 , they can allow the float mechanism 100 to be disabled to provide a rigid connection between the mounting frame 110 and the fixed frame 104 . This can be beneficial when the implement 102 is capable of being used as a loader bucket; such an implement that can be configured to operate either as a plow or as a loader bucket is taught in U.S. Pat. No. 7,360,327.
In the float mechanism 100 , each of the blocking plates 140 has an upper block passage 152 and a lower block passage 154 therethrough, either of which can be aligned with a block bracket passage 156 in the block mounting bracket 142 to allow a block pin 158 to be passed through the aligned passages ( 152 or 154 , 156 ) to fix the position of the blocking plate 140 with respect to the slot plate 122 . When the block upper passage 152 is aligned with the block bracket passage 156 and pinned, the blocking plate 140 is fixed in a retracted position (as shown in FIG. 4 ) where it is spaced apart from the slot upper plate 138 by a sufficient distance to allow the desired degree of movement of the transfer bar 116 in the guide slot 118 . However, when the blocking plate 140 is positioned such that the block lower passage 154 is aligned with the block bracket passage 156 , passing the block pin 158 through the aligned passages ( 154 , 156 ) fixes the blocking plate 140 in an extended position (shown in FIG. 5 ) where its separation from the slot upper plate 138 (measured between the opposed surfaces of the resilient pads 144 ) is about the same as the separation between the bar upper surface 146 and the bar lower surface 148 of the transfer bar 116 , thereby preventing vertical movement of the transfer bar 116 in the guide slot 118 . Since horizontal motion of the transfer bar 116 relative to the guide slot 118 is prevented by the connection of the pivot bracket 108 to the fixed frame 104 and the mounting frame 110 , pinning the blocking plates 140 into their extended positions effectively immobilizes the fixed frame 104 relative to the mounting frame 110 , allowing the implement 102 to be used as a loading bucket without undesirable free movement resulting from shifting of loads supported by the implement 102 .
FIG. 6 is an isometric view of a float mechanism 200 which shares many features in common with the float mechanism 100 discussed above, having a fixed frame 202 that is pivotably connected to a pivot bracket 204 which in turn is slidably connected to a mounting frame 206 . In the float mechanism 200 , rotation of the fixed frame 202 with respect to the mounting frame 206 is again provided by a transfer bar 208 that is slidably engaged in a pair of guide slots 210 . However, in this embodiment, the transfer bar 208 is affixed to the mounting frame 206 , while the guide slots 210 are formed by slot plates 212 affixed to the fixed frame 202 , in combination with closure plates 214 . The closure plates 214 attach to the slot plates 212 with the transfer bar 208 trapped therebetween. Again, the slot plates 212 are each provided with a block mounting bracket 216 in which a blocking plate 218 can be affixed in either an extended or retracted position. With respect to the third stabilizing element to prevent tilting between the frames ( 202 , 206 ) such is provided by the pivot bracket 204 which engages a pivot shaft 220 and is further stabilized by washers 222 and a retaining collar 224 .
FIGS. 7 and 8 illustrate an alternative float mechanism 300 , which again has a fixed frame 302 pivotably connected to a pivot bracket 304 that in turn slidably engages a mounting frame 306 . In this embodiment, the fixed frame 302 is stabilized with respect to the mounting frame 306 by a pair of guide slots 308 that extend horizontally along the fixed frame 302 , in combination with a pair of vertically-extending guide bars 310 affixed to the mounting frame 306 . However, in the float mechanism 300 illustrated, the guide slots 308 and the guide bars 310 are not employed to limit the rotation of the fixed frame 302 relative to the mounting frame 306 .
The fixed frame 302 is provided with a horizontally-extending slot bar 312 that is provided with a slot bearing surface 314 of a durable, low-friction material. A series of slot brackets 316 are also provided, to which a closure bar 318 can be attached by slot bar bolts 320 . The closure bar 318 has a bar bearing surface 322 of a durable, low-friction material, positioned so as to be opposed to the slot bearing surface 314 when the closure bar 318 is secured to the slot brackets 316 , these opposed surfaces ( 314 , 322 ) defining parallel sides of the guide slots 308 .
The guide bars 310 are each provided on a guide plate 324 affixed to the mounting frame 306 . The guide bars 310 have opposed guide surfaces 326 spaced apart to slidably engage the slot bearing surface 314 and the bar bearing surface 322 , to provide additional support regions between the frames ( 302 , 306 ), thereby reducing the torques on the pivot bracket 304 .
While the slot brackets 316 which serve to terminate the guide slots 308 and the guide bars 310 could serve to limit the rotation of the fixed frame 302 with respect to the mounting frame 306 , in this embodiment such rotation is more restrictively limited by stops 328 on the fixed frame 302 that are positioned to engage the guide plates 324 to limit such rotation, thereby providing a narrower limit of motion. Preferably, the stops 328 are each provided with a resilient pad 330 .
This embodiment also employs a different scheme for deactivating the float mechanism 300 for use supporting a loading bucket. The guide plates 324 are each provided with a guide plate passage 332 , which can be aligned with closure bar passages 334 provided in the closure bar 318 . When so aligned, deactivation pins 336 can be inserted into the aligned passages ( 332 , 334 ) to prevent movement of the fixed frame 302 with respect to the mounting frame 306 .
FIG. 9 illustrates a float mechanism 400 that has many features in common with the float mechanism 100 shown in FIGS. 4 and 5 , but which differs in the connection between a pivot bracket 402 and a mounting frame 404 . In this embodiment, the pivot bracket 402 is provided with bracket sleeves 406 that are configured to slidably engage guides 408 that are attached to the mounting frame 404 so as to provide a slide mechanism 410 . The guides 408 each terminate at a top plate 412 and a bottom plate 414 to limit the slidable engagement between the pivot bracket 402 and the mounting frame 404 . The pivot bracket 402 in turn is pivotably mounted to a fixed frame 416 in a manner similar to the connection between the pivot bracket 18 and the fixed frame 14 discussed in detail above with regard to FIGS. 1-3 .
FIG. 10 illustrates another alternative embodiment, a float mechanism 450 where a pivot bracket 452 is pivotably connected to a mounting frame 454 and slidably connected to a fixed frame 456 . In this embodiment, the mounting frame 454 is provided with a pivot shaft 458 that slidably engages a bracket passage 460 through the pivot bracket 452 . A retaining collar 462 attaches to the pivot shaft 458 to trap the pivot bracket 452 thereon to pivotably connect the pivot bracket 452 to the mounting frame 454 .
The pivot bracket 452 in turn has a pair of bracket sleeves 464 that slidably engage a pair of guides 466 that are mounted to the fixed frame 456 to allow a limited degree of translational motion between the pivot bracket 452 and the fixed frame 456 . The translation is limited by a top plate 468 and a bottom plate 470 .
While the novel features of the present invention have been described in terms of particular embodiments and preferred applications, it should be appreciated by one skilled in the art that substitution of materials and modification of details can be made without departing from the spirit of the invention. | A float mechanism for movably attaching an implement to a vehicle has a mounting frame that connects onto the vehicle and a fixed frame that affixes to the implement. A pivot bracket pivotally attaches to one of the frames and is slidably connected to the other to accommodate a limited degree of translational motion. The pivot bracket can slidably connect to the frame by a pair of guides in combination with a pair of sleeves. Rotational motion between the fixed frame and the mounting frame can be limited by slots in one of the frames that are slidably engaged by a stabilizing element on the other frame. When the stabilizing element is a horizontal bar, it can engage a pair of vertical slots. To optionally eliminate the free motion between the frames, movable blocks can be employed to limit the motion of each stabilizing element in its slot. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to tire monitoring systems particularly to wireless systems for indicating tire temperature and pressure on a display unit mounted within a motor vehicle.
The system which is described hereinafter is called the SENSATEC™ tire monitoring system. Other tire monitoring systems, such as the Fleet Specialties product, cannot provide internal tire temperature but rather measure gross pressure variation and are dedicated to a particular tire. The unit cannot be switched to another tire nor is it possible to measure temperature.
Another commercial tire monitoring unit is manufactured by Kisan Corporation which employs a transducer with a pick-up coil to generate a magnetic field producing a signal whose strength varies with tire pressure. The system requires replacement of the typical valve stem.
The prior art also includes U.S. Pat. No. 4,954,677 to Alberter, et al which comprises a tire pressure sensor including a reference gas pressure chamber and an electrically conductive diaphragm for activating a sensor circuit when the pressure is at a predetermined value.
U.S. Pat. No. 4,529,961 to Nishimura, et al employs a Bourdon tube which deforms with pressure to provide a signal. Bowler U.S. Pat. Nos. 5,231,872 and 5,335,540 describe a complicated tire monitoring apparatus for monitoring trucks while in use.
Other patents of interest include Brown U.S. Pat. No. 4,978,941 on a truck tire monitor and U.S. Pat. No. 5,035,137 to Burkard Also included are U.S. Pat. Nos. 4,966,034; 5,071,259; 5,140,851; and, 5,230,243.
The present inventions discloses a unique tire pressure and temperature monitor suitable for use on automobiles, trucks or other apparatus utilizing pneumatic tires.
SUMMARY OF THE INVENTION
This invention relates to a tire monitoring apparatus and particularly to an apparatus for displaying dynamic readings of a motor vehicle's tire pressure, temperature, and tire ride efficiency.
The apparatus comprises individual integrated units that are removable and readily screwed onto each valve stem. The monitoring units comprise a temperature sensor and a pressure sensor which feed signals to a microcontroller. The sensors are each battery powered and are keyed to a specific serial number. The resultant output signals are fed to a transmitter/receiver which transmits signals to a display unit located within the vehicle's passenger compartment. The signals are received by a transmitter/receiver set in the display unit, processed by a microcontroller and appear as a digital measurement with visual graphics/character and tri-color displays.
In operation, the system operates on vehicle start-up. The display unit queries each tire unit with a unique electronic identification or serial number that readies the tires to transmit tire data. The sensors then transmit tire pressure and temperature measurements back to the display unit which displays the pressure and temperature of each tire at various time intervals. Alarm means are provided to alert the operator if the temperature or pressure is potentially dangerous or out of range. The microcontroller in the display unit also computes and displays an overall tire-mileage/pressure/wear efficiency reading for the operator to observe.
The sensors are each self-contained and battery powered. The sensors also have a theft deterrent feature wherein each sensor has a unique electronic identification or serial number which renders them useless in other vehicles.
Accordingly, an object of this invention is to provide a new and improved tire monitoring system to provide dynamic measurements of tire pressure and temperature.
Another object of this invention is to provide a new and improved wireless tire monitoring system wherein individual monitoring units are readily attachable to valve stems.
A further object of this invention is to provide a new and improved tire monitoring system wherein sensors having a theft deterrent electronic ID are screwed on a valve stem and provide readings in a display mounted within a motor vehicle.
A more specific object of this invention is to provide a new and improved wireless tire monitoring system for pressure, temperature and tire wear efficiency wherein tire sensors removably mounted on each valve stem transmit a signal to a display through a microcontroller to alert the operator if the temperature or pressure is out of range or potentially dangerous through visual and audio warnings.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of this invention may be more clearly seen when viewed in conjunction with the accompanying drawings wherein:
FIG. 1 is a cross-sectional view of a remotely mounted sensor;
FIG. 2 is a perspective view of the display or local unit;
FIG. 3 is a schematic drawing of the remote temperature and pressure sensor system; and,
FIG. 4 is a schematic drawing of the dash unit receiver system.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 of the drawings, the invention comprises a tire monitoring system including a sensor unit 10 which screws onto a tire valve stem 11. Separate sensor units 10 are provided for each tire. The sensor unit 10 includes a bushing retainer 12 at its lower end 15 having an aperture 13 to engage the valve stem 11. The unit 10 further includes an outer casing 14 having a threaded recess 16 at its lower end 15 to engage the threaded valve stem 11. The recess 16 is in line with the bushing aperture 13 with the bushing 12 coupled to the lower end 15 of the casing 14.
A pressure sensor 20 is mounted at the upper internal end of the recess 16 and is fixed in position by a sealing nut 17 mounted on an O-ring 18. A battery 19 is located in engagement with the sealing nut 17 and pressure sensor 20. A cap 21 seals the upper end of the casing 14.
A temperature sensor 30a is also mounted within the sensor unit 10 to measure internal tire temperature as well as a sensor 30b to measure ambient air temperature. As shown in FIG. 3, the sensor unit 10 further includes a transmitter 31, a receiver 35 and a microcontroller 32 which receives and processes signals from the sensors 20 and 30a, 30b. The output of the microcontroller 32 is fed to the transmitter 31 which sends the pressure and temperature signals to a transceiver 63 mounted in a display unit 50 in the cab or passenger compartment of a motor vehicle.
The display or local unit 50 may be powered by batteries or wired to the vehicle electrical system. As shown in FIG. 2, the display unit 50 comprises a rectangular case 51 having control buttons for mode select 52, enter 53 and alarm silence 54 and a main graphics/character display 55 utilizing backlit LCD as well as tri-color LED's 58 visual indicators. Control buttons 56 and 57 with arrows located thereon are used to check the various tires. A serial port 59 is also included for connection to a computer for data logging purposes.
Mounted within the display unit 50 is a transceiver 63 and microcontroller 62 which queries the sensor unit 10 and receives sensing signals from transmitter 31 in response to its inquiry. The sensed signals are fed to a microcontroller 62 which processes the signals and supplies measured readings to the graphics/character display 55, and tire status to the tri-color LED's 58.
In operation, power is turned on in the main unit mounted within the display box 50. An initial self diagnostic check is made involving the LCD 55 and LED displays 58, communication with each sensing unit 10 and the system electronics. The operator will be alerted if a malfunction exists. If the status is acceptable, the system is ready for normal operation.
The display or control unit 50 transmits a wake up (requester) call to each sensor unit 10 in sequence. This signal activates the sensor units 10 from their normal lower power mode, specifically, the pressure sensor 20 and the temperature sensors 30a and 30b. The sensors 20 and 30a, 30b measure pressure and temperature respectively and transmit this information along with its location to the receiver 61. The resultant signal is fed to the display unit 50 and appears on both display units 55, 58. Vehicle weight information and pressure balance "quality of ride" information may also be displayed. In this case, the weight information would be derived from dynamic pressure and temperature and physical tire parameters. The quality of ride information is derived from dynamic pressure and temperature measurements. The initial measurements are complete when all tire positions have been queried once. Dynamic measurements are taken at regular intervals.
Whenever measurements are slightly out of range, a mild warning tone will sound and the graphic display 55 will show a warning signal. The effected tire position will be highlighted in yellow on the display 58.
The system is quite effective since a loud warning will sound when the measurement parameters are substantially out of the range determined by the user. At that time, the display 55 will show a warning message and the custom tri-color LED 58 tire position will highlight the effective tire position in red. As an added protection, a tone will sound and a message will appear on the display 55 when the battery is low.
At the end of monitoring inquiry, the display and control unit 50 may be turned off manually or automatically. Just before the actual power down, the unit 50 sends a requester signal to all sensors 10 which deactivates them or puts them in a sleep mode.
As a further feature, the display unit 50 includes an anti-theft connection that allows it to be wired to a vehicle's existing alarm system. The alarm is triggered by the removal of a sensor 10 which causes the particular sensor to suddenly register zero pressure.
The display or local unit 50 is internally mounted within the vehicle. This unit 50 is available in multiple styles--such as visor, dash or center console mounting. Regardless of mounting style or location, functionality will remain the same. The unit 50 will be constructed of ABS or a similar plastic material. In the trucking industry, all reference to sensor quantity will be assumed to be 18 for 18 wheel vehicles. This, however, is neither a product limitation or fixed quantity. Provisions for a "plug-in" LED display module 64 depicting a tandem trailer, as in the case of a dual trailer truck, may be included. This would raise the LED display quantity count to 26.
The display or local unit 50, shown in FIG. 4, will consist of an ultra low power CMOS Microcontroller 62, a near 900 Mhz bi-directional radio transreceiver 63, backlit LCD alphanumeric display module 55, tri-color LED 58 physical status indicators and data keypad 65. The keypad 65 will provide provisions for alarm silence, 54 mode select 52 and enter 53 buttons with up and down control buttons 56 and 57 for parameter entry.
On the first application of power, the local unit 50 will request the entry of serial numbers for the remote tire sensors 10 by their relative locations (this does not mean that they cannot be moved later). Upon completion of this introduction, this process will not have to be repeated again. On subsequent power up conditions, the local unit 50 will perform a circular query of the known sensors for both presence and operational conditions.
Functionality of the unit 50 will consist of a sequential query of each remote sensor 10 in the following manner. The local unit 50 will transmit a "wake up" signal, specifically designed to initiate the remote sensor transmission/reception process. This process will begin by sending the appropriate serial number, thus allowing the remaining sensors 10 to go back to sleep, while assuring communication with the correct device.
A request will be initiated for pressure, temperature (tire and ambient) and battery conditions. Upon reception of this information, the local unit 50 will then store the received information and then transmit an "OK" signal, thus assuring proper data receipt. In the event of inappropriate data, request for retransmission will be requested from the remote sensor 10. If all data appears to be in order, a sleep command will be issued to the appropriate sensor 10. This process, while appearing cumbersome, will thus assure maximum battery life of the remote sensor 10. The cycle will then continue for all known remote sensors 10, collecting data in a similar fashion. Upon receipt of all data, the display will then update all LED indicators 58 to their appropriate status. Green would indicate OK, yellow would indicate warning and red would indicate alarm. If a warning or alarm condition should occur, an internal beeper sounds, thus alerting the vehicle operator. This condition will also trigger a constant monitor of the particular tire in question. Provisions for theft of the sensors have also been provided. The local unit can query the sensors periodically when the vehicle is parked and if the signal for a known sensor 10 is not received, trigger an alarm or send a signal to the vehicle alarm system.
The remote sensor unit 10 will consist of an ultra low power CMOS Microcontroller 32, a near 900 Mhz bi-directional radio transceiver 34, pressure 20 and temperature sensors 30a, 30b (tire and ambient). The unit will be housed in a "screw on" valve mounted plastic housing 14. This housing 14 will also be weather-tight so as to protect the electronics from the elements, such as rain, snow and dirt. The unit 10 will perform simple data collection of pressure, temperature and battery level. This data will then be transmitted to the local unit when a request is received. Upon satisfactory data transmission, the unit will put itself in a "sleep" mode to preserve battery life. The cycle will then be repeated when a "wake up" is received. The remote sensor 10 will also have a unique serial number embedded within the microcontroller program code. This number is not configurable by the user or the factory once set. This feature will also deter theft because the unit 10 will be useless to someone not having the serial number. Also, there has been a "breakaway" area designed into the housing so in the event of physical damage--such as hitting the curb or vandalism, the unit 10 will shear off at a predetermined spot so as to not allow air pressure from escaping from the tire valve.
While the invention has been explained by a detailed description of certain specific embodiments, it is understood that various modifications and substitutions can be made in any of them within the scope of the appended claims which are intended also to include equivalents of such embodiments. | A system for displaying dynamic readings of a motor vehicle's tire pressure, temperature and tire ride efficiency comprises individual integrated units that are removably attached to each valve stem. Each unit comprises a pressure sensor and a temperature sensor coupled to a microcontroller which activates a transmitter/receiver set with a measured signal. The signal is received by a transmitter/receiver set in a passenger compartment mounted display which feeds a signal through a microcontroller to the display unit. In operation, theft prevention serial numbers of the remote sensors are entered in the display unit. Each individual sensor may then be queried sequentially with the appropriate serial number to provide a pressure and temperature reading for a particular tire as well as battery condition. The readings and warning signals are activated in the display unit. | 1 |
TECHNICAL FIELD
The invention relates to semiconductor chip packages and more particularly to systems and methods for lowering the profile of semiconductor devices using lead frames.
BACKGROUND OF THE INVENTION
Leadframes are used to provide a stable support structure for positioning a semiconductor die during semiconductor manufacturing. Typical leadframes include a centrally located die attach pad (DAP) surrounded by a plurality of conductive lead segments used to attach various electrical conductors in close proximity to the die. The remaining gaps between the lead segments and conductor pads on the die surface are typically bridged by thin metallic wires. In application, the other ends of the lead segments can be electrically connected to other structures, for example, a printed circuit board.
Limitations of typical lead frame-based IC manufacturing technologies include delamination defects, relatively large product size, relatively large product thickness (high profile) and limited thermal and electrical conductivity of the product. Typical lead frame design presents size constraints which limit the opportunity to reduce overall device volume. Delamination defects are often associated with the epoxy/device interface at the DAP. Additionally, electrical conductivity may be impaired as the layers of epoxy and DAP each have associated impedances. The combined impedance of the epoxy and DAP often degrades overall device performance.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to systems and methods for manufacturing a semiconductor integrated circuit (IC) device without use of a die attach pad (DAP). In place of a DAP, an adhesive element is used to temporarily secure a die within a lead frame opening during processing. In one embodiment, a method includes applying an adhesive tape to one side of a lead frame. At the opposite side, adhesive is exposed within an opening of the lead frame. The opening and exposed adhesive define a region used to secure a die. The die is placed on the adhesive surface within the die attach region and is held by the adhesive tape during subsequent processing, including for example, a wire bonding procedure which couples the die to external portions of the frame. Wire bonding, such as bond stitch on ball (BSOB), may be used to connect the die to external portions of the frame prior to an encapsulation process. Chip packages can be separated from the lead frame via a singulation process including, for example, punch or saw procedures.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
FIG. 1 shows a perspective view of one embodiment of a lead frame semiconductor device;
FIGS. 2 through 5 show perspective views of a lead frame assembly using the lead frame of FIG. 1 ;
FIG. 6 shows a cross-sectional view of a lead frame assembly of FIG. 5 taken along lines 6 - 6 ;
FIG. 7 shows a flow chart of a manufacturing process using the lead frame of FIG. 1 ;
FIG. 8 is a perspective exploded view of components of a prior art package.
DETAILED DESCRIPTION OF THE INVENTION
Prior to a detailed description of the inventive concepts, it might be helpful to review prior art technology with respect to FIG. 8 . Assembly 80 in FIG. 8 depicts bonding of die 800 to die attach pad 802 of lead frame 804 during a manufacturing process. Die attach pad 802 is secured relative to side rails 803 of lead frame 804 via a pair of arms 805 . Once die 800 is bonded thereto, die attach pad 802 provides a relatively stable base for die 800 during a subsequent wiring process. Die 800 is electrically connected to a plurality of leads 808 through bonding wires which connect bonding pads 812 on an upper surface of die 800 to respective corresponding leads 808 . Die 800 , die attach pad 802 and bonding wires 810 are encapsulated to provide a package body.
FIG. 1 shows a perspective view of one embodiment 10 of a semiconductor device having frame 11 suitable for employment with a method according to an embodiment of the invention. In the embodiment shown, frame 11 is a lead frame and has a pair of opposing side rails 12 and a pair of rows of leads 14 . Frame 11 may be a half-etched frame. Side rails 12 are disposed so that one is opposed to the other, and, in one example, have plural through-holes 16 formed at regular intervals. Side rails 12 , in this embodiment, are in mechanical contact with rails (not shown) having a plurality of projections when transferring lead frame 11 within a semiconductor chip packaging line. The rail projections engage through-holes 16 of side rail 12 . Thus, when the rail moves, lead frame 11 is transferred accordingly.
Frame 11 does not have a die attach pad (DAP) located between side rail 12 and leads 14 , unlike conventional lead frames as shown in FIG. 8 . In place of a DAP, die attach region 18 is defined generally as the region between side rails 12 and leads 14 into which a die will be subsequently placed. In one embodiment, die attach region 18 is defined within a lead frame aperture.
FIG. 2 is an exploded perspective view showing assembly 20 including tape 22 applied to an under surface of lead frame 11 . In the illustrated embodiment, tape 22 extends between the side rails 12 and adheres across the surface of lead frame 11 . Tape 22 in alternative embodiments may be larger or smaller in width as compared to the width of lead frame 11 . Tape 22 may be applied using any of a variety of assembly processes. In this example, tape 22 is a high temperature polyimide adhesive tape. However, other inventive methods may employ one or more other kinds of tape.
Assembly 20 depicts silicon die 23 being brought into contact with adhesive tape 22 within die attach region 18 of frame 11 . Silicon die 23 includes a plurality of bonding pads or terminals 24 on a top surface and a plurality of contact pads or terminals 25 on an opposite lower surface. Tape 22 maintains die 23 within die attach region 18 during a subsequent wiring process. Note that die 23 can be attached to adhesive tape 22 before tape 22 is positioned on frame 11 .
FIG. 3 shows assembly 30 subsequent to a wire bonding process wherein individual wires 36 are connected between the row of leads 14 and bonding pads 34 so as to electrically and mechanically connect die 23 to device 10 . A variety of different wire bonding techniques may be utilized to perform this step. Advanced bonding techniques, such as bond stitch on ball (BSOB), may be utilized to provide low profile loop heights.
FIG. 4 shows assembly 40 subsequent to an encapsulation process. The encapsulation process includes, for example, resin compound 42 placed so as to cover the die 23 , wires 36 and inner portions of leads 14 . A liquid resin compound, such as a polyimide compound, can be used. After the encapsulation process, tape 22 is removed, either partially or fully, to expose lower contact terminals 25 of die 23 . At this point individual packages can be defined through a separation process utilizing, for example, sawing, forming or punching techniques. Tape 22 can be removed from die 23 prior to or subsequent to the separation process.
FIG. 5 shows assembly 50 and depicts a separation process wherein encapsulant 42 containing die 23 is separated from lead frame 11 . Typical punch or sawing processes may be utilized.
FIG. 6 shows a cross-sectional view of die 23 within encapsulant 42 forming part of device 60 . Device 60 includes printed circuit board 62 . Contact pads 25 of die 23 are directly connected to traces 63 of printed circuit board 62 . Pads 14 are also connected to traces 63 of printed circuit board 62 or to other devices.
FIG. 7 shows process flow chart 70 in accordance with an embodiment of the invention. In an initial step 71 , lead frame 11 is provided, for example, in roll form. At step 72 , adhesive tape 22 is brought into contact with a surface of lead frame 11 covering the openings and providing an adhesive surface at an opposite side of lead frame 11 within die attach region 18 . At step 73 , die 23 is brought into contact with the adhesive surface of tape 22 within die attach region 18 . Die 23 was previously processed through, for example, wafer sawing process 74 . At step 75 , tape 22 adhesively retains die 23 within region 18 during a wiring process. The wiring process connects bonding pads 24 of die 23 to leads 14 of frame 11 . At step 76 , die 23 and portions of lead frame 11 are encapsulated using an encapsulation processes. Subsequent to encapsulation, tape 22 is removed at step 77 to exposed contacts 25 . At step 78 , a singulation process separates encapsulated dies 23 from lead frame 11 . Further processing can be employed to yield a discrete package suitable for applications, such as direct connection to a printed circuit board.
Chip fabrication processes according to various embodiments of the present invention eliminate lamination defects of epoxy/die attach pad interface. A reduction of overall device size can be attained. For example, overall profiles of 4-5 mm may be achieved. Additionally, chip performance can be increased through an impedance reduction achieved by elimination of a DAP and direct solder contact of the lower die pads 25 to corresponding pads on a printed circuit board. Note, during fabrication, pads 25 can be covered to prevent contamination from the adhesive of tape 22 . For purposes of this application, such pads will be considered in contact with the adhesive of tape 22 .
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | A semiconductor integrated circuit (IC) device is defined by a low-profile package without a die attach pad (DAP). In place of the DAP, an adhesive element is used to retain a die relative to a lead frame during processing. In one example, a method of manufacturing the device includes sealing the lead frame on one side using an adhesive tape and exposing a portion of the tape within a die attach region. The die is secured onto the tape adhesive and held in place during subsequent processing, such as a wire bonding procedure to couple the die to external portions of the frame. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to a method for joining tubing, fittings and valves of different standard diameter types.
For the purposes of the invention description presented herein, "CT" will be used to represent "standard water tube" size copper and copper alloy tubing, and "IP" will be used to represent "standard outside diameter" size steel pipe. In addition, the terms "tubing" and "pipe" are considered to be interchangeable, and reference to "copper tubing" will also be taken as referring to "copper alloy tubing" as an alternative.
A grooved end pipe coupling, e.g. of the type illustrated in FIG. 1, is used for joining together piping elements, e.g. tubing, fittings, valves, etc., in a leak tight assembly by use of grooves that are cut, cast or formed in the ends of the piping elements. Referring to FIGS. 2 and 3, critical parameters of a grooved end connection include: the gasket seat diameter, D s , groove diameter, D g , gasket seat width, W s , and groove width, W g . In the case of wrought metal piping elements, e.g., as above, tubing, fittings or valve bodies, the grooved end of the piping element, P, is conventionally produced by either a machining (cut) operation or a rolling (formed) operation as shown in piping element, P cut , of FIG. 2, and piping element P roll , of FIG. 3, respectively. In the case of a cast fitting or valve body, the grooved end connection is normally either cut in the configuration of a piping element, P cut shown in FIG. 2, or cast in the dual outward step configuration of a piping element, P cast , shown in FIG. 4.
Referring again to FIG. 1, a typical grooved end pipe coupling 10 consists of two or more housing segments 12, 14, a gasket 16, and fastening means, e.g. nuts 18 and bolts 20 for securing the assembly together with the end connections to be joined. The housing segments have keys 22 around the inner periphery at both ends, a shoulder 24 also around and just inside of each key, and a gasket cavity 26. The keys fit into the grooves 30 to axially and transversely retain the end connections. The keys and shoulders are involved to varying degrees in maintaining the coupling assembly generally centered about the grooved end connection. The shoulder fits closely around the gasket seat diameter to prevent the gasket from extruding outwardly under the internal pressure of the piping system, the gasket being retained in the gasket cavity and producing a seal on the gasket seat surfaces to form a leak tight assembly.
Traditionally, copper tubing has been joined by soldering or brazing. However, recent emphasis on use of lead free solder has considerably increased the difficulty of producing a soldered, leak free joint, especially in the 3 inch and above tubing diameter sizes. This has increased the potential cost effectiveness of using grooved end pipe couplings in copper tubing system construction.
Until now, grooved end pipe couplings for joining copper piping elements (tubing, fittings, valves, etc.) have typically been available only in couplings specifically designed to accommodate CT size wrought copper tubing, which has average outside diameters that are slightly less than those for the same nominal IP size steel pipe (as detailed, e.g., in the publication "The Copper Connection" by The Victaulic Company of America). By way of example only, a 4-inch nominal CT size copper tube has an average outside diameter ("OD") of 4.125 inches, while 4-inch nominal IP size steel pipe has an average outside diameter of 4.500 inches.
In addition to the use of specifically designed grooved end pipe couplings, however, within the present state of the art, other means have been employed to join tubing with an average outside diameter smaller than the actual diameter of an IP size steel pipe of the same nominal diameter. For example, a specially designed ring with an average outside diameter equivalent to that of IP size pipe may be secured in a sealed arrangement to the end of a tube having a smaller average outside diameter, or the average outside diameter of the pipe can be increased to that of IP size pipe through the use of a ring secured in a sealed arrangement around the ends of lower average diameter pipe. These approaches would be similar to the Type A through E pipe end ring concepts shown in AWWA Standard C-606 for Grooved and Shouldered Joints.
Also, it has been known to expand the end of a pipe (roll forming), although the published objectives of this process have been to either expand the ends of IP size grooved end steel pipe to eliminate the reduced wall thickness of machined (cut) groove joints, or to eliminate the protrusion 32 inside the pipe which is associated with conventional roll grooving as shown in FIG. 3, and described in Table A, below.
Prior art concerning roll grooving of copper tubing is also described in the brochure "The Copper Connection", by Victaulic Company of America, with respect to their specially designed copper connections. These grooved end couplings are of the same basic concept or design as grooved end pipe couplings for IP size steel pipe; however, the dimensions of the couplings have been dimensionally altered to accommodate the smaller average outside diameter dimensions for copper tubing.
TABLE A______________________________________Roll Groove Dimensions for Steel Pipe (Inches)NOMINAL W.sub.s W.sub.g D.sub.g D.sub.s______________________________________2 .625 .344 2.250-.015 2.3752-1/2 .625 .344 2.720-.018 2.8753 .625 .344 3.344-.018 3.5004 .625 .344 4.344-.020 4.5005 .625 .344 5.395-.022 5.5626 .625 .344 6.455-.022 6.625______________________________________ Tolerances: W.sub.s, W.sub.g = ±.030 D.sub.g = +.000 D.sub.s = See OD tolerance in Table I (below).
Standard roll grooving reduces the internal diameter of the tubing at the roll groove and thereby increases the restriction to the fluid flow stream. This somewhat impedes fluid flow through the pipe and also creates an area for possible damage when used in abrasive media service. This process is also described in literature for the Victaulic Company of America Style 24 expanded pipe coupling, which is used to expand carbon steel pipe in abrasive service where the radially inward indentation created by standard roll grooving would be subject to excessive abrasion. This process, however, forms only the pipe end shoulder.
SUMMARY OF THE INVENTION
According to the invention, an apparatus for forming a piping element connection having multiple outward steps comprises a first roller mounted for rotation about a first axis, the first roller defining at least a first upper surface of rotation extending axially and centered about the first axis, and a second upper surface of rotation extending axially and centered about the first axis, the first upper surface having a mean diameter and the second upper surface having a mean diameter, the mean diameter of the first upper surface being less than the mean diameter of the second upper surface, and the first roller further defining an upper leading edge between the first upper surface and the second upper surface, a second roller mounted for rotation about a second axis parallel to the first axis, the second roller defining at least a first lower surface of rotation extending axially and centered about the second axis, and a second lower surface of rotation extending axially and centered about the second axis, the first lower surface having a mean diameter and the second lower surface having a mean diameter, the mean diameter of the first lower surface being greater than the mean diameter of the second lower surface, and the second roller further defining a lower trailing edge between the first lower surface and the second lower surface, means for driving the second roller to rotate about the second axis, and the first roller and the second roller mounted for relative movement together and apart in a plane of the first axis and the second axis for engagement and forming of multiple outward steps in a piping element connection placed therebetween, the first upper surface being disposed in substantial axial registration with the first lower surface, the second upper surface being disposed in substantial axial registration with the second lower surface, and the upper leading edge being offset axially from the lower trailing edge to provide a predetermined spacing dependent upon wall thickness of the piping element in which multiple outward steps are to be formed, and at least one positioning roller mounted for rotation about a third axis parallel to the first axis and offset from the plane of the first and second axes and having a surface positioned for engagement with an outside surface of the piping element.
Preferred embodiments of this aspect of the invention may include one or more of the following additional features. The first lower surface has a taper extending axially and inwardly from a region of the lower trailing edge, toward the second axis. Preferably, the taper has an angle of approximately 1° to 3°. The second roller further defines an end surface adjacent the first lower surface and spaced from the lower trailing edge, the end surface extending radially and generally perpendicular to the second axis. The apparatus further comprises a first positioning roller mounted for rotation about a third axis parallel to the first axis and offset to a first side of the plane of the first and second axes, and a second positioning roller mounted for rotation about a fourth axis parallel to the first axis and offset to a second side, opposite the first side, from the plane of the first and second axes and having a surface positioned for engagement with an outside surface of the piping element. Preferably, the third axis is spaced from the plane by a first positioning distance and the fourth axis is spaced from the plane by a second positioning distance greater than the first positioning distance.
According to another aspect of the invention, a method for forming multiple outward steps in a piping element connection comprises the steps of: (a) providing a forming apparatus as described above; (b) positioning an end of a piping element connection to be formed with multiple outward steps between the first roller and the second roller, with the end of the piping element connection engaged with the end surface of the second roller, the piping element connection axis being angularly offset from the second axis; (c) engaging opposite inner and outer surfaces of an end region of the piping element connection between the first roller and second roller while supporting the piping element connection at a point spaced from the end to be formed, the second roller being driven; (d) causing the upper leading edge of the first roller to engage the outer surface of the piping element connection in a manner to produce a torque to draw the piping element connection toward the end surface of the second roller; (e) applying force to urge the first roller and the second roller together with the first upper surface disposed in substantial axial registration with the first lower surface, the second upper surface disposed in substantial axial registration with the second lower surface, and the upper leading edge offset axially from the lower leading edge to provide a predetermined spacing to accommodate wall thickness of the piping element connection; (f) continuing application of force until the second upper surface of the first roller and the first lower surface of the second roller contact opposite wall surfaces of the piping element connection, and the angular offset of the axis of the piping element connection from the second axis is reduced to approximately zero; (g) moving apart the first roller and the second roller; and (h) removing the piping element connection in which multiple outward steps have been formed.
According to still other aspects of the invention, a piping element connection having multiple outward steps in at least one end is formed by the described method, and a wrought metal piping connection has multiple outward steps, e.g. roll-formed, in at least one end.
Objectives of this invention include providing a convenient, low cost means for joining "standard water tube" size wrought copper and copper alloy tubing, fittings and valve connections to any combination of each other through use of conventional grooved end pipe couplings sized for use with "standard outside diameter" size steel pipe; as well as providing for joining "standard water tube" size wrought copper and copper alloy tubing, fittings and valve connections with end connections of steel, or any other suitable strength material, manufactured in accordance with the outside diameter dimensions of "standard outside diameter" size steel pipe.
The objectives also include providing a process for expansion of a tube end in a manner that does not create a restriction in the tube which can impede the flow in any way, and which also does not produce an area for potential accelerated abrasive damage. In addition, the two step radial outward expansion of the process of this invention has another advantage of producing the groove diameter and reducing the thinning associated with the pipe or tube end expansion by prior art methods.
These and other features of the invention will be apparent from the following description of a presently preferred embodiment, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end view of a typical prior art grooved end pipe coupling, and FIG. 1 is a side section view of the coupling housing and gasket taken at the line 1A--1A of FIG. 1;
FIG. 2 is a side view of opposed ends of piping for a conventional cut grooved pipe end connection;
FIG. 3 is a side view of opposed ends of piping for a conventional roll grooved pipe end connection;
FIG. 4 is a side view of an end of a pipe for a conventional cast grooved pipe end connection;
FIG. 5 is a side section view of a roll forming apparatus of the method, suitable for forming a dual outward step expansion in tubing according to the method of the invention;
FIG. 5A is a top section view of the roll forming apparatus taken at the line 5A--5A of FIG. 5;
FIG. 5B is a front view of the roll forming apparatus showing the initial relationship of the bottom roller element of the roll forming apparatus of FIG. 5 and a tubing end to be formed according to the invention;
FIG. 6 is a side section view of a tubing end having a dual outward step expansion formed according to the process of the invention;
FIGS. 7 and 7A are respective side section views of the bottom (driving) roller element and the top (driven) roller element of a roll forming apparatus of the invention;
FIG. 7B is a face view of a positioning roller mounting bracket; and
FIGS. 8, 9, 10, and 11 are sequential side section views of the roll forming apparatus of the invention showing the sequence of the dual outward step tube expansion process of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention provides a convenient, low cost method and apparatus for utilizing grooved end pipe couplings designed and used for many years with IP size steel pipe for the joining of CT size wrought copper piping elements, or with any other wrought metal piping elements having a connection with an average outside diameter equal to or less than the average groove diameter commonly used for IP size steel pipe.
Briefly, according to the method of the invention, the end of a piping element connection is expanded in two or more steps by roll forming the gasket seat diameter (D s ), groove diameter (D g ) and gasket seat width (W s ) to predetermined dimensions equivalent to those commonly used for grooved end IP size steel pipe connections.
The grooved piping industry has traditionally used the terms "groove width" and "groove diameter", and for the purpose of this describing this invention, these terms will be maintained, with "groove diameter" (D g ) representing the same surface as with conventional roll grooving and "groove width" (W g ) representing the width of the groove surface. A comparison of average outside diameters for IP size steel pipe and CT size copper tubing for the 2 through 6 inch sizes are shown in Tables I, II and III. The average outside diameter specifications for CT size tubing are given in ASTM B88, while the average outside diameters for IP size pipe are specified in ASTM A53, although other standards address these parameters as well.
Although the end connections of copper fittings and valve bodies can be formed in a manufacturing facility, it is important, in particular from a cost effective installation viewpoint, to be able to form the end connections of the copper tubing at an installation site.
TABLE I______________________________________Comparison of Average Outside DiametersFor CT Size Tubing and IP Size Pipein the 2-6 Inches Nominal Size Range Average Outside Diameters (Inches)Nominal Size(Inches) IP Size Tolerance CT Size Tolerance______________________________________2 2.375 ±.024 2.125 ±.0022-1/2 2.875 ±.029 2.625 ±.0023 3.500 +.035/-.031 3.125 ±.0024 4.500 +.045/-.031 4.125 ±.0025 5.562 +.056/-.031 5.125 ±.0026 6.625 +.063/-.031 6.125 -.002______________________________________
TABLE II______________________________________ TYPE K TYPE L TYPE M TYPE DMV ASTM ASTM ASTM ASTMNOMINAL B-88 B-88 B-88 B-306______________________________________2 .083 .070 .058 --2-1/2 .095 .080 .065 --3 .109 .090 .072 .0454 .134 .110 .095 .0585 .160 .125 .109 .0726 .192 .140 .122 .083______________________________________
TABLE III______________________________________Pipe Schedules Commonly Joined (Tube Wall Thickness (Inches))NOMINAL SCH. 40 SCH. 10 SCH. 5______________________________________2 .154 .109 .0652-1/2 .203 .120 .0833 .216 .120 .0834 .237 .120 .0835 .258 .134 .1096 .280 .134 .109______________________________________
According to the method of the invention, the multiple step expansion or forming of the copper tubing end at the installation site is accomplished by use of a rolling operation which actually expands the end of the tube. The rolling operation can be performed at the installation site using roll grooving equipment that is generally used for the roll grooving of IP size steel pipe, where the roll grooving equipment is modified according to the invention.
Referring to FIGS. 5, 5A and 5B, in the case of dual outward step expanded piping element connections, an apparatus 40 of the invention requires modification to the steel pipe roll grooving equipment to include specially designed, corresponding top (driven) roller 42 and bottom (driving) roller 44, and an additional bracket 46 (FIG. 7B) for securing two positioning rollers 48, 50.
The top and bottom rollers 42, 44 are made of a hardened steel and the rollers are designed to expand the end of the tube, T, through a rolling operation, rather than to form a groove or channel in the end of the pipe as generally done for IP size steel pipe. The positioning rollers 48, 50 hold the tube in position during the tube end expansion operation, and, furthermore, provide downward and lateral forces to the tube, T, to prevent it from spiraling out from between the top and bottom rollers 42, 44 during the forming operation. The components required for the dual outward step expansion, and the process for expansion, are described more fully below.
Referring now to FIG. 6, in the expansion of the tube end, T e , to form the groove diameter (D g ) and gasket seat diameter (D s ) according to the invention, the tubing end is radially outwardly expanded in two areas, which is referred to as a dual step expansion. The first step in the expansion forms the gasket seat diameter (surface 52) and the second step forms the groove diameter (surface 54). The critical dimensions for roll grooving of IP size steel pipe are shown in FIG. 3, and the critical dimensions associated with the dual step roll forming expansion of CT size tubing are shown in FIG. 6. The thinning of the tube wall which would be associated with a single expansion of the tube is reduced by this dual step expansion of the invention.
The ability to produce acceptable outward steps at the end of the tube requires control of the gasket seat diameter (D s ), gasket seat width (W s ), groove diameter (D g ), groove width (W g ) and the cross sectional profile of the tube end.
In the forming of the gasket seat diameter (D s ), a feature commonly referred to as "flare" must be controlled. Flare is the outward expansion of the gasket seat diameter outside of parallel with the centerline of the tubing ( T ). It is measured as the maximum gasket seat diameter at the end of the tube. Excessive flare in CT size tubing can be more critical than in IP size pipe because the smaller wall thicknesses commonly associated with CT size tubing can allow one tube end to telescope into the other where there is excessive flare. The amount of flare can be controlled, and preferably eliminated altogether, by use of a suitable design for the bottom roller. As shown in FIG. 7, the surface 56 of the bottom roller 44 which forces the expansion of the gasket seat diameter is tapered slightly radially inwardly at angle, S (e.g., for practical purposes, approximately 1° to 3°) to distribute the tube forming load toward the back of the gasket seat. This slight inward taper is critical in the control of the amount of the tube end flare.
Roll forming of the gasket seat width (W s ), groove width (W g ) and cross-sectional profile of the dual outward step tube end are dependent upon the geometric relationship between the top and bottom rollers 42, 44, the dimensional configurations of the top and bottom rollers and the thickness, t, of the tube. The top and bottom rollers must be positioned to provide a predetermined spacing, S r , between the upper leading edge of the top roller 64 and the lower trailing edge of the bottom roller 70, thereby allowing displacement of the tubing into this area during the tube end expansion operation. The spacing between the rollers is selected to be large enough to prevent the material of the wall from becoming too thin, or pinching, as the wall material is displaced between the rollers. A difference in the thickness of the tubing material will effect the amount of thinning and pinching that will occur. The top and bottom rollers are also dimensioned to provide the desired gasket seat width and groove width.
Referring again to FIG. 6, the shape of the tube end or connection profile is critical in maximizing the pressure retention capabilities of the coupling/connection joint. While the highest pressure retention capabilities can be achieved when the leading edge, E l , of the gasket seat portion of expanded tube end is at perpendicular to both the groove diameter and to the seat diameter, this relationship is not advisable from a roll forming operation standpoint, as creation of a right angle can result in excessive pinching, especially with thinner tube walls. It has been determined that a more realistic leading edge angle, L, i.e. one providing adequate pressure retention capabilities in combination with minimal thinning of the tubing wall, will range from 50 to 85 degrees relative to the centerline of the tube ( T ) and gasket seat diameter.
The dual outward step expansion roll forming process will now be described with reference to the FIGS. 8-11.
Phase 1:
Referring first to FIG. 8 (and also with reference to FIGS. 7 and 7A), tube, T e , is positioned by the operator against the end surface 58 of the bottom roller 44 and rested on inwardly tapered surface 56. The top roller 42 is brought down by a force (pressure) actuated hydraulic actuator (not shown) and surface 60 of the top roller 42 is brought into contact with the outside surface 62 of the tube. At this point, the centerline of the tube ( T ) is angularly offset vertically downward from the centerline ( D ) of the driving or bottom roller 44 by the angle, Θ (approximately 1° to 2.5°). The tube has a tendency to drop, making angle Θ greater, unless an upward force is applied to support the tube. This support force can be provided by a pipe stand used to support longer tubes, or the operator can provide the required lifting force for shorter tube lengths. In FIG. 5A, the offset angle α is shown. This is the horizontal angle, between the centerline of the tube ( T ) and the centerline of the bottom roller ( D ), and is approximately 0.5° to 2° to the right when viewed with the driving roller 44 rotating counterclockwise (indicated by arrow, R, in FIG. 5B). Still referring to FIG. 5B, the centerline of each of the positioning rollers 48, 50 is located at unequal distances (X 1 and X 2 ) from the vertical centerline of the bottom roller ( V ). The values of these dimensions will vary with the distance between the positioning rollers 48, 50 and the driving roller 44; however, typically the difference will be maintained in the range of 0.050 inch to 0.250 inch, and typically at about 0.125 inch. The placement of the tube, T, between the positioning rollers orients the centerline of the tube ( T ) at an offset angle α. The tube positioning with the offset angle α causes the upper leading edge 64 of the top or driven roller 42 to produce a torque which tends to draw the tube, T, inward between the top and bottom rollers 42, 44, preventing the tube from spiraling out. This technique is also applicable to the conventional roll grooving of IP size steel pipe.
Phase 2:
Referring now to FIG. 9, as the top roller 42 is displaced downward towards the bottom roller 44, the gasket seat surface 52 starts to form through cold working of the tube wall material. The forces involved on the tube at this point are the vertical downward force (F T ) induced by surface 60 of the top roller 42, the vertical upward reaction force (F B ) maintained by surface 56 of the bottom roller 44, the two positioning forces (F P ) induced by the positioning rollers 48, 50, and the forces created by the dynamics of the rolling action of the top roller, bottom roller and the tube (see FIGS. 5, 5A and 5B for force locations). Since the vertical forces (F T ) and (F B ) are applied at offset locations along the longitudinal axis of the tube, a moment is created which tends to lift the tube off the support. In order to resist this tendency, it is necessary that a position roller 48 also be used on the right side of the driving roller 44 (when viewing the driving roller as rotating counterclockwise), in order to impose a resisting force to help keep the tube in proper orientation. As the end of the tube becomes deformed, the offset angle Θ is reduced. As described above, the surface 56 of the bottom roller 44 is tapered inwardly to distribute the reaction force (F B ) imposed by the bottom roller away from the end (tip) of the tube. As mentioned above, this taper is critical in controlling the amount of tube end flare.
Phase 3:
Referring next to FIG. 10, the top roller 42 is further displaced by the force induced by the hydraulic actuator until the inside diameter of the tube comes in contact with surface 66 of the bottom roller 44 and surface 61 of the top roller 42 comes in contact with the outside diameter surface 62 of the tube T. It is desirable to have these two contacts occur almost simultaneously, as the top roller is displaced downward, and the downward displacement of the top roller should be stopped as soon as the contacts are made. This will reduce thinning of the tube. At this point, the gasket seat width (W s ) and the depth of the groove (i.e. the difference between the diameter of the seat (D s ) and the diameter of the groove (D g )) have been defined and the vertical offset angle Θ has been further reduced. However, also at this point, Θ is approximately 0.4° to 1.6°. The forces imposed by the top and bottom rollers 42, 44 on the tube T are acting in the same direction as in Phase 2 (FIG. 9), although the forces are now distributed across the two additional surfaces, i.e. surface 66 of the bottom roller 44 and surface 61 of the top roller 42.
Phase 4:
Referring to FIG. 11, at the beginning of this phase, no additional force is required to create further downward movement of the top roller 42; however, the existing force induced by the hydraulic actuator is sufficient to cause a small amount of vertical downward movement of this top roller as the tube wall thickness reduces. This thinning of the tube wall causes the outside diameter of the tube to be locally expanded. The trailing edge, E t , is formed by a combination of the forces which are trying to thin the tube wall and expand the tube diameter along with the forces which are resisting the tube expansion. These forces act in opposite directions to each other and form a transition area in the tube which is being referred to as the trailing edge. The rotation of the tube continues until the trailing edge is fully formed which occurs when the offset angle Θ is reduced to zero. At this point, the roll forming operation is complete, the top roller 42 is raised for removing the tube and the roll forming machine is turned off.
EXAMPLE
For the purpose of example only, the typical groove dimensions for a dual step, expanded end copper tube formed according to the method of the instant invention, are provided in Table B, shown below.
According to one preferred embodiment, the bottom roller 44 (FIG. 7) has an outer diameter of about 2.625 inches and an axial width of about 2.000 inches. The axial width of surface 59 is about 0.500 inch and the axial width of tapered surface 56 is about 0.563 inch. The maximum diameter of surface 56 is about 1.865 inches. The inner surface tapers at about 15°, from a diameter of 1.771 inches to 0.812 inch.
Referring to FIG. 7A, the top roller 42 has a maximum outer diameter (at surface 60) of about 5.218 inches and an axial width of about 2.779 inches. The axial width of surface 60 is about 1.028 inches. The outer diameter of surface 61 is about 5.064 inches and the axial width is about 0.625 inch. The outer diameter of surface 63 is about 4.121 inches and the axial width is about 0.535 inch. The outer diameter of surface 65 is about 4.877 inches and the axial width is about 0.250 inch. The inner bore 67 has a diameter of about 1.382 inches.
TABLE B______________________________________Groove Dimensions for Dual Step Flared Copper Tube (Inches)NOMINAL W.sub.s W.sub.g D.sub.g D.sub.s______________________________________2 .625 .344 2.250-.015 2.375-.0152-1/2 .625 .344 2.720-.018 2.875-.0183 .625 .344 3.344-.018 3.500-.0184 .625 .344 4.334-.020 4.500-.0205 .625 .344 5.395-.022 5.562-.0226 .625 .344 6.455-.022 6.625-.022______________________________________ Tolerances: W.sub.s, W.sub.g = ±.030
Referring to FIG. 7B, the positioning roller mounting bracket 46 defines sets of holes 47, 47' for fixing the positioning rollers 48, 50 with the desired spacing from the vertical centerline of the bottom roller (X 1 and X 2 ) and spacing below the center line, M, of the bracket mounting hole (Y), as described in Table C, below.
TABLE C______________________________________Positioning Roller Spacing (Inches)NOMINAL X.sub.1 X.sub.2 Y______________________________________2 2.018 2.142 1.4792-1/2 2.546 2.670 1.9183 2.990 3.114 2.4334 3.520 3.644 2.8495 4.042 4.166 3.3026 4.592 4.716 3.667______________________________________
These and other embodiments of the invention are within the following claims. For example, while there is shown and described herein certain specific characteristics embodying the invention, it will be apparent to those skilled in the art that various modifications and rearrangements of the components may be made without departing from the spirit and scope of the fundamental inventive concept and that this inventive concept is not limited to the particular forms shown and described herein. As an example, it would be desirable to apply the dual outward step roll form expansion technique to any type of wrought metal tubing, fitting or valve body connection having an average outside diameter which is equal to or less than the average groove diameter commonly specified for IP size steel pipe, so that it could be joined to the latter using a grooved end pipe coupling designed for use with the particular IP size steel pipe of interest. In addition, the end connection of wrought metal tubing, fittings or valve bodies having an average outside diameter significantly smaller than the average groove diameter commonly specified for IP size steel pipe could be expanded in three or more steps. The first roller may be the driving roller with the second roller being the driven roller. | An apparatus for forming a piping element connection with multiple outward steps has first and second rollers, a driver for the second roller, and a positioning roller. The first roller rotates about a first axis, with first and second upper surfaces of rotation centered thereabout, the first surface mean diameter being less than that of the second surface. The first roller has an upper leading edge between the first and second upper surfaces. The second roller is mounted for rotation about a second axis parallel to the first axis, with first and second lower surfaces of rotation centered thereabout, the first surface mean diameter being greater than that of the second surface, and the second roller having a lower trailing edge between the first and second lower surfaces. The first and second rollers are mounted for movement together and apart in a plane of the first and second axes for engagement and forming of multiple outward steps in the piping element connection placed therebetween. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus and method of collecting messy substances such as dog feces.
City life has long been criticized for its inconveniences, its smells, its filth and its dangers. A major contributor to these unpleasant city conditions is the ever increasing, randomly distributed quantity of dog stools (feces). City dwellers have long smelt the need to rid their sidewalks, plazas and parks of these unsightly statuettes. Disgust-inspired public opinion is resulting more and more in city ordinances requiring dog owners to clean up after their dogs.
Clean up is no easy or appealing task and whereas solutions to the problems of animal excrements are numerous, they are not always practical. Horses can wear diapers, cats have a litter box; newspapers and shovels have long been pressed into clean up of offensive deposits left by domestic animals. There are disposable dust pans for cleaning up garbage of all kinds. There are garbage cans, even with plastic liners, that can be loaded and the liners eventually disposed of.
Despite the numerous clean up solutions, there appears to be no practical aid for the typical dog walker who desires to travel through the parks or on the sidewalks with his dog. Most clean up devices are cumbersome and do not lend themselves to being carried along on a dog walk, i.e., from shrub to shrub and post to post. A dog walker should be able to quickly and easily collect the dog's mess and carry it some distance along the way of his public "dog walk" until a suitable disposal area can be arrived at. The means of collecting and disposing should be sanitary, and it should provide odorless and sightly transportation of the feces until it can be disposed of.
SUMMARY OF THE INVENTION
Briefly described, the present invention comprises a collapsible disposable cardboard container, a supply of disposable plastic bags which can fit as a liner within the cardboard container, and a small disposable scoop or paddle associated with each plastic bag. In use, a person walking a dog would carry the box in collapsed condition in a pants pocket or purse, along with one or more bags and scoops. In the event that the pooch does a no-no, its owner will use the paddle to urge the incriminating evidence into one of the plastic bags, with which he has lined the container. The soiled scoop is also deposited in the bag, which can then be sealed within and conveniently carried in the container. The bag and its offending contents can be deposited in the nearest waste receptacle, after which the box, which remains unsoiled thanks to the use of the plastic liner, can be collasped and placed back in the person's pocket to await subsequent reuse.
Therefore, an object of the present invention is to provide an animal feces disposal apparatus which is easily carried by a dog walker.
Another object of the present invention is to provide an animal feces disposal apparatus which is at least partially reusable and therefore does not require carrying a number of bulky devices.
Yet another object of the present invention is to provide a means by which animal feces and other messy substances can be collected, carried and disposed of in an unoffensive and sanitary manner.
Other objects, features and advantages of the present invention will become apparent upon reading the following specification, when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a pictorial rendition of the animal feces disposal apparatus according to an embodiment of the present invention, in use.
FIG. 2 is an exploded pictorial view of the disclosed apparatus.
FIG. 3 is a pictorial view of the outer container and inserted liner of the apparatus of FIG. 2.
DETAILED DESCRIPTION
Referring now to the drawings in which like numerals represent like components throughout the various views, FIG. 1 shows the toteable aniaml litter collecting box 10 of the present invention in use. The collecting box 10, as seen in FIG. 2, comprises an outer container 12 which is generally rectangular in shape. The outer container 12 includes two opposing side walls 14, 15, top wall 16, bottom wall 17, back end wall 18 and a front end wall 19. The walls 14, 15, 16, 17, 18, 19 surround and define the interior compartment space 13 of the box 10. The container 12 is constructed so as to be collapsible, bringing the top and bottom walls 16, 17 into close proximity with one another, so as to be easily stored in a purse or pants pocket. In order to facilitate collapse of the container 12, each of the side walls 14, 15 and each of the end walls 19, 18 has a fold line or crease 21 formed in the walls 14, 15, 18, 19 approximately midway between the top and bottom walls 16, 17 and running parallel to the planes of the top and bottom walls. The front end wall 19 is attached only to the top wall 16 so that the front end wall can serve as a hinged lid selectively covering the container opening 22 through which access can be had to the compartment space 13. The lid formed by the front end wall 19 has an added flap 20, protruding from its free end, which can be tucked into the compartment space 13 to hold the lid in place when it is closed. The back end wall 18 and two side walls are all attached to the top and bottom walls 16, 17, but are not attached to one another so as to facilitate collapse of the box 10.
Other components of the toteable collecting box 10 include a disposable liner or insert 24, a sealing device 25 and a scraper 26. A handle 27 is also provided, attached to the outer container 12 for easy carrying of the box 10. The liner or insert 24 can be of any material or configuration, and the purpose of the insert is to line the outer container 12 so that the container 12 does not become soiled by animal litter or other substance collected. The liner 24 should likewise have a liner opening 30 which can be aligned with the container opening 22 when the liner is inserted into the container 12.
The liner 24 of the disclosed embodiment is a bag 24, preferably a small airtight plastic bag, and the sealing device 25 is a wire twist tie 25. The scraper 26 can have any convenient form, and can simply be a rectangular flat member as depicted. Preferably, the scraper 26 is made of stiff material and is of such size that it can be inserted into the liner 24 after the scraper has been used. A rectangular piece of heavy cardboard is depicted in the present embodiment.
The outer container 12 is designed to be a resuable holder which, when empty, is collapsible and fits in a purse or pants pocket. The liner 24, twist tie 25 and scraper 26 are all disposable and are intended to be disposed of after a single use. A user 35 should have a quantity of liners 24, ties 25 and scrapers 26 on hand.
In its preferred application, the present invention is used by a dog walker 35 to clean up a dog mess 33 left in an unattractive spot by his or her dog 36. The toteable animal litter box 10 of the disclosed embodiment is used to collect and dispose of the ill-placed dog mess 33 in the following manner: the user or dog walker 35, while walking his or her dog 36 on a leash 37 carries the collapsed outer container 12, along with at least one set of liner 24, twist tie 25 and scraper 26, in his pocket or her purse (or vice-versa). Dog 36, out of necessity, haplessly evacuates, leaving a mess 33 in an unattractive or even illegal spot. Walker 35, still holding the leash 37, removes the litter box contents 12, 24, 25, 26 from his pocket; uncollapses the outer container 12; flips up the lid; inserts the bag liner 24 into the container 12 so that the liner opening 30 and container opening 22 are in alignment; and turns the edges 31 at the liner opening 30 back about the edges of the container opening 22 to protect the container 12 and to hold the liner 24 in place. Holding the container 12 with the inserted liner 24 in one hand, the walker 35 takes the scraper 26 in his other hand and scrapes the mess 33 into the bag liner 24 through the liner opening 30. After the mess 33 has been collected in the liner 24, mess collector 35 inserts the used, soiled scraper 26 into the liner 24 with the mess; gathers together the liner edges 31; seals closed the liner opening 30 by wrapping the twist tie 25 tightly around the collected edges 31; and closes the outer container lid 19. With the mess 33 and soiled scraper 26 sealed in the liner 24 within the container 12, dog walker 35 picks up the container by the handle 27 and resumes walking dog 36. During the continuation of their walk, as walker 35 and dog 36 pass a convenient appropriate disposal area such as a garbage can or litter basket, walker simply opens the container lid 19; pulls out the sealed liner 24; and deposits it, with its sealed-in contents, into the garbage can. Walker 36 then collapses the outer container 12 by pressing the top and bottom walls 16, 17 toward one another thus folding the side walls 14, 15 and end walls 18, 19 along their fold lines 21; and places the reusable container back in his pocket to await another occurrence. should nature so demand, a fresh, unsoiled set of liner 24, twist tie 25 and scraper 26 is readily pressed into service.
While this invention has been described in detail with particular reference to a preferred embodiment thereof, it will be understood that variations and modifications can be effected within the spirit and scope of the invention as described hereinbefore and as defined in the appended claims. | A reusable apparatus for disposal of animal feces. The apparatus comprises a collapsible and reusable cardboard container, a supply of disposable sealable plastic bags which can fit as a liner within the cardboard container, and a small disposable scoop or paddle associated with each plastic bag. | 4 |
FIELD OF THE INVENTION
This invention relates to internal combustion engine fuel control systems of the general type in which an exhaust gas composition sensing device is used to generate a signal which is fed back into the fuel control circuit to provide closed loop control.
DESCRIPTION OF THE PRIOR ART
One known system makes use of an exhaust gas composition sensing device which has a very high output impedance at low temperature. Once the device has been warmed by the exhaust gas to an adequate operating temperature it can provide a very accurate indication of the existence of a satisfactory exhaust gas composition, but at low temperatures the high output impedance of the device makes the use of a closed loop control unsatisfactory. In the known system complex electronic arrangements are employed for measuring the temperature or output impedance of the device and inhibiting the closed loop control until the temperature becomes adequate.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a control system of the general type referred to, in which a simple and effective arrangement is employed for overcoming the problem of the sensing devices high output impedance at low temperature.
A control system in accordance with the invention comprises an exhaust gas composition sensing device having a high output impedance at low temperature, but producing when at operating temperature, a voltage signal related to the exhaust gas composition and a fuel control circuit to which said sensing device is connected so that variations in the voltage signal therefrom vary the fuel flow to the engine so as to cause the voltage signal to approach a desired level, said fuel control circuit including an input stage connected to the sensor and to a reference voltage source such that the output of said input stage is dependent on the relative levels of the signal voltage and the reference voltage, an integrator stage connected to the output of the input stage and producing an output which changes relatively slowly as a result of changes in the output of the input stage, the output of the integrator stage determining the rate at which fuel is supplied to the engine and a high impedance negative feedback circuit connecting the output of the integrator stage to an input terminal of the input stage and including a high impedance feedback path of impedance less than that of the sensing device at low temperature and higher than that of the sensing device at operating temperature, said feedback circuit causing the output of the integrator to approach a desired value when the sensing device is at low temperature.
Preferably the input stage is a voltage comparator and the integrator stage is an operational amplifier integrator. In this case the feedback circuit may comprise a resistive potential divider connected between the operational amplifier output and earth and arranged to establish a voltage equal to the reference voltage when the operational amplifier output is at its desired value, said high impedance path being a high impedance resistor connected between said potential divider and an input terminal of the voltage comparator.
With such an arrangement, when the sensing device is cold the negative feedback via the resistor is more significant than any signals which may be generated by the sensing device, so that the output voltage of the operation amplifier integrator settles at said desired value, with the possibility of a small amplitude ripple introduced as a result of any hysteresis in the voltage comparator. When the sensing device warms up to its operating temperature the negative feedback becomes insignificant and does not interfere with the normal operation of the system.
The connection between the comparator output and the integrator input may include a switch device which is controlled so as to be conductive periodically at a frequency dependent on engine speed and for a fixed duration at each operation. In this way the integrator output changes by a fixed amount per engine revolution (rather than per unit time).
In some circumstances it is required to override the closed loop control even when the sensing device is at its normal operating temperature, for example when full engine power is demanded. This can readily be achieved with the control system described above by the simple expedient of utilizing a switch connected across the high impedance resistor. When this switch is closed the negative feedback to the comparator swamps the signal voltage and causes the integrator output to approach its desired value.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings
FIG. 1 is a block diagram showing an example of a fuel control system in accordance with the invention,
FIG. 2 is the electrical circuit diagram of an exhaust composition control forming a part of the system of FIG. 1, and
FIG. 3 is the circuit of another example of an exhaust composition control.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring firstly to FIG. 1 the fuel control system shown comprises a main digital control signal generating unit 10 which receives signals from a throttle angle transducer 11 and an engine speed transducer 12 and produces a multi-bit digital output signal in known manner by utilizing a programmed read only memory as a three dimensional digital function generator. The digital output signal from the generator 10 is applied to a pulse length control 13 where it is converted into a pulse duration in known manner using input pulses from a variable frequency clock 14. Various trims such as engine coolant temperature are applied to the clock 14 but the main controlling parameter is the output of an exhaust composition control circuit 15 which receives control signals from an exhaust composition sensor 16. The pulse length control 13 controls the quantity of fuel supplied to the engine 18 by varying the duration of energising pulses applied to a plurality of solenoid operable fuel injection valves 17.
Turning now to FIG. 2 the exhaust composition control circuit includes an input filter consisting of a resistor 20 and a capacitor 21 connected in series between an input terminal 22 and earth. This filter may have a very short time constant such as 0.1 mS so that it acts only to remove high frequency noise.
The circuit has an input stage comprising a high input impedance operational amplifier 23 connected as a voltage comparator with hysteresis. The junction of the resistor 20 and the capacitor 21 is connected to the inverting input terminal of the amplifier 23, a potential divider chain consisting of three resistors 24, 25, and 26 connected between a supply rail 27 and earth provide an input to the non-inverting input terminal of the amplifier 23. This potential divider chain is arranged to provide a reference voltage V REF in the region of 350 mV at the non-inverting input terminal of the amplifier 23. Positive feedback around the amplifier 23 is provided by a resistor 28 connected between the output terminal of the amplifier 23 and its non-inverting input terminal, the resistor 28 having an ohmic value very much greater than that of the combination of resistors 24, 25, 26 so that the hysteresis it introduces into the comparator is only small.
The output terminal of the amplifier 23 is connected to earth by two resistors 30, 31 in series with their common point connected to the base of an npn transistor 32 having its emitter earthed and its collector connected by a resistor 33 to the rail 27.
The collector of the transistor 32 (which is the output terminal of the input stage) is connected by an f.e.t. switch device 34 to an operational amplifier integrator including an operational amplifier 35, an input resistor 36 connecting the switch device 34 to the inverting input terminal of the operational amplifier and a feedback capacitor 37 connecting the output terminal of the amplifier 35 to its inverting input terminal. The non-inverting input terminal of the amplifier 35 is biased to mid-rail voltage by a potential divider chain consisting of two equal value resistors 38, 39 connected between the rail 27 and earth. The output terminal of the amplifier 35 is connected to a control terminal of the clock 14 and is also connected by two resistors 40, 41 in series to earth. The values of these resistors 40, 41 are so chosen so that when the output terminal of the amplifier 35 is at mid-rail voltage (or some other desired value) the potential at the common point of the resistors 40, 41 is approximately equal to V REF - i.e., about 350 mV. The common point of these resistors 40, 41 is connected by a high impedance resistor 42 to the inverting input terminal of the operational amplifier 23.
The switch device 34 is controlled by an integrated circuit monostable multivibrator 45 provided with a timing capacitor 46 and a timing resistor 47 to provide fixed duration output pulse each time the speed transducer (which may include a simple mechanical contact breaker or an electromagnetic device) produces a pulse. The switch device 34 is conductive for a fixed total time in each engine shaft revolution so that the integrator 35, 36, 37 integrates with respect to engine shaft displacement rather than with respect to time.
The sensing device 16 may typically be an oxygen sensor of a type supplied by Lucas Electrical Limited under their designation 2LS. Such a sensing device may be regarded as the combination of a voltage source dependent both on oxygen content and on temperature with an output resistor dependent on temperature. Both the source voltage and the resistance characteristics vary with age and use so that exact matching of the device to a control circuit for linear operation is very difficult. It is, however, found that over a wide range of "normal" operation temperatures a d.c. output of less than 350 mV into a high impedance load indicates that oxygen is present in the gas surrounding the device, whereas an output more than 350 mV indicates that no oxygen is present. Clearly, therefore, in an exhaust gas composition control application a "low" output voltage indicates that too little fuel is being supplied and a "high" output voltage indicates that too much fuel is being supplied.
In these "normal" operating circumstances the output resistance of the device 16 is insignificant when compared with the resistance of the feedback resistor 42. Thus when the device 16 output exceeds 350 mV the output of the amplifier 35 decreases linearly with engine shaft angular displacement. This causes the clock frequency to decrease, thereby reducing the output pulse duration of circuit 13 and reducing the rate of fuel flow to the engine. Similarly when the device 16 output is less than 350 mV the fuel flow increases.
At low temperature, for example when the engine has just been started, the voltage and impedance characteristics of the device 16 are such that reliable closed loop control as described above cannot be carried out. The output impedance of the device 16 becomes significantly larger than the resistance of the feedback resistor 42. In this condition the negative feedback via the resistor 42 becomes dominant and the output of the amplifier 35 settles at the mid-rail desired value with a small amplitude triangular wave ripple introduced by the hysteresis of the voltage comparator.
The ohmic value of the resistor 42 determines the temperature at which the sensing device 16 begins to take over control, the output impedance of the device falling as the temperature rises. The change-over to closed loop control is smooth since the sensor becomes dominant gradually as the temperature rises.
In some circumstances, e.g. when the engine is under full load (throttle wide open but speed relatively low) it is desirable to override the exhaust composition closed loop control and in the example described such overriding is readily obtained by means of a switch 43 connected across the feedback resistor 42. This switch may be a relay contact or an electronic switch having an extremely large off resistance. When the switch 43 is conductive, there is again dominating negative feedback from the amplifier 35 to the amplifier 23 so that the output of the amplifier 35 settles at the mid-rail value.
In the circuit shown in FIG. 3 the input stage is the same as that shown in FIG. 2 but the integrator stage is constituted by a binary up/down counter 50 which is clocked by the output pulses from the monostable multivibrator 45. The collector of the transistor 32 is connected to the up/down control terminal of the counter 50. The feedback resistor 42 is connected to the common point of two resistors 40 1 , 41 1 connected in series between the most significant bit output terminal of the counter and earth. These resistors are chosen so that when the MSB output terminal voltage is high the potential at the common point of resistors 40 1 , 41 1 is sufficiently above 350 mV to switch the comparator from high output to low output when the sensing device 16 is cold.
The clock 14 in this case is controlled by the multibit digital signal from the counter 50.
In the cold condition the counter 50 is clocked repeatedly between 000 . . . 01 and 11 . . . 10 by alternate pulses from the multivibrator 45. | An internal combustion engine fuel ignition system has feedback from an exhaust gas composition transducer which operates effectively only at normal exhaust temperatures, the transducer having a very high impedance at low temperatures. The feedback circuit includes a comparator stage and an integrator stage integrating the output of the comparator stage which compares the transducer output with a reference voltage. A feedback resistor is connected from the integrator stage output to the comparator stage input, so that, at low temperature the integrator stage output stabilises at a predetermined level. Only when the transducer warms up so that its impedance becomes significantly less than that of the feedback resistor does the exhaust feedback control loop become effective. | 5 |
RELATED APPLICATIONS
This application is the U.S. National Phase of International Application No. PCT/GB2009/000194, filed 23 Jan. 2009, published in English, which application claims priority under 35 U.S.C. §119 or 365 to Great Britain Application No. 0803315.1, filed 22 Feb. 2008. The entire teachings of the above applications are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to methods for chemically modifying proteins. Particularly, although not exclusively, the present invention relates to the transformation of cysteine residues to dehydroalanine in proteins and peptides, and to peptides and proteins modified in this way.
BACKGROUND
Genetic engineering has allowed both small and large peptides and proteins to be expressed in a number of different systems. Whilst some proteins manufactured in this way are suitable for therapeutic use, small differences in the way that the proteins are modified by the cells after they are made mean that often the intended therapeutic proteins are not exactly the same as those native proteins found in the animal or human to be treated.
Different systems produce different glycosylation patterns. For example some yeast expression systems do not glycosylate at all, and frog oocytes usually glycosylate in a different way to Chinese hamster ovaries. As a result, when these systems are used it is often desirable to subsequently modify the glycosylation pattern of the peptide or protein.
Much attention has focussed on enzymatic modification of proteins rather than chemical modification as enzymes tend to be able to carry out specific reactions in relatively mild conditions in which the protein to be modified will generally be stable. Chemical modification usually requires relatively harsher conditions and may, in some instances, be non-specific, and therefore give a number of different products that may need to be separated by, for example, chromatography.
Although chemical methods tend to be harsher and less specific than enzymatic methods, chemical modification can be carried out relatively quickly, with a minimum of laboratory equipment and with minimal expense. Methods are available for chemically modifying proteins, for example to attach sugars, and these methods generally involve chemical reaction of a side chain functional group such as asparagines, serine or threonine. Other amino acid side chain functionalities may also be reacted but further methods are desired and there is a need in the art for chemical methods of protein modification that are specific and which do not irreversibly affect amino acid side chains other than the target of modification.
It would also be useful if these chemical methods utilised a reaction that proceeded rapidly while preserving all other amino acid side chains.
The Merrifield solid state peptide synthesis has allowed the chemical synthesis of polypeptides to be carried out more efficiently than traditional solution chemistry. However, although the reactions are very nearly quantitative, small incremental losses of product and deviations from the desired amino acid order result in a practical limitation that render the method unfeasible for synthesis of polypeptides greater than about 70 residues in length. Thus, a large protein is generally chemically synthesised by coupling two or more synthesisable segments of the sequence together by native chemical ligation, a technique to react a peptide containing a C-terminal thioester with another peptide containing an N-terminal cysteine, in the presence of an exogenous thiol catalyst. Whilst this reaction proceeds with near quantitative yields, it is limited by the requirement that the resulting peptide had a cysteine residue at an appropriate position in the sequence.
It is an object of the invention to provide a method for chemically modifying proteins and peptides which addresses any limitations, needs or problems highlighted herein with the prior art methods or at least to provide the public and research community with a useful choice.
Documents cited in this specification are hereby incorporated by reference although no admission is made that any constitute prior art. The discussion of the documents states what their authors have asserted, and the applicants reserve the right to challenge the accuracy of the cited documents. Although prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art in any country.
It is acknowledged that the term ‘comprise’ may, under varying jurisdictions, be attributed with either an exclusive or an inclusive meaning. For the purpose of this specification, and unless otherwise noted, the term ‘comprise’ shall have an inclusive meaning; that it will be taken to mean an inclusion of not only the listed components or steps it directly references, but also other non-specified components or elements. This rationale applies when the related terms ‘comprised’ or ‘comprising’ are used in relation to one or more steps in a method or process.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a reaction scheme for the conversion of Cys156 to Dha156 on SBL (see Example 4), according to embodiments of the present disclosure.
FIG. 2 shows a reaction scheme for the one-pot conversion of SBL-S156C to SBL-C156SGlcNAc (see Example 5), according to embodiments of the present disclosure.
FIG. 3 shows a reaction scheme for the one-pot conversion of SBL-S156C to SBL-C156SMan (see Example 6), according to embodiments of the present disclosure.
FIG. 4 shows a reaction scheme for the conjugation of glutathione to SBL-C156Dha 7 (see Example 7), according to embodiments of the present disclosure.
FIG. 5 shows a reaction scheme for the preparation of monomethyl lysine analog 11 (see Example 8), according to embodiments of the present disclosure.
FIG. 6 shows a reaction scheme for the preparation of dimethyl lysine analog 12 (see Example 9), according to embodiments of the present disclosure.
FIG. 7 shows a reaction scheme for the preparation of trimethyl lysine analog 13 (see Example 10), according to embodiments of the present disclosure.
FIG. 8 shows a reaction scheme for the preparation of SBL-C156Farnesyl 14 (see Example 11), according to embodiments of the present disclosure.
FIG. 9 shows a reaction scheme for chemical incorporation SEt-Cys (see Example 13), according to embodiments of the present disclosure.
FIG. 10 shows a reaction scheme for the preparation of SBL-C156SGlcNAc (see Example 14), according to embodiments of the present disclosure.
FIG. 11 shows a reaction scheme for conversion of SBL-C156Dha to the histidine isostere (see Example 20), according to embodiments of the present disclosure.
FIG. 12 shows a reaction scheme for conversion of SBL-C156Dha to SBL-Dha156Ala (see Example 21), according to embodiments of the present disclosure.
FIG. 13 shows a reaction scheme for the preparation of SBL-156-Ethylglycine (SBL-156Etg) (see Example 22), according to embodiments of the present disclosure.
FIG. 14 shows a reaction scheme for the preparation of an SBL-PMSF adduct (see Example 23), according to embodiments of the present disclosure.
FIG. 15 shows a reaction scheme for the preparation of SBL-221Dha (see Example 24), according to embodiments of the present disclosure.
FIG. 16 shows a reaction scheme for the preparation of SBL-156His iso (see Example 25), according to embodiments of the present disclosure.
FIG. 17 shows a reaction scheme for the preparation of an SBL-156His iso PMSF adduct (see Example 26), according to embodiments of the present disclosure.
FIG. 18 shows a reaction scheme for the preparation of SBL-156His iso 221Dha (see Example 27), according to embodiments of the present disclosure.
DISCLOSURE OF THE INVENTION
According to a first aspect, the present invention provides a method for selectively converting an optionally substituted cysteine or selenocysteine residue in a peptide or protein to a dehydroalanine residue comprising the step of contacting the peptide or protein with a sulfonylhydroxylamine.
The cysteine or selenocysteine residue to be converted in the method of the invention may be substituted with an organic radical or may be unsubstituted. If substituted, the cysteine or selenocysteine is preferably alkyl substituted, more preferably methyl or ethyl substituted.
Throughout the specification reference will be made to a ‘cysteine residue’ and optionally substituted cysteine or optionally substituted selenocysteine are to be taken as included unless the context requires otherwise.
The sulfonylhydroxylamine for use in the method of the invention is preferably O-mesitylenesulfonylhydroxylamine (MSH). Although other sulfonylhydroxylamines may be used in the inventive method, O-mesitylenesulfonylhydroxylamine is particularly easy to use as it readily crystalises and is therefore easy to purify and to weigh.
Other agents suitable for effecting the inventive conversion conform to the general formula I,
where R is an organic radical, preferably electron withdrawing and more preferably a substituted arene such as p-tolyl or also preferably trifluoromethyl.
Preferably the step of contacting the cysteine residue with the sulfonylhydroxylamine takes place in a solution or suspension in a solvent, preferably a polar aprotic solvent. The solvent may be water, methanol, ethanol, isopropanol or another alcohol or other polar protic solvent.
Preferred polar aprotic solvents for use in the method of the invention include 1,4-dioxane, tetrahydrofuran, dichloromethane, acetone, acetonitrile, dimethylformamide and dimethylsulfoxide. The most preferred solvent for use in the method of the invention is dimethylformamide (DMF).
In preferred embodiments the cysteine residue is at the surface of the peptide or protein. The reaction may however be carried out on a cysteine residue that is internal to the peptide in its natural state by denaturing the peptide reversibly, carrying out the method of the invention and then allowing the peptide to revert to its natural state.
The method of the invention may preferably be carried out in the presence of a base. The base may be the conjugate base of any standard buffer used in the fields of chemistry and biology, including for example Tris buffer, HEPES buffer or the base may be a phosphate buffer. When buffers are used as the base in the inventive method they preferably maintain pH in the range of about 6 to about 12, more preferably about 7 to about 10 and most preferably around pH 8. Particularly advantageous results may be obtained using a pH of between 7.5 and 8.5 and the most advantageous results have been obtained at pH 8. These pH values are preferred when using the inventive method.
In preferred embodiments the base is present as an aqueous solution of sufficient volume such that at least one equivalent of the base is dissolved. In preferred embodiments the base is an alkaline or alkaline earth carbonate, more preferably potassium carbonate made up in distilled water.
Preferably, in carrying out the method of the invention the peptide or protein is first dissolved in a solvent and mixed with base, and the resulting mixture is added dropwise to a solution of the sulfonylhydroxylamine. More preferably, the peptide/base solution is cooled, more preferably to around 0° C., and the sulfonylhydroxylamine is maintained at room temperature. More preferably, the peptide/base solution is added to the sulfonylhydroxylamine over between 1 and 10 minutes, preferably over between 2 and 5 minutes and most preferably over around 3 minutes.
The method of the invention may additionally comprise a subsequent step of reacting the carbon-carbon double bond of the dehydroalanine. To this end a number of examples are given in the following pages demonstrating reaction of the double bond to form a derivitised peptide or protein. Other examples show the conversion of the dehydroalanine to a natural amino acid side chain, thereby giving the overall effect of replacing cysteine with another amino acid.
In a preferred embodiment, the step of reacting the carbon-carbon double bond comprises an addition reaction. In particularly preferred embodiments the addition across the double bond of the dehydroalanine residue is stereoselective. Suitable methods of effecting stereoselective addition across a carbon-carbon double bond are well known to the person skilled in the art, and include but are not limited to use of chiral auxiliaries. The present application details methods suitable for use on peptides or proteins that have minimal impact on structure or other amino acids present therein.
In one embodiment of the invention the carbon-carbon double bond of the dehydroalanine is reacted with a thiol to form a thioether derivitised peptide or protein. In this way various moieties may be affixed to the peptide or protein such as sugars, amino acids and any desired group.
In a further aspect the present invention provides a method for ligating a first peptide or protein having a C-terminal thioester with a second peptide or protein having an N-terminal cysteine residue comprising effecting native chemical ligation, that is transthioesterification followed by a S→N acyl shift, to form a peptide bond between the first and second peptides or proteins and characterised in that the method comprises the additional step of converting the cysteine residue previously at the N terminus of the second peptide to a dehydroalanine residue by carrying out the step of contacting the peptide or protein with a sulfonylhydroxylamine.
The dehydroalanine residue formed in the ligated peptide or protein discussed immediately above may, in preferred embodiments, be subsequently reacted to form another amino acid, or to add a sugar or other peptide.
In line with the earlier discussion whereby cysteine and selenocysteine and their corresponding optionally substituted derivatives are incorporated within the term ‘cysteine’ for the purposes of this specification, the term thioester may comprise a selenoester and the ‘native chemical ligation’ reaction may be with either cysteine or selenocysteine such that the terms ‘transthioesterification’ and ‘S→N acyl shift’ may be technically an inaccurate description of the actual reaction. The definitions of the terms ‘transthioesterification’ and ‘ S→N acyl shift’ are hereby extended to cover these additional embodiments of the inventive method.
In further aspects the present invention also provides a peptide or protein when made or modified according to methods of the invention. Many of these proteins will have application in the field of human therapeutics and so the invention also encompasses those modified peptides when incorporated into therapeutic dosage forms and the like.
The following detailed description appears as a commentary of the various examples using the inventive method followed by a discussion of the benefits and uses that the method of the invention has. The discussion is in no way to be considered as limiting the full scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
Melting points were recorded on a Kofler hot block and are uncorrected. Proton nuclear magnetic resonance (δH) spectra were recorded on a Bruker AV400 (400 MHz), or on a Bruker AVII500 (500 MHz) spectrometer. Carbon nuclear magnetic resonance (δC) spectra were recorded on a Bruker AV400 (100.7 MHz) spectrometer or on a Bruker AVII500 (125.8 MHz) spectrometer. Spectra were fully assigned using COSY and HMQC; multiplicities were assigned using DEPT 135. All chemical shifts are quoted on the δ scale in ppm using residual solvent as the internal standard (1H NMR: CDCl 3 =7.26, CD 3 OD=4.87; 13 C NMR: CDCl 3 =77.0; CD 3 OD=49.0). The following splitting abbreviations were used: s=singlet, d=doublet, t=triplet, q=quartet, a=apparent.
Infrared spectra were recorded on a Bruker Tensor 27 Fourier Transform spectrophotometer using thin films on NaCl plates for oils and KBr discs for solids and crystals. Absorption maxima (ν max ) are reported in wavenumbers (cm −1 ) and classified as strong (s) or broad (br).
Low resolution mass spectra were recorded on a Micromass Platform 1 spectrometer using electrospray ionization (ESI) or using a Walters 2790-Micromass LCT electrospray ionization mass spectrometer. High resolution mass spectra were recorded on a Walters 2790-Micromass LCT electrospray ionization mass spectrometer. m/z values are reported in Daltons.
Optical rotations were measured on a Perkin-Elmer 241 polarimeter with a path length of 1 dm and are reported with implied units of 10 −1 deg cm2 g −1 . Concentrations (c) are given in g/100 ml.
Thin layer chromatography (TLC) was carried out using Merck aluminium backed sheets coated with 60F 254 silica gel. Visualization of the silica plates was achieved using a UV lamp (λmax=254 nm), and/or ammonium molybdate (5% in 2M H 2 SO 4 ), or potassium permanganate (5% in 1M NaOH). Flash column chromatography was carried out using BDH PROLAB® 40-63 mm silica gel (VWR).
Anhydrous solvents were purchased from Fluka or Acros except dichloromethane which was distilled over calcium hydride. All other solvents were used as supplied (Analytical or HPLC grade), without prior purification. Distilled water was used for chemical reactions and Milli-Q water for protein modifications. Reagents were purchased from Aldrich and used as supplied. ‘Petrol’ refers to the fraction of light petroleum ether boiling in the range 40-60° C. All reactions using anhydrous conditions were performed using flame-dried apparatus under an atmosphere of argon or nitrogen.
Protein Mass Spectrometry:
Liquid chromatography-mass spectrometry (LC-MS) was performed on a Micromass LCT (ESI-TOF-MS) coupled to a Waters Alliance 2790 HPLC using a Phenomenex Jupiter C4 column (250×4.6 mm×5 μm). Water:acetonitrile, 95:5 (solvent A) and acetonitrile (solvent B), each containing 0.1% formic acid, were used as the mobile phase at a flow rate of 1.0 mL min −1 . The gradient was programmed as follows: 95% A (5 min isocratic) to 100% B after 15 min then isocratic for 5 min. The electrospray source of LCT was operated with a capillary voltage of 3.2 kV and a cone voltage of 25 V. Nitrogen was used as the nebulizer and desolvation gas at a total flow of 600 l hr −1 . Spectra were calibrated using a calibration curve constructed from a minimum of 17 matched peaks from the multiply charged ion series of equine myoglobin, which was also obtained at a cone voltage of 25 V. Total mass spectra were reconstructed from the ion series using the MaxEnt algorithm preinstalled on MassLynx software (v. 4.0 from Waters) according to manufacturer's instructions.
Example 1
methyl 2-[(tert-butoxycarbonyl)amino]acrylate
MSH 1 (439 mg, 2.0 mmol) was added to a 10 mL round bottom flask and dissolved in DMF (3 mL). In a separate vial, N-(tert-butoxycarbonyl)-L-cysteine methyl ester 2 (48 mg, 0.20 mmol) was added and dissolved in DMF (3 mL). The vial was cooled to 0° C. and a solution of potassium carbonate (138 mg, 1.0 mmol) in water (3.0 mL) was added. The resulting solution was added dropwise by pipette over a period of 3 min to the stirred MSH solution at room temperature. The vial was rinsed with DMF (2×1 mL) to ensure complete transfer. TLC (petrol:ethyl acetate, 4:1) analysis after completion of the addition revealed a single, UV active product (R f 0.6). The reaction mixture was transferred to a separatory funnel and diluted with diethyl ether (150 mL) and water (100 mL). After separation, the organic layer was washed successively with water (80 mL) and brine (80 mL) before drying (MgSO 4 ) and filtering. The solvent was removed under reduced pressure and the resulting residue purified by column chromatography to provide methyl 2-[(tert-butoxycarbonyl)amino]acrylate 3 as a clear oil (40 mg, 98%).
Data for Methyl 2-[(tert-butoxycarbonyl)amino]acrylate (BocCysOMe) 3: νmax (thin film) 3423, 2980, 1719, 1634, 1513, 1328, 1159, 1068 cm-1; δH (400 MHz, CDCl3) 1.46 (9H, s, C(CH3)3), 3.80 (3H, s, OCH3), 5.70 (1H, d, J 1.5 Hz, C═CHH), 6.13 (1H, app s, C═CHH), 7.00 (1H, br s, NH); δC (100.7 MHz, CDCl3) 28.2 (q, C(CH3)3), 52.8 (q, OCH3), 80.6 (s, C(CH3)3), 105.1 (t, C═CH2), 131.3 (s, C═CH2), 152.5, 164.4 (2×s, 2×CO). Found: C, 53.95%; H, 7.63%, N, 6.83%. C9H15NO4 requires: C, 53.72%; H, 7.51%; N, 6.96%.
Example 2
Methionine Recovery from Corresponding Sulfilimine
N-(tert-Butoxycarbonyl)-L-methionine methyl ester 4 (245 mg, 0.93 mmol) was added to a 50 mL round bottom flask and then dissolved in DMF (5 mL). The solution was stirred vigorously while water (5 mL) was added by pipette. MSH 1 (400 mg, 1.86 mmol) was added to the solution in one portion and the cloudy suspension homogenized after 30 seconds of stirring. After 5 minutes, TLC analysis revealed complete consumption of 4. All material was located on the baseline, and no sulfoxide 18 or sulfone 19 was detected. After 20 minutes of stirring, DTT (1.43 g, 1.86 mmol) was added as a solid. TLC analysis revealed no change after 1 hour of stirring. After 1 hour of total reaction time, Na 2 HPO 4 .12H 2 O (3.33 g, 9.30 mmol) was added to give a saturated solution of phosphate salts. After 2 hours of total reaction time (1 hour with base), TLC (30% ethyl acetate in petrol) revealed the regeneration of 4. A final hour of reaction time revealed no further change. The reaction was then diluted with diethyl ether (150 mL) and water (150 mL) and separated. The organic layer was washed sequentially with water (150 mL) and brine (150 mL), dried (MgSO 4 ), filtered, and concentrated under reduced pressure. The product was purified by column chromatography (30% ethyl acetate in petrol) to give recovered N-(tert-butoxycarbonyl)-L-methionine methyl ester 4 (230 mg, 94%).
Data for N-(tert-butoxycarbonyl)-L-methionine methyl ester 4: [α] D 20 −29.5 (c, 1 in MeOH) [Lit. [α] D 25 −34.0 (c, 1.0 in MeOH)] 5 ; δ H (400 MHz, CDCl 3 ) 1.39 (9H, s, C(CH 3 ) 3 ), 1.88 (1H, m, CH H CH 2 SCH 3 ), 2.04-2.12 (4H, m, SCH 3 , C H HCH 2 SCH 3 ), 2.49 (2H, t, J 8.0, C H 2 SCH 3 ), 3.70 (3H, s, CO 2 CH 3 ), 4.37 (1H, q, J 7.1, αH), 5.20 (1H, d, J 7.1, NH); δ C (100.7 MHz, CDCl 3 ) 15.3 (q, SCH 3 ), 28.1 (q, C( C H 3 ) 3 ), 29.8 (t, C H 2 CH 2 SCH 3 ), 31.9 (t, C H 2 SCH 3 ), 52.2 (q, CO 2 C H 3 ), 52.6 (d, αC), 79.8 (s, C (CH 3 ) 3 ), 155.2 (s, CO), 172.7 (s, C O 2 CH 3 ).
Example 3
Regeneration of BocDhaOMe 3 from BocCys(SEt)OMe 15
N-(tert-Butoxycarbonyl)-ethylthio-L-cysteine methyl ester 15 (106 mg, 0.40 mmol) was added to a 50 mL round bottom flask and dissolved in DMF (5 mL). Potassium carbonate (278 mg, 2.01 mmol) was added by pipette as a solution in water (1.0 mL). MSH 1 (172 mg 0.80 mmol) was added as a solid in one portion (open air, room temperature). TLC analysis (ethyl acetate:petrol; 1:4) after 1 min of reaction revealed a strongly UV active product (R f 0.6) and a trace of starting material (R f 0.5). A second dose of MSH 1 (172 mg 0.80 mmol) was added after 5 min of reaction time and TLC analysis revealed only the UV active product. After 10 min of total reaction time, the reaction mixture was diluted with diethyl ether (100 mL) and water (50 mL). The organic layer was separated and the aqueous layer was extracted with diethyl ether (2×50 mL). The combined organics were dried (MgSO 4 ), filtered, and the solvent removed by rotary evaporation. Column chromatography (3% ethyl acetate in petrol) provided methyl 2-[(tert-butoxycarbonyl)amino]acrylate 3 (63 mg, 79%); this material was spectroscopically identical to that obtained from N-(tert-butoxycarbonyl)-L-cysteine methyl ester 2.
Example 4
Conversion of Cys156 to Dha156 on SBL
FIG. 1 shows a reaction scheme for the conversion of Cys156 to Dha156 on SBL.
All manipulations were carried out in a cold room at 4° C. Lyophilized SBL-S156C 6 (2.5 mg, 0.094 (mol) was dissolved in 2.50 mL of pH 8.0 sodium phosphate buffer (50 mM) in a 1.5 mL plastic tube. A solution of MSH was prepared in a separate tube by dissolving 4.0 mg (18.6 μmol) in 250 μL DMF. 125 μL of the MSH solution (9.3 μmol) was added by micropipette to the protein solution and the reaction was vortexed periodically over 1 minute. The tube was left to shake for an additional 19 minutes after which time a 30 μL aliquot was analyzed by LC-MS. A single protein species was detected with a mass of 26681, corresponding to the mass of SBL-C156Dha 7 (26681=calculated mass). Small molecules were removed from the reaction mixture by loading the sample onto a PD10 desalting column (GE Healthcare) previously equilibrated with 10 column volumes of pH 8.0 sodium phosphate buffer (50 mM) and eluting with 3.50 mL of the same buffer. The collected sample (now diluted to 0.7 mg/mL) was split into 200 μL aliquots, flash frozen with liquid nitrogen, and stored at −80° C.
The same reaction conditions were used and modified where appropriate according to the following table, Table 1, where the percentage conversions show the broad range of buffers are all suitable for carrying out the method of the invention.
TABLE 1
Conversion of Cys to Dha on SBL-S156C.
MSH
time
Conv.
Entry
(equiv)
Buffer
pH
(min)
%
1
100
TRIS (50 mM)
8.0
20
50
2
100
TAPS (50 mM)
8.0
20
60
3
100
Carbonate (50 mM)
8.0
20
50
4
60
Carbonate (100 mM)
9.6
10
40
5
100
Carbonate (100 mM)
9.6
120
50
6
20
Phosphate (50 mM)
8.0
20
10
7
50
Phosphate (50 mM)
8.0
20
20
8
100
Phosphate (50 mM)
8.0
1
25
9
100
Phosphate (50 mM)
8.0
10
60
10
100
Phosphate (50 mM)
8.0
20
>95
11
100
Phosphate (50 mM)
7.5
20
90
12
100
Phosphate (50 mM)
6.5
20
40
Example 5
One-Pot Conversion of SBL-S156C to SBL-C156SGlcNAc
FIG. 2 shows a reaction scheme for the one-pot conversion of SBL-S156C to SBL-C156SGlcNAc.
All manipulations were carried out in a cold room maintained at 4° C. A 1 mg sample of lyophilized SBL-S156C 6 (0.037 μmol) was dissolved in 1.0 mL in pH 8.0 sodium phosphate buffer (50 mM). A solution of MSH 1 was prepared by dissolving 1.8 mg (8.36 μmol) in 100 μL DMF. A 50 μL portion of the MSH solution was added to the protein by micropipette. The reaction was vortexed periodically over 1 minute and then rotated on a lab rotisserie for an additional 19 minutes at 4° C. A 50 μL aliquot was analyzed by LC MS to confirm the conversion of Cys156 to Dha156 (26681 calculated, 26681 found). To the reaction mixture was added 1-thio-2-acetamido-2-deoxy-β-D-glucopyranose 22 as a solid (8.8 mg, 1000 eq) to give a 39 mM solution in thiol. After 90 minutes of shaking at 4° C., the reaction was analyzed directly by LC-MS. Complete conversion to SBL-C156SGlcNAc 8 was observed (calculated mass, 26918; observed mass, 26918).
Example 6
One-Pot Conversion of SBL-S156C to SBL-C156SMan
FIG. 3 shows a reaction scheme for the one-pot conversion of SBL-S156C to SBL-C156SMan. An analogous procedure to that above was followed for the conversion of SBL-S156C 6 to SBL-C156SMan 9. LC-MS analysis revealed full conversion to the desired glycoprotein 9 (calculated mass, 26877; observed mass, 26877).
Example 7
Conjugation of Glutathione to SBL-C156Dha 7
FIG. 4 shows a reaction scheme for the conjugation of glutathione to SBL-C156Dha 7.
All manipulations were carried out in a cold room maintained at 4° C. A 200 μL aliquot of 0.7 mg/mL SBL-C156Dha 7 previously prepared was thawed and kept on ice until needed. Glutathione (GSH) (16.1 mg, 0.05 mmol) and potassium phosphate dibasic (46 mg) were both added as solids to a 1.5 mL plastic tube and dissolved in 150 (L water (MilliQ). The solution of GSH was then added to the protein solution (pH of reaction 9.0) and vortexed over 1 min. The reaction was shaken for an additional 90 minutes. LC-MS analysis of the reaction mixture revealed near complete conversion to SBL-C156SGSH 10 (calculated mass, 26988, observed mass, 26987).
Example 8
Monomethyl Lysine Analog 11
FIG. 5 shows a reaction scheme for the preparation of monomethyl lysine analog 11.
All manipulations were carried out in a cold room maintained at 4° C. A 200 μL aliquot of 0.7 mg/mL SBL-C156Dha 7 previously prepared was thawed and kept on ice until needed. A solution of 2-(methylamino)ethanethiol hydrochloride 24 was prepared by dissolving 6.6 mg (0.052 mmol) in 200 μL water (MilliQ). Potassium phosphate dibasic (45 mg, 0.26 mmol) was added to the thiol solution as a solid and the solution vortexed. All of the thiol solution was transferred to the protein by micropipette to give a reaction mixture of pH 9.0. The reaction was vortexed and then shaken at 4° C. for 90 minutes. LC-MS analysis revealed full conversion to the monomethyl lysine analog 11 (calculated mass, 26772; observed mass 26773).
Example 9
Dimethyl Lysine Analog
FIG. 6 shows a reaction scheme for the preparation of dimethyl lysine analog 12.
All manipulations were carried out in a cold room maintained at 4° C. A 200 μL aliquot of 0.7 mg/mL SBL-C156Dha 7 previously prepared was thawed and kept on ice until needed. A solution of 2-(dimtheylamino)ethanethiol hydrochloride 25 was prepared by dissolving 3.2 mg (0.022 mmol) in 150 μL of pH 8.0 phosphate buffer (50 mM). A 50 μL aliquot of the thiol solution was added to the protein and the reaction was shaken at 4° C. for 90 minutes at which time a 40 μL aliquot was taken for LC-MS analysis. Full conversion to the desired dimethyl lysine analog 12 was observed (calculated mass, 26786; observed mass, 26787).
Example 10
Trimethyl Lysine Analog
FIG. 7 shows a reaction scheme for the preparation of trimethyl lysine analog 13.
All manipulations were carried out in a cold room maintained at 4° C. A 200 μL aliquot of 0.7 mg/mL SBL-C156Dha 6 previously prepared was thawed and kept on ice until needed. A solution of 2-(mercaptoethyl)trimethylammonium chloride 26 was prepared by dissolving 8.2 mg of 26 (0.052 mmol) and 27 mg potassium phosphate dibasic (0.20 mmol) in 200 μL of water (MilliQ). All of the thiol solution was added to protein to give a reaction mixture at pH 9.0. The reaction was shaken at 4° C. for 90 min before a 50 μL aliquot was analyzed by LC-MS. Full conversion to the trimethyl lysine analog 13 was observed (calculated mass, 26801; observed mass, 26801).
Example 11
SBL-C156Farnesyl
FIG. 8 shows a reaction scheme for the preparation of SBL-C156Farnesyl 14.
A 200 μL aliquot of 0.7 mg/mL SBL-C156Dha 7 previously prepared was thawed. A (0.35 M) farnesyl thiol 27 solution in DMSO was prepared alongside an aqueous solution of TCEP.HCl (tris(2-carboxyethyl) phosphine chloride). The TCEP was neutralized to pH 7.0 with sodium hydroxide to give a final concentration of 0.20 M TCEP. The farnesyl thiol 27 (15 μL) and TCEP solution (52 μL) were added in succession to the protein to give a cloudy emulsion. The reaction was rotated on a lab rotisserie for 90 minutes at room temperature and then analyzed directly by LC-MS. A protein species with a mass of 26940 was found which corresponds to the farnesyl thioether sodium adduct (calculated mass, 26941).
Example 12
Activity Assay for SBL-SGlcNAc 8
The enzyme concentration was determined using the bicinchoninic acid protein assay (Pierce) with bovine serum albumin as a standard. Turnover numbers are based on an enzyme monomer.
TABLE 2
kinetics data
SBL
K m (mM)
k cat (s −1 )
k cat /K m (M −1 s −1
SBL-S156C 6
0.83 ± 0.07
27.1 ± 0.7
(3.3 ± 0.1) × 10 4
SBL-SGlcNAc 8
0.72 ± 0.09
5.7 ± 0.2
(7.9 ± 0.3) × 10 3
Initial velocities for SBL-S156C and SBL-SGlcNAc 8 were determined using suc-AAPF-pNA (Bachem Biosciences Inc) with continuous detection of the formation of the product pNA at 410 nm (pNA: ε=8,800 M −1 cm −1 ) at 25° C. A typical reaction mixture contained 100 mM sodium phosphate, pH 7.5, 500 mM NaCl, 1 mM suc-AAPF-pNA in a final volume of 1 ml. Reactions were initiated by the addition of enzyme, typically 15 nM final concentration. Initial velocity kinetic data were fitted using GraFit 5.
Example 13
Chemical Incorporation SEt-Cys
FIG. 9 shows a reaction scheme for chemical incorporation SEt-Cys.
A fresh sample of SBL-156Dha 7 was prepared as described above by the action of MSH on cysteine and used directly. Accordingly, 35 μL of ethanthiol was added directly to a 625 μL of a 1 mg/mL solution of SBL-156Dha 6 (0.05 μmol) in 50 mM sodium phosphate (pH 8.0). The sample was vortexed to homogenize and then rotated for 30 minutes at room temperature. LC-MS analysis of the reaction mixture showed full conversion to the ethyl thioether protein 16 (calculated mass, 26743, observed mass, 26746). The reaction mixture was passed through a PD10 column to remove the bulk of small molecules, eluting with pH 8.0 sodium phosphate (50 mM) and then purified twice by dialysis against 4 L of the same buffer to remove remaining small molecules. After dialysis the sample concentration was ˜0.36 mg/mL.
Example 14
Preparation of SBL-C156SGlcNAc
FIG. 10 shows a reaction scheme for the preparation of SBL-C156SGlcNAc.
A 500 μL sample of SBL-156SEt 16 was thawed and kept on ice until needed. An MSH solution (1.8 mg, 8 μmol) was prepared in DMF (720 μL) and 14 μL (0.16 μmol) was added to a 250 μL sample of SBL-156SEt 16. The reaction was vortexed to homogenize and then shaken for 20 minutes at 4° C. A 40 μL aliquot was taken for LC-MS analysis that showed full conversion to SBL-C156Dha 7 (calculate mass, 26681; observed mass, 26685). To verify that this material corresponds to the dehydroalanine containing protein, GlcNAc-SH 22 (4 mg, 16.9 μmol) was added as a solid to the reaction mixture and
rotated at room temperature for 30 min. Full conversion to SBL-C156SGlcNAc 8 confirmed the regeneration of dehydroalanine (calculated mass, 26918; observed mass, 26920).
In order to carry out experiments on native chemical ligation and subsequent modification of cysteine residues a model cysteine containing dipeptide was first made.
Example 15
Native Chemical Ligation: BocAlaCysOMe 18
Native Chemical Ligation: BocAlaCysOMe
L-Cysteine methyl ester hydrochloride (5.0 g, 29.10 mmol) was added to a 100 mL, 2-neck round bottom flask and dissolved in 15 mL of pH 8.0 TRIS (50 mM). The solution was cooled to 0° C. and 5.0 mL of 5.82 M NaOH was added dropwise. BocAlaSBn 17 (2.50 g, 8.46 mmol) was added as a solution in MeCN (25 mL). The resulting solution (pH 9.0, pH paper), was stirred at room temperature for 5 hours after which time TLC indicated complete comsumption of thioester 17 (R f =0.38, 10% EtOAc in petrol) and formation of the ligated product 18 (R f =0.50, 50% EtOAc in petrol). Tributylphosphine (1.05 mL, 4.26 mmol) was added to reduce any disulfide and after 15 min the reaction was diluted with Et 2 O (250 mL) and H 2 O (150 mL). The layers were separated and the aqueous later was extracted with Et 2 O (100 mL). The combined organics were washed with H 2 O (2×150 mL) and brine (150 mL) and then dried (MgSO 4 ), filtered, and concentrated under reduced pressure. Purification by column chromatography (10% EtOAc in petrol to 50% EtOAc in petrol) provided the coupled product 18 as white crystals (2.592 g, 90%). m.p.=101-102° C.; [α] 20 D =−1.9° (c=1.0, CHCl 3 ); IR (KBr): 3387, 3298, 2979, 2565, 1746, 1700, 1653, 1503, 1443, 1390, 1362, 1308; 1 H NMR (CDCl 3 , 400 MHz): δ=7.13 (1H, d, J=5.8, NH cys ), 5.24 (1H, d, J=6.1, NH Ala ), 4.82 (1H, ddd, J=7.8, 4.3, 4.0, H α Cys ), 4.21 (1H, br. m, H α Ala ), 3.75 (3H, s, CO 2 CH 3 ), 3.03-2.90 (2H, m, CH 2 SH), 1.50 (1H, t, J=8.7, SH), 1.41 (9H, s, Boc), 1.35 (3H, d, J=7.1, CH 3 Ala ); 13 C NMR (100 MHz): δ=172.7, 170.3, 155.5 (3×C=O), 80.1 (Boc), 53.7 (C α Cys ), 52.8 (CO 2 CH 3 ), 50.1 (C α Ala ), 28.3 (Boc), 26.6 (CH 2 SH), 17.9 (CH 3 Ala ); HRMS m/z (EI+). Found 329.1142 (M+Na) + ; C 12 H 22 N 2 O 5 SNa requires 329.1147. Analysis for C 12 H 22 N 2 O 5 S: C, 47.04; H, 7.24; N, 9.14. Found: C, 47.05; H, 7.25; N, 9.09.
Example 16
Conversion of BocAlaCysOMe to BocAlaDhaOMe
MSH (1) (702 mg, 3.26 mmol) was added to a 50 mL round bottom flask and dissolved in DMF (3 mL). In a separate glass vial, BocAlaCysOMe (18) (100 mg, 0.326 mmol) was dissolved in DMF (5 mL) and cooled on ice. A solution of K 2 CO 3 (225 mg, 1.63 mmol) in H 2 O (5 mL) was added to the peptide solution. The resulting solution of 18 was then added dropwise by pipette to the stirred solution of MSH over a period of 5 min. After completion of the addition, TLC (50% EtOAc in petrol) revealed complete comsumption of peptide 18 (R f =0.49) and the formation of BocAlaDhaOMe (R f =0.74). The reaction was diluted with Et 2 O (250 mL) and H 2 O (200 mL). After separation, the organic layer was washed with H 2 O (150 mL) and brine (150 mL). After drying (MgSO 4 ), the organics were filtered and the solvent was removed under reduced pressure. The product was purified by column chromatography (20% EtOAc in petrol) to give 74 mg of the titled compound 19 as a clear, thick oil (83% yield). IR (film): 3332, 2980, 1691, 1523, 1442, 1368, 1327, 1249, 1167; 1 H NMR (CDCl 3 , 400 MHz): δ=8.46 (1H, br. s, NH Dha ), 6.60 (1H, app. s, C═CHH), 5.91 (1H, d, J=1.3, C═CHH), 5.01 (1H, app. br. s, NH Ala ), 4.26 (1H, app. br. s, H α Ala ), 3.84 (3H, s, CO 2 CH 3 ), 1.46 (9H, s, Boc), 1.40 (3H, d, J=7.3, CH 3 Ala ); HRMS m/z (EI+). Found 295.1264 (M+Na) + ; C 12 H 20 N 2 O 5 Na requires 295.1270.
Example 17
Conversion of BocAlaDhaOMe to BocAlaLeuOMe
BocAlaDhaOMe 19 (43 mg, 0.16 mmol) was added to a 50 mL 2-neck round bottom flask and flushed with argon before dissolving in 1,4-dioxane (1.0 mL). Saturated NH 4 Cl (3 mL, aqueous solution) was added to the vigorously stirred solution followed by isopropyl iodide (80 μL, 0.79 mmol) and zinc dust (105 mg, 1.60 mmol). The reaction was stirred vigorously (>1000 rpm) at room temperature for 1.5 hours before a second portion of zinc (105 mg, 1.60 mmol) and isopropyl iodide was added (80 μL, 0.79 mmol). After 3 hours of total reaction time, TLC (45% EtOAc in Petrol) indicated complete consumption of starting material. The reaction was diluted with Et 2 O (150 mL) and washed successively with H 2 O (150 mL) and brine (2×150 mL). The organic layer was dried (MgSO 4 ), filtered, and the solvent removed under reduced pressure. Purification by column chromatography (35% EtOAc in Petrol) provided BocAlaLeuOMe 20 as a mixture of diastereomers (12 mg, 24%). (Yield unoptimized, 1 st native chemical ligation at Ala-Leu). 1 H NMR (CDCl 3 , 400 MHz): δ=6.56 (1H, d, J=6.5, NH Leu ), 4.98 (1H, br. s, NH Ala ), 4.61 (1H, td, J=8.6, 4.6), 4.19 (1H, br. s, H α Ala ), 3.73 (3H, s, CO 2 Me), 1.67-1.43 (3H, m, CH 2 CHMe 2 ) 1.46 (9H, s, Boc), 1.38-1.35 (3H, m, CH 3 Ala ) 0.95-0.92 (6H, m, 2×CH 3 Leu ). LRMS (m/z, ESI+): 317 (M+H), 339 (M+Na).
Example 18
Conversion of BocAlaDhaOMe to BocAlaPheOMe
BocAlaDhaOMe 19 (50 mg, 0.18 mmol) was added to a 2-neck round bottom flask and placed under an argon atmosphere before dissolving in 1,4-dioxane (3.0 mL). H 2 O (0.30 mL) was added to the stirred solution followed by phenylboronic acid (69 mg, 0.55 mmol) and rhodium(I)hydroxide cyclooctadiene dimer ([Rh(OH)(cod)] 2 , 4.0 mg, 0.009 mmol). All were added under a stream of argon. The reaction mixture was lowered into an oil bath preheated to 80° C. and stirred for 1.5 hours after which time no starting material was detected by TLC (25% EtOAc in petrol). The reaction was diluted with Et 2 O (100 mL) and washed successively with H 2 O (2×100 mL) and brine (100 mL). The organic layer was dried over MgSO 4 and filtered. The solvent was removed under reduced pressure and the residue purified by column chromatography (45% EtOAc in petrol) to afford BocAlaPheOMe 21 as a mixture of diastereomers (50 mg, 78%). 1 H NMR (CDCl 3 , 400 MHz): δ=7.30-7.08 (5H, m, Ar), 6.75-6.61 (1H, m, NH Phe ), 5.03 (1H, br. s, NH Ala ), 4.85 ( 1 H, m, H α Phe ) 4.16 (1H, br. s, H α Ala ), 3.71 (3H, s, CO 2 Me), 3.18-3.04 (2H, m, CH 2 Ph), 1.43 (9H, s, Boc), 1.31-1.28 (3H, 2×d for each diasteromer, J=7.1, 7.3, CH 3 Ala ). d.r.=1.5:1.0, based on integration of two Me Ala doublets at 1.31 and 1.28. HRMS m/z (ESI+). Found 373.1734 (M+Na) + ; C 18 H 26 N 2 O 5 Na requires 373.1739.
Example 19
Conversion of BocAlaDhaOMe to BocAlaTyrOMe
BocAlaDhaOMe 19 (50 mg, 0.18 mmol) was added to a 25 mL 2-neck round bottom flask and placed under an argon atmosphere before 1,4-dioxane (3.0 mL) and H 2 O (0.30 mL) were added. 4-hydroxyphenylboronic acid (76 mg, 0.55 mmol) and rhodium(I)hydroxide cyclooctadiene dimer ([Rh(OH)(cod)] 2 , 4.0 mg, 0.009 mmol) were both added under a stream of argon. The stirred reaction mixture was lowered into an oil bath preheated to 80° C. and stirred for 1.5 hours at which time TLC revealed complete consumption of starting material (50% EtOAc in petrol). The reaction was diluted with Et 2 O (100 mL) and washed successively with H 2 O (2×100 mL) and brine (100 mL). The organic layer was dried (MgSO 4 ) and filtered. The solvent was removed under reduced pressure and the residue purified by column chromatography (gradient from 20% to 50% EtOAc in petrol) to afford BocAlaTyrOMe 28 as a mixture of diastereomers (48 mg, 72%). 1 H NMR (CDCl 3 , 400 MHz): δ=7.04-6.66 (5H, m, Ar Tyr and NH Tyr ), 5.16 (1H, br. s, NH Ala ), 4.82 (1H, m, H α Tyr ), 3.72 (3H, s, CO 2 Me), 3.03 (m, 2H, CH 2 Ar), 1.46 (9H, s, Boc), 1.26 (3H, m, CH 3 Ala ). LRMS (m/z, ESI+): 367 (M+H) + , 389 (M+Na) − .
Example 20
Conversion of SBL-C156Dha to the Histidine Isostere
FIG. 11 shows a reaction scheme for conversion of SBL-C156Dha to the histidine isostere.
A 200 μL aliquot of 0.7 mg/mL SBL-C156Dha 7 previously prepared was thawed. Imidazole (3.6 mg, 0.052 mmol) was added to the protein solution as a solid. The reaction was incubated at 37° C. and analyzed by LCMS at 2, 4, and 5 hours after which time complete conversion to the histidine isostere 29 was observed. (Calculated mass=26749. found=26749).
Example 21
Conversion of SBL-C156Dha to SBL-Dha156Ala
FIG. 12 shows a reaction scheme for conversion of SBL-C156Dha to SBL-Dha156Ala.
SBL-C156Dha 7 was prepared as described above by the action of MSH on cysteine and purified using a PD10 column, eluting with 50 mM potassium phosphate (pH 8.0). A 200 μL sample of this protein at 0.30 mg/mL (˜0.003 μmol) was added to 1.50 mL plastic tube. This solution was stored on ice until needed. A stock catalyst solution was prepared by adding 0.8 mg Pd(OAc) 2 (3.6 μmol) and 6.0 mg of TPPTS (10.6 μmol) to a 1.50 mL plastic tube and dissolving in 200 μL of 50 mM sodium phosphate (pH 8.0) with the aid of sonication. This solution is approximately 18 mM in Pd. A 20 μL aliquot of the catalyst solution (˜0.3 μmol) was added to the protein solution which was then vortexed to homogenize and sealed with a rubber septa. Hydrogen (1 atm, balloon) was bubbled through the solution for 5 minutes and the reaction incubated in a 37° C. water bath under an H 2 atmosphere for 3 hours. After this incubation, a 60 μL aliquot of the reaction mixture was added directly to 1 mg of GlcNAcSH (4.2 μmol; ˜5000 eq). The mixture was vortexed to dissolve the thiol and then rotated at room temperature for 30 minutes. LC-MS analysis of the sample showed no addition of GlcNAcSH, indicating that dehydroalanine had been consumed. A mass of 26685 was found which corresponds to the calculated mass of the hydrogenated protein SBL-156Ala (30), 26683.
Example 22
SBL-156-Ethylglycine (SBL-156Etg)
FIG. 13 shows a reaction scheme for the preparation of SBL-156-Ethylglycine (SBL-156Etg).
A 250 μL aliquot of SBL-156Dha (prepared above; 0.29 mg/mL in pH 6.0 NH 4 OAc, 500 mM buffer) was thawed and stored on ice until needed. Two doses each of zinc powder (4 mg) and 2 methyliodide (2 μL) were added every five minutes at room temperature. The reaction was shaken vigorously after each addition. The insoluble materials were spun down by centrifugation and the supernatant was analyzed by LC-MS. Approximately 30% conversion was observed so an additional 3 doses of 4 mg of fresh zinc powder and 2 μL of methyliodide were added to the reaction every 5 minutes. The insoluble materials were spun down by centrifugation and the supernatant was analyzed by LC-MS. Full conversion to SBL-156-ethylglycine was observed. 26697 Calculated mass; 26696 found.
The method of Example 22 has also been used to successfully produce modified proteins via addition of the organic iodides ethyl iodide, 1-iodopropane, 1-iodobutane, tert-butyliodide, iodocyclopentane, 2-iodobutane, 2-iodopropane, 2,2-dimethyl-1-iodopropane, 2-methyl-1-iodopropane, 2-iodoethanol, 3-iodopropylamine hydroiodide, 1-iodo-3-acetamidopropane, 1-iodo-3-methylaminopropane, (3-iodopropyl)-dimethylamine hydroiodide, (3-iodopropyl)-trimethylammonium iodide, 4-iodobutyl)amine hydroiodide, (2-iodoethyl)amine hydroiodide, (2-iodoethyl)guanidine hydroiodide, 3-iodopropionic acid, 3-iodopropionamide, 1-iodo-3-fluoropropane, 1-iodo-2,2,2-trifluoroethane and 1-iodo-3,3,3,-trifluoropropane and via the addition of the organic halides chloromethylmethylsulfide and benzylbromide.
Example 23
SBL-PMSF Adduct
FIG. 14 shows a reaction scheme for the preparation of an SBL-PMSF adduct.
A 1.00 mL solution of SBL-S156C was prepared at 1 mg/mL in pH 8.0 sodium phosphate buffer (50 mmol) and stored on ice until needed. A solution of phenylmethanesulfonyl fluoride (PMSF) was prepared by dissolving 4.8 mg (0.028 mmol) in 185 μL MeCN. A 50 μL aliquot of the PMSF solution was added to the protein and the reaction vortexed and rotated at room temperature for 10 minutes. LCMS analysis of the reaction mixture revealed full conversion to the PMSF adduct. (Calculated mass=26869. found 26868). Small molecules were removed using a PD10 column (GE Healthcare) that was equilibrated with the same phosphate buffer. The sample was split into 250 μL aliquots and flash frozen.
Example 24
SBL-221Dha
FIG. 15 shows a reaction scheme for the preparation of SBL-221Dha.
A 250 μL aliquot of the SBL-PMSF adduct prepared above was thawed and stored on ice until needed. 40 μL of 1M NaOH was added to the protein solution at 4° C. The reaction mixture was shaken at 4° C. for 90 minutes and then analyzed directly by LCMS. Full conversion to SBL-221Dha was observed. Calculated Mass=26697. found 26697.
Example 25
SBL-156His iso
FIG. 16 shows a reaction scheme for the preparation of SBL-156His iso .
A 1.0 mg/mL solution of SBL-S156C was prepared in pH 8.0 sodium phosphate buffer (50 mM) (5 mL total). 1.0 mL of this solution was transferred to each of five 1.5 mL plastic tubes and stored on ice. A solution of MSH (8.3 mg in 500 μL DMF) was prepared and 100 μL of this solution was added to each of the protein samples. All were shaken at 4° C. for 20 minutes. All tubes were then combined and vortexed. LCMS analysis of the mixture revealed full conversion to dehydroalanine (Calculated mass=26681, 26681 found). Imidazole (127 mg) was added to the protein solution and the reaction was shaken at 37° C. for 2 hours. An additional 165 mg of imidazole was added to push the reaction to completion. After 5 hours of total reaction time, LCMS analysis revealed full conversion to isohistidine (Calculated mass=26749, 26749 found) The protein solution was passed through a PD10 column equilibrated with the same buffer (2.5 mL for each of two PD10 columns). This protein solution was used immediately in the next reaction.
Example 26
SBL-156His iso PMSF Adduct
FIG. 17 shows a reaction scheme for the preparation of an SBL-156His iso PMSF adduct.
To 5.0 mL of the SBL-156His iso prepared above (0.71 mg/mL, pH 8.0 sodium phosphate buffer (50 mM)) was added 4.7 mg of PMSF (solution in 200 μL MeCN). The reaction was shaken at room temperature for 20 minutes and then analyzed directly by LCMS. Full conversion to the SBL-156His iso PMSF adduct was observed. Calculated mass=26903. found=26905. Small molecules were removed using PD10 columns equilibrated with the same buffer.
Example 27
SBL-156His iso 221Dha
FIG. 18 shows a reaction scheme for the preparation of SBL-156His iso 221Dha.
A 500 μL aliquot of the SBL-156His iso PMSF adduct prepared above (0.51 mg/mL, pH 8.0 sodium phosphate buffer (50 mM)) was added to a plastic tube along with 40 μL of 1.0 M NaOH. The reaction was rotated at 4° C. for two hours. LCMS analysis of the reaction mixture revealed full conversion to SBL-156His iso -221Dha. Calculated mass=26731. found 26733.
Recently, biosynthetic incorporation of selenocysteine derivatives into peptides and proteins and conversion to Dha has been reported. These strategies, however, rely on peroxide-induced oxidative elimination that compromises sensitive side chains such as methionine (Met). Dehydroalanine (Dha) is a unique chemical handle for such modifications and the present methods allow access to Dha without undesirable alteration to the remainder of a peptide or protein.
The inventive method avoids the need to ligate a desired peptide at a point where there should be a naturally occurring cysteine thereby expanding the potential scission points for retrosynthesis of large peptides and giving the researcher more options when choosing potential ligation points when synthetically constructing a polypeptide. The methods also allows the use of native chemical ligation in the synthesis of peptides that do not contain cysteine.
Routes to various naturally occurring amino acid side chains are shown in the following figure. | The invention relates to methods for selectively converting a cysteine residue in a peptide or protein to the dehydroalanine (Dha) residue. The method also works on selenocysteine and substituted cysteine and selenocysteine residues, resulting in the Dha residue which may be converted to any natural or unnatural amino acid residue desired without the alteration of the remainder of the peptide or protein. The invention also allows ligation of a desired peptide at any point rather than at a point where there should be a naturally occurring cysteine, thereby allowing native chemical ligation to be used in the synthesis of peptides that do not contain cysteine. The methodology allows for the synthesis of very large peptides. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS:
[0001] The priority benefit of U.S. provisional application Ser. No. 60/563,390 filed Apr. 19, 2004 is claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] The present invention relates to sliding screen doors.
[0005] Sliding doors are common in more contemporary homes. Many of these doors are multi-element doors and include a screen door which is simply a screens mounted to a sliding frame, typically a metal frame and most commonly, an aluminum frame. The size of these doors varies considerably, each manufacturer having its own range of sizes. Accordingly, when sliding doors need to be replaced, the size of the replacement door is a concern. Most manufacturers of after-market sliding doors provide some mechanism for adjusting the height of their replacement door at the time of installation.
[0006] Plastics are being used with increasing frequency as replacements for wood and metal and even ceramic materials. In construction, plastic piping has replaced some metal and ceramic piping. Vinyl shutters have replaced wood and aluminum shutters. Foamed plastic, particularly foamed vinyl, has found uses in molding and screen doors. Foamed vinyl is especially attractive as a substitute for wood because it can be trimmed with ordinary wood-working tools and techniques.
[0007] There are problems with foamed vinyl, of course, particularly when used on the exterior of a residence or office building where it is exposed to the sun. Heat from the sun tends to cause it to expand, only to contract when the sun sets. Repeated cycles of expansion and contraction may result eventually in deformation
[0008] Sliding doors are actually misnamed. While they appear to slide, they actually have small diameter wheels at the top and bottom that roll on tracks installed on the framing at the top and bottom of the opening they close. The tracks have low relief, perhaps a quarter inch at most. Thus, the fit of the door must be fairly precise so that these small wheels ride comfortably on these short tracks. A door that cannot be easily made to fit or that deforms over time would obviously not be suitable for such a purpose
[0009] Nevertheless, there remains a need for replacement sliding screen doors that are easily adjusted to the size needed and remain dimensionally stable over time.
SUMMARY OF THE INVENTION
[0010] The present invention is a sliding screen door having a frame made of plastic, preferably foamed plastic. The top and bottom rails (which are horizontal members) of the doorframe are easily trimmed using standard woodworking tools and techniques. The stiles (which are vertical members) of the doorframe may be reinforced so that they do not appreciably deform during the life of the door.
[0011] A feature of the present invention is the use of foamed plastic, with foamed vinyl preferred. Foamed vinyl is durable, requires no painting, is easily washable, and is lightweight and relatively inexpensive compared to aluminum and many types of wood.
[0012] Another feature of the present invention is the simplicity with which the sliding screen door can be adjusted to fit the framed opening at the job site. The top rail can be trimmed quickly, easily and precisely with a circular saw for example to the height required.
[0013] Still another feature of the present invention is the combination of reinforcing to the stiles in order to reduce deformation and add strength to a sliding screen door of foamed vinyl, so that the door operates smoothly on the sliding door tracks. The door is also light-weight so that it is easy to slide.
[0014] Other features and their advantages will become readily apparent to those skilled in the art of construction materials from a careful reading of the Detailed Description of Preferred Embodiments, accompanied by the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In the drawings,
[0016] FIG. 1 is a perspective view of a corner of a sliding screen door, according to a preferred embodiment of the present invention;
[0017] FIG. 2 is a perspective view of a corner of the sliding screen door of FIG. 1 , according to a preferred embodiment of the present invention;
[0018] FIG. 3 is a perspective view of a corner of an alternate sliding screen door, according to a preferred embodiment of the present invention;
[0019] FIG. 4 is a perspective view of a corner of the sliding screen door of FIG. 3 , according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] The present invention is a sliding screen door having a frame made of plastic, preferably foamed plastic, and most preferably of foamed vinyl. Other materials may be added, such as wood flour and coloring agents, provided that they do not significantly alter the ability of the user to trim the screen door using wood-working tools and techniques.
[0021] Additionally, in a preferred embodiment, stiffening is added to the stiles and potentially also to the rails of the present screen doorframe, in order to reduce deformation that might otherwise result from exposure to heat. Stiffening added to stiles, which, being the long, vertical elements of the sliding doorframe, are the most susceptible to heat-related deformation, will have no impact on the ability of the user to trim the rails to fit, provided that the rails run the full width of the door and the stiles do not run the full height. Moreover, stiffening added to the rails, especially if confined to the lower portion of the top rail, will have only a minor impact on the ability of the user to trim the door to fit; that is, it will limit the extend to which the upper rail can be trimmed.
[0022] Referring now to the figures, FIGS. 1 and 2 show a first embodiment of the present invention, namely the corner of a sliding screen door made according to a preferred embodiment of the present invention. The corner shown, namely the top right corner, is typical of the other four comers (top left, bottom left, and bottom right). In particular, the door, generally indicated by reference number 10 , includes a top rail 12 and an opposing bottom rail (not shown but symmetric with top rail 12 ) and a right stile 14 and an opposing left stile (not shown) that are joined at 16 to form a generally rectangular frame that defines an opening 18 . Opening 18 is covered with screen material 20 fitted into a spline groove 22 and held in place with a spline 24 .
[0023] Across top rail 12 is a header 30 formed with two legs 32 and 34 that straddle top rail 12 and arms 36 and 38 that serve to hold in alignment plural wheels 40 (one shown) with their axes horizontal so that they can ride a track (not shown) at the top and bottom of an opening, allowing door 10 to slide freely to the left and right. Wheels 40 are held between arms 36 and 38 , by leaf springs 42 attached to header 30 and a yoke 44 that holds wheel 40 . Wheels on bottom rails are held rigidly, as is well known in the prior art.
[0024] Header 30 is held to top rail 12 by screws 50 and 52 that extend through slots 54 and 56 formed in header 30 . For major adjustments, screws 50 and 52 are removed and header 30 is slid off top rail 12 . A portion of top rail 12 is trimmed away using, for example, a circular saw to remove a portion of top rail 12 and thereby shorten door 10 . The header 30 is repositioned on top rail 12 and fastened with screws 50 , 52 . If fine adjustments in the location of header 30 are required, screws 50 , 52 can be loosened and header moved slightly up or down as required. Then screws 50 , 52 , are retightened.
[0025] Referring now to FIGS. 3 and 4 , there is shown a perspective view of a top right corner of an alternative embodiment of the present sliding screen door 60 . Screen door 60 is symmetric left to right and top to bottom so that the top right corner is representative of the top left corner, the bottom left corner and the bottom right corner. Screen door 60 has a top rail 62 and an opposing bottom rail (not shown), a right stile 64 and an opposing left stile (not shown). The rails and stiles are joined together to form a rectangular frame that defines an opening 68 . Screen material 70 is used to cover opening 68 and fastened to door 60 by forcing it into a spline groove 72 with a spline 74 .
[0026] Instead of a header 30 , in the embodiment shown in FIGS. 3 and 4 , a deep groove 80 is milled in top rail 62 thereby defining members 86 , 88 , and wheels 90 (one shown) are mounted within groove 80 , and held to members 86 , 88 , by leaf springs 90 (one shown) held within a yoke 94 , in the same manner they are mounted between arms 36 and 38 , namely, biased upwards by a leaf spring 42 attached to the bottom of groove 80 by a screw.
[0027] When screen door 60 must be trimmed to reduce its height, springs 90 are removed along with wheels 90 . Then top rail 62 is cut using, for example, a circular saw to reduce the height of top rail 62 . Groove 80 , however, is deep enough so that even after removing a significant portion of top rail 62 , groove 80 is still sufficiently deep so that it can accommodate wheels 90 . Springs 92 are either bent to match the new depth of groove 80 or replaced with different springs 92 and refastened with screws to the bottom of groove 80 .
[0028] The present screen door 10 , 60 , is designed to make it a simple matter to replace screen material 20 , 70 by removing spline 24 , 74 , from spline groove 22 , 74 . New screen material 20 , 70 , can then be placed over opening 18 , 68 and its edges reinserted into spline groove 22 , 72 , by pressing spline 24 , 74 , into groove 22 , 72 over screen material 20 , 70 .
[0029] Stiles 14 , 64 , and rails 12 , 62 , can be made of solid plastic, hollow plastic, or foamed plastic, preferably vinyl, and they may be filled plastic, using for example, wood flour, or other materials to give it desirable properties or reduce costs, provided that the basic requirement of making top rail 12 , 62 trimmable using standard woodworking tools and techniques is not compromised. Stiles 14 , 64 may be made stiffer using metal bars inserts such as rods, tube, bars, or angled pieces around which the plastic is extruded. Other stiffening techniques may also be used.
[0030] It will be readily apparent that many substitutions and modifications can be made to the foregoing preferred embodiments without departing from the spirit and scope of the present invention, defined by the appended claim. | A sliding plastic screen door made of foamed vinyl can be trimmed at the job site to fit the door it will occupy. The door may have reinforcing in its styles and potentially also in its rails but not in the top portion of the rail, which is where it may be cut to fit. Two embodiments are disclosed, one with a header that can be removed prior to trimming the top rail, and the other with a deep slot for the rollers, which top rail can be trimmed directly and the wheels reattached. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a pack-off method and apparatus for wellheads and, more particularly, but not by way of limitation, to a system for and method of controlling the movement of small diameter tubing into and out of natural gas wells while providing means for preventing the tubing from being blown out of the well.
[0003] 2. History of Related Art
[0004] It is a common and well known practice in the oil and gas industry to use wellhead devices which will confine pressure in a well around a member such as a polished rod or wireline extending into a well during emergency conditions, as well as when it is necessary for servicing the well. It is well known for example that the production rates from natural gas wells can be adversely affected by corrosion and the buildup of substances such as scale, paraffin and salt. Producers have traditionally treated the wells by inserting chemicals and soap sticks at the wellhead and relying on gravity to carry the treating agent down the well to where it is needed. Recently a much more effective treatment means has been developed. Small diameter tubing is inserted into the well and the treating chemical is pumped down this capillary tubing, usually {fraction (1/4 )} or {fraction (3/8)} inch (sometimes {fraction (5/8)} inch), under pressure and allowed to enter the well where it can do the most good. A check valve at the lower end of the tubing controls the release of chemical and prevents well pressure from escaping up the capillary tubing.
[0005] A service rig is employed to insert or Asnub in@ the capillary tubing while the well remains pressurized. In this way, the service company does not Akill the well@ by pumping water and/or mud into the well casing to build up a hydrostatic pressure head which contains the well pressure. Accordingly, the wellhead must have a means for sealing around the capillary tubing both while it is being inserted or removed from the well and also on a long-term basis while the well is producing with the capillary tubing in place.
[0006] In operation, the insertion of the tubing can be problematic and has been analogized to Apushing on a string, @ due to the pressure within the well. When the weight of the tubing is less than the upward force or thrust in the well due to the pressure therein acting on the tubing, problems can occur. Once a sufficient depth is reached during tube insertion resulting in the weight of the tubing being sufficient to overcome the upward force or thrust in the well, the so-called “balance point” has been crossed. Likewise, when retrieving the tubing, the same phenomenon can occur as the weight of the tubing depending from the wellhead within the well decreases to the point that the weight is not sufficient to overcome the upward force or thrust placed there against.
[0007] Although systems are available for controlling the capillary tubing being inserted through a wellhead, problems exist when the tubing is above the balance point as referenced above. Typically, a spool of capillary tubing is disposed adjacent the wellhead in conjunction with a means for guiding the tubing into and through the wellhead. Such spools and guiding mechanisms are powered, and if for some reason, the power unit providing the appropriate power were to fail, the possibility exists that an operator could lose control of the tubing when it is above the balance point. While it is known in the art to use sealing members around the capillary tubing for insertion into the well, problems ensue in securely retaining the tubing within the sealing members while performing the above-referenced operations.
[0008] The present invention provides a means for quickly regaining control of tubing within a wellhead that has for one reason or the other not been secured by the conventional, compressible pack-off and securing mechanism currently in use. Although slip caps, used in conjunction with manual slips functioning as locking chucks having serrated teeth extending inwardly toward the capillary tubing may be used to permanently secure tubing, such mechanisms, which require manual actuation and/or twisting with a wrench to impart threaded induced movement therefrom, is not feasible and clearly provides safety issues for the operator. It would be a distinct advantage to provide an hydraulically actuated mechanism capable of reliable operation in the event of a capillary tubing control problem.
SUMMARY OF INVENTION
[0009] The present invention relates to a pack-off method and apparatus for wellheads. More particularly, the present invention relates to a system and method for controlling the movement of small diameter tubing into and out of wells while providing means for preventing the tubing from being blown out of the well. In one aspect, the invention includes a wellhead pack-off system for controlling the movement of small diameter tubing into and out of a well, comprising a body with a bore therethrough for insertion of the tubing, first means slidably coupled into the bore of the body for preventing movement of the tubing by hydraulically engaging a plurality of slips around the periphery of the tubing, and second means slidably coupled into the bore of the body for frictionally restraining movement of the tubing by hydraulically engaging the periphery of the tubing with a compressible elastomeric sealing member.
[0010] In another aspect of the invention, the body includes an upper unit and a lower unit. The lower unit is in threaded engagement with the upper unit. The upper unit comprises a first, second and third threaded aperture in communication with the bore of the upper unit. The upper unit further comprises the first means having a hollow cylindrical piston slidably coupled within the bore of the upper unit and in axial alignment therewith, a plurality of slips coupled to the piston and having serrated teeth for engagement or disengagement of the tubing, a slide member slidably coupled within the first aperture and extending therethrough for disengaging the plurality of slips from around the periphery of the tubing, and a plug, adapted for threaded engagement with the first aperture and disposed atop the slide for positioning the slide relative to the sidewall of the bore of the upper body. The flow of hydraulic fluid through the third aperture imparts an upward force to the piston thereby imparting a radially inwardly motion to the plurality of slips due to the inclined side walls of the bore of the upper unit so as to cause engagement of the plurality of slips with the tubing. Similarly, the flow of hydraulic fluid through the second aperture imparts a downward motion to the piston thereby imparting a radially outwardly motion to the plurality of slips due to engagement of the plurality of slips with the slide.
[0011] The lower unit further comprises a threaded aperture in communication with the bore of the lower unit. The lower unit also comprises the second means having a plunger in axial alignment therewith, a spring in axial alignment with the plunger, an upper bushing set disposed within the lower end of the plunger, a conically shaped lower bushing set in axial alignment with the upper bushing set, and a compressible elastomeric sealing member in axial alignment with the upper and lower bushing set and disposed therebetween. The flow of hydraulic fluid through the aperture of the lower unit imparts a downward force to the plunger, which compresses the spring and forces the upper bushing set into the lower bushing set, thereby compressing the sealing member disposed therebetween. The abutting engagement of the sealing member and the conically shaped lower bushing set imparts radially inwardly motion to the sealing member. The radially inwardly movement of the sealing member forms a seal around the capillary tubing extending through the bore of the body.
[0012] In still another aspect of the invention, the upper unit further comprises suspension means for suspending the tubing by engaging a plurality of suspension slips around the periphery of the tubing. The suspension means further comprises a slip cap in threaded engagement with the upper unit for engaging the suspension slips with the tubing.
[0013] In a further aspect, the invention provides an extra set of slips that can be quickly engaged around the capillary tubing described above, to arrest upward movement in an emergency situation. A double-acting hydraulic piston is used to move the slips upwards into an engaged position to halt the upward movement of the tubing. After the crew regains control, hydraulic pressure can be applied to the opposite side of the piston to move the slips downwardly and outwardly into a position that allows free upward or downward motion of the capillary tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention will now be described in more detail with reference to preferred embodiments of the present invention, given only by way of examples, and illustrated in the accompanying drawings in which:
[0015] [0015]FIG. 1 is a perspective view of a typical wellhead installation showing the insertion of capillary tubing;
[0016] [0016]FIG. 2 is an enlarged, side-elevational, cross-sectional view of the capillary tubing pack-off of the present invention with portions thereof cut away for illustrating the assembly thereof;
[0017] [0017]FIG. 3 is a side-elevational, full cross-sectional view of the upper body of the capillary tubing pack-off of FIG. 2, illustrating one aspect of the fabrication thereof;
[0018] [0018]FIG. 4 is a side-elevational view of the piston for the capillary tubing pack-off of FIG. 2;
[0019] [0019]FIGS. 5A and 5B comprise a side-elevational, full cross-sectional and frontal view, respectively, of the piston shown in FIG. 4;
[0020] [0020]FIGS. 6A, 6B and 6 C are multiple views of the fabricated slip of the capillary tubing pack-off of FIG. 2 illustrating various aspects of the fabrication thereof;
[0021] [0021]FIGS. 7A and 7B are top plan and side-elevational views, respectively, of the plug of the capillary tubing pack-off of FIG. 2;
[0022] [0022]FIGS. 8A through 8C comprise multiple views of the slide for the capillary tubing pack-off of FIG. 2; and
[0023] [0023]FIGS. 9A through 9C comprise multiple views of a perspective, cross-sectional view of the upper body portion of the capillary tubing pack-off of FIG. 2 with portions thereof cut away for illustrating the engagement and disengagement of the slips within the capillary tubing pack-off of FIG. 2.
DETAILED DESCRIPTION
[0024] It has been found that a wellhead pack-off incorporating hydraulically actuated sealing means in the configuration set forth and described below may enhance the operational efficiencies surrounding the insertion or removal of capillary tubing into or out of a well under pressure. The hydraulically actuated sealing means of the present invention also provides a means for suspending the capillary tubing from the wellhead for a prolonged period of time. As described below, and as set forth and shown in the drawings, the wellhead pack-off of the present invention provides a set of hydraulically activated slips specifically adapted for restraining the capillary tubing if it begins to be blown out of the well under pressure.
[0025] Referring first to FIG. 1, there is shown a typical installation by a service rig 6 of capillary tubing 7 at a wellhead 8 utilizing a prior art pack-off 9 specifically adapted for the receipt of the capillary tubing therethrough. The wellhead 8 as shown herein utilizes the typical hardware associated with wellheads, including the wellhead pack-off 9 disposed in an upper portion thereof with the capillary string extending therefrom. It is known in the prior art to use wellhead pack-off devices for controlling the capillary tubing while the well remains pressurized. As set forth above, there are many advantages to the utilization of capillary tubing. The well operator's expectations from the use of such tubing includes obtaining incremental increases in production and reserves, and the elimination of production fluctuations associated with soaping, flaring, and stop cocking. Also, the use of capillary tubing have been shown to reduce downtime and time requirements to maintain production while improving efficiency and effectiveness of chemical treatments and applications. In wells with liquid loading, the benefits of capillary tubing include the improvement of system dynamics and minimization of reservoir damage. The present invention facilitates the above advantages by increasing the reliability of the wellhead pack-off as set forth and described below.
[0026] Referring now to FIG. 2, there is shown an enlarged side-elevational, partially-cross-sectional view of the capillary tubing pack-off 10 of the present invention. The presence of a capillary tube is not shown for purposes of clarity. The pack-off 10 includes an upper unit 500 and a lower unit 501 adapted for receiving a capillary tube axially therethrough, and in axial alignment with a central axis 100 . Upper unit 500 includes a slip cap 12 disposed on the first terminal end 13 thereof. A plurality of manual upper slips 14 are disposed within the slip cap 12 with serrated teeth 15 facing radially inwardly therefrom for engagement of capillary tubing (not shown) extending through the capillary tubing pack-off 10 . The upper unit further comprises a body 16 having a threaded portion 17 adapted for threadably engaging the slip cap 12 as shown herein. The body 16 is constructed for receipt of a plurality of hydraulic lower slips 18 disposed along an inclined surface 19 formed therein. A threaded aperture 21 is formed in cylindrical wall 23 of the body 16 adapted for receipt of a slide 22 and a plug 20 therein. A separate aperture 21 , slide 22 , and plug 20 is provided for and adapted for engagement with each of the plurality of lower slips 18 in a manner described in more detail below.
[0027] Still referring to FIG. 2, there is shown the body 16 of upper unit 500 constructed with the cylindrical wall 23 , within which is disposed, for reciprocation therein, a piston 24 . The piston 24 is disposed in sealing engagement with a cylindrical wall 23 through an o-ring 26 disposed therebetween. A second o-ring 28 is disposed in a groove 27 of an upstanding cylindrical boss 29 formed around the piston 24 that is described in more detail below. Likewise, a third o-ring 30 is disposed between an inside surface 31 of the body 16 and an upper internal surface of a cap 32 . The cap 32 forms the upper region of lower unit 501 and is constructed with an outwardly facing thread portion 34 adapted for engagement with an inwardly facing threaded surface 36 of the lower end of body 16 . The cap 32 is configured for receiving a lower end 40 of piston 24 with an o-ring 41 disposed therebetween. Axially disposed within the cap 32 is a reciprocating plunger 42 sealed thereagainst through an o-ring 43 . Likewise a second o-ring 45 is disposed around an upper boss 44 of the plunger 42 for sealing against the inside of the cap 32 . The plunger 42 is also constructed with a reduced neck portion 50 adapted for receiving a spring 52 therearound. The spring is disposed in space 54 formed between the plunger 42 and the inside surface of the cap 32 for purposes of biasing the plunger 42 upwardly. A threaded aperture 46 is formed in the sidewall of cap 32 and permits hydraulic fluid to enter and egress space 47 , formed between intermediate portion 48 of plunger 42 and the sidewall of cap 32 . Furthermore, the space 47 is separated from the space 54 by upper boss 44 and sealed thereagainst by second o-ring 45 .
[0028] Referring still to FIG. 2, and, in particular, further aspects of the lower unit 501 of the capillary tubing pack-off 10 of the present invention, a steel upper bushing set 56 is disposed within a lower end 58 of the plunger 42 . The steel upper bushing set 56 is formed with a radially extending neck region 60 that abuts the terminal end of the plunger 42 on a first side and abuts an elastomeric compressible sealing member 64 , preferably formed of rubber or the like, on the opposite side thereof. The sealing member 64 is disposed in axial alignment with the steel upper bushing 56 and within the walls of an extended base 66 . Extended base 66 is formed with a lower base portion 68 forming a shoulder 70 facing upperwardly therefrom toward the sealing member 64 and upon which a lower bushing set 74 is disposed. It may be seen that the lower bushing set 74 is sandwiched between the shoulder 70 and an angulated surface 76 of the sealing member 64 . The angulated surface 76 is formed at angle that matingly engages in abutting relationship therewith angulated surface 78 of the lower bushing set 74 , also preferably formed of steel. The lower base portion 80 of the extended base 66 is further formed with threads 82 formed circumferentially therearound adapted for threadably engaging mating wellhead equipment.
[0029] The above provides a description of the general assembly of the capillary tubing pack-off 10 of the present invention. A description of many of the individual elements forming portions thereof will be described in more detail below. What is common in the assemblage, however, of the above-described elements is the fact that a central aperture 100 is formed therethrough, as indicated by the phantom line of central axis 100 therein. The aperture along axis 100 is adapted for receipt of capillary tubing therein, as referenced above. Actuation of the capillary tubing pack-off 10 , in the manner described herein, allows selective engagement and disengagement of the capillary tubing disposed within the capillary tubing pack-off for purposes of installing, removing, and locking capillary tubing within a well.
[0030] Referring now to FIG. 3, there is shown a side-elevational, full cross-sectional view of the body 16 of FIG. 2, with all other elements of the capillary pack-off 10 illustrated in FIG. 2 in association therewith removed for purposes of clarity. In this particular view, the fabrication of the body 16 can be more clearly understood as well as certain functional aspects thereof. For example, body 16 includes the threaded apertures 21 (preferably three) adapted for receiving the slides 22 and the plugs 20 (shown as FIG. 2) therein. The construction and operation of the threaded apertures 21 and slides 22 will be described in more detail below. What is clearly shown herein is the multi-chambered axial bore 102 of the body 16 facilitating the receipt of the above-referenced elements therein for the operation thereof, and in axial alignment with central axis 100 . The bore 102 includes first and second conical sections 104 and 106 oppositely disposed about a cylindrical region 108 sandwiched therebetween. An aperture 110 is formed in a sidewall body 16 in communication with chamber 106 . The Aperture 110 provides a means of visually confirming that the slips 18 are in position to engage the capillary tubing, while the aperture 21 provides outside communication into a cylindrical chamber 112 disposed contiguous to the conical section 106 . A conical transition section 114 provides communication between the chamber 112 and a cylindrical chamber 116 formed upwardly of a cylindrical region 118 . The inside diameter of the body 16 is increased to provide a cylindrical region 120 above and in communication with a lower-most region 122 . The sidewalls of the lower-most region 122 form inwardly facing threaded surface 36 for threaded engagement with cap 32 . As described above, the various bore diameters are necessitated for receipt, adaptation and operation of the various elements described, set forth and shown in FIG. 2.
[0031] Still referring to FIG. 3, the sidewall of the body 16 includes a first threaded aperture 204 providing communication into the region 116 while a second threaded aperture 202 provides communication into the chamber 118 . Finally, the walls of the lower-most region 122 are formed with the threads 36 , referenced above.
[0032] Referring now to FIG. 4, there is shown a top plan view of the piston 24 of FIG. 2. The piston 24 is constructed with an upper body portion 130 formed with slots 132 (preferably three) therein. The slot 132 is adapted for receiving the slides 22 and the lower slips 18 , as represented in phantom. Likewise, the piston 24 is constructed with a groove 134 adapted for receiving o-ring 26 as shown in FIG. 2. An o-ring may also be mounted around the piston 24 within the boss 29 extending therearound and adjacent to intermediate portion 90 of the piston 24 . An o-ring groove 142 is also formed in the lower end 40 of the piston 24 .
[0033] Referring to FIGS. 5A and 5B in combination, there is shown a side-elevational, partially cross-sectional and frontal view, respectively, of the piston 24 of FIG. 4. The slots 132 , as shown in FIG. 4, may be seen to comprise an elongated section thereof exposing a central bore 144 therein. The central bore 144 is formed concentrically about the axis 100 , as is central chamber 146 formed adjacent thereto. The reciprocal actuation of the piston 24 within the capillary tubing pack-off 10 will be described in more detail below.
[0034] Referring now to FIG. 6A, there is shown an enlarged top plan view of one hydraulic lower slip 18 (preferably of the set of three, although other numerical combinations may be used). The slip 18 includes a frontal face 150 and a rear face 152 wherein an angled body portion 154 extends therebetween. A key section 156 is disposed rearwardly thereof and extends therefrom by neck region 158 .
[0035] Referring now to FIG. 6B, there is shown a side-elevational view of the hydraulic lower slip 18 , illustrating aspects in the manufacturing thereof. The neck region 158 of the key section 156 may be seen relative to the surface 152 . The slip 18 is formed with a plurality of serrated teeth 15 , which teeth may be of similar shape as those set forth and described relative to the manual upper slips 14 described above. The key section 156 has an angled rear surface 157 for sliding engagement with slide 22 , described in more detail below.
[0036] Referring now to FIG. 6C, there is shown an end-elevational view of the hydraulic lower slip 18 illustrating other aspects of the manufacture thereof. As will be seen, the serrated teeth 15 comprise a relatively small section of the hydraulic lower slip 18 and are disposed inwardly in a position adapted for engagement with the capillary tubing placed therethrough as will be described in more detail below.
[0037] Referring now to FIGS. 7A and 7B in combination, there is shown a top plan and a side elevational view of one plug 20 (preferably 3) of the capillary tubing pack-off of FIG. 2. The plug 20 is constructed with a threaded side portion 160 adapted for threaded engagement with the threaded aperture 21 formed in the capillary tubing pack-off 10 . As shown in FIG. 2, the plug 20 is disposed atop the slide 22 for positioning the slide 22 relative to the sidewall of the cylindrical chamber 112 of the body 16 of the capillary tubing pack-off 10 . The placement of the slide facilitates the actuation of the hydraulic lower slips 18 , as will be described in more detail below.
[0038] Referring now to FIGS. 8A through 8D in combination, there is shown one of the above-referenced slides 22 . In these particular views, the manufacturing of the slide may be more clearly seen and, in particular, the construction of the angulated surface therein facilitating engagement with the angled surface 157 of the lower slips 18 discussed above.
[0039] Referring specifically now to FIG. 8A, there is shown a side elevational view of the slide wherein angulated surface 170 is shown to be disposed across body section 172 for facilitating sliding engagement with the angled rear surface 157 of the hydraulic lower slip 18 , as represented in phantom. Body section 172 is disposed beneath a head section 174 having a threaded aperture 176 formed therein. The threaded aperture 176 enables the slide 22 to be extracted with a bolt (not shown) after removing the plug 20 .
[0040] Referring now to FIG. 8B, a top plan view of the slide 22 of FIG. 8A is set forth and shown. The aperture 176 is most clearly shown in this particular view while the angulated surface 170 of body section 172 is shown in phantom.
[0041] Referring now to FIG. 8C, the slide 22 of FIG. 8A is shown in a bottom plan view wherein the body portion 172 is shown to be formed with the slide surface 170 shown in phantom and the shape of which is most clearly set forth and illustrated as it is disposed beneath the larger head section 174 .
[0042] Referring now to FIGS. 9A through 9C in combination, there is shown a perspective view of a cutaway portion of the piston 24 and the body 16 , with one of the slides 22 , and slips 18 , contained therein, illustrating the engagement one with the other for purposes of description of the operation thereof within the capillary tubing pack-off 10 . In these particular views, the engagement of the hydraulic lower slip 18 by slide 22 may be more clearly seen during retraction of the slip 18 by piston 24 in direction of arrow 201 .
[0043] Referring specifically now to FIG. 9A, there is shown the piston 24 and the slip 18 in an engaged position, with the slide 22 inserted through the threaded aperture 21 and slot 132 of piston 24 . The plug 20 is not shown for purposes of clarity.
[0044] In the engaged position, forward motion of the piston 24 induces forward movement of the slip 18 by virtue of the interlocking relationship thereof, whereby the angulated surface 154 bears against the angulated surface 19 of the body 16 , imparting inwardly radially directed motion to the slip 18 , as depicted by arrow 155 . The inwardly radial direction of movement of the slip 18 along the direction of the arrow 155 will cause the teeth 15 thereof to bear against capillary tubing (not shown) extending axially therethrough.
[0045] Referring to FIG. 9B, there is shown the same view as in FIG. 9A, illustrating a transitional stage during retraction by the piston 24 of the slip 18 . As discussed above, movement along the arrow 201 will impart a radially outwardly motion to the slip 18 . During a portion of this retraction, however, the teeth 15 remain engaged with the tubing due to the radially inwardly force imparted by the angulated surface 19 of the body 16 to the angulated surface 154 of the slip 18 .
[0046] Referring now to FIG. 9C, there is shown the same view as in FIGS. 9A and 9B, illustrating the engagement of slide 22 and slip 18 by the motion of the slip 18 imparted by the piston 24 during retraction in the direction of arrow 201 . It may be seen that the angulated surface 170 of the slide 22 engages the slip 18 across the angulated surface 157 thereof. Movement of the piston 24 induces the angulated surface 157 of the slip 18 to abut the angulated surface 170 of the slide 22 , whereby the slip 18 is induced to move radially outwardly along the surface 170 of the side 22 disengaging teeth 15 from the tubing, as depicted by arrow 159 .
[0047] While the construction and operation of the capillary tubing pack-off of the present invention may be clearly set forth and shown herein, the assembly thereof also should be addressed. The interlocking engagement between the slips 18 and the piston 24 necessitates assembly one with the other within the body 16 of the capillary tubing pack-off 10 for subsequent insertion of the slide 22 for positioning therebetween. As referenced above, the function of the slide 22 is to impart radially outwardly movement of the slip 18 during the retraction thereof in the direction of arrow 201 by virtue of the angled surface 157 of slip 18 engaging surface 170 of slide 22 .
[0048] Referring back now to FIG. 2, the overall operation of the capillary tubing pack-off 10 of the present invention will now be more clearly described. The capillary tubing pack-off 10 basically comprises the lower unit 501 and the upper unit 500 . The lower unit 501 comprises a first clamping means using the sealing member 64 . The upper unit 500 comprises a second clamping means using the plurality of hydraulic lower slips 18 and a third clamping means using the manual slips 14 .
[0049] Referring still to FIG. 2, and in particular to the lower unit 501 , which has been described in detail above. The lower unit 501 serves to provide a first clamping means for controlling the movement of small diameter tubing into and out of wells by providing an hydraulically actuatable clamping mechanism working in conjunction with a conventional elastomeric compression pack-off. The use of hydraulically actuated elastomeric pack-offs to seal capillary tubing is known in the art. In that regard, lower unit 501 includes a conventional hydraulically actuated pack-off. It may be seen that hydraulic fluid injected through port 46 into space 47 of the capillary tubing pack-off lower unit 501 will cause movement of the plunger 42 therein against spring 52 and against the upper bushing 56 which bears against sealing member 64 . Sealing member 64 is constructed with an angulated surface 74 which bears against angulated surface 76 of the lower bushing 78 whereby radially inwardly directed expansion is imparted for engaging capillary tubing disposed therein. As stated above, this type of hydraulic actuation utilizing a plunger and a compressible member is accepted in the industry. What is not of standard acceptance is the use of means for actuation of a series of mechanical locking members such as the hydraulic lower slips 18 having teeth 15 formed along an inner surface thereof (shown in FIG. 6A- 6 C) for engagement of the capillary tubing extending therethrough. In the lower unit 501 of FIG. 2, a first clamping mechanism is provided by the sealing member 64 . The sealing member 64 provides the requisite sealing of the capillary tubing and a degree of securement thereagainst. In high pressure situations, it is, however, potentially problematic to have the sole means for securing capillary tubing the sealing member 64 for which only a smooth frictional surface is afforded therewith. For this reason, in the upper unit 500 , a second clamping mechanism is provided by the hydraulic lower slips 18 which greatly improve the reliability, safety and efficiency of such wellhead operations.
[0050] Referring specifically now to the upper unit 500 and the operation of the second claimping means comprising the plurality of slips 18 described above in FIG. 2, the slips 18 may be used (preferably three) to arrest the upward motion of the capillary tubing in an emergency situation. The slips 18 are positioned by virtue of the piston 24 that is hydraulically actuated to move in a first upward direction along arrow 200 in response to hydraulic fluid flowing through the aperture 202 and bearing thereagainst. The aperture 204 allows expulsion of any hydraulic fluid contained in cavity 206 defined therebeneath and around the upper region of piston 24 . Movement of the piston 24 in the direction of arrow 200 then imparts movement to the slips 18 disposed axially against the end 133 of the piston 24 . It may be seen that the slot 132 (FIGS. 4 and 5), provided for each of the plurality of slips, permits an abutting relationship between the end 133 of the piston 24 (shown in FIG. 4) and the surface 152 of the slip 18 (shown in FIGS. 6A and 6B). Movement of the piston 24 in the direction of the arrow 200 thus imparts movement of the slips 18 in the same direction, which by virtue of the angled interface along the surface 19 induces the slips 18 to move radially inwardly in a clamping action, similar to the jaws of a chuck, against an object such as a capillary tube extending axially through the capillary tubing pack-off 10 . The teeth 15 then are positioned to physically engage the surface of the capillary tube for securement thereof actuated by the hydraulic pressure imparted thereto. Likewise, release of the hydraulic fluid through the aperture 202 while hydraulic fluid is injected through the aperture 204 will cause the piston 24 to move in the direction of the arrow 201 , and the movement will likewise cause movement of the slips 18 in the direction of the arrow 201 by virtue of the interlocking relationship therebetween. As discussed above in relation to FIGS. 9A through 9C, the teeth 15 of the slips 18 continues to engage the surface of the capillary tube due to the radially inwardly force exerted on the angled surfaces 154 of the slips 18 , until angled surfaces 170 of the slides 22 (one slide is provided for each slip) engage the angled surfaces 157 of the slips 18 , thereby imparting a radially outwardly motion to the slips 18 , disengaging the teeth 15 from the surface of the capillary tubing.
[0051] Referring still to FIG. 2, and, in particular to the third clamping mechanism set forth and described above in the upper unit 500 comprising the manual upper slips 14 which may be provided in a series of two or more (preferably three) and are manually positioned for claimping action relative to the slip cap 12 . In operation, however, the manual upper slips 14 described above which are actuated by the slip cap 12 are typically not in place on the capillary tubing pack-off 10 of the present invention, although they are positioned around the capillary tubing being fed thereto. The third clamping mechanism is utilized once the capillary tubing reaches a certain depth and is cutoff from the tubing reel on the service rig to suspend the tubing and prevent it from being pulled down by gravity. In an emergency situation, however, there are generally two means available to an operator to control the movement of capillary tubing in the pack-off 10 of the present invention. The first clamping means, as discussed above, is the hydraulic actuation of the sealing member 64 which permits sealing and securement of the capillary tube as long as the pressures within the well do not exceed that capable of being handled by such sealing members. If the well pressure become great enough, the operator of the pack-off 10 of the present invention is able to connect and have available to him the ability to immediately hydraulically actuate a mechanical chuck in the form of the plurality of hydraulic lower slips 18 described above for secured engagement of the capillary tubing extending through the pack-off 10 .
[0052] It should also be noted that the specification of the o-rings presented herein are for purposes of illustrating the requirement for sealing, as is typical in most hydraulic actuation systems due to the high pressures involved in the system, the multiple use of o-rings is deemed a preferred embodiment.
[0053] Although a preferred embodiment of the invention as been illustrated in the accompanying drawings and described in the foregoing specification, the wellhead is capable of numerous rearrangements and modifications of parts and elements without departing from the spirit of the invention. | A body having a bore therethrough for insertion of capillary tubing. A first means slidably coupled into the bore of the body frictionally restrains movement of the tubing by hydraulically engaging the periphery of the tubing with an elastomeric compressible sealing member. A second means slidably coupled into the bore of the body prevents movement of the tubing in the bore of the body by hydraulically actuating a plurality of slips to impart select engagement of the periphery of the tubing for its securement therein. A third means suspends the tubing in the bore of the body by manually engaging a plurality of suspension slips around the periphery of the tubing. | 4 |
The present invention relates to articulation members for the back portion of a vehicle seat and similar applications and comprise asymetrically guided bearing plates.
BACKGROUND OF THE INVENTION
It is well known that bearing plates facilitate an increase of the number of adjusting angular positions of the back portion of a seat with respect to the seating portion of the seat, particularly when the fixed toothing of the movable ring and the toothing of the bearing plates are both very small.
However the known articulartion members have various drawbacks, and particularly rather important plays because of the manufacture of the parts, which results in an angular displacement of the back portion which is bad for the comfort of the seat user.
These known articulation members which position the back portion with respect to the seating portion are based on a positioning of the bearing plates in such a manner that teeth which are made on the toothed ring and on the toothed bearing plates are placed opposite the one from the other with a shift of an angle equal to that of a tooth. It is therefore impossible or at least not very possible, by using these articulation members to compensate the plays and, moreover, the minimum angle between two positions of the back portion is equal to the angular pitch of one tooth.
OBJECTS OF THE INVENTION
The present invention remedies to the above drawbacks by providing an articulation member enabling a greater number of locking positions relatively to the number of teeth made on the fixed locking ring by using a minimum of three bearing plates and by an angular shift with a certain magnitude for two of the bearing members with respect to the third one, when three bearing plates are used enabling a penetration of the teeth of one of the bearing plates at the teeth bottom of the locking ring and a partial penetration of the two other bearing plates in the locking ring causing thereby a locking without any play of the articulation member in any position with a very small angular shift which is substantially equal to one third of the angular pitch of each tooth of the locking ring.
This invention enables also to make the toothing of the locking ring and that of the bearing plates by a process which is very fast and of a low cost since the angle of each tooth is sufficient for enabling to use a manufacturing process of a great efficiency. Actually, the minimum, the angular displacement is equal to one third of the angular pitch (α) of each tooth because the articulation members comprise always a minimum of three bearing plates so placed for covering the 360° of the periphery, which corresponds, in the case of three bearing plates to positions at 120°-5/8/3 ; 120°+2/3α; 120°-α/3.
SUMMARY OF THE INVENTION
According to the invention, the articulation member for a back seat portion of a vehicle seat and similar applications comprises: three asymetrically guided sliding bearing plates having an upper toothing of a pitch α; a fixed flange comprising three sectors for supporting the bearing plates; a movable flange having an inner toothing of a pitch α, a pitch corresponding to the pitch α of the upper toothing of the bearing plates; elastic means for normally pushing back the bearing plates from the movable flange; the bearing plates being angularly shifted for two of the bearing plates and being submitted to a bias of control means, wherein the angular shift of the two of the bearing plates with respect to a third one is of 120°-α/3, whereby at least one of the bearing plates is at tooth-bottom in the inner toothing while other bearing plates will bear at least in part on opposed surfaces of the inner toothing by thus ensuring a locking of the articulation member, and therefore of the backing portion of the seat with respect to the seating portion of the seat.
According to another feature of the invention, each of the bearing plates have guiding extension having an upper part with a widened area, the fixed flange being provided with sector members each having a recessed area, the widened areas cooperating with the recessed area.
Several other features of the invention will become more apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are shown by way of non limiting examples in the accompanying drawings, wherein:
FIG. 1 is a diagrammatic front view of a three bearing plate articulation member according to the invention;
FIG. 2 is a view corresponding to that of FIG. 1 but rotated by an angle equal to one third of the angular pitch of a tooth;
FIG. 3 is a variant of embodiment of the articulation member of FIGS. 1 and 2, the bearing members being disengaged from the fixed toothed ring and having a self centered guiding;
FIG. 4 is a view corresponding to that of FIG. 3 but with the bearing plates being shown engaged in the fixed tooth ring;
FIG. 5 is a view of a third embodiment of the invention, the bearing plates being disengaged from the fixed toothing ring and having a self centered guiding;
FIG. 6 is a view corresponding to that of FIG. 5 but with the bearing plates being shown engaged in the fixed toothed ring;
FIG. 7 is a side elevation view, partly in cross-section, of the articulation member of FIGS. 5 and 6; and
FIG. 8 is a diametral cross-section of the articulation member of FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 diagrammatically shows a toothed ring 1 made by stamping or fine cutting on the movable flange 2 of an articulation member of the backing portion of a vehicle seat.
As this is shown, the teeth of the toothed ring 1 are spaced apart by a center angle α (pitch of a tooth), and three bearing plates 3, 4 and 5 are positioned within the toothed ring 1. The bearing plates 3, 4, 5 have each a subtantially squared shape and have, at their upper ends 3a, 4a, 5a, a toothing 6 having exactly the same angle α as the toothing of the ring 1.
The rear part of each of the bearing plates 3, 4, 5 has a central surface 7 which cooperates with a control member which is typically a cam. The bearing plates 3, 4, 5 are guided in the fixed flange, not shown but having three sector members 8, 9 10 fixed with the fixed part of the articulation forming, by their converging sides 8a, 8b, 9a, 9b, 10a, 10b, guiding members for the bearing plates 3, 4, 5.
However, by construction of both the sector members 8, 9, 10 and the bearing plates 3, 4, 5, the bearing plates 4 and 5 are each placed at 120°-α/3 with respect to the bearing plate 3. Therefore, when the three bearing plates 3, 4, 5 are pushed back by the control member mentioned above toward the toothed ring 1 of the movable flange 2, the toothing 6 of the bearing plate 3 will penetrate at tooth-bottom into the toothed ring 1; but the toothings 6 of the bearing plate 4, 5 will bear on the edges of the toothing of the ring 1 and do not penetrate at tooth-bottom.
There is thus obtained a perfect wedging of the articulation members since the plays are compensated by a sufficient penetration of the toothing 6 of the bearing plates 4, 5 in the teeth of the toothed ring 1.
If it is desired to adjust the back portion of the seat by a very small angular magnitude and if the bearing plates 3, 4, 5 are unlocked, the bearing plates 3, 4, 5 will move back and the teeth 6 will disengage the toothing of the ring 1 by freeing thus the back portion with respect to the seating portion.
By making an angular shift equal to 1/3 of the pitch α of one tooth, and thus an angular shift which is equal to α/3, the bearing plate 4 is then brought at tooth-bottom (see FIG. 2). The toothing 6 of the bearing plate 4 will thus penetrate fully into the tooth-bottom of the toothed ring 1 while the toothing 6 of the bearing plates 3 and 5 are locked on the tooth edges of the toothed ring 1. There is thus obtained a perfect and without play locking of the backing portion of a seat with respect to the seating portion of the seat, as this has been explained in the above disclosure.
It is thus found that the minimum displacement angle of the back portion with respect to the seating portion can be equal to α/3 which is to say equal to 1/3 of the angular pitch of a tooth of the toothed ring 1. If the angle α is small, and say within the range of 2°, there is thus obtained an angular sensitivity of about 40 minutes which was not possible till now.
The embodiment of FIGS. 1 and 2 gives a very great angular sensitivity but, as this has been explained in the above disclosure, the toothings of two of the bearing members will bear only on a part of the toothing 1 of the toothed ring.
It results therefrom that it has been found necessary, and in order to increase the resistance of the mechanism of the articulation member without decreasing its angular sensitivity, to make bearing plate articulation members of the type shown in FIGS. 3 and 4.
In FIGS. 3 and 4, the toothed ring 10 of the movable flange 11 still uses teeth of a very small angular pitch and for example of 2°, which can easily be obtained by a process which is perfectly known, such as a fine cutting process.
The toothing 12 of the bearing plates 13, 14, 15 has obviously the same pitch as the toothing of the ring 10, but the bearing plates 13, 14, 15 each have, at their rear parts, two angular sides 13a, 13b; 14a, 14b; 15a, 15b and are extended by guiding stems 13c, 14c, 15c enabling, when they are pulled back as in FIG. 3, to be self centered according to axis of their stems 13c, 14c, 15c in order to be ready to penetrate into the teeth of the ring 10. The guiding stems 13c, 14c, 15c have a width slightly smaller than the space between the sectors 16, 17, 18 which are similar to the sectors 8, 9, 10 of FIGS. 1 and 2 but comprise recessed portions 16a, 16b; 17a, 17b; 18a, 18b enabling to limit a rearward movement of the bearing plates 13, 14, 15. The corresponding play between the guiding stem and the sectors is equivalent to a lateral displacement by an angle of α/3 since, when the bearing plates 13, 14, 15 are pushed back in the toothing as in FIG. 4, they will be placed, according to the position of the toothed ring 10, either with an angle of 120°+2/3α (bearing plates 14 and 15), or with an angle of 120°-α/3 (bearing plates 13, 14, and 13, 15).
It is obvious that, according to the angular positions of the ring 10, the bearing plates 13, 14, 15 can bear by pair on one of the sectors 16, 17 or 18.
Therefore and as shown in FIG. 4, when upon effect of a control member which is typically a cam as in FIGS. 1 and 2, the bearing plates 13, 14, 15 are pushed back toward the periphery of the flange 11, and the toothings 12 of the bearing plates 13, 14, 15 will penetrate into the toothing 10 of the movable flange 11 with all, the teeth of the bearing plates 13, 14, 15 penetrating at tooth-bottom (see FIG. 4), the radial axis for the bearing plates 14, 15 will be shifted by +α/3 for the bearing plate 14 and by +α/3 for the bearing plate 15 (which is equivalent to positions at 120° corresponding to the toothing of the ring 11) in order that the sides of the guiding stems 14c, 15c of the bearing plates 14, 15 will bear on the two edges of the sector member 16 by thus locking without any play the back portion of the seat with respect to the seating portion of the seat.
As in the preceding embodiment of FIGS. 1 and 2, an angular displacement of α/3 can easily be obtained since it is the minimum angle which is chosen when the bearing plates 13, 14, 15 are shifted. In a lowering of the back portion in a rearward direction, the bearing plates 15 and 13 are the ones which are shifted against the side walls of the sector member 17 while the frontwardly pivoting of a back portion by 1/3 of the angle α causes an angular displacement of the bearing plates 13, 14 and their wedging against the side walls of the sector member 18.
In FIGS. 5 and 6, the articulation member is identical to the articulation member described by reference to FIGS. 3 and 4, but the bearing plates 13, 14, 15 have a smaller height so that their lower parts have a plane surface 13', 14', 15' which will bear on the lower part of a substantially V-shaped disengagement 21 provided at the upper part of an intermediary part 22, 23, 24.
The intermediary parts 22, 23, 24 are into contact, by their lower areas 22a, 23a, 24a, with the control member which is typically a cam as in the preceding embodiments. In the unlocking position, which is when the bearing plates 13, 14, 15 are not into engagement with the toothed ring 10, the bearing plates 13, 14, 15 will occupy a position as shown in FIG. 5 while, when these bearing plates are placed in the locking position of the toothed ring 10, the teeth 12 of the bearing plates 13, 14, 15 are at tooth-bottom in the ring 10. However, the edges 14b, 15a of the bearing plates 14, 15 will bear upon the lateral sides of the V-shaped disengagement 21 of the intermediary parts 23, 24, by thus ensuring a wedging position for the bearing plates 13, 14, 15, as this has been explained hereinabove for the embodiment of FIGS. 3 and 4.
It is thus possible, by means of a small part which can be easily handled, to lock the bearing plates, and this can obviously be made in numerous positions since the minimum angular displacement is equal to α/3 as explained in the above disclosure.
Finally, in FIGS. 7 and 8, there has been shown a complete articulation member having a central control shaft 25 carrying, in its chamfered part 25a, a cam 26 having three noses 26a, 26b, 26c provided to cooperate with the intermediary parts 22, 23, 24 of FIGS. 5 and 6 controlling the movement of the bearing plates 13, 14, 15 as this has been explained in the above disclosure. Moreover, the sector members 16, 17, 18 are so shaped for enabling, by their portions 27, a positioning of a spring 28 having, in a plan view, substantially the shape of a V and which tends to push back the cam 26 against the intermediary parts 22, 23, 24 in order to lock the teeth of the bearing plates at tooth-bottom of the toothed ring 10.
As this is shown in FIGS. 7 and 8, the bearing plates 13, 14, 15, when they are at tooth-bottom, will each distort a resilient return blade 29 in order that these bearing plates will easily be disengaged from the toothed ring 10 when the cam 26, having pivoted under action of the central control shaft 25, enables a disengagement by rotation of the noses 26a, 26b, 26c from the intermediary parts 22, 23, 24 by thus ensuring a disengagement of the back portion of the seat with respect to the seating portion of the seat.
In FIG. 8, the fixed flange 30, which carries fixation studs 31 for connecting it to the seating portion of a seat, maintains peripherally a circular ring 32 which guides the movable flange 11 by means of guiding stampings 33 which can be seen both in FIGS. 7 and 8. It should also be noted that the movable flange 11 carries fixation studs 34 enabling to connect it easily to the frame of the backing portion of a seat. This fixation is moreover perfectly known. The central shaft 25 has (see FIG. 8) a grooved end 25b for fixing a manual or motorized control element for the articulation member while the grooved end 25c of the central shaft 25 enables a connection, for example by means of a hollow shaft, between the two mechanisms of the articulation member placed on each side of the seat.
In some cases, it is also possible to demultiplicate the rotation speed of the central control shaft 25 by means of a reducing mechanism for ensuring a softer and more precise control of the articulation member. | The articulation member comprises asymetrically guided bearing plates. A fixed flange is shaped in order to support, by means of sectors, sliding bearing plates having an upper toothing pitch corresponding to pitch of a toothing of a movable flange. The bearing plates are normally pushed back from the toothing by elastic means and have positions which are angularly shifted for two of them and submitted to bias of control means such as a cam. An angular shift of two of the bearing plates is of 120°-α/3 (=240°-2/3α) with for complement 120°+2/3α, αbeing an angle forming a pitch for each tooth of the toothed ring and teeth of the bearing plates. | 1 |
CLAIM FOR PRIORITY
[0001] The present application claims priority under 35 U.S.C. § 119( e ) to U.S. Provisional Application No. 60/840,974, filed Aug. 30, 2006, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to aircraft landing systems and more particularly to a device for measuring the pressure inside a landing gear shock strut. This invention is particularly useful for retrofit applications where drilling a new hole or changing the volume of the shock strut by the addition of a normal pressure transducer is not acceptable.
BACKGROUND OF THE INVENTION
[0003] Shock strut pressure is measured during maintenance of landing gear and other pressure vessels to ensure proper performance. The physical geometry of these pressure vessels (such as landing gear shock absorbers) determine (along with fluid and gas volumes) the behaviour and performance of the vessel. Measuring the pressure of the gas within the shock absorber is a critical task that must be performed regularly to ensure safe operation of the aircraft. This is presently performed by attaching a gauge to the external port of the charging valve, then opening the valve. This action is suboptimal because it requires a manual operation to connect and read the system, and because it involves the opening and closing of the valve (with the attendant loss of a small amount of fluid or gas).
[0004] In order to reduce the amount of required maintenance, an automatic means of measuring the pressure of fluid within the shock strut is desired. Conventional approaches to this problem would involve the mounting of a pressure transducer either directly into the body of the shock strut, or the fitting of a manifold to the existing port to allow both a pressure measurement and a facility to charge (alter the quantity of fluid and gas). Both of these solutions present problems when they are applied to existing shock strut designs. Fitting a transducer into the body of the shock strut involves drilling a hole in the structure of the strut—which is generally not acceptable from a strength or fatigue perspective. Adding a manifold to the shock strut changes the amount of internal working volume, which changes the energy absorbing properties of the landing gear—which is not desirable.
[0005] Many landing gears have a poppet charging valve conforming to MS28889-2/MIL-PRF-6164F. This valve allows the introduction or removal of fluid and gas from the pressure vessel. The present invention modifies this valve to include a pressure-sensing means and electrical contact means such that measurements may be made of the working fluid without interfering with the normal operation of the valve or significantly altering the volume within the pressure vessel.
[0006] This modified valve can be retrofitted to any landing gear to allow pressure measurements to be made without altering the landing gear. A change in military standards from MS28889-2 to the newer performance based specification—MIL-PRF-6164F allows the certification of a modified valve to act as a replacement for existing valves.
SUMMARY OF THE INVENTION
[0007] At the base, the design involves introducing a pressure sensitive element on one end of the valve and providing a route for the measurement wires to a connector that is mounted internally in the valve stem. The connector is configured in such a manner that it does not interfere with normal pressure charging apparatus, but a specially designed electrical connector can connect to the valve for determining the pressure either in flight or on the ground.
[0008] In one aspect the present invention provides a charging valve for use in a pressure vessel in an aircraft landing gear comprising a valve stem having a first and second end and a channel extending therebetween, a pressure-sensing device received within the channel at the first end and operable to measure the pressure of the pressure vessel, and a receptacle received within the channel between the pressure-sensing device and the second end and operable to be in communication with the pressure-sensing device and configured to allow fluid to flow through the valve.
[0009] In another aspect the present invention provides a charging valve for use in a pressure vessel in an aircraft landing gear comprising a valve stem having a first and second end and a channel extending therebetween, a pressure reading means connected to the first end of the valve body for reading the pressure in the pressure vessel and a receptacle received within the channel between the pressure reading means and the second end and operable to be in communication with the pressure reading means and configured to allow fluid to flow through the valve.
[0010] In a further aspect the present invention provides a method of modifying a charging valve having a main body including a channel therethrough, to include a pressure measuring device for use in a pressure vessel comprising the steps of (i) placing a pressure-sensing device within the channel at the end of the valve that is in communication with the pressure vessel to allow the pressure-sensing device to measure the pressure within the vessel; (ii) connecting the pressure-sensing device to a receptacle or connector to allow for communication therebetween, the receptacle being located within the channel of the valve at the opposite end of the pressure-sensing device from the measurement end and being operable to allow for fluid to flow through the valve. The pressure-sensing device may be a pressure transducer or may include a modification to the end of the valve to form a pressure sensitive diaphragm that is gauged.
[0011] In another aspect, the present invention provides a retrofit kit for use in a charging valve used with a pressure vessel comprising a pressure-sensing device sized to be received within the channel of the valve at the first end and operable to measure the pressure of the pressure vessel and a receptacle sized to be received within the channel of the valve and operable to be in communication with the pressure-sensing device and configured to allow fluid to flow through the valve. The pressure-sensing device and receptacle are as described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention will now be described in further detail with reference to the following figures:
[0013] FIG. 1 is a schematic diagram of the standard geometry of a charging valve;
[0014] FIG. 2 is an exploded perspective view showing the valve stem of the present invention in two portions and the pressure-sensing device, connector and plug to be used with the valve;
[0015] FIG. 3 is a perspective view of one embodiment of the receptacle of the present invention;
[0016] FIG. 4 is a perspective view of an alternate embodiment of the receptacle and the second portion of the modified valve stem of the present invention;
[0017] FIG. 5 is a perspective view of a further alternative embodiment of the receptacle and the second portion of the modified valve stem of the present invention;
[0018] FIG. 6 is a perspective view of a further embodiment of the receptacle of the valve of the present invention;
[0019] FIG. 7 is a perspective view of a further embodiment of the receptacle and the second part of the modified valve stem of the present invention;
[0020] FIG. 8 is a perspective exploded view of the receptacle and plug of the valve of the present invention according to the embodiment illustrated in FIG. 3 ;
[0021] FIG. 9 a is a perspective exploded view of the mating orientation of the receptacle and plug of the present invention;
[0022] FIG. 9 b is a perspective view illustrating the mating connection of the plug and the receptacle of FIG. 9 a;
[0023] FIG. 10 is an exploded perspective view of one embodiment of the plug construction of the present invention;
[0024] FIG. 11 is a schematic showing the stem machining modifications for one embodiment of the valve of the present invention;
[0025] FIG. 12 is a side cross-sectional view of the placement and connection of the pressure-sensing device of the present invention;
[0026] FIG. 13 is a side cross-sectional view illustrating the welding of the pressure-sensing device during installation according to one embodiment;
[0027] FIG. 14 is an exploded perspective view illustrating the plug, and the assembly of the receptacle, the pressure-sensing device, and the valve stem according to one embodiment of the present invention;
[0028] FIG. 15 is a perspective view of one embodiment of the fully assembled valve of the present invention with the cap off;
[0029] FIG. 16 is a cross-sectional view of an alternative embodiment of the valve of the present invention wherein the valve is modified to form a pressure sensitive diaphragm that is gauged; and
[0030] FIG. 17 is a cross-sectional view of a further embodiment of the valve of FIG. 16 in which the valve stem has been modified to include a cavity in its end.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The present invention provides a modified charging valve having a pressure sensitive element at one end and a connector or receptacle mounted within it. The receptacle is configured to determine pressure within the valve either in flight or on the ground with minimal interference with the normal pressure charging apparatus.
[0032] The modified valve of the present invention utilises the structure of known valves used in the art and incorporates within it a pressure-sensing device and a receptacle or connector that allows for pressure measurements to be made as desired without interfering with the normal operation of the valve and with minimal alteration of the volume of the working fluid within the pressure vessel. Pressure vessels and charging valves are known in the art and therefore are not described in detail herein. In an alternative embodiment, the existing end of the valve can also be modified to form a pressure sensitive diaphragm and then be gauged.
[0033] The valve of the present invention will now be described in further detail with reference to the accompanying figures.
[0034] FIG. 1 provides a schematic diagram of the standard valve geometry. As stated above, the present invention utilises the structure of valves known in the art. As will be described, the valve is modified to accommodate, for example, the pressure-sensing device, the receptacle and a measuring device. Generally such known valves include a main body (also referred to as a valve stem herein), that has a central channel, or bore, that extends from one end of the body to the other. The present invention incorporates the use of a pressure-sensing device and receptacle within the channel of the body, as described below.
[0035] Referring to FIG. 2 , one embodiment of the modified valve of the present invention will be described in further detail. FIG. 2 is an exploded perspective view illustrating the components of the modified valve, indicated in the Figures at numeral 18 , which includes a valve stem 20 which is illustrated in two portions, a first portion 22 and a second portion 24 . It will be understood that the modified valve 18 of the present invention may comprise one main body that does not consist of two separate parts, however in a preferred embodiment the valve main body comprises two portions to assist in the assembly of the modified valve. The description of the modified valve will make reference to a two part valve body, however a person skilled in the art will understand that a one part valve body may also be used. The stem 20 includes an elongate channel 26 that extends through the stem 20 from one end to the other, i.e. through the first and second portions 22 , 24 .
[0036] The modified valve 18 also includes a pressure-sensing device 28 and a receptacle 30 . The modified valve 18 may optionally include a plug 32 or the plug 32 may be a separate component that is used in combination with the modified valve 18 when a pressure reading is required, discussed in further detail below.
[0037] The pressure-sensing device 28 may be any pressure-sensing device or transducer that is operable to measure pressure and is sized to be received within the first portion 22 of the stem 20 . In an alternative embodiment, the channel 26 may be widened, for example by boring, to incorporate the pressure-sensing device 28 . The pressure-sensing device 28 is fixedly attached to the end of the first portion 22 by any means known in the art, for example welding, using a laser or other means, fixed using an adhesive or mechanically retained within the channel 26 . The connection of the pressure-sensing device 28 within the channel 26 may be by any means that allows the pressure-sensing device 28 to measure the pressure in the pressure vessel to which the valve 18 is attached.
[0038] Examples of the type of a pressure-sensing device 28 that may be used include, but is not limited to resistive strain gauges and capacitive gauges. The modified valve 18 of the present invention may also include a temperature sensitive element (not shown). Examples of the type of temperature sensitive elements that may be used include a thermocouple and a resistance temperature detector (RTD). As will be understood by a person skilled in the art, the pressure sensing device 28 and the temperature sensing device may be an integrated piece operable to measure the pressure and temperature of the fluid within the pressure vessel. That is, the integrated pressure and temperature sensing device is preferably sized to be received within the first portion 22 of the valve stem 20 . Alternatively, the channel 26 may be widened to receive the integrated pressure and temperature sensing device.
[0039] In the illustrated embodiment of FIG. 2 , the pressure-sensing device 28 includes a series of wires 38 extending from one end which allow the pressure measurement to be communicated to an external, or internal, measuring device or plug 32 via receptacle 30 . As will be understood, if an integrated temperature and pressure sensing device are used, the combined pressure and temperature measurements may be communicated to an external, or internal, measuring device or plug 32 via the receptacle 30 .
[0040] Located within the channel 26 in the second portion 24 of the stem 20 is the receptacle 30 . The receptacle 30 is operable to be in communication with the pressure-sensing device 28 and is also operable to be electrically connected to a measuring device or plug 32 at the opposite end from the connection to the pressure-sensing device 28 . The receptacle 30 is operable to communicate with the pressure-sensing device 28 , and in the illustrated embodiment, the wires 38 of the pressure-sensing device 28 are connected to the receptacle 30 . The connection of the wires 38 may be made by any means known in the art, including soldering. Thus, since the receptacle 30 is electrically connected to the pressure-sensing device 28 and the plug or measuring device 32 , it facilitates communication of a pressure reading from the pressure sensing device 28 to the plug or measuring device 32 .
[0041] FIG. 3 illustrates one embodiment of the receptacle 30 , comprising a hollow cylindrical shell portion 40 within which a series of strips 42 are received. The strips 42 are connected to the interior surface of the shell portion 40 at spaced intervals. The strips 42 are attached to the shell portion 40 by any means known in the art that will withstand the environment of the valve and maintain the strips 42 in their position. The strips 42 are made from a conductive material and allow for communication between the wires 38 of the pressure-sensing device 28 and a measuring device or plug 32 . As can be seen more clearly in FIG. 8 , the strips 42 extend outwardly past the shell portion 40 in the direction of the pressure-sensing device 28 . The wires 38 of the pressure-sensing device 28 are connected to the strips 42 by any means known in the art, for example soldering.
[0042] The conductive material that is used is preferably inert to the fluid environment of the valve 18 . The illustrated embodiment shows the receptacle 30 having four spaced strips 42 within it, however the number of strips and their size and configuration may vary provided that a conductive pathway is provided from the pressure-sensing device through the receptacle 30 .
[0043] As stated above, the modified valve 18 allows for pressure measurements to be taken when desired with minimal interference with the valve operation and working fluid. Therefore, it will be understood that although variations to the number and positioning of the strips 42 may be made it is preferable to minimise the obstruction of the fluid through the receptacle 30 .
[0044] Referring to FIGS. 3-7 , alternative embodiments of the receptacle 30 are illustrated. Other variations of the receptacle 30 may be used to provide an electrical connection between the pressure-sensing device 28 , and in particular the wires 38 , and the plug or measuring device 32 . As will be understood referring to FIGS. 3-7 , the strips 42 are positioned on the receptacle 30 such as to provide sufficient separation therebetween so as to allow separation between the electrical connections on the strips 42 . FIGS. 4 through 7 provide perspective drawings of other embodiments of the receptacle 30 . In each of these figures it will be understood that the receptacle 30 is viewed from the end that is operable to connect to plug 32 . The opposite end is connected to the wires 38 as described above.
[0045] Referring to FIGS. 4 to 7 , at the end of each of the illustrated receptacles 30 a series of apertures, indicated generally at 44 , are shown that are operable to connect to the plug 32 . In these embodiments, the plug 32 will include protrusions, not shown, that will be sized and configured to be received within the apertures 44 to provide a connection there between.
[0046] Each alternative embodiment of the receptacle 30 will now be described in more detail. FIG. 4 illustrates a receptacle 30 having a rectangular body with curved sides such as to be fittedly received within the channel 26 . This involves machining grooves in the valve stem 20 (preferably the second portion 24 ) to accommodate the receptacle 30 . In this embodiment illustrated, the apertures 44 are located within the rectangular body in a parallel line. Each aperture 44 is sized to receive a conductive strip 42 . Fluid is operable to flow on either side of the rectangle through the valve body.
[0047] FIG. 5 illustrates a circular or cylindrical embodiment of the receptacle 30 that includes a pair of locking tangs 46 for holding the connector 34 within the second portion 24 of the valve stem 20 . The circular embodiment of the receptacle 30 is centrally located within the channel 26 and allows for fluid flow around the exterior circumference of the receptacle 30 .
[0048] FIG. 6 illustrates a circular or cylindrical receptacle 30 that is suspended within the channel 26 by a cover 48 . It will be understood that in this embodiment the cover 48 , that extends around the connector 34 and is held within the valve shell 40 by a tab like attachment point, is preferably made from a thin metal to minimise interference with fluid flow around the connector and also to allow the minimum fluid flow rate in which the metal is susceptible to fatigue from twisting due to high fluid pressures.
[0049] FIG. 7 includes an alternate embodiment of the receptacle 30 . According to the embodiment illustrated, the receptacle 30 is circular or cylindrical shaped and sized to fit within the channel 26 . The illustrated circular receptacle 30 includes a hollow passageway therefore to allow for fluid flow. The apertures 44 are located within the walls of the receptacle 30 .
[0050] The plug 32 and its use will now be described in further detail. As stated above, the plug 32 may form part of the valve 18 or may be a separate unit that is used only when required. The plug 32 is operable to connect with the receptacle 30 at the opposite end from the pressure-sensing device 28 . In the illustrated embodiment, as can be seen in FIG. 8 , the plug 32 includes a contact end that includes a series of connectors 52 having contact strips 54 that are operable to mate with the strips 42 on the receptacle 30 . The connection, or mating, of these two components can be clearly seen in FIGS. 9A and 9B . The connection of the two parts allows for electrical contact between the pressure-sensing device 28 , the receptacle 30 and the plug 32 and therefore allows a pressure reading to be taken and communicated to a user.
[0051] It will be understood that the connection point between the receptacle 30 and the plug 32 may be made by other means. For example, and as described above, in the alternative embodiments of the receptacle 30 a series of apertures 44 were provided for receiving protrusions on the plug 32 to allow for a connection between the pressure-sensing device, the receptacle 30 and the plug 32 .
[0052] FIG. 10 provides an exploded perspective view of the embodiment of the plug described above, including contact strips 54 received in the connectors 52 sized to engage with the strips 42 on the receptacle 30 .
[0053] As can be seen in FIGS. 9A and 9B the contact strips 54 of the plug 32 and the strips 42 of the receptacle 30 may be slightly curved to ensure a secure lock between the components when mated. The insulation between each mating set of contact strips is the shell portion 40 of the receptacle 30 shown in FIG. 9A . The shell portion 40 that mounts the conductive strips is preferably a dielectric plastic material such as Delrin or PEEK. The conductive strips are therefore mounted on an insulating mount, i.e. the shell portion, when located in the conductive stainless steel of the valve stem.
[0054] To ensure that the plug 32 and receptacle 30 mate in the appropriate orientation (to ensure that the correct electrical connections are made), the strips 42 and contact strips 54 may be offset radially as shown in FIG. 10 to ensure that only one mating orientation works. Furthermore, one of the strips 42 of the receptacle 30 may be made deeper than the other strips to provide a mechanical guideway—the plug 32 would not fit into the hole in receptacle 30 unless rotated to the appropriate position.
[0055] An example of the machining requirements for one embodiment of the present invention is provided in FIG. 11 . However, it will be understood that these are merely provided as an example and are not meant to be limiting in any way. The machining requirements may be changed depending on the valve size and the configuration of the connector and pressure sending device and plug to be utilised within the valve.
[0056] The valve main body or stem 20 may be modified as follows: carve a 0.04″ wide groove around the circumference of the stem 0.8″ from the left and cut the stem in half at 0.84″ starting from left of stem. As discussed above, this provides a two-part valve stem 20 that assists in the positioning and securing of the receptacle 30 to the wires 38 of the pressure-sensing device 28 . However, this is not required and the receptacle 30 may be placed within the valve body/stem 20 while the stem 20 comprises one unitary piece.
[0057] Once the valve stem 20 has been divided into two pieces the first piece of the stem may be adapted to include a hole in the end facing the second stem piece with diameter 0.1170″ offset from centre with a depth of 0.6450″ using standard drill size 0.1142″+0.004/−0.001. A second hole at the opposite end (where the pressure-sensitive face of the transducer will be) may be drilled with diameter of 0.126″ and a depth of 0.1750″, using standard drill size 0.1260″+0.005/−0.001.
[0058] The second half of the stem may be hollowed out to a diameter of 0.2000″ along the length of the piece. This could be done using a standard drill size 0.2008″+0.005/−0.001.
[0059] In addition a cylindrical end piece 72 is machined with a diameter of 0.395″ and length 0.180″ with an offset through hole with diameter 0.15″, using a standard drill size 0.1496″+0.005/−0.001. This hole would align with the hole through the first stem piece 22 .
[0060] The installation of the pressure-sensing device 28 will now be described with reference to FIGS. 12 and 13 .
[0061] In the illustrated embodiment, there were two methods that may be used to secure the pressure transducer or pressure sensing device 28 in place. Either: (i) Using Room Temperature Vulcanized rubber 56 potting compound & epoxy 58 , shown in FIG. 12 or (ii) micro laser welding 60 it in place, shown in FIG. 13 .
[0062] When following the method illustrated in FIG. 12 , i.e. RTV 56 potting and epoxy 58 , the end piece 72 of the stem must be hermetically laser welded 62 onto the first half of the stem. The pressure-sensing device 28 is then put in place using the epoxy 58 near the lower portion of the transducer and potting 56 surrounding the head. This is to prevent residual stress caused by the epoxy curing from affecting the strain and pressure readings on the pressure-sensitive face of the transducer.
[0063] If using a laser weld, as illustrated in FIG. 13 , to install the pressure-sensing device, insert the transducer 28 into the end piece 72 until the pressure-sensitive face is flush with the surface of the end piece. Then weld 60 the two parts together around the circumference of the transducer over the existing weld left from the construction of the transducer where it protrudes from the other side of the end piece. Place the assembled end piece and transducer at the end of the first stem piece with the transducer wires extending through the stem hole. Weld 62 the end piece 72 to the first stem piece 22 around the circumference where the two parts meet.
[0064] The assembly of the modified valve 18 of the present invention will now be described with reference to FIGS. 14 and 15 .
[0065] To assemble the system, the pressure-sensing device 28 should first be connected to the first portion 22 of the valve main body 20 , as described above. The wires 38 from the pressure-sensing device 28 , which protrude from the first portion of the main body 20 may be formed into one wire. The wires or wire, may then be soldered onto the receptacle 30 (e.g. onto the strips 42 ). The receptacle 30 is then placed within the second portion 24 of the main body 20 and the first and second portions are connected together. Preferably the first and second portions ( 22 , 24 ) are hermetically laser welded together. The modified valve 18 can then be reassembled with the unmodified valve housing 74 and locking nut 76 to make the valve functional.
[0066] The valve 18 may also include a cap 64 , shown in FIG. 15 . The cap 64 fits on the end of the second portion of the valve body and provides a dust cap or seal. In one embodiment, the cap 64 may include the plug 32 which may be operable to be in communication with the receptacle 30 during the operation of the aircraft, i.e. pressure readings may be taken during operation of the aircraft whenever required. Alternatively, the cap 64 may be manually removed and the plug 32 be contained as a separate unit, for example a handheld unit, and connected to the receptacle 30 if and when a pressure reading is required.
[0067] The present invention provides a modified valve according to the above description that includes a pressure-sensing means and a receptacle or connector that allows for periodic or continual communication with the pressure-sensing means. In another aspect the present invention provides a method for retrofitting a valve within a pressure vessel to incorporate a pressure-sensing device within it. In a further aspect the present invention provides a pressure-sensing retrofit device that includes a connector that may be installed in a valve to allow for pressure measuring with minimal interference with the valve.
[0068] The present invention provides a standard charging valve modified to add a pressure transducer with the active diaphragm subjected to the pressure within the charged vessel. The present invention further provides an arrangement to allow the wires and connector to not interfere with the flow of gas or oil so as to not interfere with normal servicing.
[0069] In a further embodiment of the present invention the existing end of the valve may be modified to form a pressure sensitive diaphragm, which is then gauged. The gauges are indicated at numeral 70 and may be attached directly into the valve stem. FIG. 16 illustrates the inclusion of a gauge 70 in the valve stem with wires 38 extending from the gauge. The wires are as described herein and may connect in a similar manner as described above.
[0070] FIG. 17 illustrates a further embodiment of the valve including the gauge in which the stem of the valve is modified to include a cavity that has been formed in one end of the valve. The cavity may be formed by machining and then welding the stem or by electro discharge machining (EDM). The strain gauge 70 may then be adhered in the cavity and the wires extend therefrom as described above. It will be understood that the gauge and wires may replace the pressure-sensing device described in the above embodiments.
[0071] While this invention has been described with reference to illustrative embodiments and examples, the description should not be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments. Further, all of the claims are hereby incorporated by reference into the description of the preferred embodiments.
[0072] Any publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety. | The present invention is a device that allows the pressure inside an aircraft landing gear shock strut to be measured. A charging valve is modified by integrating a small pressure sensing device into the stem of the part such that the active diaphragm is subjected to the pressure within the charged vessel. The wires from the pressure sensing device are connected to a receptacle or connector in the bore of the stem such that a corresponding electrical receptacle may be mated for the purposes of making a measurement. The internal receptacle is designed such that the flow of air or oil is not excessively impeded and normal servicing tools do not interfere with the receptacle. | 5 |
TECHNICAL FIELD
This invention relates to mechanism for classifying or sorting products of two different sizes from one another and has particular, but not exclusive, utility in connection with the plastics molding industry in which it is necessary to sort relatively small molded components from their larger plastic "runners" as the runners and components are ejected from a molding machine.
BACKGROUND ART
In the production of plastic components by an injection molding process, the mold cavities corresponding to the components are interconnected by a network of supply channels through which the molten plastic material is delivered to the various cavities during each injection cycle of the molding machine. Such channels necessarily result in the formation of plastic "runners" much like the branches of a tree to which the components are attached as the molten plastic is cured. Although most modern machines automatically detach the components from the runners as the mold halves separate upon completion of the cycle, it is still necessary to sort out the runners from the components such that the runners can be reprocessed if desired and the components can be assembled with other parts or otherwise handled.
Typically, these parts have been sorted by hand, but this can be a tedious, routine and unduly costly procedure. Some machinery is presently available to replace hand sorting, but such machinery is less than entirely reliable and is quite bulky, occupying considerably more than the desired amount of space which could otherwise be directed to better purposes.
For example, one type of known machine utilizes a linear conveyor belt on which the mixture of components and runners drops by gravity. The belt moves the mixture toward a dumping point, and at that location, as the end of the belt is reached, the smaller components drop off the belt while the larger, tree-like runners are caught in the fingers of a closely positioned upwardly moving belt at the point of drop off, thereby lifting the runners off the end of the main belt and conveying them to a separate location.
SUMMARY OF THE PRESENT INVENTION
An important object of the present invention is to provide a highly reliable yet compact parts sorter having particular utility in the separation of plastic runners from their associated component parts, and to this end the present invention includes a bowl into which the mixture of parts is dumped by the molding machine. Within such bowl, a special rotor revolves relatively slowly about an upright axis, and the rotor is provided with a series of fin-like members standing on edge with their upper longitudinal extremities defining elements of a cone having its apex on the axis of rotation of the rotor. The upper extremities of the fins thus define an upper sloping surface that receives the mixture of parts when the same is dumped into the bowl, and because the fins are spaced apart by a strategic amount, only the smaller parts can drop between the fins while the larger runners are held up on top of the fins. The smaller parts are received by a similarly conical though imperforate lower surface as they drop between the fins such that both of the parts, although vertically separated from one another by the fins, are urged by gravity to the outer periphery of the rotor. Thereupon, the fins sweep or drive the separated components around the bowl toward respective, vertically offset outlets through which the parts are separately discharged.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a left, front perspective view of parts sorting mechanism constructed in accordance with the present invention and adapted for easy portability;
FIG. 2 is a top plan view of the mechanism with the cover removed and parts broken away to reveal details of construction;
FIG. 3 is a vertical cross-sectional view through the mechanism taken substantially along line 3--3 of FIG. 2;
FIG. 4 is a vertical cross-sectional view through the mechanism taken substantially along line 4--4 of FIG. 3;
FIG. 5 is an enlarged, fragmentary detail view taken transversely of a pair of adjacent fins of the rotor and illustrating the way in which the runners hang up on the top surface of the fins while the smaller parts drop to the lower surface therebelow;
FIG. 6 is a fragmentary top plan view of the mechanism illustrating the sorting process; and
FIG. 7 is a fragmentary, enlarged detail view taken transversely of the conical crown of the rotor and illustrating the way in which such crown may be constructed with overlapping, adjacent segments such as to augment the ability of the crown to drive the runners around the bowl of the mechanism.
DETAILED DESCRIPTION
The mechanism according to the present invention is shown for purposes of illustration embodied in a portable unit as in FIG. 1 although it is of course to be understood that the mechanism could indeed be embodied and arranged in many different environments without departing from the principles of the present invention. With this in mind, then, the unit in FIG. 1 is depicted as including a wheeled stand 10 supporting the mechanism 12 for disposition at a location to receive a mixture of runners and components from a molding machine (not shown). The mechanism 12 includes a box-like housing 14 provided with a lid 16 that has an inlet opening 18 through which the runners and components may drop into the mechanism 12 as they are discharged by the machine. A chute 20 projects downwardly and outwardly from the housing 14 adjacent the bottom of the latter for discharging the separated components into an awaiting receptacle (not shown) that may be supported by a platform 22 associated with the stand 10.
The mechanism 12 further includes structure in the nature of a bowl 24 within the housing 14, such bowl 24 having an annular generally upright side wall 25, an annular, downwardly and inwardly sloping side wall 26 as an extension of said upright side wall 25, and an annular, upturned and inwardly extending lip 28 as an extension of the side wall 26 at the lower extremity of the latter, said annular lip 25 defining an open bottom 30 of the bowl 24.
The mechanism 12 further includes a rotor situated within the bowl 24 and broadly designated by the numeral 32. Said rotor 32 is arranged for rotation about an upright axis coinciding with the upright axis of the bowl 24, and as illustrated in FIG. 3, motive force for driving the rotor 32 may be supplied by an electric motor 34 situated within the open bottom 30 of the bowl 24 and having an upwardly projecting output shaft 36 whose longitudinal axis defines the axis of rotation of the rotor 32. The shaft 36 carries a specially formed hub 38 fixed thereto for rotation therewith, said hub 38 including a pair of vertically spaced apart, truncated cones 40 and 42 respectively.
The rotor 32 further includes what may be referred to as a lower surface 44 that is conical in shape and is attached to the lower cone 42 for support thereby. The lower surface 44 thus slopes radially downwardly and outwardly from the axis of rotation of the rotor 32, and the outermost peripheral termination 46 of the lower surface 44 overlaps the upturned lip 28 such that termination 46 is in closely proximal relationship to the side wall 26.
The rotor 32 further includes a series of fin-like members 48 (hereinafter "fins") which are attached on edge to the lower surface 44 and rise upwardly and outwardly therefrom. The fins 48 are so oriented that their longitudinal uppermost extremities 50 substantially define elements of a cone having its apex on the axis of rotation of the rotor 32. Thus, the upper edge extremities 50 of the fins 48 diverge in a downward and outward direction as their outermost ends 52 are approached, said ends 52 being located substantially at the termination of the lower surface 44 such that ends 52 are likewise in close proximity to the side wall 26 of the bowl 24. As illustrated, each of the fins 48 is of generally planar configuration, yet each is also formed to present a pair of angularly intersecting legs 54 and 56 when viewed in end elevation as in FIG. 5. The leg 56 rises from the surface 44 in perpendicular relationship thereto, while the leg 54 is disposed at a less than 90° angle with respect to the surface 44, presenting a cam surface 58, the function of which will be hereinafter more fully described.
The upper extremities 50 of the fins 48 function as an upper, part engaging surface when the parts to be sorted are dumped into the bowl 24 through the inlet opening 18. On the other hand, because the fins 48 are indeed laterally spaced apart, such spacing has the effect of rendering the upper surface presented by the extremities 50 perforated in nature as opposed to the imperforate nature of the lower surface 44. Like the lower surface 44, however, the upper surface defined by the extremities 50 slopes radially downwardly and outwardly in parallel relationship to the lower surface 44.
Further defining a portion of the upper surface of the rotor 32 is a conical, imperforate crown 60 partially overlying the fins 48 and having an apex on the axis of rotation of the rotor 32. The crown 60 is attached to the upper mounting cone 40 via a hold-down cap 62 and threaded fastener 64 such that the crown 60 rotates with the fins 48 and the lower surface 44 when the rotor 32 is driven by motor 34. The lowermost and outermost peripheral margin 66 of the crown 60 terminates in radially inwardly spaced relationship to the outer ends 52 of the fins 48 such as to expose the latter and define what may be termed a ring-shaped slot 68 between the margin 66 and the side wall 26. The width of said slot 68, of course, depends upon the location of the margin 66 with respect to the side walls 26, and this dimension is subject to some modification depending upon the particular nature of the articles or parts being sorted by the mechanism 12.
The side wall 26 and the lip 24 are cut out for one circumferential portion thereof so as to define an outlet 70 for the smaller parts being sorted. As illustrated perhaps best in FIG. 3, the outlet 70 is disposed at such a vertical location as to be in position for gravitational feeding of the smaller parts from the lower surface 44 while, on the other hand, the upper surface defined by the upper extremities 50 of the fins 48 is located too high to be in registration with the outlet 70, said upper surface instead being in registration with that portion of the side wall 26 located above the outlet 70. The outlet 70 is in direct communication with the discharge chute 20.
Diametrically opposed to the outlet 70 for the smaller parts is an outlet 72 for the larger parts being sorted, said larger parts outlet 72 being formed not only by cut outs in the said walls 26 and 25, but also by a larger cut out in the side of the housing 14. The outlet 72, unlike the outlet 70, is in registration with the upper surface of the rotor 32 as defined by the uppermost extremities 50 of the fins 48 such that the outlet 72 can be described as being vertically offset from the outlet 70. This is true notwithstanding the fact that the outlet 72 includes a lower portion thereof which is disposed almost at the same vertical level as the lower surface 44 at its outermost termination 46, such relationship having no effect on the parts sorting ability of the rotor 32 as will be apparent.
As illustrated in FIG. 7, and as also shown in FIG. 2, the crown 60, rather than being one continuous sheet of material, may be formed from a series of mutually overlapping segments as represented by the segments 60a and 60b in FIG. 7. The overlap presents an outwardly projecting structure 60c in the nature of a rib or the like that helps the rotor 32 drive the mixture of parts, particularly the larger of the two parts, around the axis of the rotor 32 during operation, it being understood that the structure 60c is of course in a leading relationship with respect to the direction of rotation of the rotor 32.
OPERATION
Taking parts issuing from an injection molding machines as an example of those needing to be separated and sorted, such parts drop into the bowl 24 through the inlet opening 18 positioned with respect to the rotor 32 as illustrated in phantom lines in FIG. 2 and is also illustrated in FIG. 4. The direction of rotation of the rotor 32 is clockwise viewing FIG. 2, and as the mixture of parts falls onto the conical rotor 32, the mixture immediately slides in a radial outward and downward direction along the upper surface defined by the crown 60 and the upper edge extremities 50 of the fins 48. As the smaller parts, such as the components 74 illustrated in FIGS. 5 and 6, reach the ring-shaped slop 68 between the lower margin 66 of crown 60 and the side wall 26, such components 74 drop by gravity between the fins 48 onto the lower surface 44. Surface 44 in turn urges the components 74 in a downward and outward direction to the side wall 26 which prevents further radial movement thereof. At this juncture, the components 74 are swept around the side wall 26 until the outlet 70 is reached, whereupon they simply slide off the surface 44 by gravity into the chute 20 for discharge into an awaiting receptacle which, as earlier described, may advantageously be supported on the platform 22 of the stand 10.
The runners 76, on the other hand, as illustrated in FIGS. 5 and 6, are of such a size that they will not pass between the fins 48. Thus, they lie on top of the latter, and, depending upon the dimensions of the crown 60, on top of that area and are driven around the axis of rotation of the rotor 32 in engagement with the side wall 26 until the outlet 72 is reached, whereupon the runners 76 slide off the fins 48 through outlet 72 and into an awaiting receptacle or the like. Parenthetically, it is noteworthy to bear in mind that the outlet 72 for the runners 76 may advantageously be communicated with suitable transfer and grinder mechanism for pulverizing the runners 76 and recirculating the same back into the molding machine for reuse as constituents of the products to be molded.
It is also important to note that the fins 48 provide driving force for both the smaller components 72 and the larger runners 76 about the side wall 26 to their respective outlets 70 and 72. While this is indeed desirable, the oddly configured runners 76 are typically provided with countless prongs, nibs and other projections that have a tendency to hang up the runners 76 if given the opportunity, thereby preventing their discharge through the outlet 72. Moreover, the progressively diverging nature of the upper extremities 50 of fins 48 in a sense promotes such hanging up because of the tendency for such extremities 50 to become wedged between depending nibs, prongs and the like of the runners 76 as they slide radially downwardly and outwardly along the fins 48. Counteracting that tendency, however, are the cam surfaces 58 of the fins 48 which, because they are obliquely disposed with respect to the conical upper surface defined by the upper extremities 50, tend to cam up or lift the runners 76 out of wedging engagement with the fins 48 as they slide toward the side wall 26. This may be seen, for example, by viewing FIG. 5 in which the runner 76 has a downwardly projecting nib 76a and a downwardly projecting prong 76b engaged with adjacent fins 48. Remembering that the cam surfaces 58 of the fins 48 are diverging as the outer ends 52 of the fins 48 are approached, it can be seen that the cam surface 58 of the right fin 48b in FIG. 5 has the effect of pushing upwardly against the prong 76b as the runner 76 slides downwardly along the fins 48, thereby precluding hooking and wedging of the runner 46 on the fin 48.
In view of the above, by the time the rotor 32 has completed 360° of rotation from the inlet opening 18, the mixture of parts supplied during that 360° of rotation have been fully separated and sorted to leave the mechanism through their respective outlets 70 and 72. Consequently, the incoming supply or mixture of new materials to be sorted may be on a continuous basis without fear that the parts will become clogged and jammed within the mechanism 12 because of over supply thereof.
It should be further noted that the crown 60 is of particular importance in situations where clearance between the overhead molding machine and the mechanism 12 is at a premium. For example, as the runners 76 drop from the molding machine through the inlet opening 18, it is essential that the runners 76 immediately lie down and slide outwardly and downwardly as opposed to standing on end and projecting up through the inlet opening 18. Such undesirable standing up of the runners 76 might result in the mold halves closing on the upstanding runners 76 to the end that the very expensive and delicate mold halves could be damaged beyond repair. By virtue of the imperforate nature of the crown 60, however, the runners 76 are immediately encouraged to lie down flat and slide down the rotor 32 in the intended manner.
Depending upon the nature of the parts being sorted, the fins 48 might not be particularly important insofar as driving the runners 76 around the bowl 24 is concerned; in that event, the crown 60 could extend substantially further outwardly and downwardly than that illustrated herein to provide a much narrower ring-shaped slot 68 than that illustrated, such slot 68 being only sufficient to pass the smaller parts of the mixture down to the lower surface 44. Under such circumstances, the fins 48 might not be utilized at all and the structure 60c as illustrated in FIG. 7 caused by the overlapping crown segments 60a and b might be sufficient for driving the larger components about the bowl 24.
Additionally, it should be pointed out that the fins 48 may be provided with configurations other that that herein illustrated. For example, rather than being of formed construction with two offset legs 54 and 56, each of the fins 48 may be entirely planar and sloped in virtually the same manner as the cam surface 58 so that there is no perpendicular leg 56 involved. Substantially the same result would obtain as the upper most extremity 50 of such a fin would serve to slidingly engage the parts landing thereon, while the broad flat cam surface 58 thereof would perform its function of preventing hang up of the runners 46 as the latter gravitated down the fins. | As parts of two different sizes are dropped into the mechanism, they are received by a rotor that rotates about an upright axis and is provided with a generally conical configuration such that the parts slide along the conical rotor in a radially outward and downward direction. The conical upper surface of the rotor is formed in part by fin-like members having uppermost longitudinal edges that define the sliding conical surface for the parts, the lateral spacing between such fins being such as to permit the smaller parts to drop between the fins and onto a lower conical surface, also sloping radially outwardly and downwardly from the axis of the rotor, while the larger parts remain supported by the fins. The parts thus sorted into a pair of vertically separated levels are driven by the rotor along a circular wall at the periphery of the rotor until reaching respective vertically offset outlets arranged to receive their respective larger or smaller parts by gravity feed from the corresponding portions of the rotor. | 1 |
DESCRIPTION
The present invention relates to a plaster for emergency treatment of open thorax injuries.
In addition to the high risk of infections, injuries passing through the chest are extremely critical because they may immediately result in an extreme slowing of the respiration. One reason therefor is the fact that the negative pressure normally prevailing within the thorax (approximately 4 to 8 mm Hg) breaks down, since due to the injury a pressure compensation with the environment takes place causing the lobe of the lung on the injured side to deflate.
Another impairment of the thoracic respiration of the pulmonary lobe on the uninjured side arises due to the fact that the mediastinum located between the two lobes of the lung is laterally displaced towards the uninjured side because of the resulting pressure conditions. Thus, in addition to the failure of one pulmonary lobe, respiration is restrained due to a reduced respiratory volume of the lung lobe on the uninjured side.
In addition, the so-called lesser circulation is stressed so much that an overstrain may result and this means another serious danger to the life of the injured person.
Relative to the total number of accidents, thorax injuries amount to 9%. Considering this fact and taking into account that the death rate within the first, approximately 6 hours after the respective accident is very high, one can easily realize the severe problem, both with respect to quality and to quantity.
Several suggestions for the first-aid treatment of such sucking wounds have been made, however, as a whole they do not deliver satisfactory results. An example of these proposals is the so-called imbricated bandage, i.e., a compression bandage, where adhesive strips are placed on top of each other in a tile-shaped manner around approximately three quarters of the thorax so that the injury can be closed provisionally. Other forms of pressure bandages have also been proposed.
In cases where there is no bandaging material available, it has been proposed to lay the palm on the injury. Another proposal for extreme situations is to pull lung tissue of the injured side into the gap of the wound in order to close the wound provisionally. Except for the fact that this is a questionable treatment, it can obviously only be performed by a physician.
Another alternative for emergency bandaging is the "Device for emergency bandaging of an open thorax injury" according to DE 36 31 650 A1. This device is characterized by a substantially cup-shaped hollow body of a gas-tight material having a free edge being formed as an elastic, soft sealing ring which is to be located at the outer side of the thorax and which, when applied, surrounds the thorax injury at a distance; said free edge being provided with a ventilation device by means of which the interior space of said ring can be aerated under formation of negative pressure within the interior space of the hollow body.
All of the known measures without accessories at best prevent further passage of air through the wound but do not improve respiration. In addition, the person rendering the first aid is impeded in carrying out additional, probably vital measures.
When a hand is laid or pressed on the wound, the injured person who already suffers from heavy breathing in addition may be seized with anxiety. The disadvantage of the device according to DE 36 31 650 A1 is the fact that it is too expensive and too complicated for a person without medical training, i.e., is difficult to handle (cf. Medizingerateverordnung [regulation on medical appliances] of Jan. 14, 1985, §§ 2 and 6, paragraph 3 and 4).
The object of the present invention is to provide a device suitable and destined, in particular for a first-aid measure rendered within the limits of emergency treatment until clinical care. Said device shall permit external closure of the wound gap and rapidly and permanently improve the respiration of the injured person to a considerable extent.
This object is achieved by providing a plaster with a gas check valve responding to even slight pressure variations. This valve closes during the inspiration phase, in which a negative pressure is built up within the thorax, so that no additional air may enter the chest, whereas it opens during the expiration phase in which positive pressure is formed by lowering the ribs and lifting the diaphragm so that the air which already entered the pleural cavity may escape through the valve.
This enables the lobe of the lung to gradually deploy again after each expiration until--in the most favorable case--it achieves its full function. According to an advantageous embodiment of the present invention, the plaster may additionally be provided with a wound dressing and rendered sterile; in this case bandaging of the injury under nearly aseptic conditions is ensured at the same time. Effective treatment in case of larger injuries or those which are difficult to localize can be effected by different sizes of the dressings.
The plaster is provided with a carrier layer preferably being substantially air-tight. Said carrier layer may be a textile fabric, such as a woven, non-woven, or a film, e.g., a plastic film or a metal foil. The carrier layer has a pressure-sensitive adhesive coating. In this connection the pressure sensitive adhesive may be a natural one, e.g., a rubber adhesive, or a technical one, such as an acrylic adhesive. The carrier layer exhibits an aperture to accommodate the gas check valve which may be a diaphragm, ball, plug, or a spring-type valve. It responds to even slight pressure variations and operates reliably. On the bottom side of the carrier layer there is a wound dressing consisting of textile material. It may have a multi-layer structure. The material is permeable to air and highly absorptive; its surface is designed in such a way that it does not stick to the wound. The latter may be achieved by aluminizing.
The plaster is applied to a protective layer which is removed prior to application. The plaster is preferably aseptically packed in a suitable package (e.g. in a peelable bag).
The present invention provides a simple and safe first-aid treatment of an open thorax injury. The plaster may be used in any situation without delay and even an untrained layman can apply it. After application of this plaster the person rendering the first aid has his hands free to perform further, probably vital first-aid measures. The plaster does neither burden nor restrict the injured person as would be the case, e.g., when the hand is pressed on the chest, so that an anxiety condition due to such a treatment will not occur.
The figures represent an embodiment example of the present invention; they are described in more detail in the following:
FIG. 1: represents a plan view on the plaster with a diaphragm valve after removal of the membrane.
FIG. 2: shows a cross-section along line I/I of FIG. 1 of the valve plaster with applied membrane.
FIG. 3: is a schematic representation of the thorax with an open injury during expiration.
FIG. 4: is the representation according to FIG. 3 during inspiration.
FIG. 5: is a representation according to FIG. 3 with the plaster according to FIG. 1 applied during expiration.
FIG. 6: is a representation according to FIG. 5 during inspiration.
FIG. 1 represents in plan view an embodiment example of the valve plaster for first-aid measures of open thorax injuries; FIG. 2 is a cross-section along line I/I. The plaster has a diaphragm valve 2 positioned in the middle of the carrier material 5. The diaphragm valve 2 consists of a plastic disc with four holes 1 having a diameter of 4 mm; they are covered by a membrane (shown in FIG. 2) being glued thereon. The membrane 6 is capable of closing the holes 1 hermetically.
From the bottom side of the carrier material 5 a ring 3 consisting of the same material as the carrier material 5 is glued in order to improve fixation of the diaphragm valve 2; the ring 3 partly sticks on the diaphragm valve 2 and partly on the carrier material 5.
The schematic drawing of FIG. 3 shows a sectional view on a part of a chest with thorax injury 10. It can be recognized that the lobe of the lung 8 on the injured side already collapsed to a large extent since the pressure within the respective thoracic cavity 12 has undergone a pressure compensation with the environment; the other pulmonary lobe 7 is in a substantially normal position during expiration shown in FIG. 3, since the mediastinum 11 is also in almost central and thus normal position.
During inspiration according to FIG. 4, the mediastinum is displaced towards the pulmonary lobe 7 whereby the lobe 8 continues to collapse.
If a plaster 13 according to the present invention is applied on the outer side of the thorax (FIG. 5) in such a way that the wound dressing 4 is lying above the injury 10, a slight positive pressure within the interior 12 of the thorax is formed during expiration. As a result the valve 6 opens and the air flows out through holes 1.
If the plaster 14 according to the present invention is applied as shown in FIG. 6, negative pressure within the thoracic cavity is formed during inspiration; the valve closes and the collapsed lobe 8 can slightly recover due to the negative pressure.
Each breath thus improves the state of the injured person.
It is understood that the specification and examples are illustrative but not limitative of the present invention and that other embodiments within the spirit and scope of the invention will suggest themselves to those skilled in the art. | A plaster which comprises a gas check valve being inserted in an aperture and which, on the side facing the skin, is provided with a carrier being coated with a pressure sensitive adhesive, makes the emergency treatment of open thorax injuries possible. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Application 60/908,806, filed Mar. 29, 2007, the contents of which are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of contract No. N00014-06-C-0040 awarded by the Office of Naval Research.
FIELD OF THE INVENTION
[0003] The present invention relates to a system for defeating enemy missiles and rockets generally, and more particularly to a system of generating a non-lethal cloud of projectiles or pellets intended to collide with an enemy missile to cause premature detonation of the missile, and/or possible severe damage to the missile, and/or deflection of the missile, due to the relatively high velocity of the missile.
BACKGROUND
[0004] During the times of terrorism and war, various guided and unguided missiles have been used resulting in casualties. A system that protects structures, ground/air/sea vehicles, and the people inside them against missile attack could save the lives of military troops as well as civilians. A common unguided missile currently used is the rocket-propelled-grenade (RPG).
[0005] Existing technologies for RPG or missile defeat systems include application of slat armor to the military vehicles. The principle of slat armor is to stop the missile before it strikes the body of the target, to crush the missile and short circuit its electric fuze, or to cause shaped charge detonation at a standoff distance, rather than directly on the body of the vehicle. Disadvantages to slat armor are that it adds significant weight to the vehicle, and sacrifices maneuverability. Other RPG or missile defeat systems launch a single or small number of projectiles toward the incoming missile. These systems require accurate sensing of the missile trajectory, accurate aim of the projectiles in order to intercept the missile, and fast reaction time to slew and fire the projectile.
[0006] Another existing strategy for RPG defeat is to deploy a commercial air bag to trap the RPG before it strikes the vehicle. Still another is to deploy a net-shaped trap made of super high strength ballistic fiber. The net is claimed to defeat the RPG by crushing its ogive and rendering the fuze inoperable. Both the airbag and the net intercept the RPG at a standoff distance of up to two meters. At this standoff distance, the RPG shaped charge jet still has significant penetrating ability. Neither of these competing technologies prevents the detonation of the RPG by its built-in self-destruct mechanism, nor do they protect nearby personnel from shrapnel from the exploding RPG.
SUMMARY
[0007] A system is disclosed for defeating enemy missiles and rockets, particularly rocket propelled grenades (RPG's). The first step is to identify the firing of a missile by the use of sensors that give the approximate distance and bearing of the incoming missile. A non-lethal cloud of projectiles or pellets is then launched from the target, which can be a building or vehicle or the like, in the general direction of the missile. The pellets are housed in a series of warhead containers mounted at locations on the target in various orientations. The warheads are triggered to fire a low velocity cloud of pellets toward the incoming missile. The pellets then collide with the missile a certain distance away from the target causing premature detonation of the missile, and/or possible severe damage to the missile, and/or deflection of the missile, due to the relatively high velocity of the missile.
[0008] In a preferred embodiment of the present disclosure, the system does not require highly accurate sensing of the incoming missile location, nor does it require slewing of a countermeasure weapon. This leads to increased potential for interception of missiles fired from very close range. The shot can be fired at non-lethal velocities, since the missile velocity will provide nearly all of the required impact energy. The present system preferably contains no high explosives or fuzes, which will lead to ease of transportability and implementation. Also, the system is preferably not lethal to people standing in the path of the shot when fired. The shot cloud system is relatively lightweight and easy to deploy. The result of the system is that the incoming missile will detonate prematurely before hitting its target and greatly reduce the resulting damage and loss of life. Appropriate density shot has also been demonstrated to limit the travel of shrapnel from the point of RPG detonation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates a typical RPG.
[0010] FIG. 2 illustrates voltage output from RPG fuze due to pellet impact.
[0011] FIG. 3 illustrates a RPG ogive that has been damaged by the protective system of the invention.
[0012] FIG. 4A illustrates one embodiment of a pair of warheads for implementing the system of the present invention.
[0013] FIG. 4B illustrates one embodiment of a warhead of the invention attachable to a base.
[0014] FIG. 5 illustrates one embodiment of a section of a canister of the present invention.
[0015] FIG. 6 illustrates one embodiment of a warhead assembly of the present invention.
[0016] FIG. 7 illustrates one embodiment of electrical connections useful for operating the system of the present invention.
[0017] FIG. 8 illustrates clouds of pellets surrounding a target.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] This disclosure describes the best mode or modes of practicing the invention as presently contemplated. This description is not intended to be understood in a limiting sense, but provides an example of the invention presented solely for illustrative purposes by reference to the accompanying drawings to advise one of ordinary skill in the art of the advantages and construction of the invention. In the various views of the drawings, like reference characters designate like or similar parts.
[0019] FIG. 1 illustrates one embodiment of a typical rocket-propelled grenade (RPG) 100 comprising an ogive 110 , a sustainer motor 120 , stabilizer fins 130 , a rear offset fin 140 and a fuze 160 . While an RPG is illustrated, it will be appreciated that the protective system of the present invention could be employed on any incoming enemy threat such as a missile, rocket, or the like. For purposes of convenience, the enemy threat will be described simply as an RPG.
[0020] The firing of the RPG 100 can be detected by various sensing means (not shown) including infrared (IR) sensors, radar and/or cameras. These sensors can be mounted on the potential target structure, which can be a vehicle or building, for determining approximate distance and bearing of the incoming RPG. Alternatively, sensors can be mounted separate from the target structure but in close proximity to the target structure if necessary. Alternatively, offsite or remote sensors could be utilized instead of, or in addition to onsite sensors, to improve the accuracy and/or tracking of the protective system of the present invention. Various sensor means could be employed as desired by the user and in accordance with appropriate field conditions.
[0021] Sensors are used to trigger warhead devices (described in more detail below) mounted on a target or an adjacent location to produce a cloud or screen of projectiles or pellets (see FIG. 8 ) intended to engage and disable an incoming RPG. More preferably, a variety of warhead devices are mounted in strategic locations relative to the target so that the target is sufficiently protected through a surrounding screen of pellets that will allow up to the entire target structure to be protected. The warhead can be any device or combination of devices that will propel shot in a manner that will produce a cloud or screen of pellets 820 (see FIG. 8 ) distributed such that they have a significant probability of hitting an incoming RPG.
[0022] In one non-limiting example, warhead containers (to be described below) with tubular cross-sections of 40 mm to 100 mm were tested, although other dimensions will be operable. The tubes were filled to various depths with projectiles or pellets, which were discharged at varying velocities. The pellets were discharged with and without the aid of a pusher plate (to be described below). The shot dispersion angle at the muzzle of the tubes was measured using a high speed camera. Results of this testing are shown in Table 1.
[0000]
TABLE 1
Dispersion Testing
Pusher
Dispersion
Tube Diameter, mm
Velocity, ft/s
Depth, in.
Plate
Angle
40
60
3
No
38°
40
80
6
No
37°
40
60
12
No
31°
40
75
3
Yes
34°
40
95
6
Yes
34°
40
100
12
Yes
24°
100
60
2
No
45°
100
90
4
No
59°
100
55
2
Yes
45°
100
65
4
Yes
53°
[0023] Statistical calculations revealed that a dispersion angle of 30° or more resulted in a shot pattern that provides a high probability of impact with an incoming RPG. The use of a pusher plate resulted in a more even dispersion pattern, although other methods to achieve this are possible. Warhead shot containers with rectangular or elliptical cross-sections may also be used. Other cross-sectional configurations are contemplated. A wide range of organic and inorganic materials, including, but not limited to, reinforced plastic, polymeric composites, aluminum and steel, can be used for the shot containers. Other materials are contemplated.
[0024] A significant amount of testing was performed, using the RPG of FIG. 1 , to establish size, shape, and material of the shot. Pellets 150 of various materials were fired in the laboratory at inert RPG grenades with piezoelectric fuzes 160 , and fuze output voltages were measured. It was determined that suitably dimensioned pellets with a range of shapes, compositions and sizes can be used to pre-detonate the RPG. FIG. 2 ( 200 ) shows that both steel and tungsten carbide shot, preferably greater than 0.156 inch diameter, produced sufficient fuze output voltage and generated a sufficient voltage pulse in the RPG detonation fuze to pre-detonate an RPG if the impact was on the RPG fuze. Other shot materials evaluated include reactive particles, piezoelectric particles and triboelectric particles, where in one embodiment for example, the shot material is ejected to impart an electric charge to the body of the incoming threat so that its detonator prematurely activates. These particles react on impact with the RPG to defeat it by one of the mechanisms described above. Other materials are also contemplated.
[0025] As shown in FIG. 3 , an RPG ogive 300 can be significantly damaged by impact with the pellets. Both steel and tungsten carbide pellets were found to dent or penetrate the ogive 300 , with other materials anticipated to have similar results. Pellets that penetrate the ogive can disrupt the shaped charge and reduce its lethal penetrating ability. Ogive dents and/or penetrations 310 can cause short circuiting of the electric detonation circuit (not shown) thereby causing the shaped charge not to actuate upon impact with the target. An observation during testing was that pellet impacts also have the potential for deflecting a RPG off course.
[0026] FIG. 4A illustrates a non-limiting embodiment of a pair of warhead shot containers 400 comprised of steel cylindrical tubes 410 mounted at its back ends 415 on bases 420 preferably having, as tested, an inside diameter of approximately 100 mm, a length of approximately 14 inches, and wall thickness of approximately 0.1 inches. While two containers are shown, it will be understood that only one container may be utilized, or more than two as the need or situation arises. Furthermore, while the containers are oriented in a consistent relationship, it will be understood that the other orientations are possible as long as there is no detrimental cross-fire.
[0027] As shown in FIG. 4B , a tube 410 is mounted at its back end 415 to a base 420 through the engagement of locking tabs 430 on the tube 410 with locking slots 440 on the base 420 . A wave spring 450 is further provided on the base for biased contact between the tube 410 and base 420 , while a locking pin 460 provides additional secured engagement at the junction of the tube 410 and base 420 . A contact socket 470 in the base 420 allows for passage of the actuation mechanism that activates the warhead 400 .
[0028] One embodiment of a proven design of a propulsion system at the back end 415 of a warhead 400 is shown in FIG. 5 . The warheads 400 house pellets 500 and a pusher cup or plate 510 . The pellets 500 are held in the warhead 400 preferably by a frangible or dislodgeable cover 480 ( FIGS. 4A , 4 B) secured, for example, by a plastic ring 485 . Behind the pusher plate 510 is a cylindrical pressure chamber which will propel the pusher plate 510 and pellets 500 when sufficient pressure occurs. A high-low adapter 520 and a canister base 515 are welded to the preferably 100 mm canister 505 . A high pressure 12-gauge insert 525 , with a brass burst disk 530 in front of it, is threaded into the high-low adapter 520 . A pyrotechnic mechanism such as a 12-gauge shotgun shell 540 with a pre-wired primer is inserted into the high pressure insert 525 . A threaded rod 550 , with a large axial hole 552 at the back and a small axial hole 554 at the front, is screwed into the high pressure insert 525 behind the shotgun shell 540 . Primer wires 560 are threaded through the axial holes 552 , 554 and attach to the shot gun shell 540 . A grooved rubber plug 565 is inserted into the large axial hole 552 , with the wires 560 in the groove. The wires 560 are threaded through the hole 570 in the threaded cap 575 , which is then screwed onto the threaded rod 550 . When electronically triggered, the propellant will ignite and will launch the pusher cup 510 and shot 500 . This propulsion system was employed and performed successfully during live RPG testing. Other propulsion systems are possible, such as sheet explosives, which have the potential for warhead size and weight reduction.
[0029] Another embodiment of the proven design of a propulsion system useful in the present invention is shown in the warhead tube 600 of FIG. 6 . A cartridge holder 610 and an O-ring seal 615 are bolted, with lock washers, on the inside of the warhead tube 600 . A pusher plate 620 and pellets (not shown) are then placed in the tube 600 and held there by a frangible cap 625 , secured to the tube 600 by a steel washer 630 and cap screws 635 . A 20 mm cartridge 640 with an electric primer 645 and containing propellant (not shown) is inserted into the cartridge holder 610 at the back of the warhead and a metal contact bar 650 , rubber washers 655 , a plastic insulating sleeve 660 , an O-ring 670 and a support plate 675 are attached. The metal contact bar 655 contacts the center of the primer in the cartridge 640 . Rubber and plastic components insulate the contact bar 650 from the rest of the assembled warhead tube 600 .
[0030] Another embodiment of a propulsion system useful in the present invention involves using a pneumatic assembly at the back of the warhead tube 600 comprising a pressurized cartridge and a fast acting release valve, wherein such propulsion system utilizes compressed air to propel the pellets.
[0031] In accordance with one embodiment of the present invention, two warheads 700 (only one being shown; see FIG. 4A that shows two) are then inserted into breech blocks 710 with electrical contacts as shown in FIG. 7 . Specifically, the metal contact bar 720 on the warhead 700 contacts the positive electronic firing pin 725 in the breech block 710 . The metal support ring 730 on the warhead 700 contacts the negative firing pin 735 . When electronically triggered, the propellant will ignite and will launch the pusher cup and pellets.
[0032] In a preferred, non-limiting embodiment, for the RPG ogive identified in FIG. 3 , for example, each warhead is filled with pellets made of tungsten carbide having a diameter of approximately 0.215 inches, a density of approximately 14.9 g/cm 3 , and a Rockwell C hardness of approximately 75. This configuration results in approximately 15,000 pellets housed in each warhead. Other shot configurations are contemplated. When triggered, the pellets are ejected from the two warheads in a non-directed manner and typically radiate as clouds with expanding circular cross-sections that progressively overlap. The pellets leave the warheads at speeds between 50 ft/s and 150 ft/s, and more preferably at speeds that are non-lethal to nearby personnel. In this example implementation, the pellets will have a dispersion angle of approximately 40 degrees radiating from each warhead tube, and an overall dispersion angle from a pair of warhead tubes of approximately 60 degrees. This configuration using a large number of pellets will result in a high probability of encountering the piezoelectric device on the nose of the missile, and thereby causing premature detonation of the missile. This was confirmed by testing one described typical embodiment system against several separate live RPGs fired from an RPG launcher. The RPGs that entered the protected area of the screen all detonated upon impact with the pellets.
[0033] As shown in FIG. 8 , a series of warheads 800 can be mounted on a vehicle 810 and can protect the vehicle 810 from missile attack. Any structure can be provided with complete coverage by proper placement and orientation of a series of warhead tubes. In the typical embodiment, the shot screen 820 is fired in order to strike the missile 10 to 20 feet from the target vehicle or building. Once the sensor 830 detects that a missile has been fired, the speed and approximate trajectory of the missile must also be determined by measurement, typically supported by rapid calculation. Calculations are made to determine if, when and approximately where the missile will strike the vehicle or building, therefore determining which warhead tubes must be fired, and when they need to be fired. This will require a distributed or central processing unit (not shown) that is capable of collecting data from the sensors and making the appropriate calculations. It should be noted that, in the preferred embodiment, the warhead tubes are mounted statically and are not slewed. The result is an automatic system capable of defeating multiple missiles and thereby protecting vehicles, buildings, and people.
[0034] The shot is preferably fired at non-lethal velocities, since the missile velocity will provide nearly all of the required impact energy. The present system preferably contains no high explosives or fuzes, which will lead to ease of transportability and implementation. Also, the system is preferably not lethal to people standing in the path of the shot when fired. The shot cloud system is relatively lightweight and easy to deploy. The result of the system is that the incoming missile will detonate prematurely before hitting its target and greatly reduce the resulting damage and loss of life.
[0035] While the present invention has been described at some length and with some particularity with respect to the several described embodiments, it is not intended that it should be limited to any such particulars or embodiments or any particular embodiment, but it is to be construed with references to the appended claims so as to provide the broadest possible interpretation of such claims in view of the prior art and, therefore, to effectively encompass the intended scope of the invention. Furthermore, the foregoing describes the invention in terms of embodiments foreseen by the inventor for which an enabling description was available, notwithstanding that insubstantial modifications of the invention, not presently foreseen, may nonetheless represent equivalents thereto. | A system is disclosed for defeating enemy missiles and rockets, particularly rocket propelled grenades (RPG's). The first step is to identify the firing of a missile by the use of sensors that give the approximate distance and bearing of the incoming missile. A non-lethal cloud of pellets is then launched from the target, which can be a building or vehicle or the like, in the general direction of the missile. The pellets are housed in a series of warhead containers mounted at locations on the target in various orientations. The warheads are triggered to fire a low velocity cloud of pellets toward the incoming missile. The pellets then collide with the missile a certain distance away from the target causing premature detonation of the missile, and/or possible severe damage to the missile, and/or deflection of the missile, due to the relatively high velocity of the missile. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application which claims the benefit under 35 U.S.C. §121 of U.S. patent application Ser. No. 11/316,455, filed Dec. 21, 2005, now U.S. Pat. No. 7,644,587, the disclosure of which is hereby incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND
Technical Field
One issue confronting electrical power generating utilities is the rapid variability in demand during the day. Also, with the increasing use of alternate power sources by utilities such as wind and solar energy, there can be rapid variability in power generation. Power variances can prove problematic. For example, inability to meet peak demands and alternate source reductions can lead to “brown-outs” and/or “black-outs”. Another disadvantage faced by utilities involves paying a premium for electrical power purchased during peak load hours.
Peaking power plants must have a rapid response capability to match a rapidly changing demand and/or interruptions in supply. Although gas turbines have the ability to provide the rapid response required by peaking plants in about 1 to about 3 hours, they generally require a clean fuel. A clean gaseous fuel can be provided by the tail gases from a Fischer-Tropsch (FT) process.
In contrast to the method described in U.S. Pat. No. 5,543,437 (Benham et al) whereby the FT reactor synthesis gas flow rate, and hence production rate, was varied to accommodate a varying power demand, the instant method permits the FT reactor to operate at a constant synthesis gas flow rate.
U.S. Pat. No. 3,986,349 (Egan) teaches an integrated process for generating electrical power using gasification of solid carbonaceous material and FT technology. Gases from the gasifier and tail gases from the FT system are used in a power plant to produce base-load power. Liquid hydrocarbons from the FT system are stored and used as fuel in a gas turbine-generator set to provide supplemental power for peak-load demand.
Benham U.S. Pat. No. 5,543,437 contemplates the use of FT processes in combination with electric power generating facilities. When a fuel source for a steam power plant is obtained from coal or natural gas, the '437 patent suggests a variation in power production by changing the firing rate of the boilers. When the fuel source is from gas produced by a coal gasification facility, the '437 patent suggests adding an alternative use for the excess coal gas during off-peak hours. The alternate use can then be “turned down” when most of the gas is required for peak power production. An alternate use is a slurry-phase FT reactor for producing liquid hydrocarbons from the coal gas. Thus, the coal gasification facility supplies sufficient gas to meet peak electric load requirements while a minimum flow of gas is supplied to one or more FT reactors to produce liquid hydrocarbons during off-peak hours. In the change from peak-load operation to off-peak operation, coal gas is diverted from the boiler to the FT reactors and the pressure in the FT reactors is reduced to reduce the density of the coal gas and thereby increase the superficial velocity of the gas in the slurry FT reactor. During peak power production, the liquid hydrocarbon production rate of the slurry FT reactors drops.
SUMMARY
The present method integrates a FT hydrocarbon production facility with an electrical power generating facility. In addition to meeting peak-load demands, the methodology can also produce a part of the base load requirement. For example, for power produced from a wind energy system or other alternative energy system which is subject to wide variability in energy source during the day, the present method can be used to “smooth out” power production with time. A gasifier provides a constant supply of synthesis gas to one or more FT reactors. Tail gases and optionally naphtha from the FT units provide fuel for one or more gas turbine-generator sets.
In the disclosed method, variable electrical power generation is achieved by increasing or decreasing the amount of FT tail gases supplied to the gas turbine-generator sets. The amount of tail gases can be adjusted by varying the operating temperature of the FT reactors. Using this technique, not only can the gasifier operate under constant conditions, but the flow rate of synthesis gas to the FT reactors can be continuous. Also, there is a potential of generating much greater power by using tail gases and naphtha from low-temperature FT operation than the power generated by using FT liquids alone.
Feedstocks useful for gasification comprise coal, petroleum coke, saw dust, agricultural wastes, sewage sludge and energy crops. Almost any feedstock containing carbon can be used in the process to produce a clean synthesis gas for fueling a combined cycle system and for reacting in a FT system.
The gasification reaction, i.e. partial oxidation reaction, can be expressed as:
CH z +0.5O 2 →z/ 2H 2 +CO (1)
where z is the H:C ratio of a feedstock and it is assumed that the amount of any other species produced in the gasification reaction is negligible.
The water gas shift reaction also takes place:
H 2 O+CO H 2 +CO 2 (2)
If x represents the number of moles of water reacted per mole of carbon in the feedstock, then equations 1 and 2 can be combined to give:
CH z +0.5O 2 +x H 2 O→( x+z/ 2)H 2 +(1 −x )CO+ x CO 2 (3)
The desired H 2 :CO ratio exiting the gasifier dictates the amount of water reacted with the feedstock. For example, if r represents the desired H 2 :CO ratio, then
x =( r−z/ 2))/(1 +r ) (4)
The FT reaction for each carbon number can be expressed as:
(2 n−f+ 1)H 2 +n CO→(1 −f )C n H 2n+2 +f C n H 2n +n H 2 O, (5)
where f represents the fraction of olefins for carbon number n. For n=1, f=0. For an iron based catalyst the water gas shift reaction is also active:
H 2 O+CO H 2 +CO 2 (6)
The present method provides rapid response power to a power plant for meeting peak demand.
The present method may also provide rapid response power to compensate for variability of alternate sources of power such as wind generators and solar cells.
In addition, the present method produces synthesis gas using a gasifier operating under constant conditions, which provides a continuous flow of synthesis gas for use in FT and power operations.
The present method can produce variable amounts of FT tail gases and naphtha by operating the FT reactors at variable temperatures.
The present method uses a gas turbine for driving a generator to achieve rapid startup and shutdown for meeting peak power demands or fluctuating power production.
These and other features and advantages of the disclosed method reside in the construction of parts and the combination thereof, the mode of operation and use, as will become more apparent from the following description, reference being made to the accompanying drawings that form a part of this specification wherein like reference characters designate corresponding parts in the several views. The embodiments and features thereof are described and illustrated in conjunction with systems, tools and methods which are meant to exemplify and to illustrate, not being limiting in scope.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a diagram of an integrated Fischer-Tropsch plant and electrical power generating plant.
FIG. 2 is a plot diagram of the price of diesel versus the price of peak power.
Before explaining the disclosed embodiments in detail, it is to be understood that the embodiments are not limited in application to the details of the particular arrangements shown, since other embodiments are possible. Also, the terminology used herein is for the purpose of description and not of limitation.
DETAILED DESCRIPTION
FIG. 1 is a diagram of an integrated FT plant and electrical power generating plant. In the disclosed process of FIG. 1 , fuel 1 , and oxidizing gas selected from one or more of steam 2 , oxygen 3 , and carbon dioxide 4 are fed to synthesis gas generating unit 5 . Oxygen may be provided by air separation unit 21 . Synthesis gas 6 is fed to gas cleanup unit 7 to remove contaminants such as sulfur, chlorine, particulate matter, and water. Clean synthesis gas 8 is split into two streams 9 and 10 . Stream 9 can be used to fuel a combined cycle gas turbine/steam turbine unit 11 for generating electrical power for base-load requirements. The other synthesis gas stream 10 can be fed to a FT reactor 12 to produce stream 14 comprising liquid hydrocarbons, wax, water and tail gases. Tail gases 15 a are separated from liquid hydrocarbons and water in unit 15 . A part 16 of tail gas 15 a can be fed to a gas turbine driven peak-load power generating unit 18 and a part 17 can be fed to the combined cycle gas turbine/steam turbine unit 11 for generating electrical power for base-load requirements. Naphtha 16 a may be introduced into gas turbine-generator set 18 .
During peak power demand times, the temperature of FT reactor 12 can be decreased by reducing the pressure of the saturated steam pressure in the FT cooling coils 13 . This action reduces the saturated steam temperature in the cooling coils thereby increasing the heat transfer from the slurry to the water/steam coolant. The lower slurry temperature can cause the FT reaction rate to decrease and reduce the conversion of synthesis gas to liquid hydrocarbons. Reduction of the conversion of synthesis gas to liquid hydrocarbons results in more unconverted synthesis gas to be present in the FT tail gases. The increased flow rate of tail gases 15 a during operation at the decreased FT temperature can increase the power output of generator 18 . In one mode of operation, a portion 19 of tail gases 15 a can be recycled to the FT reactor by combining with synthesis gases 10 . The examples below illustrate the recycle of about 80% of the tail gases back to the inlet of the FT reactor under various operating conditions. However, it is possible to recycle from about 30% to about 90% of the tail gas to the FT unit during non-peak hours, or as long as the H 2 :CO ratio of the synthesis gas is in the range of about 0.7 to about 2.5.
CALCULATED EXAMPLES
The examples presented below are intended to elucidate the general aspects of the disclosed method. Gasifier performance is based on equations 1 through 4 above. A H:C molar ratio of about 0.828 and a carbon content of about 74 weight percent are used for Pittsburgh #8 coal. It is assumed that the synthesis gas has a H 2 :CO ratio of about 0.8. Based upon the values presented above, a coal feed rate of about 1000 tons per day can produce about 29.4 MMSCFD of H 2 , about 36.7 MMSCFD of CO, and about 10.0 MMSCFD of CO 2 . It is assumed that the carbon dioxide is removed upstream of the FT reactor. The disclosed examples all assume the same flowrates for H 2 and for CO as stated above.
The Fischer-Tropsch performance is based on proprietary in-house computer programs incorporating an iron-based catalyst. The FT model uses two chain growth parameters (alphas) to describe the carbon number distribution of the hydrocarbon product. The alphas relate moles of successive carbon numbers using the Anderson-Shultz-Flory procedure:
N n+1 =α 1 N n for n<9 (7)
N n+1 =α 2 N n for n≧9 (8)
In addition to reactor pressure and temperature, other key parameters specified for the FT model are CO conversion and moles of CO 2 produced per mole of CO converted.
For the disclosed examples, the wax produced is hydrocracked to produce diesel, naphtha and tail gases. The gas turbine efficiency was assumed to be about 38%. The calculated results for each disclosed example can be used to estimate peak power and diesel fuel production. It is assumed that peak power is produced for about 8 hours per day and that the base load power produced from tail gas is the same as that produced under high temperature operation, since the tail gas produced under high temperature operation must be utilized about 24 hours per day. Peak load power during an 8-hour period is provided by stored naphtha and by tail gas in excess of base load requirements. The amount of naphtha available during an 8-hour peak load operation is the sum of the naphtha production during high temperature operation for about 16 hours and during low temperature operation for about 8 hours.
Example 1a
This Example shows the calculated performance of the FT system operating at a high CO conversion and a high alpha for a single pass operation. The quantities of electrical power from tail gas and naphtha and diesel fuel producible under the stated operating conditions are set forth in Table 1. For this example, the following FT parameters are considered:
Pressure = 2.8 MPa
Temperature = 255° C.
α 1 = 0.69
α 2 = 0.955
CO Conversion = 85%
CO 2 Productivity = 0.42
Example 1b
This example shows the effect of recycling 80% of the tail gas under the operating conditions of Example 1a. The resulting quantities of tail gas, naphtha, which represent the amount of electrical power producible, with diesel fuel are set forth in Table 1.
TABLE 1
Quantity
No TG Recycle
80% TG Recycle
FT Product
Example 1a
Example 1b
Tail Gas (Mw e )
23.2
14.0
Naphtha(Mw e )
13.0
14.8
Diesel (BPD)
1598
1816
Example 2a
This Example shows the calculated performance of the FT system operating at a lower temperature and therefore at a lower CO conversion, but with a high alpha catalyst as assumed in Example 1. The quantities of electrical power, represented by the tail gas and naphtha values, and diesel fuel producible under the stated operating conditions are set forth in Table 2. For this example, the following FT parameters are considered:
Pressure = 2.8 MPa
Temperature = 225° C.
α 1 = 0.69
α 2 = 0.965
CO Conversion = 22%
CO 2 Productivity = 0.35
Example 2b
This Example shows the effect of recycling 80% of the tail gases back to the inlet of the FT reactor under the operating conditions of Example 2a. The resulting quantities of tail gas, naphtha, which represent the amount of electrical power producible, with diesel fuel are set forth in Table 2.
TABLE 2
Quantity
No TG Recycle
80% TG Recycle
FT Product
Example 2a
Example 2b
Tail Gas (Mw e )
71.8
38.3
Naphtha(Mw e )
3.6
9.6
Diesel (BPD)
493
1309
Example 3
This Example shows the calculated performance of the FT system operating with a low alpha catalyst at a high temperature. The quantities of electrical power and diesel fuel producible under the stated operating conditions are set forth in Table 3. Because it appeared that in this case there would not be sufficient hydrogen to permit recycle of more than 20% of the tail gas, the recycle case was not considered. For this example, the following FT parameters are considered:
Pressure = 2.8 MPa
Temperature = 255° C.
α 1 = 0.70
α 2 = 0.70
CO Conversion = 85%
CO 2 Productivity = 0.42
TABLE 3
FT Product
No TG Recycle
Tail Gas (Mw e )
41.2
Naphtha(Mw e )
23.4
Diesel (BPD)
380
Example 4a
This Example shows the calculated performance of the FT system operating at a lower temperature and therefore at a lower CO conversion, and also with a low alpha catalyst. The calculated values for electrical power from tail gas and naphtha and the amount of diesel fuel producible under the stated operating conditions are set forth in Table 4. For this example, the following FT parameters are considered:
Pressure = 2.8 MPa
Temperature = 225° C.
α 1 = 0.71
α 2 = 0.71
CO Conversion = 22%
CO 2 Productivity = 0.35
Example 4b
This Example shows the effect of recycling 80% of the tail gases back to the inlet of the FT reactor under the operating conditions of Example 4a. The calculated quantities of tail gas, naphtha, and diesel fuel are set forth in Table 4.
TABLE 4
Quantity
No TG Recycle
80% TG Recycle
FT Product
Example 1a
Example 1b
Tail Gas (Mw e )
77.1
53.2
Naphtha(Mw e )
6.9
17.9
Diesel (BPD)
122
307
As stated above, Egan U.S. Pat. No. 3,986,349 teaches an integrated process for generating electrical power using gasification of solid carbonaceous material and FT technology. Egan's conventional method produces base-load power from gasifier gases and FT tail gases and supplemental power for peak-load demand from stored liquid hydrocarbons from the FT system. In Table 5 the advantage of using the instant method over the conventional method taught by the Egan '349 patent is shown in terms of increased peak power production for the high temperature and high alpha case. Utilizing the instant method of lowering the temperature provides for more synthesis gas for peak power. A smaller quantity of diesel is formed due to conservation of energy.
TABLE 5
High
High and Low
Temperature
Temperature
FT Output
Only
Operation
Base Power (Mwe)
23.2
23.2
Peak Power (Mwe)
39.0
78.1
Diesel (BPD)
1598
1229
The decision to employ diesel as well as naphtha for the production of power is an economic issue. FIG. 2 is a plot of diesel price in US$ per barrel versus the price of peak power in US$ per kilowatt-hour, which balances the revenues from the additional 39.1 Mwe of power against the loss of 369 BPD of diesel based on the data in Table 5.
In the case of a recycle operation, there would be less tail gas available for supplying base load because the tail gas is recycled to the inlet of the FT reactor during non-peak hours. During peak load operation tail gas recycle would be terminated, thereby providing a larger amount of tail gas for generating peak load power. The Egan '349 patent uses stored naphtha to provide peak power.
In Table 6 the advantage of using the instant method over the conventional method taught by Egan in the '349 patent is shown in terms of increased peak power production for the high alpha case wherein 80% of the tail gas is recycled to the inlet of the FT reactor during non-peak hours. Table 6 also shows the values associated with not only lowering the temperature but also curtailing the tail gas recycle. In this case, more tail gas is provided to the gas turbine for peak power. A smaller quantity of diesel is formed due to conservation of energy.
TABLE 6
High
High and Low
High and Low
Temperature
Temperature
Temperature
FT Output
80% Recycle
80% Recycle
No Recycle
Base Power (Mwe)
14.0
14.0
14.0
Peak Power (Mwe)
44.3
63.5
90.9
Diesel (BPD)
1816
1647
1375
The disclosed method exploits the benefits of a Fischer-Tropsch system comprising an air separation unit for producing a stream of oxygen, a feedstock preparation unit, a gasification unit for reacting feedstock, oxygen and steam to produce synthesis gas comprising primarily hydrogen and carbon monoxide, a synthesis gas purification unit for removing sulfur and other impurities from synthesis gas, a combined cycle power production unit fueled by synthesis gas, a Fischer-Tropsch unit for producing liquid hydrocarbons and tail gases comprised of unreacted synthesis gas and gaseous hydrocarbons, and a gas turbine-generator set fueled by Fischer-Tropsch tail gases, and maximizes the system for electrical power production. Typical gasifier feedstock can comprise coal, petroleum coke, saw dust, sewage sludge, agricultural waste, and/or other energy crop. Not only is cleaned synthesis gas used to fuel a combined cycle gas turbine/steam turbine unit for generating electrical power for base-load requirements, the synthesis gas can serve as feed for a FT reactor to produce liquid hydrocarbons, wax, water and tail gases. Typical FT catalysts comprise iron, cobalt, nickel, and/or ruthenium. Some of the FT tail gas may then be fed to a gas turbine driven peak-load power generating unit. It may also be used as feed for a combined cycle gas turbine/steam turbine unit for generating electrical power for base-load requirements.
When desired, and especially during peak power demand times, the temperature of the FT reactor may be decreased to bring about an increase in power output of the generator. Lowering the pressure of the saturated steam in the reactor cooling coils reduces the temperature of the saturated steam temperature, which thereby results in a lower slurry temperature. When the FT reaction rate decreases, thereby reducing the conversion of synthesis gas to liquid hydrocarbons, more unconverted synthesis gas is present in the FT tail gases and available as feed for the gas turbine driven power generating unit. The power produced in the power generating unit is variable to meet varying electrical load requirements. The FT reactor may range in temperature from about 190° C. and 275° C.
The disclosed method can also be used to maximize an existing power generation system and smooth out fluctuations in power production. For example, an FT system can be integrated with an electrical power production facility comprising electrical power generator 22 powered, for example, by wind turbines or solar cells. Although a wind powered facility is described here, other types of electric power production facilities, alternative or conventional, may be integrated with the disclosed method.
While a number of exemplifying features and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and subcombinations thereof. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. | A method for meeting both base-load and peak-load demand in a power production facility. By integrating a Fischer-Tropsch (FT) hydrocarbon production facility with an electrical power generating facility, peak-load power demand can be met by reducing the temperature of the FT reactor thereby increasing the quantity of tail gases and using FT tail gases to fuel a gas turbine generator set. The method enables rapid power response and allows the synthesis gas generating units and the FT units to operate with constant flow rates. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to improvements relating to surfactant compositions, a method of treatment of textiles and a nano-composite textile.
BACKGROUND OF THE INVENTION
[0002] It is well known to use particles to modify the surface of cotton fibres. Consequently, particulate inorganic materials such as clays, silica and alumino-silicate have been widely used in detergent compositions. Typically, these are present as ‘softeners’ which associate with the surfaces of fibres and fibrils of cotton.
[0003] In recent years it has been proposed to use so-called ‘nanoparticles’ for fabric treatment. WO 02/064877 (P&G) discloses coating compositions, which comprise a ‘nanoparticle’ system of a size of less than or equal to 750 nm, with a lower limit of ‘0’ nm. Examples provided include synthetic silica (10-40 nm), boehemite alumina (2-750 nm) and ‘nanotubes’ (2-50 nm). Clays, particularly plate-like laponites (25-40 nm wide and ˜1 nm thick) are considered suitable and organic materials such as nano-latexes are proposed.
[0004] Nanosilica particles are negatively charged and are not expected to deposit on the fabric surface (also negatively charged) during wash because of their negative charge. At pH 8, for example, the Zeta-potential of a nanosilica was measured to be −21 mV.
[0005] EP 1371718 (Rohm and Haas) discloses 1-10 nm polymeric nanoparticles as a fabric care additive. These can be organically modified with silicones.
[0006] WO 02/18451 (Rhodia) discloses the use of nanoparticles in a polymeric or nano-latex form.
[0007] DE 10248583 (Nanogate Technologies GmbH) discloses the use of inorganic nanoparticles as a carrier for a silane material.
BRIEF DESCRIPTION OF THE INVENTION
[0008] We have determined that it is advantageous to use monomeric hybrid organic/inorganic nanoparticles of the size range 1-10 nm. These materials are not polymeric and typically comprise an inorganic core with chemically bound organic pendant groups.
[0009] Accordingly therefore, the present invention provides a laundry treatment composition comprising:
[0010] a) 0.001-5% wt of monomeric hybrid organic/inorganic nanoparticles having a particle size of 1-10 nm,
[0011] b) 0.1-95% wt of surfactant
[0012] c) optionally, one or more of enzymes, perfumes, bleach, and sequesterants.
[0013] A first benefit of the present invention is believed to be that fabrics treated with the composition are easier to wash after subsequent soiling.
[0014] According to a further aspect of the present invention there is provided a method of treating cellulosic textiles, which comprises contacting the textile with a solution of the composition according to the present invention.
[0015] Textile here is intended to mean both a fibre in the form of a yarn, and especially, in the form of a woven or knitted garment. Generally the method of the invention will be applied as part of a domestic laundering process although it can also be applied as finishing process in textile or garment manufacture.
[0016] While not wishing to be limited by any theory of operation, it is believed that the nanoparticles of the composition of the invention penetrate into the cellulosic regions of the cotton fibre rather than simply associating with the surface of the fibres or penetrating into the lumen of the fibres. It is considered that the mechanism of delivery of nanoparticles is nano-filtration, through cotton fibre pores. These pores are believed to be of a typical size between 5-9 nm.
[0017] It is also believed that nanoparticles prevent the absorption of particulate soil into cotton fibre pores.
[0018] This is believed to be due to two mechanisms. In the first of these, the nanoparticles are thought to block the pores and prevent adsorption of particulate soils.
[0019] It is preferable that the nanoparticles are negatively charged under the conditions of a domestic wash, i.e. that they have a negative Zeta-potential at an alkaline pH suitable for washing clothes. It is believed that this enables the particles to deliver additional negative charge to the fabric therefore decreasing the deposition tendency of soils.
[0020] It would appear that it is particularly advantageous to use nanoparticles for cotton treatment which are close to the pore size of the cellulosic region of the cotton fibre (5-9 nm) and which have a negative Zeta potential at pH 8. While these negatively charged particles are naturally repelled from the fibre surface it is believed that their nano-scale dimensions are small enough that the particles can enter the pores of the fibre and become physically trapped.
[0021] Further benefits of the inventions relate to the mechanical properties of fabrics treated with the composition. The nanoparticles are believed to cause an increase in the flexural rigidity of the fabric, which enhances the fibre resistance to creasing. In addition, there are tactile benefits, believed to be associated with a reduction in friction. It is envisaged that such a reduction in friction would have secondary benefits, as a reduction in fibre-fibre friction is believed to prevent fibre damage and therefore reduce pilling and loss of colour.
[0022] While the mechanism why the invention works remains speculative, to some extent the present invention also extends to nano-composite cellulosic material obtainable by the method of the invention. Such a material may be in the form of a yarn or in the form of a cloth, or in the form of a finished garment.
[0023] As noted above, the nanoparticles are organically modified, inorganic nanoparticles. Preferably these are organically modified siloxanes. Suitable molecules include polyhedral oligomeric silsesquioxane (POSS) species. Preferred POSS species are of the general formula:
(R 1 ) m (—OH) n —O h Si g
[0024] Wherein h=3a, g=2a (for a=4 or 6), m+n=g. Preferably, R1 is independently selected from C1-C6 alkyl, aryl or cycloalkyl, phenyl, O − , trifluoropropyl, trimethylsiloxy, phenyl ethyl.
[0025] Ionic R1 groups are preferred, particularly, for the reasons given above ones which bear a negative charge. More preferably the materials are water soluble or dispersible.
[0026] In a preferred embodiment the nanoparticles comprise octa-trimethylamine POSS (C 32 H 96 N 8 O 20 Si 8 —CAS registry number [69667-29-4]). Suitable counter-ions include quaternary ammonium ions such as NMe 4 + .
[0027] A range of POSS materials are available in the marketplace as Nanostructured™ Chemicals from the Hybrid Plastics company (www.hybridplastics.com).
DETAILED DESCRIPTION OF THE INVENTION
[0028] Various preferred and/or optional features of the product and method aspects of the present invention are described in further detail below. As used elsewhere in the specification all percentages are percentages by weight unless the context demands otherwise.
[0000] Product Form:
[0029] The composition of the invention may be in the form of a liquid, solid (e.g. powder or tablet), a gel or paste, spray, stick or a foam or mousse. Examples include a soaking product, a rinse treatment (e.g. conditioner or finisher) or a main-wash product.
[0030] Liquid compositions may also include an agent which produces a pearlescent appearance, e.g. an organic pearlising compound such as ethylene glycol distearate, or inorganic pearlising pigments such as microfine mica or titanium dioxide (TiO 2 ) coated mica. Liquid compositions may be in the form of emulsions or emulsion precursors thereof.
[0000] Surfactants:
[0031] The surfactant may be chosen from soap and non-soap anionic, cationic, nonionic, amphoteric and zwitterionic detergent active compounds, and mixtures thereof.
[0032] Surfactants can assist with the delivery of hydrophobic nanoparticles, particularly so-called linear hybrid monomers.
[0033] An example of such a linear hybrid monomer is the molecular silica sold under the trade name ‘iso-octyl POSS cage mixture’, whose chemical formula is C 64 H 88 O 12 Si 8 . These nanoparticles are intrinsically insoluble in water due to the iso-octyl chains covalently bonded to the silica structure.
[0034] Many suitable surfactants are available and are fully described in the literature, for example, in “Surface-Active Agents and Detergents”, Volumes I and II, by Schwartz, Perry and Berch (Wiley Interscience).
[0035] The preferred surfactants that can be used are soaps and synthetic non-soap anionic and nonionic compounds.
[0036] Anionic surfactants are well-known to those skilled in the art. Examples include alkylbenzene sulphonates, particularly linear alkylbenzene sulphonates having an alkyl chain length of C 8 -C 15 ; primary and secondary alkylsulphates, particularly C 8 -C 15 primary alkyl sulphates; alkyl ether sulphates; olefin sulphonates; alkyl xylene sulphonates; dialkyl sulphosuccinates; and fatty acid ester sulphonates. Sodium salts are generally preferred.
[0037] Nonionic surfactants that may be used include the primary and secondary alcohol ethoxylates, especially the C 8 -C 20 aliphatic alcohols ethoxylated with an average of from 1 to 20 moles of ethylene oxide per mole of alcohol, and more especially the C 10 -C 15 primary and secondary aliphatic alcohols ethoxylated with an average of from 1 to 10 moles of ethylene oxide per mole of alcohol. Non-ethoxylated nonionic surfactants include alkylpolyglycosides, glycerol monoethers, and polyhydroxyamides (glucamide).
[0038] Cationic surfactants that may be used include quaternary ammonium salts of the general formula R 1 R 2 R 3 R 4 N + X − wherein the R groups are independently hydrocarbyl chains of C 1 -C 22 length, typically alkyl, hydroxyalkyl or ethoxylated alkyl groups, and X is a solubilising cation (for example, compounds in which R 1 is a C 8 -C 22 alkyl group, preferably a C 8 -C 10 or C 12 -C 14 alkyl group, R 2 is a methyl group, and R 3 and R 4 , which may be the same or different, are methyl or hydroxyethyl groups); and cationic esters (for example, choline esters) and pyridinium salts.
[0039] The total quantity of detergent surfactant in the composition is suitably from 0.1 to 60 wt % e.g. 0.5-55 wt %, such as 5-50 wt %.
[0040] Preferably, the quantity of anionic surfactant (when present) is in the range of from 1 to 50% by weight of the total composition. More preferably, the quantity of anionic surfactant is in the range of from 3 to 35% by weight, e.g. 5 to 30% by weight.
[0041] Preferably, the quantity of nonionic surfactant when present is in the range of from 2 to 25% by weight, more preferably from 5 to 20% by weight.
[0042] Amphoteric surfactants may also be used, for example amine oxides or betaines.
[0043] Viscous liquid nanoparticle containing material can be heated, preferably to a temperature greater than 60 Celsius to obtain a significant drop in viscosity. This can then be admixed with a surfactant containing solution, preferably under high shear, to obtain a dispersion. Symperonic™ A7 (C13E6.5) is a suitable surfactant.
[0044] This concentrated dispersion can be either added as is in a final liquid detergent formulation or can be further processed (i.e., spray drying) to incorporate the hydrophobic nanoparticles load into a powder detergent formulation.
[0045] Alternative routes to deliver the hydrophobic nanoparticles is by mixing the viscous molecular silica with a suitable oil, which may be a perfume oil, that would serve as a carrier.
[0000] Builders:
[0046] The compositions may suitably contain from 10 to 70%, preferably from 15 to 70% by weight, of detergency builder. Preferably, the quantity of builder is in the range of from 15 to 50% by weight.
[0047] The detergent composition may contain as builder a crystalline aluminosilicate, preferably an alkali metal aluminosilicate, more preferably a sodium aluminosilicate.
[0048] The aluminosilicate may generally be incorporated in amounts of from 10 to 70% by weight (anhydrous basis), preferably from 25 to 50%. Aluminosilicates are materials having the general formula:
0.8-1.5 M 2 O. Al 2 O 3 . 0.8-6 SiO 2
where M is a monovalent cation, preferably sodium. These materials contain some bound water and are required to have a calcium ion exchange capacity of at least 50 mg CaO/g. The preferred sodium aluminosilicates contain 1.5-3.5 SiO 2 units in the formula above. They can be prepared readily by reaction between sodium silicate and sodium aluminate, as amply described in the literature.
[0049] Alternatively, or additionally to the aluminosilicate builders, phosphate builders may be used.
[0000] Textile Softening and/or Conditioner Compounds:
[0050] If the composition of the present invention is in the form of a textile conditioner composition, the surfactant will be a textile softening and/or conditioning compound (hereinafter referred to as “textile softening compound”), which may be a cationic or nonionic compound.
[0051] The softening and/or conditioning compounds may be water insoluble quaternary ammonium compounds. The compounds may be present in amounts of up to 8% by weight (based on the total amount of the composition) in which case the compositions are considered dilute, or at levels from 8% to about 50% by weight, in which case the compositions are considered concentrates.
[0052] Compositions suitable for delivery during the rinse cycle may also be delivered to the textile in the tumble dryer if used in a suitable form. Thus, another product form is a composition (for example, a paste) suitable for coating onto, and delivery from, a substrate e.g. a flexible sheet or sponge or a suitable dispenser during a tumble dryer cycle.
[0053] Suitable cationic textile softening compounds are substantially water-insoluble quaternary ammonium materials comprising a single alkyl or alkenyl long chain having an average chain length greater than or equal to C 20 . More preferably, softening compounds comprise a polar head group and two alkyl or alkenyl chains having an average chain length greater than or equal to C 14 . Preferably the textile softening compounds have two, long-chain, alkyl or alkenyl chains each having an average chain length greater than or equal to C 16 .
[0054] Most preferably at least 50% of the long chain alkyl or alkenyl groups have a chain length of C 18 or above. It is preferred if the long chain alkyl or alkenyl groups of the textile softening compound are predominantly linear.
[0055] Quaternary ammonium compounds having two long-chain aliphatic groups, for example, distearyldimethyl ammonium chloride and di(hardened tallow alkyl) dimethyl ammonium chloride, are widely used in commercially available rinse conditioner compositions. Other examples of these cationic compounds are to be found in “Surface-Active Agents and Detergents”, Volumes I and II, by Schwartz, Perry and Berch. Any of the conventional types of such compounds may be used in the compositions of the present invention.
[0056] The textile softening compounds are preferably compounds that provide excellent softening, and are characterised by a chain melting Lβ to Lα transition temperature greater than 25° C., preferably greater than 35° C., most preferably greater than 45° C. This Lβ to Lα transition can be measured by DSC as defined in “Handbook of Lipid Bilayers”, D Marsh, CRC Press, Boca Raton, Fla., 1990 (pages 137 and 337).
[0057] Substantially water-insoluble textile softening compounds are defined as textile softening compounds having a solubility of less than 1×10 −3 wt % in demineralised water at 20° C. Preferably the textile softening compounds have a solubility of less than 1×10 −4 wt %, more preferably less than 1×10 −8 to 1×10 −6 wt %.
[0058] Especially preferred are cationic textile softening compounds that are water-insoluble quaternary ammonium materials having two C 12-22 alkyl or alkenyl groups connected to the molecule via at least one ester link, preferably two ester links. Di(tallowoxyloxyethyl) dimethyl ammonium chloride and/or its hardened tallow analogue are especially preferred of the compounds of this type. Other preferred materials include 1,2-bis(hardened tallowoyloxy)-3-trimethylammonium propane chloride. Their methods of preparation are, for example, described in U.S. Pat. No. 4,137,180 (Lever Brothers Co). Preferably these materials comprise small amounts of the corresponding monoester as described in U.S. Pat. No. 4,137,180, for example, 1-hardened tallowoyloxy-2-hydroxy-3-trimethylammonium propane chloride.
[0059] Other useful cationic softening agents are alkyl pyridinium salts and substituted imidazoline species. Also useful are primary, secondary and tertiary amines and the condensation products of fatty acids with alkylpolyamines.
[0060] The compositions may alternatively or additionally contain water-soluble cationic textile softeners, as described in GB 2 039 556B (Unilever).
[0061] The compositions may comprise a cationic textile softening compound and an oil, for example as disclosed in EP-A-0829531.
[0062] Nonionic softeners include Lβ phase forming sugar esters (as described in M Hato et al Langmuir 12, 1659, 1666, (1996)) and related materials such as glycerol monostearate or sorbitan esters. Often these materials are used in conjunction with cationic materials to assist deposition (see, for example, GB 2 202 244). Silicones are used in a similar way as a co-softener with a cationic softener in rinse treatments (see, for example, GB 1 549 180). The compositions may also suitably contain a nonionic stabilising agent. Suitable nonionic stabilising agents are linear C 8 to C 22 alcohols alkoxylated with 10 to 20 moles of alkylene oxide, C 10 to C 20 alcohols, or mixtures thereof.
[0063] Advantageously the nonionic stabilising agent is a linear C 8 to C 22 alcohol alkoxylated with 10 to 20 moles of alkylene oxide. Preferably, the level of nonionic stabiliser is within the range from 0.1 to 10% by weight, more preferably from 0.5 to 5% by weight, most preferably from 1 to 4% by weight. The mole ratio of the quaternary ammonium compound and/or other cationic softening agent to the nonionic stabilising agent is suitably within the range from 40:1 to about 1:1, preferably within the range from 18:1 to about 3:1.
[0064] The composition can also contain fatty acids, for example C 8 to C 24 alkyl or alkenyl monocarboxylic acids or polymers thereof. Preferably saturated fatty acids are used, in particular, hardened tallow C 16 to C 18 fatty acids. Preferably the fatty acid is non-saponified, more preferably the fatty acid is free, for example oleic acid, lauric acid or tallow fatty acid. The level of fatty acid material is preferably more than 0.1% by weight, more preferably more than 0.2% by weight. Concentrated compositions may comprise from 0.5 to 20% by weight of fatty acid, more preferably 1% to 10% by weight. The weight ratio of quaternary ammonium material or other cationic softening agent to fatty acid material is preferably from 10:1 to 1:10.
[0000] Other Components
[0065] Compositions according to the invention may comprise soil release polymers such as block copolymers of polyethylene oxide and terephthalate.
[0066] Other optional ingredients include emulsifiers, electrolytes (for example, sodium chloride or calcium chloride) preferably in the range from 0.01 to 5% by weight, pH buffering agents, and perfumes (preferably from 0.1 to 5% by weight).
[0067] Further optional ingredients include non-aqueous solvents, fluorescers, colourants, hydrotropes, antifoaming agents, enzymes, optical brightening agents, and opacifiers.
[0068] Suitable bleaches include peroxygen bleaches. Inorganic peroxygen bleaching agents, such as perborates and percarbonates are preferably combined with bleach activators. Where inorganic peroxygen bleaching agents are present the nonanoyloxybenzene sulphonate (NOBS) and tetra-acetyl ethylene diamine (TAED) activators are typical and preferred.
[0069] Suitable enzymes include proteases, amylases, lipases, cellulases, peroxidases and mixtures thereof.
[0070] In addition, compositions may comprise one or more of anti-shrinking agents, anti-wrinkle agents, anti-spotting agents, germicides, fungicides, anti-oxidants, UV absorbers (sunscreens), heavy metal sequestrants, chlorine scavengers, dye fixatives, anti-corrosion agents, drape imparting agents, antistatic agents and ironing aids. The lists of optional components are not intended to be exhaustive.
[0071] Lubricants and other ‘wrinkle release’ agents are a particularly preferred optional component of compositions according to the invention.
[0072] In order that the invention may be further and better understood it will be described below with reference to several non-limiting examples.
EXAMPLE 1
[0073] In this and in the following examples polyhedral oligomeric silsesquioxane (POSS), size 3-7 nm was used, unless stated otherwise. This material is available from Hybrid Plastics (www.hybridplastics.com).
[0074] In a model (bottle) main-wash, woven cotton sheeting and Poplin fabrics (fabric weight 2.7 g) were treated at pH 8 in an aqueous dispersion of POSS in the absence of surfactants. Experiments were performed at a 1:8 cloth to liquor ratio. Four loading levels of POSS on weight of fabric (owf) were used: 0.5% owf, 1% owf, 2% owf and 5% owf. The samples were placed in a water-bath at 40° C. and were shaken for 40 min.
[0075] Particle deposition on cloths (mg silica/g fabric) was quantified by Inductively Coupled Plasma (ICP) element analysis.
[0076] After being washed and dried the cloths were ironed, conditioned at relative humidity 65% and 20° C. for 24 h and their mechanical properties: crease recovery angle (CRA) and bending length (BL) were further measured. CRA technique gives information about wrinkle resistance and recovery properties of fabrics and the bending length for their flexural rigidity.
[0077] Nano-silica (3-7 nm) at 5% owf gave a significant increase of the rigidity (˜35% increase) with both fabrics.
[0078] Deposited silica levels [0.6-1.1 mg silica/g fabric] gave best CRA benefits (˜18% improvement). Any further increase in the deposited silica led to a decrease of the CRA. This could be a result of particle aggregation and full plugging of pores which impedes the recovery of already formed wrinkles.
[0079] SEM-Si mapping (EPMA) of cross-sections of the nano-silica treated fabric demonstrated that the silica is positioned inside the wall of the fibre-mostly in the cellulose porous part and less in the lumen.
EXAMPLE 2
[0080] Cotton sheeting fabrics were washed according the protocol described in example 1 above with nano-silica present at 2% owf. For comparison, colloidal silica of significantly larger size and different morphology was also used. After drying the same monitors were soiled with low concentrations of carbon black and Bandy black clay. Further cloths were tested for reflectance at 460 nm. Results are shown in Table 1 below.
TABLE 1 Cotton sheeting fabrics-redeposition study Reflectance Fabric Sample 460 nm Untreated cotton 89 (0.16) Untreated + Soiled with Carbon black 77 (1.03) Untreated + Soiled with clay 83 (0.51) Cotton treated (−ve charged) nanosilica 88 (0.14) Treated + Soiled with Carbon black 82 (0.83) Treated + Soiled with clay 85 (0.75) Cotton treated (+ve charged) silica (50 nm) 88 (0.22) Treated + Soiled with Carbon black 78 (1.29) Treated + Soiled with clay 83 (0.82)
[0081] Data in brackets show 95% confidence.
[0082] Both clay and carbon black are typical laundry particulate soils. It is believed that carbon black and Bandy black clay are poly-disperse systems of wide size distribution (1 nm-2 microns). From table 1 (upper triad of results) it can be seen that the reflectance is reduced significantly by soiling with both carbon black and clay (max. difference=12).
[0083] The middle triad of results shows only a small decrease in the reflectance of treated monitors before and after soiling (max. difference=6). It is believed that the fabric treated with nano-silica can be considered as a nano-composite textile and that nanoparticles inside the fibre pores prevent soil deposition inside the fibre. In addition the electrostatic repulsion between negatively charged silica and the soil particles (also negatively charged) results in less soiling.
[0084] In the third triad of results colloidal silica of size 50 nm was used as a comparison. This silica is believed to be positively charged and to modify the fibre surface without penetrating inside it. It can be seen that the reflectance was significantly changed as a result of soiling.
EXAMPLE 3
[0085] Fabric saturated with a test solution was forced between pressure controlled rollers (the padder) to squeeze excess solution from the fabric, leaving the desired amount of material on the fabric. Fabrics were line-dried before testing.
[0086] Mechanical properties (stiffness and elasticity) of cotton sheeting fabrics padded with 2% owf POSS nano-silica were tested using Kawabata shear technique. This measures inter-fibre friction and gives information about the fabric shear stiffness (G) and shear elasticity (2HG5). Nano-particulate silica treated cotton sheeting fabrics show increased stiffness (+25%) and reduced elasticity (−20%).
[0087] Surface friction coefficient was measured for cotton sheeting treated with nano-silica and found (using the Eldredge Tribometer) to be substantially lower than that of untreated fabric under both dry and wet conditions.
EXAMPLE 4
[0088] The damage of blue drill cotton padded with 2% owf POSS nano-silica was assessed through SEM analysis of fabric fibrillation and measurement of the fabric-fabric friction coefficient using the Eldredge Tribometer and compared to the damage of drill cotton both untreated and treated with other lubricant materials.
[0089] The comparison lubbricant was formed by admixing 28 g of glycerol monoisostearate (Prisorine™ 2040, Uniquema, Wirral, UK) with 12 g of polydimethylsiloxane PEG isostearate blend (Silwax™ DMC-IS, Siltech, Ontario, Canada).
[0090] The surface friction measured at wet conditions (wash liquor, pH 10) for the drill cotton treated with nano-silica was significantly lower than the friction of untreated cloth and also lower than those of the fabric treated with the comparison lubricant (also at 2% owf).
EXAMPLE 5
Preparation of a Surfactant Containing Composition
[0091] This example was performed with ‘iso-octyl POSS cage mixture’ (ex Hybrid Plastics, whose chemical formula is C 64 H 88 O 12 Si 8 . The viscous liquid comprising the nanoparticles was heated to a temperature slightly greater than 60 Celsius at which point a significant drop in viscosity is observed.
[0092] 0.5 g of the heated liquid containing the hydrophobic nanoparticles was added drop-wise to a container with 20 ml of a concentrated surfactant solution (10 g/l) of Symperonic A7 (C13E6.5) in water. The liquid was stirred using a universal electronic stirrer (Heidolph RZR 2051, Heidolph Instruments GmbH & Co. KG, Schwabach, Germany) at 1500-2000 rpm for a total of 5 to 10 minutes. A concentrated emulsion of droplets containing the hydrophobic nanoparticles in water is obtained. | Laundry treatment compositions comprising 0.001-5 wt % of monomeric hybrid organic/inorganic nanoparticles having a particle size of 1-10 nm and 10-95% surfactant give ease of wash benefits to soiled fabric as well as prevention of adsorption of particulate soils. | 3 |
RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. § 119 of Provisional Patent Application Ser. No. 60/418,823 filed on Oct. 16, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to power supplies in general, and more particularly, to generating a supply voltage using capacitive coupling in a main current path.
BACKGROUND OF THE INVENTION
[0003] Power supplies serve the purpose of converting an input voltage into one or several output voltages. An AC power source may be used to provide an AC power line input, which gets converted to a DC regulated output voltage. Transformers are typically used to provide isolation between a “hot” ground and a “cold” ground for a power supply or a converter. A primary winding of a transformer typically conducts a non-isolated direct current (DC). In the event of a overloading, the current in the primary winding might be, disadvantageously, excessive and may damage, for example, a power transistor that drives the transformer. Additionally, transformers are typically large in size (due to the size of the magnetic elements within them), bulky and expensive devices. It may be desirable to have a power supply that is inherently short circuit protected in a manner that avoids using dedicated circuit components.
[0004] In carrying out an inventive feature, a regulated power supply utilizes capacitive elements to transform an input voltage from, for example, a DC power source to a specified output voltage level across a load. The capacitive element, advantageously, could provide capacitive isolation between a “hot” ground and a “cold” ground.
SUMMARY OF THE INVENTION
[0005] A power supply, embodying an inventive feature, includes a supply inductor and a first capacitor coupled to form a resonant circuit to generate a resonant waveform in a resonant operation, during a first portion of an operation cycle of the power supply. A charge storage element develops an output voltage to energize a load. A rectifier is coupled to the charge storage element and to the resonant circuit and is responsive to the resonant waveform for applying the output voltage back to the resonant circuit to interrupt the resonant operation, at an end time of the operation cycle first portion, when the resonant waveform produces a first change of state in the rectifier. A first sensor senses when the first change of state in the rectifier occurs. A source of a supply current is coupled to the rectifier and rectified in the rectifier to produce a rectified current that is coupled to the charge storage element to replenish a charge therein, during a second portion of the operation cycle. A switching transistor is responsive to an output signal of the first sensor for enabling the supply current to be coupled to the rectifier, during the operation cycle second portion, and for disabling the supply current from being coupled to the rectifier, during the operation cycle first portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 shows a power supply with capacitive mains isolation in accordance with an embodiment of the present invention;
[0007] FIGS. 2 a , 2 b , 2 c , 2 d , 2 e and 2 f show waveforms associated with the operation of the power supply shown in FIG. 1 ;
[0008] FIGS. 3 a , 3 b and 3 c show three equivalent circuits of the power supply of FIG. 1 during three separate intervals, respectively, of a period of operation of FIGS. 2 a - 2 f;
[0009] FIG. 4 shows a power supply operating using inventive features of the power supply of FIG. 1 and in more details;
[0010] FIGS. 5 a , 5 b and 5 c show waveforms associated with the operation of the power supply shown in FIG. 4 for a first load;
[0011] FIGS. 6 a , 6 b and 6 c show waveforms associated with the operation of the power supply shown in FIG. 4 for a load higher than the first load;
[0012] FIG. 7 illustrates a graph showing an example of the variation of the efficiency of the power supply of FIG. 4 as a function of the output power; and
[0013] FIG. 8 illustrates schematically a manner by which an immunity against radio frequency interference (RFI) is obtained with the power supply of FIG. 4 .
DETAILED DESCRIPTION
[0014] FIG. 1 illustrates a power supply 300 , partially in a schematic form, with capacitive mains isolation, embodying an inventive feature. An input supply voltage Vin referenced to a “hot” ground conductor 50 is produced in, for example, a conventional bridge rectifier, not shown, and is non-isolated from “hot” ground conductor 50 . Voltage Vin is coupled via a supply inductor L 1 to a terminal 302 of a switch S 1 formed by a switching power transistor, not shown, that is controlled by a control circuit 301 to switch a high frequency. Terminal 302 is coupled to ground conductor 50 when switch S 1 is conductive.
[0015] When switch S 1 is non-conductive, terminal 302 is coupled to ground conductor 50 via a series arrangement of a first isolation capacitor C 1 , a second isolation capacitor C 2 , a second supply inductor L 2 that is coupled between capacitors C 1 and C 2 and a current sampling resistor Rtrig 2 . Current sampling resistor Rtrig 2 is coupled between capacitor C 2 and ground conductor 50 . When switch S 1 is non-conductive, terminal 302 is also coupled to ground conductor 50 via a series arrangement of a capacitor Ctrig and a current sampling resistor Rtrig 1 . Current sampling resistor Rtrig 1 is coupled between capacitor Ctrig and ground conductor 50 . A rectifier diode D 1 and a filter capacitor C 3 form a series arrangement that is coupled across inductor L 2 for developing a rectified output supply voltage Vout in capacitor C 3 forming a charge storage element. A load resistor RL is coupled in parallel with capacitor C 3 and energized by voltage Vout. Voltage Vout is isolated with respect to electrical shock hazard from ground conductor 50 by the high impedance at low frequencies of capacitors C 1 and C 2 .
[0016] An anode of diode D 1 is coupled to a junction terminal 303 between capacitor C 1 and inductor L 1 . A terminal of capacitor C 3 that is remote from a cathode of diode D 1 forms a “cold” ground conductor 51 . Voltage Vout that is referenced to “cold” ground conductor 51 is isolated with respect to electrical shock hazard from ground conductor 50 . A terminal of inductor L 2 that is remote from diode D 1 and a terminal of capacitor C 2 that is remote from resistor Rtrig 2 also are at the reference potential of “cold” ground conductor 51 .
[0017] Capacitors C 1 and C 2 provide ground isolation due to the fact that the capacitors have a high impedance at the relatively low frequency of Vin. However, the capacitors represent a low impedance at the relatively high frequency of operation of switch S 1 , which is at a higher frequency than that of voltage Vin. Switch S 1 is responsive to a control signal 62 from control circuit 3 for selectively opening/closing the connection between terminals 302 and 50 to disable/enable application of the input supply voltage Vin to inductor L 1 . In this manner the switch is operated cyclically at a given frequency f in accordance with the control signal. Capacitors C 1 and C 2 have low impedance with respect to this frequency. For example, capacitors C 1 and C 2 may have a low impedance in relation to operation of switch S 1 at 50 KHz, while providing a high impedance and isolation at an input voltage Vin of, for example, 50 Hz or 60 Hz. Power supply 300 is a self-oscillating power converter, which is optimized for maximum energy transfer at minimum switching loss.
[0018] An operating cycle or a period T of power supply 300 can be divided in three time intervals T 1 , T 2 and T 3 , shown in FIGS. 2 a - 2 f , for a value of inductor L 1 of FIG. 1 equal to twice that of inductor L 2 . Similar symbols and numerals in FIGS. 1 and 2 a - 2 f indicate similar functions or items. FIG. 3 a represents the equivalent circuit to the circuit of FIG. 1 during interval T 1 of FIG. 2 a - 2 f . Similar symbols and numerals in FIGS. 1, 2 a - 2 f and 3 a indicate similar functions or items.
[0019] During interval T 1 of FIGS. 2 a - 2 f , switch S 1 of FIG. 1 is conductive. Capacitors C 1 and C 2 are charged during interval T 2 of FIGS. 2 a - 2 f , as described later on. After closing switch S 1 of FIG. 1 , during interval T 1 of FIGS. 2 a - 2 f , a current IL 1 of FIG. 2 b rises linearly and energy is stored in inductor L 1 of FIG. 1 . At the same time, a current IL 2 of FIG. 2 d in inductor L 2 of FIG. 1 , forming a resonant circuit 305 of FIG. 3 a with capacitors C 1 and C 2 of FIG. 1 , goes negative sinusoidally in a resonant manner and the energy previously stored in capacitors C 1 and C 2 is transferred in a resonance manner to inductor L 2 in the form of current I 2 .
[0020] At the end of interval T 1 of FIGS. 2 a - 2 f , voltage V 2 of FIG. 2 e becomes equal to voltage Vout of FIG. 1 causing diode D 1 to become conductive. Consequently, a sum of voltages in capacitors C 1 and C 2 is clamped to voltage Vout and current I 2 changes abruptly to become zero. Thus, capacitors C 1 and C 2 are discharged to a maximum extent and a voltage V 2 of FIG. 2 e in inductor L 2 of FIG. 1 becomes equal to voltage Vout. At the beginning of interval T 2 of FIGS. 2 a - 2 f , diode D 1 of FIG. 1 is, consequently, conductive. Therefore, the voltage across sensor resistor Rtrig 2 of FIG. 1 approaches zero volts. When the voltage across resistor Rtrig 2 becomes zero, control circuit 301 turns off switch S 1 via signal 62 . Advantageously, by turning switch S 1 on immediately after diode D 1 becomes conductive, the possibility of a “dead time” in the period T of FIGS. 2 a - 2 f , that does not contribute to the throughput via capacitors C 1 and C 2 , is avoided.
[0021] FIG. 3 b represents the equivalent circuit to the circuit of FIG. 1 , during interval T 2 of FIGS. 2 a - 2 f . Similar symbols and numerals in FIGS. 1, 2 a - 2 f and 3 b indicate similar functions or items. During interval T 2 of FIGS. 2 a - 2 f , switch S 1 of FIG. 1 is turned off. Conductive diode D 1 and capacitor C 3 form effectively a negligible low impedance because capacitor C 3 has a much larger value than the other capacitors. Capacitors C 1 and C 2 and Ctrig are charged via inductor L 1 until, at the end of interval T 2 , voltage V 1 of FIG. 2 a reaches a maximum value and current I 2 of FIG. 2 c becomes zero. At this instant almost all energy present in the circuit is stored in capacitors C 1 and C 2 .
[0022] FIG. 3 c represents the equivalent circuit to the circuit of FIG. 1 , during a following interval T 3 of FIGS. 2 a - 2 f . Similar symbols and numerals in FIGS. 1, 2 a - 2 f and 3 c indicate similar functions or items. During interval T 3 of FIGS. 2 a - 2 f , a trigger signal 62 for turning on switch S 1 of FIG. 1 is produced. During interval T 3 of FIGS. 2 a - 2 f , capacitors C 1 and C 2 of FIG. 1 can be neglected since their values are much larger than that of capacitor Ctrig. Capacitor Ctrig forms a parallel resonance circuit 304 of FIG. 3 c with inductors L 1 and L 2 , and a half cycle of oscillation occurs. Voltage V 1 reaches its minimum at the end of interval T 3 and current IL 2 returns to zero. At the end of interval T 3 , a voltage developed across current sampling resistor Rtrig 1 of FIG. 1 changes polarity from negative to positive. This zero crossing transition is sensed and causes control circuit 301 to turn on switch S 1 . Advantageously, the switching losses are negligible, because voltage V 1 is at a minimum. All capacitors are part of a resonant network, which prevents the presence of high dv/dt's, thus ensuring a high efficiency.
[0023] FIG. 4 illustrates a power supply 400 in details that is similar to that of FIG. 1 . Similar symbols and numerals in FIGS. 1, 2 a - 2 f and 3 a- 3 c and 4 indicate similar functions or items.
[0024] Components L 1 , L 2 , C 1 , C 2 , S 1 , D 1 and C 3 of FIG. 4 perform the same functions as in FIG. 1 . Inductor L 2 is tapped in order to transform voltage Vout to lower levels. At the mains connection side an additional line filter 601 is implemented to guaranty the required isolation between the primary and the secondary side. Therefore, the line filter inductor establishes a high asymmetrical attenuation at the operation frequency. The internal drain to source capacitance of transistor switch S 1 is used to perform the function of capacitor Ctrig of FIG. 1 .
[0025] In a first embodiment, power supply 400 of FIG. 4 generates an output power of 25 W with an input voltage of 115V AC. In a second embodiment, power supply 400 of FIG. 4 generates an output power of 100 W with an input voltage of 230V AC. Only switch S 1 and the tap ratio of inductor L 2 are different. The power transferred by power supply 400 is given by: P=Vc12·(the value of capacitor C 1 )·f if the value of capacitor C 2 equal to that of capacitor C 1 , Vc 1 is the voltage across C 1 and “f” is the switching frequency.
[0026] The transformation ratio depends on the ratio of the inductances of inductors L 1 and L 2 and the duration of interval T 3 . This ratio can be increased by providing inductor L 2 with a tap 401 . The converter consists of a power oscillator 401 and a burst mode controller 402 . Oscillator 401 runs at about f=300 kHz. When a comparator IC 2 of burst mode controller 402 senses nominal output voltage, oscillator 401 is turned off by interrupting the power to the oscillator via an opto-coupler IC 1 and a transistor Q 8 . A lower voltage at the output turns it on again. Thus the power supply operates in burst mode. The interval between the bursts varies with input voltage and load. Maximum power output is obtained when the oscillator is continuously on. The relation between efficiency and output power is shown in FIG. 7 .
[0027] A supply voltage 404 of the control circuit is generated by a charge current through a filter capacitor Cmains via a diode D 12 and a capacitor C 7 that forms a capacitive voltage divider with capacitor Cmains. The circuit includes a transistor Q 9 , a transistor Q 10 and a reference voltage diode D 11 that limit the voltage across capacitor C 7 to 20V.
[0028] A transistor Q 7 , a transistor Q 8 , an opto-coupler IC 1 and a comparator IC 2 act as an on/off switch for the supply voltage of oscillator 401 to control the duration of a burst. A resistor R 10 and a diode D 10 enable initial start-up of power oscillator 401 . Transistors Q 7 and Q 8 turn on with a fast rising edge causing switch S 1 to turn on via transistor Q 3 . Transistor Q 6 turns on at the same edge, but because of a time constant of a capacitor C 5 and a resistor R 6 it turns off a few microseconds later. This turns on transistor Q 2 and switch transistor S 1 is switched off. This arrangement is used to guarantee a proper start-up of the oscillator. As a result, interval T 2 of FIGS. 2 a - 2 f is initiated.
[0029] The energy stored in inductor L 1 during the on-time of switch S 1 (analogous to interval T 1 of FIGS. 2 a - 2 f ) charges capacitors C 1 and C 2 of FIG. 4 with a current of sinusoidal shape (similar to current IL 1 of FIG. 2 b ), which flows also through secondary rectifier D 1 of FIG. 1 .
[0030] When switch S 1 becomes non-conductive, the internal drain-source capacitance of the transistor that implements switch S 1 , which acts as capacitor Ctrig of FIG. 1 , is connected in parallel to the series connection of capacitors C 1 and C 2 . When the current through diode D 1 becomes zero, a high frequency resonance circuit including capacitor Ctrig, and inductors L 1 and L 2 operate in a resonance manner. This is analogous to interval T 3 of FIGS. 2 a - 2 f . A current flowing through diodes D 3 , D 4 and D 5 of FIG. 4 keeps transistors Q 4 and Q 5 off during a half cycle of resonant oscillation. As soon as this current changes polarity, transistors Q 4 and Q 5 turn on. Consequently transistor Q 2 turns off and transistor switch S 1 is turned on via transistor Q 3 . Transistors Q 4 and Q 5 act as a current sensor. Transistor Q 4 is kept on by the current through transistor switch S 1 .
[0031] When the energy in capacitors C 1 and C 2 has been transferred to inductor L 2 , the voltage across inductor L 2 reaches a magnitude that causes secondary diode D 1 to turn on and the current in capacitor C 2 , for example, ceases. The current through switch S 1 and inductor L 1 flows through diode D 6 instead of through capacitor C 2 and turns on transistor Q 2 . Thus, diode D 6 and transistor Q 2 form a current sensor for turning transistor switch S 1 off. The procedure will repeat itself as described until burst mode controller 402 turns off the supply of oscillator 401 .
[0032] FIGS. 5 a , 5 b and 5 c show waveforms associated with the operation of the power supply shown in FIG. 4 for load resistor RL equal to 7.5 Ohm; whereas, FIGS. 6 a , 6 b and 6 c show waveforms associated with the operation of the power supply shown in FIG. 4 for a higher load formed by resistor RL equal to 1 Ohm. Similar symbols and numerals in FIGS. 1, 2 a - 2 f , 3 a - 3 c , 4 , 5 a - 5 c and 6 a - 6 c indicate similar functions or items.
[0033] If oscillator 401 operates continuously and not in burst mode, and the load, not shown, increases still further as a result of a fault condition, output voltage Vout will drop. As a result, interval T 1 of FIGS. 2 a - 2 f increases, the oscillator 401 frequency decreases and the level of voltage V 1 of FIG. 6 c will be lower than before at the beginning of interval T 3 of FIGS. 2 a - 2 f . In this way the amount of transferred energy, advantageously, decreases significantly. This tendency remains until the short-circuit condition is reached. Thus the circuit protects itself against overload.
[0034] Power supply 400 of FIG. 4 also guarantees a soft start-up. Interval T 1 of FIGS. 2 a - 2 f decreases gradually and likewise the frequency and the transferred energy increase until the required level of output voltage Vout is reached. As shown in FIGS. 4 and 8 , a line filter 600 is provided for RFI suppression and safety. The filter inductor 601 of FIG. 4 establishes a high symmetrical attenuation at the operating frequency of oscillator 401 . An inductor of 20 mH fulfils the required attenuation up to 50 W. During experiments, a considerable temperature increase of the capacitors C 1 and C 2 was observed. The selection of the proper type and construction of these capacitors is important. If capacitors C 1 and C 2 are selected with a negative temperature coefficient, some inherent safety is provided, because the amount of transferred power and the temperature decrease with the capacitor value. | A power supply includes a supply inductor and a first capacitor coupled to form a resonant circuit to generate a resonant waveform in a resonant operation, during a first portion of an operation cycle of the power supply. A charge storage element develops an output voltage to energize a load. A rectifier is coupled to the charge storage element and to the resonant circuit and is responsive to the resonant waveform for applying the output voltage back to the resonant circuit to interrupt the resonant operation, at an end time of the operation cycle first portion, when the resonant waveform produces a first change of state in the rectifier. A first sensor senses when the first change of state in the rectifier occurs. A source of a supply current is coupled to the rectifier and rectified in the rectifier to produce a rectified current that is coupled to the charge storage element to replenish a charge therein, during a second portion of the operation cycle. A switching transistor is responsive to an output signal of the first sensor for enabling the supply current to be coupled to the rectifier, during the operation cycle second portion, and for disabling the supply current from being coupled to the rectifier, during the operation cycle first portion. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a surgical saw blade fastening means and more specifically to a combination of a saw blade and chuck assembly for use on a powered reciprocating surgical instrument.
Prior art surgical saw blades have almost universally consisted of a shank portion and a blade portion formed from separate stock and secured to the shank portion by suitable means such as by brazing. The shank portion of such blades have usually been cylindrical with a flat provided thereon for locking engagement by a set-screw on the surgical instrument into which the shank is inserted. Replacement of such blades, of course, requires that the set-screw be loosened to permit the shank to be withdrawn. Also, discarding of such blades when dulled meant that the shank was also discarded.
U.S. Pat. No. 2,951,482, issued Sept. 6, 1960, discloses a surgical saw blade for a hand saw having a generally rectangularly shaped shank portion which fits into a slotted stem of a chuck and is clamped therein by the action of a threaded collar being threaded onto the bifurcated stem.
U.S. Pat. No. 3,041,724, issued July 3, 1962, relates to a hand extension tool for non-surgical uses and comprises a plurality of elongated tool elements divided by transverse score lines so that when a working surface such as a knife edge has been worn it can be broken off and a new working surface exposed. The upper longitudinal edge of the tool elements is threaded over its entire length and the opposite (lower) longitudinal edge is threaded at spaced locations along its length with working surfaces provided between the threaded portions. The threads are engaged by a nut rotatably mounted within one end of the handle. The tool element is prevented from rotation within the handle by a slotted cylindrical member fixed to the handle.
Although the foregoing patents show that prior workers have not been unaware of the desirability of having a tool wherein blades could be changed without the use of additional tools, so far as is known, no one has addressed the problem as it relates to a powered reciprocating instrument and particularly a surgical instrument for use on living bone and its attendant critical requirements.
SUMMARY OF THE INVENTION
The surgical saw blade fastening means of the present invention comprises a combination of a surgical saw blade and a chuck assembly providing for quick and simple yet positive attachment of the saw blade to the power source without the use of additional tools.
A typical power source for a surgical saw reciprocates the saw blade at a frequency of approximately 20,000 reciprocations per minute with a stroke of about 0.10 inch. It is, therefore, imperative that the blade be securely held in place to prevent wobbling and levering of the blade during use. Any degree of wobbling would be greatly aggravated by the short rapid reciprocating action of the power source and such wobbling would be particularly intolerable in a surgical procedure involving living bone and surrounding tissue.
The surgical saw blade of the present invention which is used for sectioning bone in a surgical procedure is greatly simplified when compared to those of the prior art and comprises a relatively thin planar blade member having a plurality of cutting teeth formed on an edge of said blade member, the other edge of the blade member being curved adjacent one end thereof to form a generally pointed relatively blunt front or leading end. The rear or trailing end of the blade is provided with locating and locking means in the form of a V-shaped notch which, in cooperation with the chuck assembly, securely attaches the blade to a suitable power source.
The chuck assembly comprises a shank portion adapted for attachment to a surgical instrument in the conventional manner and a body portion provided with at least one axial slot therein to accept the rear or trailing end of the saw blade therein. The base of the slot is provided with locating and locking means comprising a pyramidal taper complementary to the V-shaped notch in the blade. The end of the body portion remote from the shank, hereinafter referred to as the forward end, is formed as an enlarged truncated cone segment oriented with the taper directed toward the shank portion. An internally threaded collar slidably fits over the body portion and is prevented from sliding off said body portion by the enlarged cone segment. The collar is provided with an internal shoulder engageable with the tapered cone segment of the forward end of the body portion and serves as a stop. The threads of the collar engage the teeth of the saw blade, which preferably have no set at the trailing edge for a distance substantially equal to the depth of the slot in said body portion, such that tightening of the collar onto the blade draws the blade into the body portion until the V-shaped notch in the blade engages and is firmly seated on the pyramidal taper at the slot base. Tightening of the collar also urges the collar onto and against the tapered cone segment whereby the saw blade is clamped by the opposed halves of the body portion.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings which illustrate the invention:
FIG. 1 is an exploded view of the saw blade fastening means of the present invention; and
FIG. 2 is an enlarged sectional view through the saw blade fastening means in its assembled condition.
DETAILED DESCRIPTION OF THE INVENTION
Referring particularly to the drawings, 10 denotes a surgical saw blade about 30 to 40 mils thick formed from 17-7 PH stainless steel stock and heat treated to 45-48 on the Rockwell C scale to withstand repeated steam sterilization. The blade is provided with sharp cutting teeth 11 along one edge thereof. The teeth 11 are normally set such that the outer edges of two adjoining teeth are inclined in opposite directions to provide for greater cutting efficiency. It is preferred that the teeth adjacent the trailing end 12 of the blade have no set for a distance equal to the length of the collar 25 on the chuck assembly 15. The other edge of blade 10 is curved adjacent the leading end 13 to form a smoothly pointed relatively blunt front or leading end. The blade may, of course, have a sharply pointed or a more rounded front or leading end as desired. The trailing end 12 of the blade 10 is provided with a V-shaped notch 14 with the apex of the "V" bisecting the midline of blade 10. The sides of the "V" are each inclined at an angle of 45° to the midline of the blade. The depth of the V-shaped notch is about 0.075 inch and its width at the open end is about 0.15 inch.
The chuck assembly 15, formed of 416 stainless steel heat treated to 28-30 on the Rockwell C scale, comprises a shank portion 16 and a body portion 18. The shank portion 16 is formed as a cylindrical rod about 0.625 inch long and 0.155 inch in diameter with an approximately 0.25 inch long flat 17 provided thereon at its junction with the body portion 18 for locking engagement by a set-screw on the surgical instrument (not shown) into which the shank portion 16 is inserted.
The body portion 18 is also a cylindrical rodlike member having a length of about 1.05 inch and a diameter of 0.26 inch. The forward end 19 is in the form of an enlarged truncated cone segment tapering toward the shank portion of the body. As will be clearly seen in FIG. 1, body portion 18 is axially slotted for approximately half its length by slots 20 which are perpendicular to each other and have a width sufficient to freely accept saw blade 10 therewithin. The base of the slots 20 terminates in a pyramid 21 located such that the apex 22 is at the point of intersection of the slots 20 and is directed toward the open end of said slots. The sides of the pyramid 21 are inclined at an angle of 45° and thus are complementary to the V-shaped notch 14 in the trailing end 12 of blade 10.
Body portion 18 is transversely circumferentially grooved at a point substantially at the apex 22 of the pyramid 21. This transverse groove 23, formed by removing stock from the body portion, makes it possible to more easily compress the segmented forward end 19 when pressure is applied circumferentially to the segments by collar 25.
Body portion 18 is provided with a second transverse circumferential groove 24 at a point spaced from the truncated cone segment a distance sufficient to permit collar 25 to be loosely retained on body portion 18 by a retaining ring (not shown) fitting within groove 24.
Collar 25, formed from 440C stainless steel heat treated to 58-60 on the Rockwell C scale, is provided with internal threads 26 whose lands and grooves engage the lands and grooves of the teeth 11 of blade 10. In order to function effectively and permit repeated fastening cycles under use conditions, it has been found that collar 25 should be formed of a harder alloy than saw blade 10. Tests have shown that collars formed of materials of equivalent or lesser hardness than that of the saw blades could not be readily unfastened without the use of an auxiliary tool while those which were fabricated from harder materials performed without incident in the intended manner through repeated cycles. The exterior surface of collar 25 is knurled or otherwise patterned to provide a slip resistant gripping surface 27.
In a typical surgical procedure involving sectioning of bone, the surgeon would utilize a surgical saw powered by a hand-held air driver unit. Attached to the air driver, as an interchangeable accessory attachment, is a reciprocating saw attachment which translates the normal rotational motion of the air driver to the reciprocating motion required for sawing through bone. These attachments produce about 20,000 reciprocations per minute with a stroke of about 0.10 inch.
The surgical saw blade fastening means of the present invention would be securely fastened onto the reciprocating saw attachment by inserting shank 16 of chuck assembly 15 into a socket provided and tightening a set-screw onto the flat 17, in the usual manner.
With collar 25 loosely retained on body portion 18 of chuck assembly 15, a saw blade 10 is inserted into one of the axial slots 20 until the first of teeth 11 contacts the first thread 26 of collar 25. At this point tightening collar 25 by grasping same by the slip resistant gripping surface 27 and turning collar 25 to the right will cause blade 10 to be pulled further into slot 20 until V-shaped notch 14 is firmly seated on pyramid 21. At about the same time, collar 25 would be pulled forwardly onto truncated cone segment 19 thereby compressing the body portions on either side of slot 20 onto saw blade 10 to firmly clamp the saw blade 10 in position.
During such surgical procedures, it is frequently necessary to change saw blades or the position thereof in the chuck assembly. In such event, the above-noted procedure for inserting a surgical saw blade 10 is simply reversed and the position of the blade can then be changed to any of three other positions or a new blade inserted, all without the use of any additional hand tools as would be required for a conventional prior art saw blade having a shank brazed to the blade itself and where the shank is held firmly in place by a set-screw.
While the surgical saw blade fastening means of the present invention has been described herein as having certain shapes and dimensions and being formed of specific materials, it is to be understood that such recitations are exemplary and various modifications are possible and are contemplated. For example, surgical saw blades are presently offered in off-set configurations and in different lengths and thicknesses and these variants are contemplated. Similarly, other stainless steels and alloys which can withstand repeated steam sterilization cycles can be utilized. Also, although the chuck assembly 15 has been described as having two axial slots 20 intersecting at right angles so that the saw blade can be positioned in any of four positions at 90° intervals, other slot arrangements can be utilized to provide for other positioning options. | A surgical saw blade fastening means comprising a saw blade and chuck wich provides for positive locking of the blade while permitting rapid removal of the saw blade without the use of additional tools is disclosed. The chuck which is provided with an adapter portion so it can be attached to surgical instruments presently in use comprises a slotted body portion having a pyramid locator at the base of the slots into which the notched end of a saw blade is seated by the action of a knurled internally threaded collar carried on said chuck body in cooperation with the teeth of the saw blade. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a storage container for a dental adhesive used for treatment of dental caries in dentistry.
[0003] 2. Description of the Related Art
[0004] “Tooth decay” generally called dental caries is a common disease in dentistry, and many people experience tooth decay regardless of age or sex. When tooth decay advances, the tooth decay does not naturally heal but needs to be treated by a dentist. A widely used method for the treatment is to shave a tooth decay portion down with a dental grinding tool to form a cavity, fill a dental restoratives such as composite resin into the cavity, and reproduce natural tooth anatomy. The composite resin is mainly classified into chemical polymerization resin and photo polymerization resin by a difference in curing method, and these resins are used for different applications.
[0005] The composite resin cannot adhere to teeth substance by itself, and requires a dental adhesive applied between the composite resin and the teeth substance. In recent years, technical developments in the field of dental adhesives have been rapidly made, and firm adhesion to adherend such as metal, ceramic, or composite resin has been achieved in addition to firm adhesion to the teeth substance. Conventionally, a plurality of steps such as etching, priming, and bonding are required during use of an adhesive. Liquid materials such as adhesives stored in storage containers for the respective steps are dropped onto different wells on a dish, and applied to an application site in order according to a procedure. However, driven by users' needs for a simplified operation procedure and a stable adhesive property, a self-etching primer used in a combined step of etching and priming, and an all-in-one adhesive used in a combined step of etching, priming, and bonding have been developed to improve operability and an adhesive property and reduce the number of storage containers for storing liquid materials. However, the all-in-one adhesive or the like does not totally replace, but a two liquid mixing type adhesive used by dropping desired amounts of liquid materials from two storage containers in order onto the same well on a dish so as to contact with each other and mixing the liquid materials has been also widely used.
[0006] A trace amount of dental adhesive is applied at one time, and thus too large an amount of drops from a storage container increase an amount of waste and thus increase cost. Thus, to reliably control a trace amount of drops, a shape or a diameter of a discharge port of a nozzle located at a distal end of the container, and a length and a hole diameter of a channel connecting to the nozzle are strictly controlled. Particularly, more strict control is performed for achieving designed performance with a two liquid mixing type adhesive because amounts of drops of adhesives and a mixing ratio thereof are important. Since a trace amount of adhesive is applied at one time as described above and also there is an expiration date, a storage container for the adhesive is naturally small, and a height from a bottom to a cap is 5 cm maximum. Thus, to drop the adhesive onto a dish, the storage container is generally turned downward and pressed at side surfaces by a thumb and an index finger holding the side surfaces. This pressing operation is generally called “squeeze”.
SUMMARY OF THE INVENTION
[0007] As described above, technical developments of adhesives have been rapidly made, and composition of adhesives has been changed. The composition of adhesives has been shifting to low viscosity composition including water or a volatile solvent as a main ingredient for increased wettability or permeability to an application site and reliable drying after application. Thus, with the conventional dropping manner to press the side surfaces of the container with the thumb and the index finger, surface tension of an adhesive is low, and the adhesive may flow out by itself and naturally drops onto a place other than the dish when the storage container is tilted. Also, when the storage container is pressed, an error in an amount of drops beyond an acceptable range may occur according to a slight difference in a level of force. As such, the conventional dropping manner does not match the actual situation with the shifting composition of adhesives, and is unsuitable for fine dropping work due to insufficient stability of a dropping operation and an amount of drops.
[0008] Also, a position of the storage container during squeeze differs depending on dentists' preferences. For example, the nozzle is turned substantially downward or turned substantially horizontally. Such a change in the position changes a positional relationship between a liquid level in the container and a discharge port. This causes variations in the amount of drops, leading to a case where the adhesive is dropped more than necessary. For the two liquid mixing type adhesive, an accurate mixing ratio cannot be maintained.
[0009] Further, a dental adhesive needs to be stored in a refrigerator to maintain its quality. The adhesive is left at room temperature before use, and actually used after reaching room temperature. When a storage container thus taken out of the refrigerator is handled, body heat from fingers is transferred via the storage container to the adhesive. Thus, a volatile solvent contained in the adhesive may expand, and a phenomenon unexpected to a user may occur such that the adhesive spouts from a distal end of a nozzle when a cap is removed, or the adhesive continuously drops from the distal end of the nozzle during dropping. A technique as disclosed in Japanese Patent No. 3572158 has been developed to prevent a temperature increase by heat transfer from fingers in such a dropping operation process. The technique relates to a container having a double structure, and an air layer is formed between an outer container and an inner container to prevent heat transfer from fingers, thereby preventing expansion of an adhesive stored in a storage container caused by a temperature change.
[0010] The present invention is achieved in view of such circumstances, and has an object to provide a storage container for a dental adhesive that allows a stable dropping operation during use of a dental adhesive and smooth fine dropping work such as strict control of an amount of drops with high reproducibility, and can prevent expansion of an adhesive stored in the storage container caused by a temperature increase.
[0011] To solve the above described problems, the invention according to claim 1 provides a storage container for a dental adhesive, including an elongated container portion that can store a liquid therein, wherein one end surface of the container portion has a discharge port communicating with an outside, the other end surface of the container portion is closed by a bottom wall, and a tail portion is formed protruding from the bottom wall to the side opposite from the discharge port.
[0012] The storage container according to the present invention is intended for supplying a dental adhesive to a dentist or the like, and is not used in a production stage. The container portion as a component of the storage container is a hollow portion for storing various liquids used in a series of adhesive steps such as etching, priming, and bonding, and has an elongated cylindrical shape with reliable sealability, but may have any sectional shape such as a circular shape or a square or hexagonal shape. The discharge port has a function of discharging the liquid stored in the container portion to the outside, and is provided in the one end surface of the container portion. The discharge port does not always need to be integrally formed with the container portion, but may be incorporated into the container portion using a plug having a discharge port. Both cases require a separate removable cap for closing the discharge port.
[0013] The one end surface of the container portion thus has the discharge port, and the opposite side has the bottom wall for sealing the inside of the container portion. In the present invention, the tail portion is formed protruding from the bottom wall to the side opposite from the discharge port. The tail portion may be integrally formed with the container portion, or may be separately fabricated and joined to the container portion. The tail portion preferably has an integrated shape without a step or the like at a boundary between the tail portion and the container portion, and may further have a tapered end for good appearance. The tail portion merely protrudes from the bottom wall of the container portion, and cannot store the liquid therein. Forming the tail portion can increase an entire length of the storage container without increasing the content, and allows the container to be supported by a thumb and an index finger and also by a side of a middle finger and a base of the index finger like a writing instrument such as a pencil during use, thereby increasing stability. In the present invention, the container portion, the discharge port, and the tail portion are all made of resin, but a detailed material is not limited.
[0014] In the invention according to claim 2 , a shape of the storage container is limited, and a length between the discharge port and an end surface of the tail portion is 8 to 15 cm. This length refers to a linear distance between a distal end of the discharge port and a rear end surface of the tail portion with the cap being removed. The length is thus limited, and the tail portion comes into contact with the base of the index finger when a portion near the discharge port is held by the thumb and the index finger, thereby increasing stability. Also, the length is not too long, thereby providing easy handling and high operability. With a length of less than 8 cm, the tail portion does not come into contact with the base of the index finger in some cases, thereby preventing convenience offered by the present invention from being obtained.
[0015] In the invention according to claim 3 , an outer container surrounding an outer periphery of the container portion is further provided, and the tail portion is formed to extend in a longitudinal direction of the outer container. The outer container surrounds the outside of the container portion, and in the present invention, the outer container is formed to extend in the longitudinal direction so as to have a function of the tail portion. Thus, the outer container according to the present invention is longer than the container portion, and protrudes rearward beyond the bottom wall. The outer container also functions as a heat insulating material for reducing temperature changes of the liquid stored in the container portion. It is not always necessary to ensure an air layer between the container portion and the outer container, but the both may entirely come into contact with each other. However, it is necessary that pressing the outer container deforms the container portion to allow the liquid therein to be reliably dropped.
[0016] In the invention according to claim 4 , the shape of the outer container is limited, and a slit is formed in the longitudinal direction in a side surface of the outer container. The slit is formed by cutting the side surface of the outer container in the longitudinal direction, and with one line of slit, the outer container has a C-shaped cross section. Thus, when the side surface of the outer container is pressed, the outer container is easily deformed so as to reduce an inner diameter thereof, thereby allowing the container portion in contact with the inside of the outer container to be easily pressed, and allowing the liquid to be smoothly discharged. Particularly, when a thickness of the outer container is increased for increasing a heat insulating property or gripping feeling, rigidity of the outer container is necessarily increased to provide a noticeable advantage of the slit.
[0017] The slit is basically formed in the longitudinal direction of the storage container, but may be slightly oblique. The slit is formed to connect both end surfaces of the outer container so that the entire outer container has a C-shaped section. Alternatively, the slit may be formed in a region only overlapping the container portion, and a remaining region may have no slit so that the outer container in the remaining region has an annular section. When the slit is thus formed in a limited region, two or more lines of slits may be formed, thereby further increasing flexibility.
[0018] As in the invention according to claim 1 , the tail portion protruding to the side opposite from the discharge port is provided in addition to the container portion for storing the liquid such as the adhesive. Thus, the portion near the discharge port can be supported by the thumb and the index finger, and also the tail portion of the storage container can be supported by the base of the index finger during use. Thus, the storage container of the present invention can be held at three or more points like when a writing instrument such as a pencil is held, thereby providing high stability of a holding state during a dropping operation. This stabilizes squeeze during dropping, thereby allowing a minimum necessary amount of liquid to be accurately and quickly dropped, allowing a minimum amount of liquid to remain on a dish after treatment, and reducing cost.
[0019] The position of the conventional storage container during use differs depending on dentists' preferences, and this causes variations in the amount of drops. In the present invention, the storage container is naturally fixedly held like when a writing instrument is held, and this always provides a stable position and a constant amount of drops. Also, the operation can be performed in a natural position like when a writing instrument is handled, thereby achieving a smooth and quick dropping operation, and preventing a temperature increase of the liquid in the storage container caused by heat transfer. Further, a two liquid mixing type adhesive requires an accurate and strict amount of drops for achieving an original adhesive property. In the present invention, as described above, the adhesive can be quickly and smoothly dropped with the same feeling as when a writing instrument is handled, a mixing ratio of liquids to be dropped can be accurately controlled, a predetermined adhesive property can be achieved, and a working time can be reduced. The tail portion in the present invention does not have a function of storing the adhesive, and thus the content and control of an expiration date are the same as in the conventional storage container.
[0020] As in the invention according to claim 2 , the entire length of the storage container is limited, and the portion near the discharge port of the storage container is held by the thumb and the index finger during use, the tail portion of the storage container naturally comes into contact with the base of the index finger, thereby reliably providing the advantage of the invention in claim 1 . Also, the length is not too long, thereby providing high operability and easy storage.
[0021] As in the invention according to claim 3 , the outer container is provided separately from the container portion for storing the liquid, and the one end of the outer container is protruded to form the tail portion. This achieves the same operability as a writing instrument as in the invention according to claim 1 . Also, the double structure including the container portion and the outer container increases a heat insulating property, thereby preventing rapid expansion of a volatile liquid, and preventing the liquid from dropping in an unexpected situation. As in the invention according to claim 4 , the slit is provided in the outer container to reduce rigidity of the outer container, and thus light pressing of the outer container allows a desired amount of liquid to be dropped.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1A and 1B show a shape example of a storage container according to the present invention, FIG. 1A is a perspective view of an appearance, and FIG. 1B is a vertical sectional view of a central portion;
[0023] FIGS. 2A , 2 B, 2 C and 2 D show details of the storage container in FIG. 1 , FIG. 2A is a side view, FIG. 2B is an end view taken along the line B-B in FIG. 2A , FIG. 2C is an end view taken along the line C-C in FIG. 2A , and FIG. 2D is a vertical sectional view with components being separated;
[0024] FIGS. 3A , 3 B, 3 C and 3 D show a storage container having a different structure from the storage container in FIG. 1 , FIG. 3A is a side view, FIG. 3B is an end view taken along the line B-B in FIG. 3A , FIG. 3C is an end view taken along the line C-C in FIG. 3A , and FIG. 3D is a vertical sectional view;
[0025] FIGS. 4A and 4B are vertical sectional views of storage containers including a container portion and a tail portion integrally formed unlike the storage container in FIG. 1 or the like, FIG. 4A shows a storage container with a hollow tail portion, and FIG. 4B shows a storage container with a solid tail portion;
[0026] FIGS. 5A , 5 B, 5 C and 5 D show a shape example of a storage container, FIG. 5A is a side view, FIG. 5B is an end view taken along the line B-B in FIG. 5A , FIG. 5C is an end view taken along the line C-C in FIG. 5A , and FIG. 5D is a perspective view of an outer container only; and
[0027] FIG. 6 is a perspective view of a state of use of the storage container according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] FIG. 1 shows a shape example of a storage container 10 a according to the present invention, FIG. 1A shows an appearance, and FIG. 1B is a vertical sectional view of a central portion. The storage container 10 a according to the present invention is in the shape of a rod having a substantially circular section, and includes therein a container portion 11 for storing various liquids used in a series of adhesive steps such as etching, priming, and bonding, and a discharge port 12 for dropping the liquids in a left end surface in FIG. 1 . A side peripheral surface of the container portion 11 is covered with an outer container 21 , and a right end of the outer container 21 is tapered into a conical shape. The discharge port 12 is formed in a distal end of a plug 31 produced separately from the container portion 11 , and a cap 36 is threaded on the plug 31 to seal the inside of discharge port 12 . Thus, threaded portions 34 are formed on an outer periphery of the plug 31 and an inner periphery of the cap 36 . The container portion 11 and the outer container 21 are made of relatively soft polypropylene resin, and the plug 31 and the cap 36 are made of harder polyethylene terephthalate resin for ensuring sealability.
[0029] The container portion 11 has a simple cylindrical shape, and absolutely requires sealability for storing the liquid therein. A left end of the container portion 11 is press fitted in the plug 31 , and a right end is closed by a bottom wall 14 integrally formed. The outer container 21 does not require sealability, a slit 25 extending in a longitudinal direction is formed in a side peripheral surface, and a right end surface is not closed and opened in a circular shape. Thus, the outer container 21 entirely has a C-shaped cross section with the slit 25 , and is elastically deformed to reduce a space of the slit 25 when the side peripheral surface is pressed by fingers or the like. A ridge 22 extending in the longitudinal direction is formed on an inner peripheral surface of the outer container 21 , and a top portion of the ridge 22 comes into contact with the side peripheral surface of the container portion 11 . Thus, when the outer container 21 is pressed, the container portion 11 is squeezed to allow the liquid therein to be dropped from the discharge port 12 .
[0030] As shown in FIG. 1B , the outer container 21 significantly protrudes to the right beyond the bottom wall 14 of the container portion 11 . Such a portion protruding rearward beyond the bottom wall 14 of the container portion 11 for storing the liquid is defined as a tail portion 13 in the present invention. The tail portion 13 has no function of storing the liquid, and is a portion intended for easier carrying. The left end surface of the outer container 21 comes into contact with a flange 32 formed on the plug 31 , and is integrated with the plug 31 so as not to be removed. Further, a rear pawl 24 is formed at a right end of the ridge 22 on the inner peripheral surface of the outer container 21 , and presses the container portion 11 against the plug 31 .
[0031] FIG. 2 shows details of the storage container 10 a in FIG. 1 , FIG. 2A is a side view, FIG. 2B is an end view taken along the line B-B in FIG. 2A , FIG. 2C is an end view taken along the line C-C in FIG. 2A , and FIG. 2D is a vertical sectional view with components being separated. As shown in FIG. 2A , the storage container 10 a according to the present invention has an elongated shape like a pencil, and one line of slit 25 extending in the longitudinal direction is formed in the outer container 21 surrounding the container portion 11 . As in the end surface views in FIGS. 2B and 2C , the outer container 21 has a C-shaped section and a total of six lines of ridges 22 . The outer container 21 comes into contact with the container portion 11 via the ridges 22 , and an air layer is formed in places other than the ridges 22 to ensure a heat insulating property.
[0032] Further, as shown in FIG. 2D , the plug 31 and the cap 36 are removable with the threaded portions 34 formed on both thereof. The plug 31 and the outer container 21 are integrated by a groove 33 formed in the outer peripheral surface of the plug 31 meshing with a front pawl 23 formed on the inner peripheral surface of the outer container 21 . Further, the rear pawl 24 protruding toward the center is formed at a right end of each ridge 22 on the inner peripheral surface of the outer container 21 for restraining a bottom wall 14 of the container portion 11 .
[0033] FIG. 3 show a storage container 10 b having a different structure from the storage container in FIG. 1 , FIG. 3A is a side view, FIG. 3B is an end view taken along the line B-B in FIG. 3A , FIG. 3C is an end view taken along the line C-C in FIG. 3A , and FIG. 3D is a vertical sectional view. This structure includes the same container portion 11 , plug 31 and cap 36 as in FIG. 1 . An outer container 21 has a slit 25 , but does not have ridges 22 on an inner peripheral surface thereof, and the entire inner peripheral surface of the outer container 21 except the slit 25 comes into contact with the container portion 11 . This can simplify the shape of the outer container 21 , and achieve a heat insulating property by ensuring a sufficient thickness of the outer container 21 . A tail portion 13 of the outer container 21 in FIG. 3 is shorter than the tail portion 13 in FIG. 1B , but similarly protrudes to the right beyond a bottom wall 14 of the container portion 11 . As such, the detailed shape of the outer container 21 may be freely decided on the basis of a size or a material.
[0034] FIG. 4 are vertical sectional views of storage containers 10 c and 10 d including a container portion 11 and a tail portion 13 integrally formed unlike the storage container in FIG. 1 or the like, FIG. 4A shows a storage container with a hollow tail portion 13 , and FIG. 4B shows a storage container with a solid tail portion 13 . In the present invention, an outer container 21 is not always necessary as long as the tail portion 13 is formed. Thus, the tail portion 13 may be integrally formed with the container portion 11 for storing a liquid to simplify a structure. With such an integral structure, the tail portion 13 refers to a region rearward of the bottom wall 14 where the liquid cannot be stored, but a simply thickened bottom wall 14 of the container portion 11 is not regarded as a tail portion 13 . In FIG. 4 , a component corresponding to the plug 31 as in FIG. 1 is not included, and a discharge port 12 is formed at a left end of the container portion 11 . As such, the shape around the discharge port 12 can be freely decided without any limitation.
[0035] FIG. 5 shows a shape example of a further storage container 10 e , FIG. 5A is a side view, FIG. 5B is an end view taken along the line B-B in FIG. 5A , FIG. 5C is an end view taken along the line C-C in FIG. 5A , and FIG. 5D shows a shape of an outer container 21 only. This structure also includes the same container portion 11 , plug 31 , and cap 36 as in FIG. 1 . The outer container 21 similarly has a total of six lines of ridges 22 on an inner peripheral surface thereof, but two lines of slits 25 are formed on opposite sides to increase deformability of the outer container 21 and allow more reliable pressing of the container portion 11 . Since the two lines of slits 25 are formed, a forming range of the slits 25 is limited so as not to divide the outer container 21 .
[0036] FIG. 6 shows a state of use of the storage container 10 a according to the present invention. As such, the storage container 10 a according to the present invention has an appearance like a pencil by a combined use of the tail portion 13 . Thus, as shown in FIG. 6 , like when a pencil is held, a distal end of the storage container 10 a is held by a thumb and an index finger, and then the side peripheral surface is restrained by a middle finger. Further, the tail portion 13 can be supported by a base of the index finger, thereby providing good gripping feeling and allowing handling as desired. Further, the storage container 10 a according to the present invention provides high stability of a holding state and a dropping angle during liquid dropping. This also stabilizes a squeeze operation during dropping, thereby allowing a strict desired amount of liquid to be quickly dropped, and preventing a temperature increase caused by heat transfer to the liquid stored in the storage container 10 a. | There is provided a storage container for a dental adhesive that allows a stable dropping operation during use of a dental adhesive and smooth fine dropping work such as strict control of an amount of drops with high reproducibility, and can prevent expansion of an adhesive stored in the storage container caused by a temperature increase. A storage container for a dental adhesive is used, including a cylindrical container portion that can store a liquid such as an adhesive therein, wherein one end surface of the container portion has a discharge port communicating with an outside, the other end surface of the container portion is closed by a bottom wall, and a tail portion is formed protruding from the bottom wall to the side opposite from the discharge port. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 11/212,987, filed Aug. 25, 2005, which will issue as U.S. Pat. No. 7,164,595, on Jan. 16, 2007, the disclosure of which is hereby incorporated herein by this reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention: The present invention relates generally to memory cells, arrays and devices and, in particular, to improvement of a refresh margin in a DRAM memory device.
State of the Art: Memory devices are typically provided as internal storage areas in a computer. There are several different types of memory, one of which is known as random access memory (RAM) that is typically used as main memory in a computer environment. Most RAM is volatile, meaning it requires a periodic regeneration of stored electrical charge to maintain its contents. A dynamic random access memory (DRAM) is a type of RAM that is made up of cells wherein each cell or bit includes one or more transistors and capacitors. A cell is capable of storing information in the form of a “1” or “0” bit as an electrical charge on the capacitor. Since a capacitor will lose its charge over time, a memory device incorporating a DRAM cell must include logic to refresh or recharge the capacitors of the cells on a periodic basis. Otherwise, the information stored therein will fade and be lost. One form of refreshing or recharging the capacitor is performed by reading the stored data in a memory cell and then writing the data back into the cell at a predefined voltage level, causing the information to be stored for a temporary period of time.
More specifically, a conventional 2T DRAM array 10 shown in FIG. 1 stores digital information in the form of “1” and “0” bits by storing the bits as electric charges on storage capacitors 38 , 40 in a first memory cell and capacitors 48 , 50 in a second memory cell as arranged along wordlines WL 0 56 and WL 1 58 . For clarity, a single 2T memory cell 20 is depicted in an upper portion of the array and is shown to include two capacitors (2C) and two transistors (2T) and is coupled to a sense amplifier 24 when isolation gates 30 , 32 are activated by a sense amp isolation signal 26 . Furthermore, while DRAM array 10 is illustrated as including only eight memory cells in order to simplify description, the DRAM array 10 typically includes thousands or millions of memory cells.
The DRAM array 10 stores a “1” bit in an exemplary memory cell, for example, the memory cell comprised of pass transistor 36 , storage capacitors 38 , 40 and pass transistor 42 , by initially energizing the wordline WL 0 56 to activate the pass transistors 36 , 42 . The DRAM array 10 then applies a “1” bit voltage equal to a supply voltage V cc (e.g., 3.3 volts) to the true D 0 digit line 16 , causing current to flow from the digit line 16 via connection 54 through the activated pass transistor 36 and the storage capacitor 38 to a cell plate voltage 34 . As the current flows, the storage capacitor 38 stores positive electric charge received from the digit line 16 , causing a voltage on the storage capacitor 38 to increase. When the voltage on the storage capacitor 38 equals the “1” bit voltage on the digit line 16 , current stops flowing through the storage capacitor 38 . Similarly, energizing the wordline WL 0 56 also activates the pass transistor 42 . The DRAM array 10 then applies a “0” bit voltage equal to V ss (e.g., 0 volts) to the complementary D 0 * digit line 18 causing current to flow from the cell plate voltage 34 to the storage capacitor 40 . As the current flows, the storage capacitor 40 stores positive electric charge received from the cell plate voltage 34 . A short time later, the DRAM array 10 deenergizes the wordline WL 0 56 to deactivate the pass transistors 36 , 42 and isolate the storage capacitors 38 , 40 from the digit lines 16 , 18 , thereby preventing the positive electric charge stored on the storage capacitors 38 , 40 from discharging back to the digit lines 16 , 18 .
Similarly, the DRAM array 10 stores a “0” bit in a memory cell, for example, by energizing the wordline WL 0 56 to activate the pass transistors 36 , 42 and applies a “0” bit voltage approximately equal to a reference voltage V ss (e.g., 0.0 volts) to the digit line 16 , causing current to flow from the cell plate voltage 34 to the storage capacitor 38 and the activated pass transistor 36 and to the true D 0 digit line 16 . As the current flows, storage capacitor 38 stores electric charge received from the cell plate voltage 34 causing the cell plate voltage 34 to be stored in a negative polarity in capacitor 38 . Similarly, the pass transistor 42 is also activated and causes the “1” bit voltage on complementary D 0 * digit line 18 to flow through pass transistor 42 and be stored in a negative polarity in storage capacitor 40 . The voltage stored across storage capacitor 40 is approximately equal to the supply voltage V cc minus the cell plate voltage 34 . When the voltage across storage capacitors 38 , 40 stabilizes, current stops flowing through the storage capacitors 38 , 40 and a short time later the DRAM array 10 deenergizes the wordline WL 0 56 to deactivate the pass transistors 36 , 42 and isolate the storage capacitors 38 , 40 from the digit lines 16 , 18 , thereby preventing the stored electrical charge on the storage capacitors 38 , 40 from discharging back to the digit lines 16 , 18 .
The DRAM array 10 retrieves “1” and “0” bits stored in the manner described above in a memory cell by discharging the electric charges stored on the storage capacitors 38 , 40 to the digit lines 16 , 18 and then detecting a change in voltage on the digit lines 16 , 18 resulting from the discharge with the sense amplifier 22 when isolation gates 30 , 32 are activated by a sense amp isolation signal 26 .
For example, the DRAM array 10 retrieves the “1” bit stored in the memory cell by first equilibrating the voltages on the digit lines 16 , 18 to the cell plate voltage 34 . The DRAM array 10 then energizes the wordline WL 0 56 to activate the pass transistors 36 , 42 , causing the positive electric charge stored on the storage capacitor 38 to discharge through the active pass transistor 36 and negative electrical charge stored on the storage capacitor 40 to discharge through the active pass transistor 42 to the digit lines 16 , 18 . As a positive electric charge discharges, the voltage on the digit line 16 rises and the voltage on the digit line 18 decreases, causing a differential voltage between digit line 16 and digit line 18 as detected at sense amplifier 22 . When a differential voltage between the digit lines 16 and 18 exceeds a detection threshold of the sense amplifier 22 , the sense amplifier 22 responds by driving the voltage of the digit line 16 to the supply voltage V cc and by driving the voltage on the digit line 18 approximately to the reference voltage V ss and the detection of a “1” bit from the memory cell is completed.
Likewise, the DRAM array 10 retrieves the “0” bit stored in the memory cell, for example, by first equilibrating the voltages on the digit lines 16 and 18 to the cell plate voltage 34 . The DRAM array 10 then energizes the wordline WL 0 56 to activate the pass transistors 36 , 42 causing the negative electric charge stored in the storage capacitors 38 , 40 to discharge through the activated pass transistors 36 , 42 and positive electrical charge stored on the storage capacitor 40 to discharge through the active pass transistor 42 to the digit lines 16 and 18 . As the negative electric charge discharges, the voltage on the digit line 16 decreases below the cell plate voltage 34 and the voltage on digit line 18 increases above the cell plate voltage 34 causing a difference in voltages between digit lines 16 and 18 to exceed a detection threshold of the sense amplifier 22 causing the sense amplifier 22 to respond accordingly by driving the voltage on the digit lines 16 , 18 to the appropriate voltages, namely, driving the voltage on digit line 16 to the reference voltage V ss and the voltage on the digit line 18 to the supply voltage V cc .
While an ideal configuration of a DRAM array has been described for storing and retrieving the logic states that were originally stored therein, DRAM arrays sometimes contain defective memory cells which cause the stored logic states to become undetectable or at least intermittently unreliable. In some instances, this occurs because the capacitance of the storage capacitors in these memory cells are too small, preventing the capacitors from retaining a sufficient electric charge to cause a change in the sensing voltage on the digit line when discharged to the digit line, such as in the case when the discharged voltage does not adequately influence the equilibrated digit lines in such a manner as to cause the sense amplifier's detection threshold to be reached. In other instances, memory arrays and their corresponding memory cells may be defective because the electric charge stored on the storage capacitors in such memory cells leaks away through a variety of mechanisms which also prevents the capacitors from retaining a sufficient electric charge to cause a detectable change in the threshold voltage on the digit lines when the storage capacitors are discharged to the digit lines. In either case, because the change in the sensed voltage caused by the discharging of the storage capacitors cannot be detected by the sense amplifier, the “1” and “0” bits represented by the electric charges stored in the memory cells are unretrievable.
With respect to FIG. 1 , the presence of a cell plate voltage 34 between the charges stored across storage capacitors 38 and 40 may deviate unequally if the cell plate voltage 34 is held to a constant voltage. For example, if a “1” bit is stored across a memory cell, a voltage potential approximately equal to V cc minus the cell plate voltage 34 is stored across storage capacitor 38 . Similarly, a voltage of approximately the cell plate voltage 34 minus the reference voltage V ss is stored across storage capacitor 40 . If storage capacitor 38 is defective and leaks a portion of the charge stored therein, the overall loss in stored charge is reflected only across the voltage as presented to digit line 16 during a sense operation. Accordingly, the charge coupled to digit line 16 during a sense operation may not be sufficient to exceed a sensing threshold during the sense operation. Similarly, any leakage on storage capacitor 40 would result solely in a change to the voltage as coupled to digit line 18 during a sense operation. Therefore, there is a need for an improved memory cell configuration for storing therein digit information that is less susceptible to a single defective storage capacitor.
BRIEF SUMMARY OF THE INVENTION
The present invention, in exemplary embodiments, relates to a system and method using a dynamic cell plate in a memory cell. In one embodiment of the present invention, a memory cell includes a first and second portion with the first portion including a first pass transistor and a first capacitor coupled in series and configured for coupling in series between a first digit line at a port of the first pass transistor and a cell plate conductor at a terminal end of the first capacitor. The first pass transistor is further controlled by a first wordline. The second portion of the memory cell includes a second pass transistor and a second capacitor coupled in series and configured for coupling in series between a second digit line at a port of the second pass transistor and the cell plate conductor at a terminal end of the second capacitor. The second pass transistor is further controlled by a second wordline and the first and second portions are symmetrically configured with respect to each other. The memory cell further includes an interconnection formed on the cell plate conductor between the terminal end of the first capacitor and the terminal end of the second capacitor with the interconnection being electrically isolated from other portions of the cell plate conductor.
In another embodiment of the present invention, a memory device is provided. The memory device includes a plurality of memory cells, wherein each of the memory cells includes a first and second pass transistor and a first and second capacitor. The first pass transistor and capacitor and the second pass transistor and capacitor are each configured in series for individual respective coupling between a first digit line and a second digit line. The first and second pass transistors are further configured for respective control by first and second wordlines. The first pass transistor and first capacitor are symmetrically configured with the second pass transistor and the second capacitor. The memory cell further includes an interconnection formed on a cell plate conductor between a terminal end of the first capacitor and a terminal end of the second capacitor. Furthermore, the interconnection is electrically isolated from other portions of the cell plate conductor. The memory device further includes a plurality of sense amplifiers configured for selectably coupling with pairs of the first and second digit lines.
In a further embodiment of the present invention, a semiconductor wafer is provided. The semiconductor wafer includes an integrated circuit configured as a memory array wherein the memory array includes a plurality of memory cells. Each of the memory cells includes first and second pass transistors and first and second capacitors with the first pass transistor and first capacitor and the second pass transistor and second capacitor each being configured in series for individual respective coupling between a first digit line and a second digit line. The first and second pass transistors are further configured for respective control by first and second wordlines. In the memory cell, the first pass transistor and first capacitor are symmetrically configured with the second pass transistor and second capacitor. The memory cell further includes an interconnection formed on a cell plate conductor between a terminal end of the first capacitor and a terminal end of the second capacitor. Furthermore, the interconnection is electrically isolated from other portions of the cell plate conductor.
In yet another embodiment of the present invention, an electronic system is provided. The electronic system includes an input device, an output device, a memory device, and a processor device coupled to the input, output and memory devices. The memory device comprises a memory array including a plurality of memory cells, wherein each of the memory cells includes a first and second pass transistor and a first and second capacitor. The first pass transistor and capacitor and the second pass transistor and capacitor are each configured in series for individual respective coupling between a first digit line and a second digit line. The first and second pass transistors are further configured for respective control by first and second wordlines and the first pass transistor and capacitor are symmetrically configured with the second pass transistor and capacitor. The memory cell further includes an interconnection formed on a cell plate conductor between a terminal end of the first capacitor and a terminal end of the second capacitor. Furthermore, the interconnection is electrically isolated from other portions of the cell plate conductor.
In yet a further embodiment of the present invention, a method of operating a memory array is provided. A series configured symmetrical first and second capacitors are charged to a logic potential through opposing series configured first and second pass transistors respectively coupled to first and second digit lines. The first and second digit lines are pre-charged to an intermediate reference. The logic potential of the first and second capacitors are discharged through the first and second pass transistors coupled to the first and second digit lines. At least a portion of the logic potential is sensed on the first and second digit lines to determine a logic state.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the drawings, which illustrate what is currently considered to be the best mode for carrying out the invention:
FIG. 1 is a schematic diagram of a conventional dynamic random access memory;
FIG. 2 is a plan view diagram of a dynamic cell plate of a memory cell, in accordance with an embodiment of the present invention;
FIG. 3 is a schematic diagram of a dynamic random access memory array, in accordance with an embodiment of the present invention;
FIG. 4 is a schematic diagram of a dynamic random access memory array, in accordance with another embodiment of the present invention;
FIG. 5 is a schematic diagram of a dynamic random access memory array, in accordance with a further embodiment of the present invention;
FIG. 6 is a schematic diagram of a dynamic random access memory array, in accordance with yet another embodiment of the present invention;
FIG. 7 is a block diagram of a memory device, in accordance with an embodiment of the present invention;
FIG. 8 is a block diagram of an electronic system, in accordance with an embodiment of the present invention; and
FIG. 9 is a diagram of a semiconductor wafer including an integrated circuit die incorporating a memory cell of one or more of the previous embodiments, in accordance with a further embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the claims and equivalents thereof.
It is noted that the term “pass transistor” as used herein implies a gated device that includes two ports or I/O that are coupled together through control of a gate input. Additionally, the term “capacitor” as used herein implies an information retention device whether through energy storage, structural orientation and reorientation, or otherwise.
As used herein the term “refresh margin” relates to the amounts of time that a memory cell is capable of retaining an adequate quantity of charge for accurately representing a logic state. Once the refresh margin is exceeded prior to refreshing the memory cell, the discerned logic states become unreliable.
A plan view of a portion of a DRAM memory array in accordance with the present invention is illustrated in FIG. 2 . FIG. 2 illustrates an exemplary layout of a specific feature dimension, however, the present figure is illustrative and not to be considered as limiting. In this example of a DRAM memory array layout, cells are paired to share a common contact to the digit line (DL), which reduces the array size by eliminating duplication. This layout is arranged in an open digit line architecture wherein each half of memory cell 80 , one half of which is shown as half 98 and another half of which is shown as half 101 , has an area equal to 6F 2 . That is, the area of a memory cell 80 in this layout is described as 12F 2 . As illustrated in FIG. 2 , a box is drawn around a memory cell 80 to show the cell's outer boundary. In the present embodiment, a conventional 6F 2 memory cell process configured to include a 1T-1C memory cell architecture couples an adjacent one of a 1T-1C memory cell together through the modification of a single processing layer to form a 2T-2C memory cell without subjecting the 6F 2 process to further modifications. The benefits of a 2T-2C architecture are manifest in an extended refresh margin by utilizing a dynamic cell plate reference to each of the capacitors in the 2T-2C architecture. Therefore, variations in a static cell plate voltage and significant leakage in a single capacitor may be minimized by the presence of a dynamic cell plate reference local to each memory cell.
By way of example, FIG. 2 illustrates the dimensioning of a 6F 2 process for the formation of the one half 98 of the dynamic cell plate 2T-2C memory cell 80 , in accordance with an embodiment of the present invention. As illustrated, along the horizontal axis of the one half 98 of memory cell 80 , the box includes one-half digit line contact feature 102 , one wordline feature 104 , one capacitor feature 106 , illustrated as a stacked capacitor, and one-half field oxide feature 108 for a total of three features. Along the vertical axis of the one half 98 of memory cell 80 , the box contains two one-half field oxide features 112 , 114 and one active area feature 110 for a total of two features. Therefore, the total area of one half 98 of the memory cell 80 is 3F*2F=6F 2 . Moreover, as FIG. 2 illustrates, the halves 98 , 101 of a memory cell 80 are adjacent and connectable through isolated and an individual capacitor pair interconnect 84 , which releases the memory cell 80 from being configured as a static cell plate memory cell and is thereafter configured as a dynamic cell plate memory cell 80 . This is accomplished, in this example, by altering a mask layer of a 6F 2 process for a 1T-1C memory cell process. A discussion of DRAM circuit design including open digit line architecture is provided in Brent Keeth and Jacob Baker, DRAM Circuit Design, A Tutorial, 1-103 (IEEE Press 2001), which is incorporated herein by reference.
Referring to FIG. 3 , a schematic diagram of a memory array 100 according to the present invention including a 1T-1C 6F 2 portion of a memory cell of an open digit line DRAM array is illustrated, wherein the 2T-2C memory cells have an area of 12F 2 . For clarity, a single memory cell 120 is depicted in an upper portion of the array and is shown to include two capacitors (2C) and two transistors (2T) and is coupled to a sense amplifier 124 when isolation gates 130 , 132 are activated by a sense amp isolation signal 126 .
As illustrated, a sense amplifier 122 is coupled between digit line D 1 116 and complementary digit line D 1 * 118 when isolation gates 130 , 132 are activated by a sense amp isolation signal 126 and another sense amplifier 124 is coupled between digit line D 0 170 and complementary digit line D 0 * 172 when isolation gates 130 , 132 are activated by a sense amp isolation signal 126 . Cells with a “1” bit can be expressed as having a +(Vcc−Vss)/2 stored on each capacitor 138 and 140 and cells with a “0” bit can be expressed as having a −(Vcc−Vss)/2 stored on capacitors 138 and 140 . To read a memory cell, a digit line coupled to the cell and its complementary digit line are first initially equilibrated to Vcc/2 volts. Applying Vcc/2 bias voltage to the digit lines and then allowing the digit lines to float causes the digit lines to be equilibrated to Vcc/2 volts. Once the digit lines have been equilibrated to Vcc/2 volts, they remain in that state due to their capacitance. The equilibration of the digits is deactivated immediately before activating the wordline ensuring that the digits are floating when the cells and digits charge share. A voltage that is at least one transistor Vth above Vcc (this voltage is referred to as Vccp) is then applied to a wordline coupled to the cell to be read. For example, if memory cell M 1 180 is to be read, a voltage of Vccp is applied to wordline WL 0 156 to activate pass transistors 136 , 142 after the digit lines D 1 116 and D 1 * 118 are equilibrated to Vcc/2. The charge on the capacitors of memory cell M 1 180 is shared with digit line D 1 116 . In response to the shared charge, the voltage on the digit line of memory cell M 1 180 either increases if memory cell M 1 180 stored a 1-bit, or decreases if memory cell M 1 180 stored a 0-bit. Thereafter, sense amplifier 122 compares the voltage in digit line D 1 116 against the voltage in digit line D 1 * 118 . Because of the shared buried contacts 144 , 154 , operation of memory cell M 2 182 occurs similarly through the activation of wordline WL 1 158 and the coupling of charge from capacitors 148 , 150 with digit line D 1 116 and digit line D 1 * 118 through pass transistors 146 , 152 .
In the various embodiments of the present invention, the refresh margin may be improved through processing a memory cell that is not statically bound to a fixed cell plate voltage, but is processed to include a dynamic cell plate node that is not fixed to a static voltage. In a memory cell architecture that includes a 2T (two transistor) memory cell, a common node or common capacitor interconnect 184 connects or associates the 2C (two capacitors) of memory cell M 1 180 with each other by isolating the cell plate node from an otherwise continuous cell plate conductor or cell plate node layer that conventionally couples to each of the memory cells in a conventional memory array. In the various embodiments of the present invention, improvements in refresh margin may be obtained by modification to the continuous cell plate node layer by forming the common capacitor interconnects 184 , 186 from individual isolated conductive islands in the continuous cell plate node layer that electrically couples the storage capacitors in a series configuration without further connecting the common node to a static cell plate voltage.
Referring to FIG. 4 , a schematic diagram of a memory array 200 according to one embodiment of the present invention including a 6F 2 portion of a memory cell of an open digit line DRAM array is illustrated, in accordance with another embodiment of the present invention, wherein the 2T-1C memory cells have an area of 12F 2 . For clarity, a single memory cell 220 is depicted in an upper portion of the array and is shown to include one capacitor (1C) and two transistors (2T) and is coupled to a sense amplifier 224 when isolation gates 230 , 232 are activated by a sense amp isolation signal 226 .
As illustrated, a sense amplifier 222 is coupled between digit line D 1 216 and complementary digit line D 1 * 218 when isolation gates 230 , 232 are activated by a sense amp isolation signal 226 and another sense amplifier 224 is coupled between digit line D 0 270 and complementary digit line D 0 * 272 when isolation gates 230 , 232 are activated by a sense amp isolation signal 226 . Cells with a “1” bit can be expressed as having a +(Vcc−Vss) stored on the capacitor 238 (illustrated as a common capacitor) and cells with a “0” bit can be expressed as having a −(Vcc−Vss) stored on the capacitor 238 . To read a memory cell, a digit line coupled to the cell and its complementary digit line are first initially equilibrated to Vcc/2 volts. Applying Vcc/2 bias voltage to the digit lines and then allowing the digit lines to float causes the digit lines to be equilibrated to Vcc/2 volts. Once the digit lines have been equilibrated to Vcc/2 volts, they remain in that state due to their capacitance. A voltage that is at least one transistor Vth above Vcc (this voltage is referred to as Vccp) is then applied to a wordline coupled to the cell to be read. For example, if memory cell M 1 280 is to be read, a voltage of Vccp is applied to wordline WL 0 256 to activate pass transistors 236 , 242 after the digit lines D 1 216 and D 1 * 218 are equilibrated to Vcc/2. The charge on the capacitor of memory cell M 1 280 is shared with digit line D 1 216 . In response to the shared charge, the voltage on the digit line of memory cell M 1 280 either increases if memory cell M 1 280 stored a 1-bit, or decreases if memory cell M 1 280 stored a 0-bit. Thereafter, sense amplifier 222 compares the voltage in digit line D 1 216 against the voltage in digit line D 1 * 218 . Because of shared buried contacts 244 , 254 , operation of memory cell M 2 282 occurs similarly through the activation of wordline WL 1 258 and the coupling of charge from capacitor 248 with digit line D 1 216 and digit line D 1 * 218 through pass transistors 246 , 252 .
In the present embodiment of the invention, the refresh margin may be improved through processing a memory cell that is not statically bound to a fixed cell plate voltage but is processed to include a dynamic cell plate node that is not fixed to a static voltage. In a memory cell architecture that includes a 2T (two transistor) memory cell M 1 280 , a common capacitor 238 connects and isolates the cell plate node from an otherwise continuous cell plate node layer that conventionally couples to each of the memory cells in a conventional memory array. In the various embodiments of the present invention, improvements in refresh margin may be obtained by modification to the otherwise continuous cell plate node layer by forming the common capacitor 238 without further connecting to a static cell plate voltage.
Referring to FIG. 5 , a schematic diagram of a memory array 300 according to one embodiment of the present invention including a 1T-1C 8F 2 portion of a memory cell of an open digit line DRAM array is illustrated, wherein the 2T-2C memory cells have an area of 16F 2 . For clarity, a single memory cell 320 is depicted in an upper portion of the array and is shown to include two capacitors (2C) and two transistors (2T) and is coupled to a sense amplifier 324 when isolation gates 330 , 332 are activated by a sense amp isolation signal 326 .
As illustrated, a sense amplifier 322 is coupled between digit line D 1 316 and complementary digit line D 1 * 318 when isolation gates 330 , 332 are activated by a sense amp isolation signal 326 and another sense amplifier 324 is coupled between digit line D 0 370 and complementary digit line D 0 * 372 when isolation gates 330 , 332 are activated by a sense amp isolation signal 326 . Cells with a “1” bit can be expressed as having a +(Vcc−Vss)/2 stored on each capacitor 338 and 340 and cells with a “0” bit can be expressed as having a −(Vcc−Vss)/2 stored on capacitors 338 and 340 . To read a memory cell, a digit line coupled to the cell and its complementary digit line are first initially equilibrated to Vcc/2 volts. Applying Vcc/2 bias voltage to the digit lines and then allowing the digit lines to float causes the digit lines to be equilibrated to Vcc/2 volts. Once the digit lines have been equilibrated to Vcc/2 volts, they remain in that state due to their capacitance. A voltage that is at least one transistor Vth above Vcc (this voltage is referred to as Vccp) is then applied to a wordline coupled to the cell to be read. For example, if cell M 1 380 is to be read, a voltage of Vccp is applied to wordline WL 0 356 , 358 to activate the pass transistors 336 , 342 after the digit lines D 1 316 and D 1 * 318 are equilibrated to Vcc/2. The charge on the capacitors of memory cell M 1 380 is shared with digit line D 1 316 . In response to the shared charge, the voltage on the digit line of memory cell M 1 380 either increases if memory cell M 1 380 stored a 1-bit, or decreases if memory cell M 1 380 stored a 0-bit. Thereafter, sense amplifier 322 compares the voltage in digit line D 1 316 against the voltage in digit line D 1 * 318 . Because of shared buried contacts 344 , 354 , operation of memory cell M 2 382 occurs similarly through the activation of wordline WL 1 360 , 362 and the coupling of charge from capacitors 348 , 350 with digit line D 1 316 and digit line D 1 * 318 through pass transistors 346 , 352 .
In the present embodiment of the invention, the refresh margin may be improved through processing a memory cell that is not statically bound to a fixed cell plate voltage but is processed to include a dynamic cell plate node that is not fixed to a static voltage. In a memory cell architecture that includes a 2T (two transistor) memory cell, a common node or common capacitor interconnect 384 connects or associates the 2C (two capacitors) of memory cell M 1 380 with each other by isolating the cell plate node from an otherwise continuous cell plate conductor or cell plate node layer that conventionally couples to each of the memory cells in a conventional memory array. In the various embodiments of the present invention, improvements in refresh margin may be obtained by modification to the continuous cell plate node layer by forming common capacitor interconnects 384 , 386 from individual isolated conductive islands in the otherwise continuous cell plate node layer that electrically couples the storage capacitors in a series configuration without further connecting the common node to a static cell plate voltage.
Referring to FIG. 6 , a schematic diagram of a memory array 400 according to one embodiment of the present invention including a portion of a memory cell of an open digit line DRAM array is illustrated, wherein the 2T-1C memory cells have an area of 16F 2 . For clarity, a single memory cell 420 is depicted in an upper portion of the array and is shown to include one capacitor (1C) and two transistors (2T) and is coupled to a sense amplifier 424 when isolation gates 430 , 432 are activated by a sense amp isolation signal 426 .
As illustrated, a sense amplifier 422 is coupled between digit line D 1 416 and complementary digit line D 1 * 418 when isolation gates 430 , 432 are activated by a sense amp isolation signal 426 and another sense amplifier 424 is coupled between digit line D 0 470 and complementary digit line D 0 * 472 when isolation gates 430 , 432 are activated by a sense amp isolation signal 426 . Cells with a “1” bit can be expressed as having a +(Vcc−Vss)/2 stored on the capacitor 438 and cells with a “0” bit can be expressed as having a −(Vcc−Vss)/2 stored on the capacitor 438 . To read a memory cell, a digit line coupled to the cell and its complementary digit line are first initially equilibrated to Vcc/2 volts. Applying Vcc/2 bias voltage to the digit lines and then allowing the digit lines to float causes the digit lines to be equilibrated to Vcc/2 volts. Once the digit lines have been equilibrated to Vcc/2 volts, they remain in that state due to their capacitance. A voltage that is at least one transistor Vth above Vcc (this voltage is referred to as Vccp) is then applied to a wordline coupled to the cell to be read. For example, if memory cell M 1 480 is to be read, a voltage of Vccp is applied to wordline WL 0 456 , 458 to activate the pass transistors 436 , 442 after the digit lines D 1 416 and D 1 * 418 are equilibrated to Vcc/2. The charge on the capacitor of memory cell M 1 480 is shared with digit line D 1 416 . In response to the shared charge, the voltage on the digit line of memory cell M 1 480 either increases if memory cell M 1 480 stored a 1-bit, or decreases if memory cell M 1 480 stored a 0-bit. Thereafter, sense amplifier 422 compares the voltage in digit line D 1 416 against the voltage in digit line D 1 * 418 . Because of the shared buried contacts 444 , 454 , operation of memory cell M 2 482 occurs similarly through the activation of wordline WL 1 460 , 462 and the coupling of charge from capacitor 448 with digit line D 1 416 and digit line D 1 * 418 through pass transistors 446 , 452 .
In the present embodiment of the invention, the refresh margin may be improved through processing a memory cell that is not statically bound to a fixed cell plate voltage but is processed to include a dynamic cell plate node that is not fixed to a static voltage. In a memory cell architecture that includes a 2T (two transistor) memory cell M 1 480 , a common capacitor 438 connects and isolates the cell plate node from an otherwise continuous cell plate node layer that conventionally couples to each of the memory cells in a conventional memory array. In the various embodiments of the present invention, improvements in refresh margin may be obtained by modification to the otherwise continuous cell plate node layer by forming the common capacitor 438 without further connecting to a static cell plate voltage.
FIG. 7 is a block diagram of a memory device and system, in accordance with an embodiment of the present invention. A DRAM memory device 500 includes control logic circuit 520 to control read, write, erase and perform other memory operations. A column address buffer 524 and a row address buffer 528 are adapted to receive memory address requests. A refresh controller/counter 526 is coupled to the row address buffer 528 to control the refresh of memory array 522 . A row decode circuit 530 is coupled between the row address buffer 528 and the memory array 522 . A column decode circuit 532 is coupled to the column address buffer 524 . Sense amplifiers-I/O gating circuit 534 is coupled between the column decode circuit 532 and the memory array 522 . The DRAM memory device 500 is also illustrated as having an output buffer 536 and an input buffer 538 . An external processor 540 is coupled to the control logic circuit 520 of the DRAM memory device 500 to provide external commands.
A memory cell M 1 550 of the memory array 522 is shown in FIG. 7 to illustrate how associated memory cells are implemented in the present invention. States or charge are stored in the memory cell M 1 550 that correspond to a data bit. A wordline WL 0 542 is coupled to the gates of the memory cell M 1 550 . When the wordline WL 0 542 is activated, the charge stored in memory cell M 1 550 is discharged to digit lines DL 0 552 and DL 0 * 554 . Digit line DL 0 552 and digit line DL 0 * 554 are coupled to a sense amplifier in circuit 534 . Although the memory cell M 1 550 is illustrated as being coupled to one wordline WL 0 542 in FIG. 7 , it will be appreciated by those in the art that a pair of wordlines (i.e., WL 0 and WL 1 ) that are fired at the same time (e.g., memory cell of FIGS. 5 and 6 ) could be used, and the present invention is not limited to one wordline for each memory cell.
FIG. 8 is a block diagram of an electronic system, in accordance with an embodiment of the present invention. The electronic system 600 includes an input device 672 , an output device 674 , and a memory device 678 , all coupled to a processor device 676 . The memory device 678 incorporates at least one memory cell 640 of one or more of the preceding embodiments of the present invention.
FIG. 9 is a diagram of a semiconductor wafer including an integrated circuit die incorporating the memory array of one or more of the previous embodiments, in accordance with a further embodiment of the present invention. As shown in FIG. 9 , a semiconductor wafer 700 includes a yet-to-be-cut integrated circuit die 740 that incorporates one or more memory cells as herein disclosed.
The various embodiments of the present invention as described herein provide for an improved refresh margin by applying a dynamic cell plate to a 2T architecture memory cell. Instead of a common cell plate node connected to a voltage generator, each pair of pass transistors and one or more storage capacitors associated to a given address or memory cell/bit has a floating isolated cell node which connects to the capacitive elements. In a conventional memory cell layout, changes to processing may be minimized and result in as little as a single layer change in a conventional or typical DRAM process. While additional embodiments have been disclosed which include a single capacitive element, such process alterations are also minimized but may incur more deviations from a standard or typical DRAM process than with a dual or two capacitor memory cell.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof. | A memory cell, device, system and method for operating a memory cell utilize an isolated dynamic cell plate. The memory cell includes a first and second pass transistor and a first and second capacitor. The first pass transistor and first capacitor and the second pass transistor and second capacitor are each configured in series for individual respective coupling between a first digit line and a second digit line. The first and second pass transistors are further configured for respective control by first and second wordlines. The memory cell further includes an interconnection formed on a cell plate conductor between a terminal end of the first capacitor and a terminal end of the second capacitor. Furthermore, the interconnection is electrically isolated from other portions of the cell plate conductor. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to automatically lubricating the upper cylinder area of an internal combustion engine.
2. Description of the Prior Art
Internal combustion engines generally are inadequately lubricated in their upper cylinder areas. As a result, it is well-known that the cylinders and other parts of an internal combustion engine have a much shorter life span than the parts of a diesel engine. In addition, the parts operate less efficiently than they would if properly lubricated. With the advent of non-leaded gasolines, and especially high octane non-leaded gasolines, that are dryer burning than leaded gasolines, this problem of inadequate lubrication is exacerbated. Internal combustion engines that operate with methane fuel are even more notoriously poorly lubricated in their upper cylinder areas than are gasoline internal combustion engines because of the extremely dry burning conditions. The problem exists with internal combustion engines with fuel injectors as well as those without.
Attempts in the prior art to provide upper cylinder area lubrication include the system described in U.S. Pat. No. 3,115,874, which basically puts lubricant into the upper cylinder by drawing a vacuum on a lubricant reservoir and applying the lubricant through a valve in a manifold. Metering is provided through a "bi-metal" valve that determines the opening depending on the heat of the engine. The amount of lubricant applied is often entirely too much, however, since lubricant is constantly applied. As a result, the lubricant reservoir empties faster than is economical or practical and there is a gumming effect on the operating parts that are over-lubricated.
U.S Pat. No. 2,721,545 describes another system for lubricating the upper cylinder area of an internal combustion engine, this system using a fine spray or mist head to dispense the lubricant more uniformly over the parts than with a delivery scheme not including such a head. The lubricant is constantly applied, however, as with the '874 system. There is no known spray head that dispenses with a fine enough spray to be both efficient and non-wasteful. That is, the '545 scheme also dispenses much too much lubricant to be commercially acceptable.
Therefore, it is a feature of the present invention to provide an improved system for lubricating the upper cylinder area of an internal combustion engine that dispenses only the required amount of lubricant at intermittent intervals.
It is another feature of the present invention to provide an improved system for lubricating the upper cylinder area of an internal combustion engine that utilizes long-acting solid state timer means.
It is still another feature of the present invention to provide an improved system for lubricating the upper cylinder area of an internal combustion engine that utilizes a long-acting electric pump that does not impart a constant pressure condition on the operating engine parts, as with the '874 system.
SUMMARY OF THE INVENTION
The upper cylinder area lubrication system for an internal combustion engine in accordance with the present invention generally includes a conduit means, such as for example a mixing chamber where the gasoline or other fuel is mixed with lubricant, a lubricant supply means and timer means for automatically dispensing the lubricant in a predetermined manner. The lubricant supply means includes a reservoir for the lubricant and an electric pump that dispenses lubricant for typically a second or so when it is controlled on. More specifically, the electric pump is controlled on/off by timer means preferably comprising two timers, one for determining the duration of off periods (typically, of 30 minutes duration) and one for determining the duration of the on periods that occur between the off periods (again, typically one second periods). This intermittent dispensing scheme is sufficient to adequately lubricate the area without rapidly depleting the reservoir or creating gumming or other undersirable engine conditions when too much lubricant is applied. The parts are long-acting and do not interfere with the normal operation of the parts by imparting a constant pressure condition.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above-recited features, advantages and objects of the invention, as well as others which will become apparent, are attained and can be understood in detail, more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof which are illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the appended drawings illustrate only preferred embodiments of the invention and are therefore not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
In the drawings:
FIG. 1 is a mechanical schematic representation of an upper cylinder area lubrication system in accordance with a preferred embodiment of the present invention.
FIG. 2 is an electrical schematic diagram of the electrical portion of the system shown in FIG. 1.
FIG. 3 is a mechanical schematic representation of a portion of the upper cylinder area lubrication system in accordance with an alternate preferred embodiment of the present invention.
FIG. 4 is a mechanical schematic representation of a portion of an upper cylinder area lubrication system in accordance with another alternate preferred embodiment of the present invention.
FIG. 5 is a mechanical schematic representation of a portion of an upper cylinder area lubrication system in accordance with yet another alternate preferred embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Now referring to the drawings and first FIG. 1, a preferred embodiment of a fully automatic, electronic lubrication system in accordance with the present invention is shown in mechanical schematic representation. The system is designed to lubricate the upper cylinders, rings, piston chamber walls and valves of a gasoline or similarly fueled internal combustion engine every time the engine is turned on. Referring to the components illustrated in FIG. 1, an enclosure 1 is located underneath the hood or under the dashboard area of the cockpit of the vehicle serviced by the internal combustion engine to be lubricated and includes positive terminal strip 3 and negative terminal strip 7 for making electrical connections to the power system of the vehicle. Included in the enclosure is timing control 4 described more fully hereafter, that activates an electric relay 5. An isolation switch 2 is included for disabling the entire system, if desired, and is located mounted to cover 17 of the enclosure. Hence, switch 2 provides a convenient electrical disconnect for the unit from the electrical system of the vehicle.
Also included underneath the hood of the vehicle is lubricant reservoir 10 filled with an appropriate lubricant 12 for dispensing via tubing 8 to electric lubricant pump 6. A filter 13 maybe included at the intake to tubing 8, if desired. Also, if desired, a float switch 11 may be included for ensuring that the electric pump is deactivated when the lubricant level falls below a predetermined level. Float switches are commonly employed in the art and their manner of operation is well known.
Lubricant pump 6 is connected by way of tubing 9 to flow control valve 22. If desired, a pressure regulator 24 may be included in the tubing line between lubricant pump 6 and flow control valve 22. Also, a one way flow valve 14 may be included in this line to prevent any possible backup of flow to pump 6. Also, a normally closed electric flow valve 28 must be included to prevent vacuum pull when the system is off provided that pump 6 is the kind that does not shut off when not in use. In such case, valve 28 would not be required. Preferably, the solenoid coil of valve 28 is located in parallel across pump 6, as shown in FIG. 2 and physically the valve itself would be located just beneath pump 6, as shown in FIG. 1 or ahead of valve 22 in FIGS. 3, 4 and 5.
In FIG. 1, flow control valve, which may be a simple pitcock valve, allows the application of lubricant from pump 6 to enter a lubricant mixing chamber 15. Chamber 15 also receives the gasoline supply to the engine to be lubricated. Although theoretically the mixing chamber may be located anywhere in the gasoline supply line, it is most conveniently and efficiently located near the engine to be serviced.
The system is operated or controlled by two timers, which are most conveniently mounted on cover 17 of the enclosure. Timer 25 includes a potentiometer that may be set so that each time the timer operates, the coil of electric relay 5 is energized. The setting for this potentiometer allows relay energizing periods from approximately one half (1/2) second to 30 seconds. Timer 26 includes a potentiometer for establishing the off periods that occur between the on periods set by timer 25. The potentiometer of this timer allows the setting of the off periods over a range from about 15 minutes to one hour. Normally timer 25 is set to provide for one second "on" operation and timer 26 is set to provide 30 minute "off" operation, or less time if desired. In case the vehicle operates primarily in town, or in short time operation, the control box can be located near the driver so the off timer can be set to a shorter time (15 minutes is suggested for town driving) and then set back to 30 minutes for highway driving.
Also included and mounted in enclosure cover 17 are a fuse 20, a pilot light 27 to show the circuit is protected operational, and deactivating switch 2, previously described. In operation, each time the ignition switch is turned on to activate the engine, the system is enabled and the timers are started. For the duration of each off period, no lubrication is supplied to the engine. However, when the "off" period expires, the "on" period timer energizes the coil of relay 5, thereby closing its contacts and causing electric pump 6 to operate for a short period of time, typically one second. During the "on" period, electric pump 6 draws a measured quantity of lubricant from the reservoir and pressure pumps the lubricant into mixing chamber 15, located in the gasoline line as described above. The lubricant is mixed with the gasoline in chamber 15 precisely in a proportionately measured amount. Thereafter, the mixture is injected into the firing chambers of the engine. The dispensing head which is connected to the output tubing from the mixing chamber can conveniently include atomizer spray nozzles located in tapped holes in the intake air manifold. If desired, as shown in FIG. 3, the output from valve 22 can be applied directly into the engine air filter at the carburetor of the engine. In this case, a mixing chamber is not used. Alternatively as shown in FIG. 4, the lubricant can be pumped directly from valve 22 into conveniently located atomizer spray nozzles located in holes in the engine air intake manifold without going through a mixing chamber first. This is particularly applicable to engines with turbo or fuel injectors. Finally, as shown in FIG. 5, spray nozzles can be located directly in the engine intake manifold.
Now referring to FIG. 2, the wiring diagram for the vehicle upper cylinder area lubrication system is shown. The electrical power for the system may be either AC or DC. It will be seen that timing control device 4 is connected at terminal T3 through fuse 20, switch 2 and ignition switch 18 to one side of the power system. The opposite side is wired directly to terminal T1. Terminal T2 is wired to the coil of relay 5 through float switch 11, which is connected back to terminal T3. The potentiometers or variable resistors for the timers, are also shown in the FIG. 2 diagram. The potentiometer for timer 25 is shown connected to terminals T6 and T7 and the potentiometer for timer 26 is connected to terminals T4 and T10. The contacts for relay 5 are shown in series with electric pump 6. Electric pump 6 is connected directly to one side of the power wiring and through the switch contacts to the opposite side at the junction with fuse 20. A pilot light 27 is connected between the same points, as shown on the diagram.
A preferred timing device that includes both an "on" time delay and an "off" time delay is the TRS Repeat Cycle Timing Control marketed by Infitec Inc. of Syracuse, N.Y. This device is a fully solid state digital C/MO timing device and has a specification life of one hundred million operations minimum under full load. Although this timing means has proven effective, equivalent means are available. The electric pump employed as pump 6 can be TRW type no. 55469 or other fast response fuel pump.
The upper cylinder area lubrication system described above results in reduction of friction, heat and engine wear and thus increases engine operating life substantially. The operation is fully automatic. The only operator requirement is to maintain lubricant in the reservoir. The reservoir does not empty dramatically when the vehicle is in operation however, since it is not continuously being drained, as with reservoirs in some prior art systems.
The ability to adjust the time periods on and off enables a precise measured amount of lubricant to be pumped to the engine upper cylinder area to optimize the performance of the engine without fouling the spark plugs or adversely affecting engine operation in any way.
While particular embodiments have been shown and described, it will be understood that the invention is not limited thereto. Many modifications may be made and will be become apparent to those skilled in the art. | An upper cylinder area lubrication system is disclosed that dispenses a small amount of lubricant to the upper cylinder area of an internal combustion engine at regular intervals for a metered period of time. Typically, the lubricant is dispensed for one second every thirty minutes. An electric pump is used to draw the lubricant from the reservoir and apply it, preferably through a mixing chamber in the gasoline line located just before the gasoline is applied to the firing chambers. The control of the pump is via a solid-state timing device that separately sets the alternate on periods and the off periods. | 5 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a method and a system for controlling a windshield wiper, particularly on a motor vehicle, wherein the windshield wiper is automatically turned on as a function of the intensity of the rain.
Devices for controlling windshield wipers are known in which the windshield-wiper motor automatically starts when a predetermined threshold of wetting of the windshield by rain is exceeded. Various sensors are known for detecting the wetting of the windshield, but with them various disturbing influences such as, for instance, dependencies on temperature, long-term drifts, manufacturing tolerances and vehicle-specific differences lead to errors.
SUMMARY OF THE INVENTION
It is an object of the present invention to permit control of a windshield wiper as a function of the intensity of the rain without error introduced the above-indicated disturbing influences.
According to the invention, a frequency-limited variation of the signal of a sensor serves as measure of the intensity of the rain.
In this connection, it can either be provided that the signal is conducted over a band-pass filter and that the effective value of the band-limited signal is formed, or it can be provided that an average value of the signal is formed and the variance or standard deviation of the instantaneous signal from the average value is calculated.
The invention is based on the fact that continuous movements of water drops produce stochastic signals which are entirely absent in the case of dryness.
In accordance with a further development of the invention, a measure of the accumulated rain is obtained in the manner that the value of the instantaneous variation is integrated, and the windshield wiper is connected when the integrated amount exceeds a threshold value.
In this connection, it may be provided preferably that the integration is restarted after each wiping process.
Another further aspect of the invention is that, after the integration, differentiation with large time constant is effected in order to compensate for evaporation of water.
Furthermore, in accordance with another further feature, erroneous results by stochastic signals which are produced in the absence of water drops is avoided because only values of the variation which exceed a threshold value are evaluated and integrated.
In a further development of the invention, it is provided that a variation which is less than a predetermined threshold value is detected as a dry windshield, and that the sensor signal present at this time serves as comparison value for subsequent triggering criteria. In this case the windshield wiper is preferably connected when the sensor signal exceeds the comparison value.
According to the invention, there is provided an advantageous arrangement for the carrying out of the method in which the sensor is connected via an analog/digital converter (4) to a microcomputer (5), and that a program in accordance with the method of the invention is provided for the microcomputer (5). In this case, the sensor is preferably a capacitive wetness sensor (1).
BRIEF DESCRIPTION OF THE DRAWINGS
With the above and other advantages in view, the present invention will become more clearly understood in connection with the detailed description of a preferred embodiment, when considered with the accompanying drawing, of which:
FIG. 1 is a block diagram of an arrangement for the carrying out of the method of the invention;
FIG. 2 is a flowchart of a program intended for the microcomputer in the arrangement according to FIG. 1; and
FIG. 3 is another flowchart.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the device shown in FIG. 1, the degree of wetting of the windshield is determined by means of a capacitive sensor 1 to which operating voltage is fed via the terminal 15 of the car electrical system via a noise-voltage filter 2 and a stabilization circuit 3. Capacitive wetness sensors are known per se and need not be explained in detail for an understanding of the present invention. An amplifier (not shown) is included with the sensor 1 so that the output voltage of the sensor is fed directly to an analog/digital converter 4 of a so-called single-chip microcomputer 5. The microcomputer 5 is connected to an operating switch 6 which is preferably developed as a steering-column switch, and has detent positions for continuous operation and automatic operation as well as a touch position for a single wipe. The motor 8 of a windshield wiper is connected via a relay stage 7 to an output of the microcomputer 5.
In the program shown in FIG. 2, a comparison value for the sensor signal is first of all established by evaluation of the variation of the sensor signal S whereupon a signal for the starting of the wiper motor is produced by comparison of the actual sensor signal with the comparison value. For this purpose, after the starting of the program at 11 in the program part 12, a value is read in for S and subjected to band-pass filtering together with previous signal values. The variation of the filtered signal is then determined at 13. The variation can, for instance, be the effective value. The value S eff thus obtained is compared with a first threshold value S 1 . This threshold value is somewhat larger than the stochastic variations (noise) which are present in the sensor signal if the windshield is dry.
If the value S eff exceeds the first threshold value S 1 this is a clear indication that rain is present. After the branching 14, a comparison value S ref which is to be stored is set equal in the program part 15 to the actual statistical sensor signal S. This comparison value S ref unambiguously characterizes the static sensor signal S when the windshield is dry. Thereupon, starting with the filtering 12, the program described above is repeated until, upon the occurrence of rain, the effective value S eff exceeds the threshold value S 1 . It is then tested at 16 whether the actual sensor signal S is greater than or equal to the stored comparison value S ref plus a second threshold value S 2 . It is thus determined, independently of the aforementioned disturbing variables, that rain is present so that the windshield wiper can be started at 17.
In the method of the invention, the windshield wiper can in itself be turned off in various manners. It may advantageously be provided that the windshield wiper in each case carries out one wiping movement and is, in each case, started again by the method of the invention. In the event of stronger rain, this results in a continuous wiping movement since a signal for the starting of the wiper is then possibly produced already during the wiping process.
Instead of the band-pass filtering in the program part 12, a low-pass filtering can also be provided. Band-pass filtering, however, has the advantage that portions of the band of the sensor signal which are of higher frequency and are not caused by the fluctuation of the rain drops are suppressed. These can, for instance, be steep flanks of the sensor signal which are produced when the windshield wiper passes over the sensor.
The advantage of the invention will once again be shown on basis of the following numerical example which is based on practical tests. The sensor signal has, for instance, a value of 1V when the windshield is dry and of 3V when it is wet with rain. Without the method of the invention, a threshold value between these two values would have to be present, for instance, 2V. The above-mentioned influences, such as temperature, aging or dirtying of the windshield, can, however, cause a change of up to 100% in the sensor signal. The variation of the sensor signal is, however, considerably greater when rain is present. The effective value, for example, when the windshield is dry is <2mV and in the case of rain about 20mV. Even if the variation is subjected to the same relative disturbing changes, an unambiguous detection is possible with the aid of a threshold value of, for instance, S 1 =5mV.
In the program shown in FIG. 3, a filtering is first effected at 12 as in the program shown in FIG. 2 and a determination of the variation in signal effected at 13. The value S eff which is thus determined is integrated at 21, whereby the accumulation of water taking place by the impingement of individual drops of rain on the windshield is practically represented. A differentiation with a large time constant which represents the evaporation of the water is superimposed at 22 on the integration. The differentiation at 22 can be considered also as a high pass filter.
After the completion of program parts 21 and 22, a decision is made at 23 as to whether the integrated and differentiated value ΣS eff has already reached a threshold value S 1 . As long as this is not the case, steps 12, 13, 21 and 22 are repeated. However, if ΣS eff ≧S 1 , then the wiper motor is started at 17. The integrator is then reset at 24 to the initial value, whereupon the program is repeated, starting with the filtering 12. | A method and a system for controlling a windshield wiper, particularly on a motor vehicle, provides that the windshield wiper is automatically activated as a function of the intensity of rain. A frequency-limited variation of the signal of a sensor serves as a measure of the intensity of the rain. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a linkage pin and a manufacturing method for the same. More specifically it relates to a linkage pin for connecting two or more members of a work machine.
BACKGROUND
[0002] Work machines such as tracked loaders, excavators and the like commonly use metal pins to connect two sections of the machine together. This may be done for several reasons, such as to create a pivot arrangement or to allow simplified removal and fitting of components like hydraulic rams which often are specifically provided with eye ends to receive such pins. Pins like this are often exposed to severe and a wide range of differing loads such as torsional, longitudinal and lateral loading. To maintain the pin in the desired position a common form of retention is to provide a lever arm which is typically a metal plate fixed perpendicularly to the pin. One end of the lever arm is fixed to the pin whilst another end forms a portion that may be bolted or clamped to prevent displacement of the lever arm and hence the pin. The lever arm may be fixed so as to substantially prevent any movement, but if preferred some degree of movement may be allowed. Pins having a construction as described often fail prematurely, especially the connection between the lever arm and the pin being prone to fatigue.
[0003] It is often preferred to provide the components with a surface treatment such as an anti-corrosion protective coating. The manufacturing process of such pins would be greatly improved if the individual components receive such treatment before they are joined together, but commonly used processes such as welding damage the coating and require the assembly to be recoated after the operation.
[0004] The present invention aims to overcome one or more of the above disadvantages.
SUMMARY OF THE INVENTION
[0005] According to a first aspect of the present disclosure there is provided a linkage pin having a pin with an elongated boss at a first end whereby the elongated boss defines a first longitudinal axis. The linkage pin further has a lever arm which is provided with an aperture corresponding to the elongated boss whereby the lever arm defines a second longitudinal axis. The pin is fixedly connected to the lever arm such that the elongated boss is located in the corresponding aperture and that the first and second longitudinal axes are substantially parallel to each other.
[0006] Another aspect of the present disclosure is a method for manufacturing a linkage pin wherein the following steps are present:
a) forming a pin having an elongated boss at a first end whereby the elongated boss defines a first longitudinal axis, b) forming a lever arm and providing the lever arm with an aperture that corresponds to the elongated boss whereby the lever arm defines a second longitudinal axis, c) positioning the elongated boss in the corresponding aperture, d) fixing the pin to the lever arm such that the first and second longitudinal axes are substantially parallel to each other.
[0011] A third aspect of the disclosure provides a linkage pin having a pin with a first longitudinal axis and an elongated boss at a first end whereby the elongated boss defines a second longitudinal axis. The linkage pin further has a lever arm provided with an aperture corresponding to the elongated boss whereby the lever arm defines a third longitudinal axis. The pin and second lever arm are fixedly connected whereby the elongated boss is positioned within the aperture and the first and third longitudinal axes form a virtual angle α. The pin is adapted to be subjected to forces in a direction that primarily influence angle α by having the second and third longitudinal axes substantially parallel to each other.
[0012] Other features of the present disclosure will be apparent from the following description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic isometric view of a linkage pin according to the current invention.
[0014] FIG. 2 is an exploded view of the linkage pin shown in FIG. 1 .
[0015] FIG. 3 shows a schematic cross-sectional view of the pin from FIGS. 1 and 2 applied to a typical linkage arrangement.
[0016] FIG. 4 shows an exploded partial end representation of interfaces of a lever arm and a pin according to the present invention.
[0017] FIG. 5 is a part representation of an assembled pin and lever arm from FIG. 4 .
DETAILED DESCRIPTION
[0018] With reference to FIGS. 1, 2 and 3 , a linkage pin 10 has a pin 12 and a lever arm 14 . Pin 12 is shown as a substantially cylindrical body but may also have a non-cylindrical body and may be shaped irregular such as stepped or tapered if preferred. Pin 12 defines a longitudinal axis 13 . FIG. 3 shows a typical application of linkage pin 10 , wherein it forms a link between a first member 16 and a second member 18 . The first and second members 16 and 18 may be for example loader arm segments of a work machine such as an excavator or the like. Where the linkage pin 10 is designed to function as a pivot point for the two members 16 and 18 the pin 12 will be at least partially cylindrical to accommodate the rotational movement of the first member relative to the second member. The pin 10 may however still be stepped or vary in diameter along its length if that is suitable for the application. Either or both of the members 16 and 18 may be provided with some kind of load bearing and wear part arrangement such as a bushing 20 .
[0019] With reference to FIG. 2 , the pin 12 is at one end provided with a projection such as boss 22 with a longitudinal axis 24 . This boss may be formed by milling two radially opposite sides of one end of the pin 12 such that an elongated projection remains. The end portions 26 and 28 of the boss which intersect the longitudinal axis 24 may be left intact so the length of the boss 22 is substantially identical to the diameter of the pin 12 , but alternatively the ends may be machined to form for example a straight edge. Providing the pin 12 with the boss 22 also leads to the formation of a shoulder 30 on the pin 12 . The end of the pin 12 opposite to the end provided with boss 22 may be tapered to facilitate installation.
[0020] The lever arm 14 may be a flat steel plate in a multitude of possible shapes and defines a longitudinal axis 32 . Lever arm 14 is furthermore provided with an aperture such as slot 34 . Slot 34 defines a longitudinal axis 35 which is substantially parallel to and may even coincide with the axis 32 of the lever arm 14 . Of course it is to be understood that due to manufacturing tolerances a perfect parallelism may not be achieved. In one embodiment, the lever arm 14 may be provided with a second aperture 36 for receiving a fastener such as bolt 38 .
[0021] The longitudinal axis 32 of lever arm 14 and the longitudinal axis 13 of pin 12 may lie in the same plane or in different planes but appear to intersect at a virtual angle α when seen from the side as shown in FIG. 3 . In one embodiment α is substantially 90°, but other angular relationships may be adopted if preferred. The lever arm 14 and the pin 12 are connected by locating the boss 22 in the slot 34 . The dimensions of both the boss 22 and the slot 34 are matched so as to provide a good fit. The lever arm 14 and the pin 12 are then engaged in a permanent or semi-permanent fixation by an operation such as glueing, welding, swaging or by using a fastener such as a setscrew.
[0022] FIGS. 4 and 5 show one embodiment for achieving a fixation of the lever arm 14 and the pin 12 . The lever arm 14 has a first surface 39 and a second surface 40 . The height of the boss 22 as measured from the shoulder 30 is greater than the distance between the surfaces 39 and 40 . With the lever arm 14 placed around the boss 22 such that the surface 40 abuts the shoulder 30 , the boss 22 then extends into and beyond the surface 39 . The part of the boss 22 that extends beyond the surface is then mechanically deformed by a process such as swaging with a swaging tool 44 to create a retaining portion.
[0023] As can be seen from FIGS. 4 and 5 the contact area between the pin 12 and the lever arm 14 may be increased by providing at least part of the circumference of the slot 34 with a chamfered edge 42 . This will allow a greater portion of the pin 12 to be deformed whilst attaining a more elaborate shape so as to form a stronger joint.
INDUSTRIAL APPLICABILITY
[0024] The pin 12 and the lever arm 14 may be manufactured separately. Once all the preferred features have been provided to both the pin 12 and the lever arm 14 , both may undergo a protective treatment to shield them from corrosion or other types of damage being either functional or aesthetic. The treatment may include a process such as for example zinc-plating or phosphate coating. Once treated, the pin 12 and the lever arm 14 are assembled and a swaging process may be applied to form a permanent fixation. The elongated shapes of both the slot 34 and the boss 22 combined with the swaged end portion of the pin 12 prevent the two parts from moving relatively to one another. Swaging the components results in no or minimal disturbance of the protective coating and does therefore not require a coating to be reapplied after the joining operation.
[0025] The pin may thereafter be assembled into a work machine such as described earlier. The aperture 36 may be aligned with a threaded portion in the first member 16 and an at least partially threaded fastener 38 may be positioned in the aperture 36 and threadingly engaged with the first member 16 . This will retain the pin in its desired position and thus prevents lateral movement or rotation of the pin relative to the member 16 . Alternative retention means may of course be applied. It is for example known in the art to apply a semi-fixed retention method wherein the pin 10 may be allowed a certain degree of rotational movement. This could for example be achieved by providing the lever arm with an oversize aperture and providing a spacer and washer arrangement whereby the pin 10 can rotate for a limited amount. Another alternative retention means known in the art is to provide the surface 16 with one or more projections to which a retainer plate can be fixed so as to form a ‘cage’ in which the lever arm can be locked or semi-locked.
[0026] Once assembled into a work machine, the pin 10 is exposed to a wide range of forces. For example, the pin 10 may be used in applications where the pin 10 provides a hinge function, i.e. it is fixed in a position relative to member 16 whilst member 18 can pivot around the pin 10 . If lubrication between the surfaces of the pin 10 and the member 18 or its bushing 20 is insufficient, the friction may increase even to the point where the pin 10 and the bushing 20 are cold-welded together. When the two members are operated to pivot relative to one another and friction is high a torsional force is generated in the pin 10 as one end is restraint by the lever arm 14 . This torsional force is counteracted by the non-cylindrical or elongated shape of both the slot 34 and the boss 22 .
[0027] In one embodiment a plurality of external forces acting in the same or different directions act upon the pin 10 . One force or a particular set of forces are identified as being the so-called primary forces because they are the main contributor to causing flexing of the lever arm 14 relative to the pin 12 , or vice versa. Angel α may be described as the angle between the pin 10 and the lever arm 14 that lies substantially in or parallel to the plane of the primary forces acting on the pin. For example, the primary forces may act on the pin 10 or the lever arm 14 in a manner to increase or decrease the angle a α. By using a pin 10 as described, and aligning the longitudinal axes of boss 22 , and slot 34 with the direction of the flexing, the robustness of the joint between the pin 12 and lever arm 14 is significantly increased.
[0028] Although embodiments of this invention have been described herein, improvements and modifications may be incorporated without departing from the scope of the following claims. | Linkage pins are commonly used to join two members to provide a rigid connection or to function as a pivot point. They are often manufactured from piece parts that ideally are provided with a protective coatings before assembly. The joint needs to be able to withstand the harsh environments linkage pins may be used in and the joining process must cause minimal disturbance to the coating to prevent it from having to be reapplied after manufacturing. The present invention discloses a method and linkage pin including a mechanical deformation to form a joint. The components are arranged in a particular orientation to provide optimum durability by aligning them in a direction dependent on the direction of the flexing caused by the forces acting upon the pin. | 5 |
BACKGROUND OF THE INVENTION
The hydronic heating system used to heat homes and other dwellings has been in existence for many years and despite the development of many other hot air systems still remains a reliable and efficient means of heating. Generally in these systems, water is heated in a boiler and is pumped or forced under pressure throughout a myriad of pipes interconnected between each room in the building. As the hot water collects in one or more of the basins or radiators attached thereto, the metal pipes get hot and warm the surrounding air.
It is very important in these systems to keep the pipes full of water at all times. However, due to the expansion and contractions of water as it is heated and cooled, provisions must be made in the system to accomodate this. As the system temperature changes, the water in the system expands and contracts at a different rate than the metal that contains it.
As a result of the need to provide space or room for expansion, a necessary development was the expansion tank which is an accessory reservoir attached to the boiler. U.S. Pat. Nos. 4,414,464 to Cloutier and 3,627,203 to Martin are both indicative of the known state of the expansion tank art and their use in hydronic heating systems. These patents are hereby incorporated by reference. Generally, the tank is half filled with water with the remaining space occupied by air. This air space provides room for expansion/contraction of the water. The problem that arises however, is that water absorbs air slowly over time and as the air volume is reduced there is a corresponding reduction in the pressure that is produced thereby and is responsible for keeping additional water out. As more water enters the tank it eventually reduces the air cushion in the expansion tank to a point where no provision for water expansion is left. Furthermore, the water in the expansion tank is constantly circulating between the tank and the boiler and as it does, it carries the tank air out into the rest of the system. The air that gets into the system results in the often unsettling knocking and gurgling noises in the pipes with which everyone is familiar.
Another problem that arises by the removal and absorption of air by water is that the expansion tank eventually becomes completely filled with water and flooded and as a result no leeway exists for expansion. In the past, in order to alleviate the problem, air has to be pumped back into the tank. Numerous devices have been developed for collecting expansion tank air which is then pumped back into the expansion tank. Some devices collect the air as it is released in the boiler others collect it at some point in the system's pipes and pump it back to the tank. These are marginally effective however, and require the use of air vents on all the radiators, pipes and the boiler. Other manual means of pumping air back into the system requires drainage of the system, pumping air back into it and refilling the boiler and pipes which is both time consuming and costly. This unfortunately, is what is most often required.
The present invention is a means to put air back into the expansion tank without having to drain the entire system and later refill it. Other attempts to do this have been made in the past but nowhere are the results achieved in such a simple and efficient manner.
U.S. Pat. No. 4,013,221 to Eder entitled Pressure Balancing Device for Heating Systems discloses an expansion tank with a number of internal chambers which are connected to a heating system by feed and drain pipes whereby the flow of water into and out of the expansion tank is regulated by a valve and a pump. The pressure sensitive device actuates the pump to force water from the expansion tank to the heating system when there is a drop in pressure in the system. The device also detects when there is too much pressure in the system and opens the solenoid valve so that water can escape back into the expansion tank. The device works by means of a bellow within the expansion tank which is in contact with the outer air. The invention is directed to the regulator device which monitors pressure and water problems rather than solves them. There is no appreciation of the problems resulting from flooded expansion tanks nor is there any suggestion of any means to cure the problem.
U.S. Pat. No. 4,424,024 to Wilson, et. al. discloses a conventional heating system whereby an expansion tank is in operative communication with a furnace or hot water storage unit so that any back up of water or expansion thereof from the boiler unit is released to the expansion tank wherein it is contained. Any subsequent drop in pressure in the heating system results in a release of the water back to the boiler unit.
U.S. Pat. Nos. 4,301,320 to Hochstrasser, et. al. and 4,417,871 to Tarumi, et. al. also disclose conventional expansion tanks with release and/or drain valves as a part of heating systems known in the art. As before, neither of these patents appreciate the problems inherent in expansion tank flooding and the alleviation thereof. Valves and drain cocks are disclosed which presumably are used to drain the entire system as is known in the art.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall schematic view of a boiler unit and attached expansion tank together with the flusher component of the present invention attaching the air pump directly to the expansion tank drain valve.
FIG. 2 is a cross-sectional view of the flusher component useful in the practice of the present invention.
FIG. 3 is an exploded schematic diagram of the flusher component useful in the practice of the present invention.
FIG. 4 is a second embodiment of present invention wherein the flusher component and air pump are attached to a hose.
SUMMARY OF THE INVENTION
The present invention is a simple and effective means to partially clear flooded expansion tanks used in conventional hydronic heating systems. An air pump means is attached to the drain valve of the expansion tank by a specially modified flusher connection component. Air is then pumped into the tank, forcing the water contained therein out into the system. Knowing the dimensions of the expansion tank, the amount of water needed to be removed is calculated and the water then can be drained from the boiler without the need for purging and refilling the entire system.
DETAILED DESCRIPTION OF THE INVENTION
In order to properly flush a flooded expansion tank using the device of the present invention, it is necessary to know the proper water/air ratio that exists for the tank in question. It is therefore necessary to determine the volume of the expansion tank. Once this volume is known, approximately one-half that volume of water can be removed and the proper water/air ratio will be achieved.
Since the average residential expansion tank is designed to fit between floor joists that allow fourteen inches (14") between joists (16"center to center), conventional residential expansion tanks are generally twelve inches (12") in diameter, the radius being six inches (6"). This measurement is a constant. The length of the tank varies depending upon the size of the system and its requirements.
The volume of the expansion tank can be determined by using the formula for determining the volume of a cylinder (V=.sup.[r 2 ) and multiplying that by the length of the tank.
______________________________________ Example: (V = IIr.sup.2) × length .sup. V = (3.14 × 6.sup.2) × length .sup. V = (113.04.sup.2) × lengthIF: length = 30" Then: .sup. V = 3391.2 in..sup.3______________________________________
Knowing that the volume of one gallon of water is 231 in 3 , and given the above information, by dividing the cubic inches of the tank by 231 cubic inches, one can determine how many gallons of water are contained in the expansion tank. By knowing how many gallons the expansion tank holds, how much water should removed from a given system can be determined in order to achieve a proper air/water ratio. Generally, one-half of the volume of a filled expansion tank will be drained in order to create the proper water/air equilibrum. By using the constant r=113.03 in. 2 and multiplying that constant by the length of the expansion tank, the following chart can enable one to determine how much water to remove from a given tank. The diameter constant is that for conventional residential expansion tanks.
______________________________________Diameter Tank Capacity GallonsConstant Length Volume to RemoveII.sup.2 in. in..sup.3 Gals. 1/2 of Vol______________________________________113.04 22" 2486.8" 10.76 5.38113.04 24" 2712.9" 11.74 5.87113.04 26" 2939.0" 12.72 6.36113.04 28" 3165.1" 13.70 6.85113.04 30" 3391.2" 14.68 7.34113.04 32" 3617.2" 15.65 7.82113.04 34" 3843.3" 16.63 8.31113.04 36" 4069.4" 17.16 8.58113.04 38" 4295.5" 18.59 9.29113.04 40" 4521.6" 19.57 9.78113.04 42" 4747.6" 20.55 10.27113.04 44" 4973.7" 21.53 10.75113.04 46" 5199.8" 22.50 11.25113.04 48" 5425.9" 23.48 11.74______________________________________
As shown in FIG. 1, in order to remove the water from the flooded expansion tank, the flusher element (2) of the present invention is attached directly to the drain valve (4) of the expansion tank (6). Preferably the air pump (8) is attached directly to the flusher element (2) and operated accordingly. In a second embodiments a hose or tube (26) may also be used to attach the air pump (8) to the drain valve (4) of the expansion tank (6), as shown in FIG. 4. The flusher element (2) is then attached at the distal end from the valve. The hose is generally utilized in this manner in instances where the pumping mechanism must be located some distance from the valve due to space limitations.
A second hose (10) is then attached to the boiler drain valve (12) at one end and fed to a graduated bucket at the other end (not shown) so that the amount of water drained from the system can be monitored. The pressure that is inherently built up in the system must first be released at the drain valve (12) attached to the boiler. Referring again to FIG. 1, the flusher component (2) of the present invention is attached to the expansion tank drain at this time and acts as a connective piece for the pump which provides the pressure to expel the excess water and residual pressure. Again, a hose as shown in FIG. 4 can also optionally be connected therebetween if necessary.
Referring now to FIG. 2, the flusher connector element is comprised of a standard Schrader Air Valve (16) which is threadably attached (18) to a one-half (1/2) or three-quarter (3/4) inch by one-eighth (1/8) inch bushing (20). A duel female adapter (22) threadly engages both the male end of the bushing (36a) and the male threads of the expansion tank drain valve (4), thereby attaching the air valve (16) to the drain valve (4). The air pump (8) attaches directly to the air valve (16) and is operated accordingly.
Referring now also to FIG. 3, the flusher connector (2) then, is a means for connecting the male threading (28) of an air valve (16) that is smaller and incompatible with the male threading (30) on the expansion air tank drain valve (4). This is made possible using the bushing (20) which contains both male (32) and female (34) threaded ends. The duel female adapter (22) possessing two different sized female threaded ends (36a,36b) enables the attachment of the smaller sized bushing (20) and air valve (16) to the larger expansion tank valve (4).
FIG. 4 is a further embodiment of the present invention for use when the boiler and expansion tank is in an area in which tight space prohibits attachment of the air pump directly to the Schrader Air Valve. A hose or tubing (26) may be attached to the drain valves and the pump so that the actual air source can be operated some distance from the valve.
Air is pumped into the system, i.e. the expansion tank (6), and the drain valve of the boiler unit (12) is opened and pressure is released. As additional air is pumped into the system, water is forced out and the pumping continues until the desired amount of water is flushed out of the expansion tank and subsequently the boiler unit. The right amount is known by monitoring the amount of water collected in the calibrated bucket. Once the amount of water equivalent to one-half the volume of the expansion tank is collected, the valves are closed and the system stabilized and equilibrated by continued pump of air into the system until the desired system pressure is reached. This is determined by reading the boiler pressure/altitude gauge. Usually a reading of 10-12 psi is suitable.
Whereas minor variations and modifications are always possible which can change the present invention by varying degrees, they are all contemplated as falling within the spirit and scope of the following claims. | A method for purging water from flooded expansion tanks without necessitating the complete drainage and subsequent refilling of the systems allows for a stabilized hydronic water system in much less time with less effort and expense. | 8 |
BACKGROUND OF INVENTION
1. Field of the Invention
The invention relates to a method for assessing the roughness of planar surfaces of manufactured products, and an apparatus for carrying out the method. More specifically, the invention relates to such a method using a processor based optical system.
2. Description of Prior Art
Surface roughness measurement is becoming one of the important measurement processes in production as manufacturing industries are more concerned about their product quality and reliability. Proper control of surface finish of machined parts not only reduces the production cost of the part but also lowers the amount of scrap. In addition, surface roughness measurement is required not only for ensuring the quality of the part, but also for monitoring tool vibration and tool wear. Early detection in tool wear allows a replacement of tools before any impending failure.
Surface roughness is also one of the important considerations in the selection of paper for printing as it affects both print quality and paper handling characteristics in hard copy devices.
Various methods have been developed to assess surface quality and to derive a roughness parameter which can be related to the quality of the surface.
The traditional way of directly measuring the surface roughness is by a Talysurf in which the movement of a stylus is correlated to the surface profile. These devices electronically correlate the motion of a diamond-tip stylus to the roughness of the surface under investigation. The major disadvantage for such instruments is that they require direct physical contact which limits the measuring speed. In addition, the instrument readings are based on a limited number of line samplings which may not represent the real characteristics of the surface. Because of the slow measuring speed, quality controls based on such instruments are often performed on a very limited number of samples.
Air-leak instruments are most commonly used in the printing industry because they are simple and convenient to use. These include Bekk, Bendtsen, Gurley Hill, and Sheffield testers. Despite the popularity of the test carried out with these instructions, the tests are, in general, not conducted under the same pressure as an actual printing, and thus they do not necessarily correlate well with print quality. For improvement, the Parker Print surf was developed to adapt to different printing pressure. However, the inherent drawback of this latter device is that the measured air-leak is not only a function of paper roughness but also the material porosity which is difficult to measure separately.
Electro-optical devices have been introduced as a better alternative for non-contact roughness measurements. Linear diode arrays are often used in these systems for measuring the intensity of reflected light from coherent light sources. These systems can achieve a faster inspection speed, however, they do not provide enough information to characterize the surface topography and surface texture which are needed for applications in machining process monitoring. Furthermore, most of these systems are for laboratory use, and are not suitable for high speed automated inspection in a production environment.
SUMMARY OF INVENTION
It is therefore an object of the invention to provide a novel method for assessing the roughness of planar surfaces of manufactured products which overcomes the above disadvantages.
It is a further object of the invention to provide an apparatus for carrying out the method.
In accordance with the invention, the method is carried out by a relatively low cost processor based optical system. An area of the surface whose roughness is to be assessed is illuminated by a light source, and the reflected light is directed to the lens of a video camera. The analog output of the video camera is digitized, and the digital signal is provided to a processor which performs an analysis to provide a parameter indicative of the roughness of the surface.
The novel method makes use of the property of the unique light scattering pattern of a machine surface from which several descriptors are derived to check surface flaws and to measure surface roughness.
A histogram of grey-level distribution of the image is obtained from which statistical parameters are calculated to derive an optical roughness value.
BRIEF DESCRIPTION OF DRAWINGS
The invention will be better understood by an examination of the following description, together with the accompanying drawings, in which:
FIG. 1 is a block diagram of the inventive system for carrying out the inventive method;
FIG. 2 illustrates frequency distributions of the intensity of the reflective lights from tool steel samples machined to different roughnesses;
FIG. 3 is a histogram of a surface with surface flaws; and
FIG. 4 is a calibration curve relating optical roughness to surface roughness.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, a surface 1, whose roughness is to be assessed, is disposed in the path of illumination of a source of illumination 3 which illuminates an area of the surface. The light source is preferably a collimated 12 W tungsten lamp which is directed at the inspected surface at a small grazing angle G. Although not shown in FIG. 1, it will of course be appreciated that the source of illumination 3 will include means for adjusting the grazing angle G as well as means for adjusting the distance of the source of illumination 3 from the surface 1. In a particular embodiment of the invention, the optimum setting of the grazing angle was 7.5 degrees and the optimal distance was 100 mm. (Luk, F., Huynh, V. and North, W., "Measurement of Surface Roughness by a Vision System", ASME International Computers in Engineering Conference, 1987, the contents of which are incorporated herein by reference.)
A video camera 5, having an input lens 6, is mounted above the surface so that the lens is trained on the area illuminated by the source of illumination 3. Reflected light 4 from the illuminated area is directed at the lens of the video camera 5 whereby to provide an analog output representative of surface characteristics of the area. The reflected light 4 is preferably directed to the lens 6 through microscope optics 7. In one embodiment, the video camera is a Pulnix industrial CCD (charge coupled device) camera fitted with a Unitron microscope optical system which is capable of giving 200× magnification. This camera is a black and white video camera with a resolution of 384(h)×491(v) pixels.
The analog output is provided to frame grabber 9, which may comprise a Matrox PIP-1024 imaging board which includes a digitizer 11 and a frame buffer 13. The digitized signal is then fed to processor 15 which may comprise an IBM PC-AT microprocessor having a monitor 17. The output of the processor 15 may then be fed to a printer 19, a plotter 21, or both.
The output of the digitizer 11 may also be fed to a video monitor 23 whose second output is fed from the processor 15. The video monitor displays a magnified image of the area of the surface 1 under inspection.
In operation, the surface of a product to be inspected is disposed under the camera as in FIG. 1. The source of illumination is adjusted for its optimum grazing angle G and distance from the surface, and the source of illumination is turned on. The analog signal generated by the camera is transferred to the frame grabber board 9 for signal processing and analysis. The digitizer digitizes the analog signals through its A/D converter to generate an image, when the Matrox PIP-1024 imaging board is used, of 512×512×8 bit pixels in approximately 1/30th of a second. Each pixel is contained in a single byte and hence represents the intensity of light at a given point in 256 discrete intensity levels of which 0 is the darkest and 255 the brightest. A histogram of the frequency distribution of the grey levels of the digitized image is subsequently obtained. From this histogram, calculations are made to determine the roughness parameter R which is defined by:
R=SD/RMS
where:
SD=standard deviation of the distribution
RMS=root mean square height of the distribution.
The numerical calculations for these parameters were performed as follows: ##EQU1## F i =number of pixels at grey level X i as determined from the histogram, and
n=255 for the Matrox PIP-1024 board.
The skewness of the distribution is defined as follows: ##EQU2##
Specific examples are given in F. Luk and V. Huynh, "Vision System for In-Process Surface Quality Assessment", Proceedings of Vision '87 Conference, June 8-11, 1987, Detroit, MI., the contents of which are incorporated herein by reference.
FIG. 2 illustrates the grey-level histograms of the scattered light patterns of tool steel samples which are ground to different roughnesses. The frequency distributions in this Figure are uni-modal and skewed slightly to the right (skewness is positive). As the surface roughness increases, the spread and the mean value of the distribution increase, while the height of the distribution decreases. This indicates that for rougher surfaces, the light scattering effect is greater.
We have above described one method for determining the roughness parameter. Other methods are available as described, for example, in F. Luk, V. Huynh, W. North, "Application of Spatial Spectral Analysis to In-line Machine Inspection of Surface Roughness", Proceedings of the IXth ICPR Conf., Vol. I, Aug. 17-20, 1987, Cincinnati, Ohio, the contents of which are incorporated herein by reference.
It is also possible to detect surface flaws using the inventive method and system. Surface flaws are irregularities which do not occur in any consistent pattern such as surface defects, scratches, indents, etc. These irregularities change the light scattering characteristic of the surface. The grey-level histogram of the damaged surface is the combination of two entirely different populations: one belongs to the regular surface and the other, the flaws. The population belonging to surface flaws has a lower mean and a much smaller spread. The addition of this population to that of the regular surface causes a shifting of distribution from uni-modal to bi-modal with the second peak at the left side of the distribution as illustrated in FIG. 3 hereof. The form of this peak depends on the size, the amount and severity of the flaws.
The addition of the flaw population to the original distribution also causes the skewness of the histogram to decrease from a slightly positive value to a negative value. By utilizing this property, one can check the presence of the surface flaws by simply detecting the sign of the skewness of the distribution.
Accordingly, in one embodiment, and especially with machine parts, one would first check for the presence or absence of flaws. The check is performed by calculating the sign of skewness using the above formulae. If there is a flaw, then the part can be immediately discarded. If there is no flaw, then the roughness parameter can be calculated to determine whether it falls between two predetermined levels. If it does not, then it is discarded. If it does, then it is acceptable.
In one set of tests, a system as above-described was calibrated using a series of tool steel samples. By measuring the optical roughness of the samples, a set of R values was obtained. These were plotted against the average surface roughness Ra obtained from a Talysurf instrument. A curve was fitted to the data as shown in FIG. 4. It can be seen that this curve is linear for Ra between 0.1 to 0.5 μm which is the practical range for most machining processes. Beyond this range, the slope of the curve gradually decreases with increasing roughness.
This curve, once established, can be used as a calibration curve to relate the optical roughness measurement as determined by the system to mechanical roughness. In practice, only a few limited samples need to be used to generate the linear portion of the calibration curve even though the calibration curve for different materials is different.
Although the method has been above-described for use in determining the roughness of machine surfaces, it can also be used to determine the roughness of paper surfaces as described in Huynh, V., Miller, W. H., "A New Optical Method for the Measurement of Roughness of Paper Surfaces", Proceedings of the SID, Vol. 28/4, 1987, the contents of which are incorporated herein by reference.
Although several embodiments have been above described, this was for the purpose of illustrating, but not limiting, the invention. Various modifications, which will come readily to the mind of one skilled in the art, are within the scope of the invention as defined in the appended claims. | A relatively low cost processor based optical system is used to carry out the method. An area of the surface whose roughness is to be assessed is illuminated by a light source, and a reflected light is directed to the lens of the video camera. The analog output of the video camera is digitized, and the digital signal is provided to a processor which performs an analysis to provide a parameter indicative of the roughness of the surface. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a procedure for acquiring orientation of a spacecraft relative to the earth during an encirclement of the earth by the spacecraft and, more particularly, in a first embodiment of the invention, to a procedure employing an alignment of a yaw axis of the spacecraft with the sun followed by a scanning movement of the spacecraft for sighting the earth by an earth sensor.
The orientation of a satellite, or spacecraft, encircling the earth is described in terms of a local coordinate system centered at the spacecraft and having three mutually perpendicular axes, namely, a yaw or z axis, a roll or x axis, and a pitch or y axis. In the case of a geosynchronous spacecraft traveling along an essentially circular orbit around the earth, and correctly oriented with the earth, the positive z axis points toward the center of the earth, and nominally, without yaw biasing, the positive x axis points in the direction of travel along the flight path of the spacecraft. The x, y and z axes form a right handed coordinate system.
In the performance of many types of missions, it is essential for the spacecraft to maintain its orientation relative to the earth during travel along a path encircling the earth. An example of such a mission is the generation of a sequence of photographs of the earth's cloud cover, wherein a displacement of certain cloud features among successive ones of the photographs would be indicative of cloud movement. The accuracy with which the cloud movement can be determined is dependent on the stability of the spacecraft orientation because any instability in the orientation would give a false reading of cloud displacement among the sequence of photographs. A further example of a mission requiring stable orientation arises in the case of a communications satellite wherein antenna radiation patterns are directed to specific geographical areas. A rotation of the spacecraft away from its desired orientation would offset an antenna radiation pattern from its designated geographical area resulting in degradation of the communication.
In the event that the spacecraft orientation becomes destabilized, it is important to reestablish the desired orientation rapidly. This is readily appreciated in the case of the communications mission wherein a lapse of several hours for reestablishing spacecraft orientation would create an unacceptable inconvenience to persons utilizing the communications function of the spacecraft. A problem arises in that with presently available procedures, the amount of time required to reestablish orientation is excessively long and that, furthermore, implementation of the procedures may require a significant amount of aid from a ground station which tracks the spacecraft. Preferably, the reorientation of the spacecraft should be accomplished with little or no aid from a ground tracking station.
SUMMARY OF THE INVENTION
The aforementioned problems are overcome and other advantages are provided by a spacecraft orientation procedure which, in accordance with a first embodiment of the invention, can be practiced with an earth sensor of the spacecraft in conjunction with one instruction provided either autonomously by on-board equipment, or by a ground tracking station regarding an orientation of a spacecraft reference plane to enable locating the earth by the earth sensor. Furthermore, in accordance with a second embodiment of the invention, the orientation can be established without aid from the ground tracking station by use of at least one telemetry and command (TC) antenna having a total field of view, as measured in one plane, which is greater than a semicircle. In the second embodiment, the orientation procedure provides for rotation of the spacecraft about the x axis for a scanning of the antenna to intercept command signals broadcast from the earth, thereby to locate the earth in a first reference plane. Rotation about the y (pitch) axis enables measurement of command signal strength for location of the earth in a second reference plane perpendicular to the first reference plane. Gyrocompassing establishes yaw in both embodiments of the invention.
The invention is to be described with reference to a specific configuration of spacecraft to facilitate explanation of the invention. By way of example, the spacecraft is a communications satellite encircling the earth in a circular, geosynchronous, generally equatorial orbit with no yaw bias. Two TC antennas with their associated electronic communication equipment are carried by the spacecraft to enable communication of control signals from ground stations to the spacecraft. One of the TC antennas is oriented in the positive z direction so as to face the earth, and the second of the telemetry antennas is oriented in the negative z direction to face away from the earth. The opposed orientations of the telemetry antennas, in concert with their relatively broad fields of view, enable ground control personnel to communicate with the spacecraft for all possible orientations of the spacecraft as might occur if the spacecraft were tumbling. The spacecraft is provided furthermore with an earth sensor which is oriented in the positive z direction for viewing the earth when the spacecraft has its desired orientation relative to the earth. A sun sensor is oriented in the negative x direction, and a gyro sensor assembly provides accumulated change in angular orientation of the spacecraft, including the three components of roll, pitch and yaw.
In the method for obtaining the desired orientation of the spacecraft, there are steps of pointing the sun sensor at the sun and then employing inertial rotations using a gyro to point the negative z axis toward the sun. This inertial rotation employs the gyro sensor assembly which has three gyro sensors disposed respectively on each of the x, y and z axes for indicating angular movement of the spacecraft during a reorientation of the spacecraft. In the practicing of these two steps, it is understood that the sun sensor is directed along the negative x axis, and that the earth sensor is directed along the positive z axis. In the practice of still further steps found in the second embodiment of the invention, it is understood that the TC antennas are oriented respectively in the positive and the negative z directions. Generally speaking, spacecraft are constructed in a variety of configurations corresponding to specific missions which are to be accomplished. In the event that one of the foregoing sensors or antennas were to be directed along a different axis than is disclosed in the foregoing example of spacecraft, then the procedure is to be modified accordingly. For example, if the the sun sensor were to point in the positive y direction, then sun acquisition would be accomplished initially by pointing the positive y axis toward the sun, after which gyrocompassing could be employed to reorient the spacecraft to bring the z axis in the desired orientation. Thus, the description of the method steps is based on the locations and/or orientations, relative to the body of the spacecraft, of the sensors and antennas used in practicing the method of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The aforementioned aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawing figures wherein:
FIG. 1 shows a stylized view of a spacecraft encircling the earth and constructed with sensors and antennas useful in determining orientation of the spacecraft in accordance with the invention;
FIG. 2 is a top view, partially diagrammatic, of a body of the spacecraft of FIG. 1 showing beam radiation patterns (fields of view) of TC antennas carried by the spacecraft;
FIG. 3 is a side view, partially diagrammatic, of the body of the spacecraft of FIG. 1 showing beam radiation patterns (fields of view) of the TC antennas carried by the spacecraft;
FIG. 4 is a diagram showing relative positions of the spacecraft, the earth, and the sun wherein the spacecraft is located between the earth and the sun;
FIG. 5 is a diagram showing relative positions of the spacecraft, the earth, and the sun wherein the spacecraft has moved ninety degrees around the earth from the spacecraft location of FIG. 4; and
FIG. 6 is a graph showing one period of signal strength received by use of two opposed TC antennas of the spacecraft of FIG. 1 during rotation of the spacecraft about its roll axis.
Identically labeled elements appearing in different ones of the figures refer to the same element in the different figures but may not be referenced in the description for all figures.
DETAILED DESCRIPTION
With reference to FIG. 1, there is shown a spacecraft 20 traveling in a geosynchronous orbit about the earth (shown in FIGS. 4 and 5). A system of coordinate orthogonal axes, including x, y and z axes, extends from a body 22 of the spacecraft 20, and serves to identify orientations of components of the spacecraft 20 as well as various steps of rotation of the spacecraft 20 as will be described for the practice of the invention. A solar panel 24 (shown in FIG. 1) extends northerly from the body 22 along the negative y axis, and in the opposite direction, there extends from the body 22 a boom 26 carrying a solar sail 28 (shown In FIG. 1). The solar panel 24 has solar cells for converting solar energy to electric energy for powering electrical circuitry of the spacecraft. Two communication antennas 30 and 32 are disposed on opposite sides of the body 22, and operate in different frequency bands of a communication system with ground stations (not shown) located on the earth. Each of the antennas 30 and 32, by way of example, has a feed comprising an array of radiators, one such feed 34 being shown for the antenna 30. The antennas 30 and 32 comprise reflectors 36 and 38, respectively, for directing beams of radiation from their respective feeds in the positive z direction for signal transmission to and from the earth. It is noted that the directional identifications of north, south, east and west provided respectively for the axial directions identified as -y, +y, +x and -x apply only in the situation wherein the spacecraft 20 is properly oriented relative to the earth with the +z direction facing toward the earth and the -z direction facing away from the earth, preferably without yaw bias. The spacecraft 20 is traveling along its orbit in the easterly direction which is the direction of the +x axis.
In order to practice the invention, as well as for communication of command signals with ground stations for control of the spacecraft 20, the spacecraft 20 carries a first TC antenna 40 and a second TC antenna 42 electrically connecting with communication hardware, the TC antennas 40 and 42 extending from the body 22 respectively in the positive and the negative z directions. A set of well known thrusters, two of which are shown at 46 by way of example, are disposed on the body 22 for imparting rotations to the spacecraft 20 about any one or ones of the axes x, y and z to provide a desired orientation of the spacecraft 20. An earth sensor 48 views radiation from the earth for locating the earth, the sensor 48 being carried by the body 22 and facing in the +z direction. A sun sensor 50 views radiation from the sun for locating the sun, the sensor 50 being carried by the body 22 and facing in the -x direction. The spacecraft body 22 also carries a gyro sensor assembly 52 for providing data of incremental change of angular orientation of the spacecraft 20 to a navigation computer 54, also located in the body 22. The computer 54 outputs signals for control of the thrusters 46.
The gyro sensor assembly 52 is understood to comprise a set of sensors oriented along respective ones of the axes x, y and z for sensing angular rate of the spacecraft 20 about the respective axes. The gyro sensors may be mechanical or electromagnetic. It is preferable to employ a gyro sensor assembly including digital signal processing which provides for integration of sensed angular rates to output sampled data of accumulated angular increments between the output samples. Such a gyro sensor assembly may be referred to as a Digital Integrating Rate Assembly (DIRA). The DIRA provides the navigation computer 54 with an amount of rotation undergone by the spacecraft 20, with respect to all of the three axes x, y and z, during maneuvers of the spacecraft 20 undertaken in the practice of the invention, which maneuvers will be described hereinafter as procedural steps of the invention.
The TC antennas 40 and 42 are used, as disclosed above, for communication of command signals, and are used furthermore, in accordance with a feature of one embodiment of the invention, for sensing the presence of command signals to indicate the presence of the earth, much in the same manner as the operation of the earth sensor 48 for locating the earth. This is accomplished by rotating the spacecraft 20 about the x axis, and also about the y axis, after suitably positioning the spacecraft in a manner to be described. Upon a positioning of the spacecraft 20 such that the foregoing rotation can bring the radiated command signals from the earth into the fields of view of the TC antennas 40 and 42, there is obtained a periodic pulsation in received signal amplitude at each of the antennas 40, 42. One period of the pulsation in signal strength received by use of both of the TC antennas 40 and 42 is shown in FIG. 6 for the case of rotation of the spacecraft 20 about the roll axis. Peak amplitude or a centroid of the received signal pulsation serves as an indication of the location of the earth. Such a detection can be accomplished even with a single one of the TC antennas 40, 42, but is accomplished preferably by use of both of the TC antennas 40 and 42. In the case of the use of both antennas 40 and 42, nulls in the amplitude of the detected signal pattern also provide data for the location of the earth. While two peaks are shown in the graph of FIG. 6, it should be noted that, under certain circumstances depending on the specific configuration of the field of view of the antenna 42, it is possible to obtain only one peak. Rotation of the spacecraft 20 about the x axis provides earth location data referenced to the x-z plane, while rotation of the spacecraft 20 about the y axis provides earth location data referenced to the y-z plane. This detection of the earth's location is sufficiently accurate to allow the spacecraft 20 to be rotated to face the earth such that the earth sensor 48 can view the earth. The earth sensor 48 is employed then to enable a further rotation and accurate alignment of the spacecraft 20 with the earth.
FIGS. 2 and 3 show radiation patterns of the TC antennas 40 and 42. In order to guarantee a sensing of earth presence in one roll of rotation of the spacecraft, the TC antenna 40 has a field of view in excess of 180 degrees as measured in the x-z plane presented in FIG. 2. A combination of TC antennas with overlapping fields of view greater than 180 degrees may also be used. If this condition is not met, then detection of the earth may be delayed due to the spacecraft's position in the orbit. In the y-z plane, the field of view of the antenna 40 is 100 degrees, the being the same width of the field of view of the antenna 42 as measured in both the x-z and the y-z planes. Beam orientations relative to the z axis, as well as the fields of view, are shown in FIGS. 2 and 3. In the y-z plane of FIG. 3, the fields of view of the antennas 40, 42 are symmetrical relative to the z axis; however, in the x-z plane of FIG. 2, the fields of view of the antennas 40, 42 are angled outwardly toward opposite sides of the spacecraft body 22. These configurations and orientations of the fields of view of the antennas 40 and 42 enable the antennas 40 and 42 to be employed in the dual roles of telemetry/command communication and earth position sensing.
In both FIGS. 4 and 5, rays of light from the sun are disposed parallel to each other, and illuminate the earth as well as the spacecraft 20 in various positions along the spacecraft orbit. In FIG. 4, the space craft 20 is directly in line with the earth and the sun, and located between the earth and the sun. In FIG. 5 the spacecraft 20 has advance along its orbit in an arc of 90 degrees. It is noted that in the passage of the spacecraft 20 along its orbital path, the spacecraft 20 may rotate such as to maintain its z axis pointing toward the center of the earth or, alternatively as in a sun-acquisition mode, the x axis may be kept parallel to an initial reference orientation as the spacecraft 20 progresses about its orbital path. These forms of travel will be discussed in the practice of the method steps of the embodiments of the invention, to be described in the following methodology. The methodology for regaining spacecraft orientation is to be provided in the situation wherein the spacecraft 20 has lost its orientation to such an extent that the earth is no longer in the field of view of the earth sensor 48, and is applicable even in situations where one of the coordinate axes is reversed in direction.
In the first embodiment of the invention, the method of orienting the spacecraft 20 begins with a sun acquisition step in which the spacecraft 20 is rotated about the y and/or the z axis to bring the sun into the field of view of the sun sensor 50. The sun sensor which has, in a typical form of construction, a photocell detector able to generate signals which locate the sun relative to the sun sensor 50. These signals of the sun sensor 50 are employed by spacecraft control electronics of the navigation computer 54 to point the spacecraft 20 accurately towards the sun. Since the sun sensor 50 is directed along the negative x direction, the -x axis points toward the sun at the conclusion of the sun acquisition step. Again, it is emphasized that this description is based on the spacecraft configuration of FIG. 1. For example, if the sun sensor were oriented along the -y direction in some other spacecraft configuration (not shown), then the this step of the method would be accomplished by rotation of the spacecraft 20 about the x and/or z axes resulting in a pointing of the -y axis toward the sun. It is to be understood, therefore, that in the practice of the invention, the designated axes of rotation of the spacecraft 20 are to be altered to conform to the specific orientations of sensors which may be present upon spacecraft having configurations different from the present spacecraft 20.
The method continues by commanding zero rotational rates in roll, pitch and yaw. These commands are issued by either the ground controllers via the TC antenna 40, 42 to the navigation computer 54, or autonomously by the navigation computer itself. It is understood in the practice of this embodiment of the invention that the ground personnel can command the spacecraft 20 at any point in the spacecraft orbit and that, furthermore, the ground station or the on-board navigation computer 54 can determine the spacecraft position with respect to the earth and the sun at any point in the spacecraft orbit.
The next step involves use of the gyro sensor 52 (the DIRA) for imparting a rotation of the spacecraft 20 about the y axis through an angle of 90 degrees in the x-z plane to align the z axis with the sun by pointing the -z axis toward the sun. In the foregoing steps it has been presumed that the spacecraft 20 is located between, or approximately between, the earth and the sun as in FIG. 4. However, if the spacecraft 20 is located such that the earth is between the spacecraft 20 and the sun, then the foregoing step would be modified so that the +z axis is to be pointed toward the sun. The foregoing steps of the procedure are to be performed only when the spacecraft 20 is within +/-45 degrees of the sun/earth line. When the spacecraft 20 is outside these roughly "colinear" regions of space, it is not necessary to perform the foregoing steps since the earth sensor, in conjunction with biasing the sun sensor, shall already detect the earth within one roll of rotation of the spacecraft.
In the following step, use is made of the sun line, a vector extending from the spacecraft toward the sun, the vector being parallel to a sun ray shown in FIGS. 4 and 5. A further vector, the earth vector, extends from the spacecraft to the earth. The step is accomplished by rotating the y axis of the spacecraft to bring the magnitude of the included angle between the spacecraft z axis and the sun line to equal the magnitude of the included angle between the earth vector and the sun line.
An off-axis spin of the spacecraft 20 is provided in the next step by rotating the spacecraft 20 about a vector extending to the sun from the center of the xyz coordinate system in the spacecraft body 22. The off-axis spin is accomplished by use of position and rate information provided by the DIRA. Due to the geometry of the off-axis spin, this procedure of orienting the spacecraft 20 may be referred to as the cone earth acquisition procedure. The off-axis spin has the effect of moving the earth sensor 48 through an arc which brings the earth into the field of view of the earth sensor 48. Once the earth is in the field of view of the earth sensor 48, the spacecraft 20 is rotated about the x and the y axes using information from the earth sensor, this constituting roll and pitch maneuvers, to center the earth in the field of view of the earth sensor 48 and thereby acquire the earth by the earth sensor 48. The z axis is now pointing at the center of the earth. Gyrocompassing is then employed to estimate a yaw error based on earth sensor and DIRA measurements to perform a yaw maneuver to point the x and the y axes in their correct east-west and north-south directions.
In the second embodiment of the invention, the method of orienting the spacecraft 20 by use of the TC antennas 40, 42 is accomplished in the following manner. This procedure may be referred to as the antenna assisted earth acquisition procedure. The spacecraft x axis may be facing the sun as in the first embodiment of the invention, by this is not a requirement of the second embodiment of the invention. This embodiment of the invention requires only the DIRA for attitude sensing in order to maneuver the spacecraft so that its +z axis is pointed toward the earth, regardless of the initial spacecraft orientation.
As has been described with reference to FIG. 1, the TC antennas 40, 42 face outwardly from the x-y plane and, therefore, may be rotated through an arc for viewing command signals emanating from an earth station by rotation of the spacecraft 20 in roll about the x axis or in pitch about the y axis. For purposes of the practice of the method of orientation of the spacecraft 20, the viewing of the command signals by the TC antennas 40, 42 may be regarded as a viewing of the earth, much in a manner analogous to the operation of the earth sensor 48 in viewing the earth by detection of infrared radiation emanating from the earth.
The method continues with a step of rolling the spacecraft 20 about the x axis. As the spacecraft 20 rolls, command signals are received by the antennas 40, 42 with signal strength that varies as a function of the roll angle as has been described above with reference to FIG. 6. A history of the signal strength is stored in a memory (not shown) of the electronic circuitry, such as the communication circuitry 44 or the navigation computer 54, of the spacecraft 20 as a function of the roll angle. The roll angle is provided by the DIRA. As described above, the peak signal strengths of signals received by the two TC antennas 40, 42 may be employed to give earth location in terms of roll angle. The spacecraft 20 is then rotated about the x axis to the roll coordinate of the earth's location to place the earth in the x-z plane. The next step is to rotate the spacecraft 20 about the y axis, this being a pitch maneuver, to obtain a further history of command signal strength as a function of pitch angle, the pitch angle being provided by the DIRA. Again, the locations of signal peaks may be employed, as described above, to locate the earth in the pitch coordinate. The spacecraft 20 is then rotated about the y axis to the pitch coordinate of the earth's location to place the earth in the y-z plane.
At this point in the procedure, the earth is located in or approximately in each of the x-z and the y-z planes. The locating of the earth in each of these planes may be only approximate because the signal histories of FIG. 6 provide a measurement which is not as accurate as that obtained by the earth sensor 48. The intersection of these the x-z and the y-z planes is the z axis which, therefore, points at or approximately at the earth. The accuracy of the pointing of the z axis should be adequate to bring the earth into the field of view of the earth sensor 48. However, in the event that the pointing of the z axis is not accurate enough to bring the earth into the field of view of the earth sensor 48, the the steps of rolling and pitching the spacecraft 20 can be repeated to obtain more accurate measurements of the location coordinates of the earth in terms of the x-z and the y-z planes. The resulting pointing of the z axis is then sufficiently accurate to bring the earth into the field of view of the earth sensor 48.
Once the earth is in the field of view of the earth sensor 48, the spacecraft 20 is rotated about the x and the y axes using information from the earth sensor, this constituting roll and pitch maneuvers, to center the earth in the field of view of the earth sensor 48. The z axis is now pointing at the center of the earth. Gyrocompassing is then employed during a yaw maneuver to point the x and the y axes in their correct east-west and north-south directions. Thereby, the second embodiment of the method of the invention has also accomplished the desired orientation of the satellite, but without aid from the ground station, and without need for performing the off-axis spin.
In each of the embodiments of the invention, it is noted that during performance of the respective sequences of method steps, the earth may enter the field of view of the earth sensor during any step of the sequence of steps. If this occurs, the computer 54 terminates the sequence of steps, and directs the spacecraft to perform roll and pitch maneuvers based on the earth sensor data, thereby to center the +z axis on the earth. Gyrocompassing can then be employed to estimate yaw error based on earth sensor and gyro measurements to perform a yaw maneuver to point the x and y axes in their correct east-west and north-south directions.
It is to be understood that the above described embodiments of the invention are illustrative only, and that modifications thereof may occur to those skilled in the art. Accordingly, this invention is not to be regarded as limited to the embodiments disclosed herein, but is to be limited only as defined by the appended claims. | A spacecraft orientation procedure, in accordance with a first embodiment of the invention, is practiced with a sun sensor to bring the x (roll) axis of the spacecraft parallel to a ray of the sun, and with a gyro sensor and an earth sensor of the spacecraft in conjunction with one instruction provided either autonomously or by a ground tracking station regarding an orientation of a spacecraft reference plane to enable locating the earth by the earth sensor. Furthermore, in accordance with a second embodiment of the invention, the orientation is established without aid from the ground tracking station by use of at least one telemetry and command antenna having a continuous field of view, as measured in one plane, which is greater than a semicircle. In the second embodiment, the orientation procedure provides for rotation of the spacecraft about the x axis for a scanning of the antenna to intercept command signals broadcast from the earth, thereby to locate the earth in a first reference plane. Rotation about the y (pitch) axis enables measurement of command signal strength for location of the earth in a second reference plane perpendicular to the first reference plane. Gyrocompassing establishes yaw in both embodiments of the invention. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to the use of a method for the manufacture of an electric thin film circuit according to the Muenz et al U.S. Pat. No. 4,200,502 issued Apr. 29, 1980 incorporated herein by reference for the manufacture of conductor crossovers with TaAl/SiO 2 capacitors having as low a capacitance as possible.
The above noted patent application relates to a method for the manufacture of an electric thin layer circuit which comprises at least one capacitor and a conductor and/or resistance. In order to form these circuit elements on an insulating substrate, first a layer of a tantalum-aluminum alloy with a tantalum fraction of between 30 and 70 gram-atomic %, and subsequently an additional layer of a tantalum-aluminum alloy with a tantalum fraction on the order of magnitude between 2 and 20 gram-atomic % are applied. Then, by means of a first mask and etching technique, at the location of a capacitor to be formed, an interruption in both tantalum-aluminum layers is introduced. In order to produce a two-layer capacitor-dielectric, the tantalum-aluminum layers in the capacitor region are anodically oxidized and a silicon-dioxide layer is applied on the resulting tantalum-aluminum oxide layer. In a second masking and etching technique areas of the two-layer capacitor dielectric not required are removed as well as the tantalum-aluminium layer with the lower tantalum fraction. Finally, by means of an additional mask and etching technique, an electrically highly conductive surface layer is produced on the capacitor-dielectric such as in the region of conductors.
The problem solved in the above noted patent application is in disclosing for electric thin layer circuits a means for further reduction in the total number of masks required for the manufacture of the thin layer circuits. The solution according to the above mentioned patent application is that in a method of the type described in the introduction, with the aid of the first mask and etching technique, additionally the regions of both tantalum-aluminum layers lying outside the circuit element regions are etched away. Then the exposed surfaces of the tantalum-aluminum layers are anodically oxidized over the entire surface and covered with the silicon-dioxide layer applied over the entire surface. The regions of the silicon-dioxide layer which are not required are removed with the aid of a second mask and etching technique. The regions of the tantalum-aluminum-oxide layer and the tantalum-aluminum layer with a low tantalum concentration which are not needed are selectively etched off by utilizing the remaining silicon-dioxide layer as the etching mask. Subsequently, the surface layer is applied.
For the completion of the electric circuits with the aid of the thin film technique, installation locations for hybrid components are most often provided which are connected in separate working steps with the thin film circuit. For economic reasons, an optimum surface use of the thin film circuit is always strived for. Its dimensions are essentially determined by technologically-conditioned properties (surface resistance, surface capacitance) and by the wiring of the thin film components with one another necessary for this circuit, and with the connections leading to the exterior.
Conductor crossovers are constructed from a first "lower" electrically conductive layer, an electrically insulating layer, and a second "upper" electrically conductive layer or layer sequence. Viewed perpendicularly to the substrate surface, crossing points are obtained for two conductors electrically insulated from one another which are known as conductor crossovers. The latter can, as is known, be realized in different techniques.
The TaAl double layer technique, known from U.S. Pat. No. 3,949,275 (German OS No. 2,331,586) incorporated herein by reference, permits the manufacture of TaAl resistances and TaAl-oxide capacitors on a substrate. Through the introduction of a sandwhich-dielectric consisting of TaAl-oxide and SiO 2 of specified layer thickness, the temperature coefficients of resistances and capacitors can be compensated such as is described in German OS No. 2,506,065 incorporated herein by reference. A manufacturing method for this purpose is described in the German patent application No. P 26 53 814.7 incorporated herein by reference.
SUMMARY OF THE INVENTION
It is an object of the present invention to further develop the idea disclosed in the above noted U.S. Pat. No. 4,200,502 for intergrating conductor crossovers in RC circuits. According to the invention, this is achieved through use of a method for the manufacture of conductor cross-overs with TaAl/SiO 2 -capacitors having as low as possible a capacitance. In this manner, it is possible, in applying the TaAl/SiO 2 -RC technology, to manufacture, for example, active filter networks very economically, since no additional process is required.
In the method of the invention, as shown in FIGS. 1 and 3 the "lower" crossunder conductor path leads 13 are formed by a conductor layer 5 (for example TiPdAu) which is underlaid with a TaAl I layer 1 (i.e. TaAl layer with high tantalum fraction) serving as a base. A portion of a TaAl-double layer (layers 1 and 2) is provided in the crossover region 10. The crossing-over conductor path leads 14 are constructed from a conductor layer 5 likewise underlaid with a TaAl I base layer 1 outside the crossing region 10. A piece of conductor layer 5 only is present as the crossover path 11 in the crossing region 10. The insulating layer consists of the TaAl-oxide/SiO 2 sandwich dielectric (layers 3 and 4). In this manner, a very flexible circuit layout is obtained. It is possible to accommodate more cross-linked layouts. In the case of conductor structures having a width of 100 μm, there results, with the surface capacitance of 10 nF/cm 2 , a capacitance of 1 pF between the crossunder and crossover paths of the conductor crossover region.
In accordance with an additional method (embodiment No. 2) of the invention, stray capacitances of 0.1 pF can be obtained if, prior to a specified structuring of the dielectric, an additional layer, preferably consisting of polyimide, is applied in the crossover region. This polyimide can be applied and structured with the silk screen printing process or in the form of a photo-cross-linkable film. In the case of this variant, the preceding and the following processes correspond to that of embodiment 1. The advantage of this method is that the capacitance of the conductor crossovers is less by approximately the factor of 10. Moreover, the polyimide can be applied in a simple process. The additional sandwich-dielectric, in addition, effects a greater reliability.
Solutions were hitherto disclosed as to how conductor crossovers can be integrated in temperature-compensated TaAl/SiO 2 RC-circuits. It is also possible to realize applications for non-temperature compensated RC-circuits or pure R-circuits where conductor crossovers are likewise to be integrated. In utilizing the TaAl-double layer technique in conjunction with a polyimide insulating layer, two additional embodiments for the manufacture of conductor crossovers are possible for these specific instances according to the invention.
For non-temperature-compensated TaAl RC-networks (embodiment No. 3) the RC method sequence is performed without an SiO 2 -dielectric, whereby the insulating layer consists of TaAl-oxide-polyimide. In this manner, it is possible to arrange the capacitors substantially more densely if no temperature compensation is required. Thus, circuits with greater area capacity can be obtained.
In accordance with a further embodiment of the invention (embodiment No. 4), for pure resistance networks, for the purpose of integrating conductor crossovers, the coating with polyimide at the crossover locations can occur after the application and structuring or shaping of the TaAl-double layer, and the insulating layer can consist solely of polyimide. The etching-off of the TaAl II layer (i.e. TaAl layer with low tantalum fraction) can proceed here after the vapor-deposition and structuring or shaping of the conductor layer, which are then underlaid with the TaAl double layer. Through the omission of thin film capacitors which are not required, the manufacture process is shortened, whereby resistance networks and conductors are included.
In summary, it can be stated that the four sample embodiments according to the invention render possible the integration of conductor crossovers in thin film R and RC networks. The application of the TaAl-double layer technique in conjunction with the TaAl/SiO 2 -technology, which is introduced for temperature-compensated RC-networks, therefore becomes even more attractive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the manufacture sequence of TaAl/SiO 2 (embodiment 1) and TaAl/SiO 2 -polyimide (embodiment 2) conductor crossovers;
FIG. 2 illustrates the manufacture sequence of conductor crossovers according to embodiments 3 and 4; and
FIG. 3 illustrates a basic construction of the conductor crossover for embodiments 1 through 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to FIG. 1 an insulating base is provided as initial base, which, for example, can be produced by means of applying an oxide onto a non-conducting carrier. One can also proceed from a completed insulating base, which, for example, consists of glass, quartz, sapphire or a fine-grained polished ceramic. Onto that base, which is not shown in FIG. 3 a TaAl double layer (high tantalum content TaAl type I layer 1 and low tantalum content TaAl type II layer 2) is applied. The application of the tantalum-aluminum alloy double layers proceeds in a manner which is known per se, for example, by means of cathode sputtering.
The double layer thus prepared is now covered with a mask which e.g. can be manufactured photolithographically with the aid of a positively acting photoresist. The mask manufacture is designed by phototechnique I. The mask covers all the areas corresponding with the capacitor base electrode represented by the crossunder path 12 of the cross-over capacitor and also covers the leads 13 and 14 of the crossunder and crossover paths 12 and 11 respectively to be produced so that the remaining regions of the tantalum-aluminum alloy double layer I+II (layers 1 and 2) can be etched off by one etching step or by two successive etching steps. In the case of two successive selective etching steps, an under-etching of the tantalum-aluminum-alloy double layer I+II is avoided.
After the removal of the mask formed by the photo-technique I, an anodic oxidation over the entire surface is carried out in which the surface region or zone of the tantalum-aluminum alloy layer 2 is converted into a tantalum-aluminum-oxide layer 3. In the interruption or break bordering on or adjacent to the capacitor zone (crossover region 10), the tantalum-aluminum-oxide layer 3 also preferably extends over the free frontal face of the tantalum-aluminum-alloy double layer I+II 1+2. Following the anodic oxidation, a silicon-dioxide layer 4 is applied, preferably by means of cathode sputtering, over the entire surface.
In embodiment 1, there immediately follows at this location photo-technique II, whereas in the case of embodiment 2, an insulating layer, e.g. polyimide, is additionally applied by means of screen printing. Aside from this exception, the manufacturing sequence for embodiments 1 and 2 again proceeds in common manner, namely, a second mask is applied, which is preferably manufactured photolithographically with the aid of a positively acting photoresist. This mask manufacture is designated by photo-technique II. The second mask covers the dielectric zone of the capacitor i.e. the crossover region 10 to be produced, so that the remaining zones of the silicon-dioxide layer 4 and of the tantalum-aluminum-oxide layer 3 outside a desired crossover region 10 can be etched off by two successive selective etching steps. The structuring or shaping of the silicon-dioxide layer 4 can also be conducted by a wet-chemical process. However, it preferably proceeds by means of plasma etching. A corresponding structuring or shaping of the tantalum-aluminum-oxide layer 3 takes place after removal of the second photomask by a wet-chemical process. In this etching operation, the remaining silicon-dioxide layer 4 serves as the etching mask.
After this etching operation, in an additional selective etching operation, the tantalum-aluminum layer 2-residue outside the cross-over region 10 is etched off, whereby the remaining silicon-dioxide layer 4 again serves as the etching mask.
In the following method step, an electrically highly conducting layer 5, preferably of TiPdAu is applied over the entire surface. This application is performed e.g. by means of successively proceeding vapor-deposition.
In the last method step, the surface layer 5 is structured or shaped. For this purpose, a third mask is applied on the layers which is manufactured e.g. photolithographically with the aid of a positively acting photoresist. This mask manufacture is designated by photo-technique III. The third mask covers the crossover path 11 of the crossover region 10 and the leads 13 and 14 of the crossover and crossunder paths 11 and 12, so that the remaining regions of the TiPdAu layer 5 can be etched off. After these selective etching operations, only the third mask need be removed for the purpose of finishing the thin film circuit crossover. The manufacturing sequence of conductor crossovers according to embodiments 3 and 4 is apparent from the operating sequence diagrams illustrated in FIG. 2.
In the third embodiment shown in FIG. 2, the method is the same as the second embodiment except that the SiO 2 layer 4 is deleted and the dielectric of the crossover capacitor is formed by the TaAl oxide layer 3 and a polyimide layer 4 as can be seen in FIG. 3. (legend)
______________________________________Legend to FIG. 3embodiment embodiment embodiment embodiment1 2 3 4______________________________________1 TaAl I TaAl I TaAl I TaAl2 TaAl II TaAl II TaAl II TaAl II3 TaAl-Oxyd TaAl-Oxyd TaAl-Oxyd --4 SiO.sub.2 SiO.sub.2 + Polyimide Polyimide Polyimide5 TiPdAu TiPdAu TiPdAu TiPdAu______________________________________
In the fourth embodiment shown in FIG. 2, the method is the same as the third embodiment except that the TaAl oxide layer 3 is also deleted and the crossover capacitor dielectric is formed only of polyimide layer 4. Also the etching off of the TaAl layer 2 (low tantalum content) of the double layer can occur after the deposition and structuring of the conductor layer so that the leads 13 and 14 are underlaid with both layers 1 and 2 rather than just layer 1 as in embodiments 1, 2, and 3.
Although various minor modifications may be suggested by those versed in the art, it should be understood that we wish to embody within the scope of the patent warranted hereon, all such embodiments as reasonably and properly come within the scope of our contribution to the art. | A method is disclosed for the manufacture in electric thin film R and RC circuits of a conductor crossover. A first conductor is structured at the crossover from a TaAl double layer. A portion of the top layer of the double layer is converted to a TaAl oxide and an SiO 2 layer is then applied over the TaAl oxide as a double dielectric. A second conductor is then structured over the double dielectric. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to the preparation of a fluoropolymer exhibiting improved whiteness upon fabrication. The fluoropolymer is a multiphase copolymer or blend of fluropolymers. Fluoropolymer compositions of this invention could have application in both melt processing and solvent casting operations for such products as pipes, tubes, sheets, rods, solvent-casted and melt-processed films.
BACKGROUND OF THE INVENTION
[0002] Flouropolymers are melt-processable resins that are formed into polymer structures by many different processes, such as extrusion, injection molding, fiber spinning, extrusion blow molding and blown film. They are also used as polymer processing aids due to their low surface energies and phase behaviors.
[0003] Flouropolymers, and especially polyvinylidene fluoride polymers and copolymers often have a white color. In the manufacture of fluoropolymer articles, thermoforming processes are often used, which often lead to undesirable discoloration of the fluoropolymer in the final product.
[0004] Several methods have been proposed to reduce discoloration of fluoropolymers during the processes for manufacturing articles. U.S. Pat. No. 3,781,265 describes the synthesis of poly (vinylidene fluoride) resin having good thermal stability by polymerizing VDF in suspension using diisopropyl peroxydicarbonate as the initiator and 1,1,2-trichlorotrifluoroethane as the polymerization accelerator. The synthesis of heat resistant PVDF by an emulsion process using ammonium persulfate as the initiator and methyl/ethyl acetate as the Chain transfer agent is reported in JP 58065711.
[0005] The use of special chain transfer agents has been reported to provide improved whiteness in PVDF synthesis, such as trichlorofluoromethane in U.S. Pat. No. 4,569,978 emulsion polymerization; Dialkyl ethers in JP 01129005 suspension polymerization; ethane in emulsion polymerization in U.S. Pat. No. 6,649,720; and HCFC-123 in emulsion polymerization in EP 655468.
[0006] U.S. Pat. No. 6,187,885 describes improved color using copolymerization of vinylidene fluoride (VDF) with hexafluoropropylene (HFP). According to this invention 1-20% HFP was added when 50-90% of VDF was already charged into the polymerization reactor.
[0007] EP 816397 describes improved resistance to heat-induced color distortion by a reduction of impurities, using a perfluoropolyether as the surfactant.
[0008] Suspension polymerization of VDF using organic peroxide initiators has been reported in JP 02029402. The application claims that pH treatment of the reaction mixture with NaOH yielded a milky white product that was resistant to discoloration at high temperatures.
[0009] Post-treatment of the fluoropolymer with sodium acetate for improved resistance to discoloration is described in US 2004225096.
[0010] Surprisingly it has been found that a fluoropolymer composition can be produced having excellent whiteness even after melt processing, by producing a multi-phase composition having a polyvinylidene fluoride continuous phase and a non-continuous phase having an average domain size of 20-900 nm, and a refractive index mismatch of between 0.007 and 0.07 between the phases.
SUMMARY OF THE INVENTION
[0011] The invention relates to a multiphase polyvinylidene fluoride composition comprising two phases consisting of:
a) 70 to 99.0 weight percent of a polyvinylidene fluoride polymer continuous phase; and b) 1.0 to 30 weight percent of a non-continuous fluoropolymer phase
wherein the non-continuous phase has a Refractive Index (RI) of from 0.007 to 0.07 below the RI of the continuous phase, and wherein the average domain size of the non-continuous phase is in the range of from 10-1000 nm.
[0014] The invention also relates to process for forming a two-phase polyvinylidene fluoride composition comprising the steps of
a) introducing into a reactor a first vinylidene fluoride monomer feed, and b) introducing a second monomer feed into said reactor at a point after at least 90 percent by weight of the continuous phase monomers feed has been added to form a second distinct polymer phase, wherein said two-phase polyvinylidene fluoride composition comprises 70 to 99.0 weight percent of a continuous phase; and 1.0 to 30 weight percent of a non-continuous phase, and wherein the non-continuous phase has a Refractive Index (RI) of from 0.007 to 0.07 below the RI of the continuous phase, and wherein the average domain size of the non-continuous phase is in the range of from 10-1000 mm.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The invention relates to a multi-phase fluoropolymer composition exhibiting a high level of whiteness after heat processing, and for methods of producing the fluoropolymer.
[0018] The fluoropolymer composition of the invention is a multiphase composition containing two distinct phases, a continuous polyvinylidene fluoride polymer matrix, and a discontinuous phase.
[0019] The continuous phase matrix polymer is a vinylidene fluoride polymer. The term “vinylidene fluoride polymer” used herein includes both normally solid, high molecular weight homopolymers and copolymers within its meaning. Such copolymers include those containing at least 50 mole percent of vinylidene fluoride copolymerized with at least one comonomer selected from the group consisting of tetrafluoroethylene, trifluoroethylene, chlorotrifluoroethylene, hexafluoropropene, vinyl fluoride, pentafluoropropene, perfluoromethyl vinyl ether, perfluoropropyl vinyl ether and any other monomer that would readily copolymerize with vinylidene fluoride. Particularly preferred are copolymers composed of from at least about 70 and up to 99 mole percent vinylidene fluoride, and correspondingly from 1 to 30 percent tetrafluoroethylene, such as disclosed in British Patent No. 827,308; about 70 to 99 percent vinylidene fluoride and 1 to 30 percent hexafluoropropene (see for example U.S. Pat. No. 3,178,399); and about 70 to 99 mole percent vinylidene fluoride and 1 to 30 mole percent trifluoroethylene. Terpolymers of vinylidene fluoride, hexafluoropropene and tetrafluoroethylene such as described in U.S. Pat. No. 2,968,649 and terpolymers of vinylidene fluoride, trifluoroethylene and tetrafluoroethylene are also representatives of the class of vinylidene fluoride copolymers which can be used as the continuous phase polymer matrix.
[0020] The non-continuous phase of the polymer composition is one in which the average domain size is in the range of from 10-1000 nm, preferably 20-900, more preferably 30-800. The non-continuous phase will have a Refractive Index (RI) that is different from that of the matrix polyvinylidene fluoride polymer by from 0.007 to 0.07, preferably 0.009-0.07. In general, the RI of the non-continuous phase will be lower than that of the polyvinylidene fluoride matrix.
[0021] The non-continuous phase will make up from 1.0 to 30 weight percent of the multiphase copolymer, preferably 2-30, while the continuous phase makes up from 70-99 weight percent, and preferably 70-98 weight percent of the multiphase polymer.
[0022] The multiphase polymer composition of the invention may be formed by two main methods: sequential copolymerization and blending. The contrast between the two phases regardless of the method of preparation (blending or synthesis) would create a whiter resin.
[0023] In the case of sequential co-polymerization, the polymer is formed by synthesizing the matrix polymer in a typical fashion for forming a polyvinylidene fluoride polymer, as known to one of skill in the art. This can be by an emulsion, solution or suspension polymerization. At a point in the polymerization after at least 90 percent, preferably 92 percent, and more preferably 95 percent of the continuous phase monomer/monomers have been added, a second monomer feed is introduced into the reactor. The second monomer feed can be a single monomer or a mixture of monomers capable of homopolymerizing or copolymerizing with the first component monomers. The second monomer feed creates a polymer generating a separate phase dispersed in the polymer matrix of the first phase.
[0024] The discontinuous phase can be formed from any monomer or monomers that capable of copolymerizing with the first component monomers. These include vinylidene fluoride mixed with other fluoropolymers, such as those described under the preceding definition of vinylidene fluoride polymer, and even containing small amounts of other monomers known to polymerize or be compatible with fluoromonomers.
[0025] In one embodiment, the multiphase polymer is formed by emulsion process in which a reactor is charged with deionized water, water-soluble surfactant capable of emulsifying the reactant mass during polymerization and paraffin antifoulant. The mixture is stirred and deoxygenated. A predetermined amount of chain transfer agent is then introduced into the reactor, the reactor temperature raised to the desired level and vinylidene fluoride (VDF) or VDF combined with other fluoromonomers fed into the reactor. Once the initial charge of monomer/monomers is introduced and the pressure in the reactor has reached the desired level, an initiator emulsion/solution is introduced to start the polymerization reaction. The temperature of the reaction can vary depending on the characteristics of the initiator used and one of skill in the art will know how to do so. Typically the temperature will be from about 60° to 120° C., preferably from about 70° to 110° C.
[0026] Similarly, the polymerization pressure may vary, but, typically it will be within the range 40 to 50 atmospheres. Following the initiation of the reaction, the monomer/monomers are continuously fed along with additional initiator to maintain the desired pressure. Once the desired amount of major component polymer has been reached in the reactor (greater than 90% of the continuous phase monomer/monomers fed), the monomer/monomers of the minor component (forming the discontinuous phase) will be introduced into the reactor. These monomers are generally charged as a slug into the reactor at the maximum feed rate. Once the feed of the minor phase monomers is complete, initiator feed rate will be increased for a set period of time to facilitate polymerization of these monomers. All feeds will then be stopped. Residual gases (containing unreacted monomers) are vented and the latex recovered from the reactor. The polymer may then be isolated from the latex by standard methods, such as, acid coagulation, freeze thaw or high shear.
[0027] In one preferred embodiment, a polyvinylidene fluoride homopolymer is formed as the continuous phase, followed after at least 90 percent of the total monomer is charged by the introduction of of a monomer mixture of vinylidene fluoride and hexafluoropropane (HFP). The level of HFP in the second monomer mixture is up to 30 weight percent of the second monomer feed, preferably up to 25 weight percent, and more preferably up to 20 weight percent. If a 30 weight percent HFP monomer mixture is added just after 90 percent of the total monomer has been fed to the reactor, the resulting copolymer will have a total of 10 weight percent of HFP monomer units, which will be concentrated in a second, discontinuous phase.
[0028] In addition to formation by a copolymerization process, the multiphase composition of the inventgion may also be formed by blending a polyvinylidene fluoride polymer with another fluoropolymer which may be a homopolymer, copolymer or terpolymer. The blending of the two polymers may be in the form of a melt blending, solution blending or latex blending. Melt blending can be done with powders or pellets which must be extruded to form a homogeneous blend, with powders being preferred.
[0029] While not being bound by any particular theory, it is believed that the matrix continuous phase will be crystalline, and the second phase will be much less crystalline, resulting in the formation of a distinct separate discontinuous phase.
[0030] The multi-phase fluoropolymer of the invention shows excellent whiteness after heat processing. Upon heat aging or after melt processing, the resin of this invention will exhibit a whiteness improvement, ΔYI, of greater than 4 units relative to virgin resin (polymer), as measured by a spectrophotometer.
[0031] The polymer composition of the invention may also contain one or more additives typically added to fluoropolymer compositions. Such additives include, but are not limited to, pigments, dyes, fillers, surfactants, antioxidants, heat stabilizers, and other polymers miscible with PVDF.
[0032] The multi-phase polymer of the present invention is especially useful in forming articles by heat processing methods in which a highly white color is desired. Some of the articles that can be advantageously be made from the composition of the invention include, but are not limited to Pipes, fittings and valves; pump assemblies; sheet and stock shapes; films; tubing; tanks and vessels; nozzles; membranes and filter housing; powder coatings; and foams.
EXAMPLES
Comparative Example 1
[0033] The following comparative example is based on the teachings of U.S. Pat. No. 6,187,885 B1. Into an 80-gallon stainless steel reactor was charged, 345 lbs of deionized water, 225 grams ammonium perfluorodecanoate and 6 grams of paraffin wax. Following evacuation, agitation was begun at 23 rpm and the reactor was heated to 82° C. After reactor temperature reached the desired set point, 0.44 lbs propane was charged into the reactor. Reactor pressure was then raised to 650 psi by charging about 40 lbs VDF into the reactor. After reactor pressure was stabilized, 5.25 lbs of an NPP (di-N-propyl peroxydicarbonate) emulsion was added to the reactor to initiate polymerization. The initiator emulsion was 3.0 wt. % NPP in deionized water containing 0.2 wt. % ammonium perflorodecanoate. The rate of further addition of the NPP emulsion was adjusted to obtain and maintain a VDF polymerization rate of roughly 70 pounds per hour. The VDF homopolymerization was continued until approximately 150 pounds VDF was introduced in the reaction mass. Thereafter, 10 pounds HFP was pumped into the reactor at a rate of approximately 70 pounds/hour, while the VDF feed was continued. The fast introduction of fairly slow reacting HFP monomer temporarily slowed the reaction rate. The initiator additio rate was adjusted to restore the polymerization rate back to 70 pounds/hour. The reaction continued until a toatl 210 pounds of VDF had been added to the reaction mass. The VDF feed was stopped and the batch was allowed to react-out at the reaction temperature and by feeding initiator to consume residual monomer at decreasing pressurer. After 20 minutes, the agitation was stopped and the reactor was vented and the latex recovered. Polymer resin was isolated by coagulating the latex, washing the latex with deionized water, and drying. The resin had a melt viscosity of 21.7 kilopoise measured at 232° C. and 100 sec −1 (ASTM D3835), a DSC melt point of 140-145° C. and a 10 min plaque Delta YI of 5.3.
Example 1
[0034] Into an 80-gallon stainless steel reactor was charged, as in the manner of the comparative example 1, 345 lbs of deionized water, 225 grams ammonium perfluorodecanoate and 6 grams of paraffin wax. Following evacuation, agitation was begun at 23 rpm and the reactor was heated to 82° C. After reactor temperature reached the desired set point, 0.44 lbs propane was charged into the reactor. Reactor pressure was then raised to 650 psi by charging about 40 lbs VDF into the reactor. After reactor pressure was stabilized, 5.25 lbs of an NPP (di-N-propyl peroxydicarbonate) emulsion was added to the reactor to initiate polymerization. The initiator emulsion was 3.0 wt. % NPP in deionized water containing 0.2 wt. % ammonium perflorodecanoate. The rate of further addition of the NPP emulsion was adjusted to obtain and maintain a VDF polymerization rate of roughly 70 pounds per hour. The VDF homopolymerization was continued until all the VDF monomer (approximately 202 pounds) was introduced in the reaction mass. Thereafter, 17.6 pounds HFP was pumped into the reactor at a rate of approximately 70 pounds/hour. The fast introduction of fairly slow reacting HFP monomer temporarily slowed the reaction rate. The initiator addition rate was increased for 15 min and then restored at normal rate and the batch was allowed to react-out at the reaction temperature and at decreasing pressurer. After 20 minutes, the agitation was stopped and the reactor was vented and the latex recovered. Polymer resin was isolated by coagulating the latex, washing the latex with deionized water, and drying. The resin had a melt viscosity of 25.3 kilopoise measured at 232° C., a DSC melt point of 163-168° C. and a 10 min plaque Delta YI of 14.6.
Example 2
[0035] The procedure of example 1 was repeated except that 26.4 pounds HFP was pumped into the reactor at a rate of approximately 70 pounds/hour. The resulting resin displayed a melt viscosity of 21.7 kilopoise measured at 232° C. and a 10 min plaque Delta YI of 16.8.
Example 3
[0036] The procedure of example 1 was repeated except that 4.4 lbs HFP was pumped into the reactor at a rate of approximately 70 pounds/hour. The resulting resin displayed a melt viscosity of 25.2 kilopoise measured at 232° C. and a 10 min plaque Delta YI of 7.3.
Example 4
[0037] The procedure of example 1 was repeated except that 13.2 lbs HFP was pumped into the reactor at a rate of approximately 70 pounds/hour and the initiator feed at increased rate was continued for 30 min. The resulting resin displayed a melt viscosity of 28.8 kilopoise measured at 232° C.
Example 5
[0038] The procedure of example 1 was repeated except that 8.8 lbs HFP was pumped into the reactor at a rate of approximately 70 pounds/hour and the initiator feed at increased rate was continued for 45 min. The resulting resin contained 1.7 wt. % HFP measured by solution-state 19 F NMR, displayed a melt viscosity of 28.8 kilopoise measured at 232° C. and a 10 min plaque Delta YI of 5.4.
Example 6
[0039] The procedure of example 5 was repeated except that HFP was introduced into the reactor at a rate of approximately 70 pounds/hour after reactor pressure dropped to 550 psi. The resulting resin displayed a melt viscosity of 13.32 kilopoise measured at 232° C.
EXAMPLE 7
[0040] The procedure of example 5 was repeated except that HFP was introduced into the reactor at a rate of approximately 70 pounds/hour after reactor pressure dropped to 450 psi. The resulting resin contained 1.4% HFP measured by 19 F NMR, displayed a melt viscosity of 22.7 kilopoise measured at 232° C. and a 10 min plaque Delta YI of 6.5.
EXAMPLE 8
[0041] The procedure of example 7 was repeated except that 2.2 pounds HFP was introduced into the reactor at a rate of approximately 70 pounds/hour.
EXAMPLE 9
[0042] The procedure of example 7 was repeated except that propane was replaced with 1.3 lbs ethyl acetate and the initiator increased feed rate period was reduced to 23 min. The resulting resin displayed a melt viscosity of 16.69 kilopoise measured at 232° C.
EXAMPLE 10
[0043] The procedure of example 9 was repeated except that HFP was introduced into the reactor at a rate of approximately 70 pounds/hour after reactor pressure dropped to 300 psi. The resulting resin displayed a melt viscosity of 17.26 kilopoise measured at 232° C. | The present invention relates to the preparation of a fluoropolymer exhibiting improved whiteness upon fabrication. The fluoropolymer is a multiphase copolymer or blend of fluropolymers. Fluoropolymer compositions of this invention could have application in both melt processing and solvent casting operations for such products as pipes, tubes, sheets, rods, solvent-casted and melt-processed films. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a sanitary napkin for absorption and containment of the menstrual discharge.
Japanese Patent Application Disclosure No. 1990-7956 describes a sanitary napkin having a pair of wings on its sides. According to this Application, the napkin is formed along its transversely opposite side edges with flaps adapted to be stretchable longitudinally of the napkin. Portions of these flaps extending outward from an undergarment worn by the wearer beyond peripheries of leg-openings are stretchable to follow the curvature of the peripheries as these portions when folded onto the outer surface of the crotch region of the undergarment. The portions of the flaps folded in this manner can be fastened to the outer surface of the undergarment by means of adhesive agent applied on the flaps.
The known napkin as has been mentioned above enables the flaps to cover the peripheries of leg-openings of the undergarment and thereby to prevent the peripheries from being stained with the menstrual discharge. However, it is still difficult for the known napkin to prevent the menstrual discharge leaking sideways from flowing down along the wearer's thighs.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a sanitary napkin that is adapted to be fastened to the outer surface of the undergarment worn by the wearer so that menstrual discharge leaking sideways from the undergarment can be reliably prevented from flowing down along the wearer's thighs.
According to this invention, there is provided a sanitary napkin having a pair of transversely opposite side edges extending longitudinally of the napkin and a pair of longitudinally opposite ends extending transversely of the napkin, the napkin comprising: a liquid-pervious topsheet, a liquid-impervious backsheet, and a liquid-absorbent core disposed therebetween; the transversely opposite side edges comprising upper and lower layer flaps separably placed upon each other, each of the upper layer flaps having a length corresponding to 1/2˜1/1 of a full length of the napkin, the maximum width of 10˜30 mm and an elastic stretchability of 120˜300% longitudinally of the napkin, and each of the lower layer flaps laterally extending outward beyond an outer side edge of the upper layer flap and including a wing coated on a lower surface thereof with an adhesive agent.
This invention includes embodiments that: each of the upper layer flaps is formed by a sheet being elastically stretchable at least longitudinally thereof; each of the upper layer flaps comprises a sheet being non-stretchable longitudinally thereof and an elastic member secured thereto under tension longitudinally thereof to form the sheet with a plurality of gathers defined by crests and troughs alternately arranged longitudinally thereof; each of the upper layer flaps comprises the non-stretchable sheet formed with a plurality of zones crowded with the gathers so that these zones are intermittently arranged longitudinally of the non-stretchable sheet; and the lower layer flaps are elastically stretchable longitudinally thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a partially cutaway sanitary napkin according to this invention;
FIG. 2 is a sectional view taken along a line II—II in FIG. 1;
FIG. 3 is a sectional view of the napkin in its flat condition as put on the wearer's body;
FIG. 4 is a view similar to FIG. 1 of one embodiment; and
FIG. 5 is a view similar to FIG. 1 of another embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Details of a sanitary napkin according to this invention will be more fully understood from the description given hereunder with reference to the accompanying drawings.
FIG. 1 is a perspective view of a partially cutaway sanitary napkin 1 . The napkin 1 has a pair of transversely opposite side edges 6 extending longitudinally of the napkin 1 and a pair of longitudinally opposite ends 7 extending transversely of the napkin 1 , and comprises a liquid-pervious topsheet 2 , a liquid-impervious backsheet 3 and a liquid-absorbent core 4 disposed between these two sheets 2 , 3 . The topsheet 2 and the backsheet 3 extend outward beyond a peripheral edge of the absorbent core 4 and are joined to each other along these extensions. The side edges 6 have upper layer flaps 11 each comprising a sheet 10 having a plurality of gathers 8 formed by crests and troughs transversely extending and alternately arranged longitudinally of the napkin 1 and an elastic member 9 extending longitudinally of the napkin 1 , and lower layer flaps 12 each underlying the upper layer flap 11 and provided with a wing 13 . The absorbent core 4 is generally hour glass, shaped.
FIG. 2 is a sectional view taken along a line II—II in FIG. 1 . The sheet 10 making a part of the upper layer flap 11 may be a non-stretchable or stretchable sheet and the inner edge 16 of this upper layer flap 11 may be joined to the side edge of the topsheet 2 and/or to a portion of the backsheet 3 extending laterally beyond the side edge of the topsheet 2 along a joining line 17 . Along the outer side edge 18 of the upper layer flap 11 , the sheet 10 is folded downward to wrap the elastic member 9 which is, in turn, secured under tension to the inner side of the sheet 10 so that the gathers 8 are formed under contraction of this elastic member 9 . A stretch stress of the elastic member 9 as this elastic member 9 is secured to the sheet 10 is preferably in a range of 10˜150 g. As will be apparent from FIGS. 1 and 2, the joining line 17 for the inner side edge 16 longitudinally extending along the side edge of the absorbent core 4 describes a curve convex inwardly of the napkin 1 and its longitudinally opposite ends cross the outer side edge 18 of the upper layer flap 11 . A longitudinal dimension B of the upper layer flap 11 is in a range of 1/2˜1/1 of a full length A of the napkin 1 and preferably can be stretched to 200 mm or larger. The maximum transverse dimension C of the upper layer flap 11 is preferably in a range of 10˜30 mm. A dimension D between the outer side edges 18 of the pair of upper layer flaps 11 is preferably in a range of 60˜120 mm and more preferably in a range of 80˜100 mm.
Each of the lower layer flaps 12 has its proximal side edge 14 formed by the portions of the topsheet 2 and the backsheet 3 extending laterally beyond the side edge of the absorbent core 4 . These two sheets 2 , 3 are placed upon and joined to each other by means of hot melt adhesive agent in the vicinity of the side edge of the absorbent core 4 . The backsheet 3 further extends laterally beyond the side edge of the topsheet 2 to the outer side edge 18 of the upper layer flap 11 and partially further extends laterally to the wing 13 . The lower surface of the wing 13 is coated with an adhesive agent 22 which is, in turn, protected by a release sheet 23 .
FIG. 3 is a sectional view of the napkin 1 of FIG. 1 as put on the wearer's body. As shown, the napkin 1 is placed on the inner surface of a crotch region of an undergarment and the lower layer flaps 12 are folded onto the outer surface of the crotch region with the wings 13 fastened to the outer surface by means of the adhesive agent 22 . The lower layer flaps 12 folded in this manner cover the peripheries 27 of leg-openings of the undergarment 26 and prevent the peripheries 27 from being soiled with the menstrual discharge.
The upper layer flaps 11 are folded downward along the peripheries 27 of the leg-openings of the undergarment 26 and closely pressed against the wearer' thighs 28 . This is because the gathers 8 as well as the elastic members 9 are forcibly stretched longitudinally of the napkin 1 as the upper layer flaps 11 are folded downward and therefore the gathers 8 as well as the elastic members 9 are biased to restore their initial positions that is, the napkin 1 is in its flat condition as shown in FIG. 2 . Therefore, the upper layer flaps 11 prevent the menstrual discharge from leaking at side edges of the napkin 1 and flowing down along the inner sides of the wearer's thighs 28 .
FIG. 4 is a view similar to FIG. 1 of one embodiment of this invention. With this napkin, the absorbent core 4 has a rectangular shape and, along the transversely opposite side edges of the absorbent core 4 , substantially rectangular upper layer flaps 11 and the lower layer flaps 12 provided with the wings 13 are formed. The upper layer flaps 11 are similar to them of FIG. 1 in that each of them extends substantially over the full length of the napkin 1 and has a width of 10˜30 mm but different from those of FIG. 1 in that an elastic sheet 10 A being stretchable by 120˜300% at least longitudinally thereof is used as stock material for the upper layer flaps 11 . The lower layer flaps 12 are similar to those of FIG. 1 . The napkin 1 according to this embodiment also takes the same posture as the napkin 1 of FIG. 1 when the napkin 1 is put on the wearer. The elastic sheet 10 A may be a stretchable sheet such as a natural rubber sheet or synthetic rubber sheet.
FIG. 5 is also a view similar to FIG. 1 of another embodiment of this invention. According to this embodiment, each of the upper layer sheets 11 is formed by a sheet 10 B which is non-stretchable longitudinally thereof and zones 15 crowded with gathers 8 defined by crests and troughs are alternately and intermittently arranged. The upper layer flaps 11 provided along their outer side edges with the elastic members 9 and the gathers 8 as well as the elastic members 9 are forcibly stretched longitudinally thereof as the napkin 1 is put on the wearer's body as shown in FIG. 3 . In this manner, the upper layer flaps 11 are closely pressed against the wearer's thighs 28 .
For exploitation of this invention, a nonwoven fabric or porous plastic film may be used as stock material for the topsheet 2 . As stock material for the backsheet 3 , a plastic film may be used. The absorbent core 4 may be formed by a fluff pulp or a mixture of fluff pulp and superabsorptive polymer particles. Stock material for the upper layer flaps 11 may be formed by a stretchable or non-stretchable and, in addition, preferably breathable, more preferably, breathable and sweat-absorbent nonwoven fabric or plastic film. While the lower layer flaps 12 are formed by portions of the backsheet 3 widely extending laterally in the illustrated embodiments, it is also possible for the lower layer flaps 12 to be formed by a nonwoven fabric or plastic film provided separately of the topsheet 2 and the backsheet 3 and joined to the topsheet 2 and/or the backsheet 3 . In order to facilitate the lower layer flaps 12 to be folded along the leg-openings of the undergarment, not only the proximal side edges 14 may be curved as shown in FIG. 1 but also the outer side edges 29 (See FIG. 1) may be curved inwardly of the napkin 1 . A dimension by which each of the lower layer flaps 12 extends laterally may be selected independently of such dimension in the upper layer flaps 12 . However, it is obvious that the wings 13 should have sufficient dimensions to reach the crotch region of the undergarment regardless the dimension of the lower layer flaps 12 . Furthermore, the lower layer flaps 12 may have an elastic stretchability also longitudinally thereof. Joining of the topsheet 2 and the backsheet 3 and the upper and lower layer flaps 11 , 12 may be performed using a suitable adhesive agent such as a hot melt adhesive agent or sealing technique such as heat-sealing technique.
The sanitary napkin according to this invention has the upper layer flaps and the lower layer flaps so that the upper layer flaps may be closely pressed against the wearer's thighs and the lower layer flaps may be folded onto the outer surface of the crotch region of the undergarment with the wings being fastened to the outer surface. In this manner, the convenience for use offered by a so-called winged napkin is advantageously combined with the effect to prevent the menstrual discharge from flowing down along the wearer's thighs. | A sanitary napkin 1 includes respective pairs of upper and lower layer flaps 11, 12 placed upon each other, each of the upper layer flaps 11 is elastically stretchable longitudinally of the napkin 1 and each of the lower layer flaps 12 is provided with a wing 13, and thereby prevent the menstrual discharge from leaking sideways. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to mobile data networks. More particularly, the invention relates to a network application program such as a web browser which allows a user to navigate a set of network web pages based on a user's location and the setting of one or more auxiliary control parameters.
[0003] 2. Description of the Related Art
[0004] The concept of providing a local broadcast domain through which a mobile unit passes is well known. For example, when on a cross-country trip, an automobile passes through various areas of FM radio coverage. In the art of cellular communications it has become common practice to reduce the size of a given broadcast domain. This allows frequencies to be efficiently reused. In spread spectrum communications, it is also recognized that multiple users may share frequency within a small-area broadcast domain using differently encoded waveforms for different users. Companies such as Nokia Inc. have proposed systems whereby information is broadcast to mobile subscribers within a telecommunications cell. In some envisioned methods, this broadcast information is accessible from a network application such as a web browser. A mobile subscriber is able to click on an icon and view, for example, restaurants located in the vicinity of the telecommunications cell occupied by the mobile subscriber.
[0005] Recently systems have been introduced whereby a mobile unit such as an automobile passes through a series of very small broadcast domains. Each broadcast domain is called a “picocell”. For example, as a mobile user in an automobile travels along a road, the automobile encounters a sequence of network air-interface transceivers that are mounted on telephone poles and periodically placed along the roadside. The vehicle can maintain a network connection by accessing the nearest air interface at any given time. Similar picocell based systems allow a user walking through a building or campus environment to stay connected to a wireless local area network (LAN). The term “air interface” is used in the art to mean a set of physical layer protocols used to communicate information via radio and other forms of wireless connections.
[0006] Data networks are also available whereby a mobile unit maintains a wireless network connection with a central server. For example, cellular digital packet data (CDPD), Internet packet Data Network (IPDN) and related technologies exist to allow a mobile unit to interact with an application such as a database. In other systems, radio frequency (RF) modems allow a mobile unit to maintain a network connection to stay connected to the Internet or some other type of network. For example, Global System Mobile (GSM) and Personal Communication Systems (PCS) technologies also allow wireless data connections to be established. Pico-cell based systems also provide wireless networks for similar use within buildings and campus environments.
[0007] A co-pending application, Ser. No. 09/167,698 by Eric M. Dowling and Mark N. Anastasi is incorporated herein by reference and is referred to as the “Dowling reference” hereinafter. In the Dowling reference, a method is disclosed to allow a mobile unit to maintain a virtual session with a central server. In a virtual session, an application layer program maintains a communication session in the absence of a physical communication path. When the session is inactive, no communication path exists. When data needs to be communicated, a physical connection is automatically established. This allows a remote unit to maintain a presence with a central server using, for example, a cellular connection. The virtual session only establishes the cellular connection when it is actually being used for network communications. In the context of the present disclosure, the “remote unit” as defined in the Dowling reference is termed a “mobile unit.” In a virtual-session based system, the mobile unit uses a cellular connection to maintain a virtual session with a network server attached to a network. The mobile unit runs an application program such as a web browser to communicate with a web site, an Internet site, an intranet site or other application program provided by the network server. Only when the user is actively selecting a link or downloading information is a physical communication path established to support the virtual session.
[0008] Another known technology is the global positioning system (GPS). GPS receivers use telemetry information broadcast form satellites to calculate a set of grid coordinates to provide positional information. A mobile unit equipped with a GPS receiver can thereby maintain a fix on its geographical position.
[0009] Systems have been introduced by several automobile manufacturers that use a GPS receiver to control the display of digital map information in automobiles. The map data includes locations of various types of business establishments. The map and business establishment data for these systems is stored in a PROM or EPROM memory. Typically these storage devices contain data pertinent to one state. In order to update this data the owner of the vehicle must return to the dealer once a year to have change the PROM or reprogram the EPROM. A traveler wishing to travel between states must purchase additional memory modules programmed with data for the states to be traveled in advance of an out-of-state trip. While the aforementioned technologies provide valuable services and capabilities, these systems are lacking in various ways. For example, consumer radio broadcast technology still uses large broadcast domains such as AM and FM radio stations. While next generation systems have been proposed that will effectively broadcast information such as local advertisements and service announcements to vehicles or pedestrians passing through a telecommunications cell, small locality, no technology exists to provide local broadcast information to automatically control a network application such as a web browser by selectively filtering broadcast information using a packet filter. Current approaches require a user to select an icon or navigate a browser application via conventional means to access information specific to a local area. Also, systems do not exist which allow information processed by a GPS receiver to control the flow of information on a network connection with a server. For example, no web browsers exist which process GPS transmissions to determine geographical position, and use this geographical position information to control what web pages are displayed by the browser. Likewise, no systems exist which accept locally broadcast transmissions such as from a local telephone pole and use this information to control information displayed by the web browser.
[0010] It would be desirable to have a system that could provide a user with a means to receive information from a first connection to a network based on the user's position. It would be desirable to allow an application such as a web browser to control a flow of information comprising web pages based on a locally received broadcast. It also would be desirable to allow an application such as a web browser to control the flow of web pages based on processed GPS data. It would be desirable to have a mobile unit that could receive one or more transmissions via a second connection and then generate a request packet on a first connection to navigate an application program such as a web browser. It also would be desirable to have a network server that is operative to receive request packets that are generated based on information received from these transmissions.
[0011] Systems currently envisioned by telecommunication firms rely on the knowledge of the user's operating wireless cell. As a position or location measurement system, this knowledge is coarse. Further, as a means for regulating pertinent information, reliance solely on cell data is limiting. Cell coordinates are too coarse to allow data such as direction of travel, speed of travel, etc to be used to predict items of interest to the user. It would therefore be desirable to base broadcast content on detailed user information including, but not limited to, past and present GPS location data.
[0012] For certain applications it would be desirable to be able to effectively use a relatively small broadcast domain to produce an “electronic sign.” As defined herein, an “electronic sign” involves a system whereby a transmitter broadcasts one or more data packets to be received by a mobile unit as carried by a vehicle or a pedestrian. For example, instead of a passenger looking out of a window to see a billboard, the passenger looks at a computer display screen associated with a dashboard computer device within the vehicle. Alternatively it would also be desirable to make use of the relatively small broadcast domain to produce an “indirect electronic sign.” As is also defined herein, an “indirect electronic sign” involves a system whereby a transmitter broadcasts at least one data packet to the mobile unit that then extracts information from the packet and uses it to access an associated web page. In such a system, it would be desirable to download the web pages from the server using the first network connection which is preferably a CDPD connection or a virtual session connection. Moreover, it would be desirable for the mobile unit to be able to supply a filter parameter to allow locally received broadcast packets to be selectively rejected (e.g. based on content or subject matter) and thereby not alter the web page displayed by the mobile unit.
[0013] Currently in cities and on major highways there are deployed updateable billboard sized displays that are used to inform drivers of upcoming traffic and road conditions. This information may potentially add convenience to the drivers and allow the roadway to be better utilized more efficiently. For example, a large, updateable billboard sized display can inform drivers of an accident on the roadway ahead. This information is used to prompt lane selection or alternate route selection. However, the information contained on these displays is limited in amount, and allows no dialogue or multilevel queries. It would therefore be desirable to have a display system capable of displaying detailed information in a structured manner to allow for navigation, route planning and advanced traffic management.
[0014] In other applications it would be desirable to update a large memory device within the mobile unit with current information directly from the network without the need to change memory modules or reprogram memory modules. These on-board memory devices could then be accessed for information without the necessity to access an internet connection. It would thus be desirable to be able to update this stored information by downloading information from the Internet or some other convenient and accessible network.
SUMMARY OF THE INVENTION
[0015] The present invention solves these and other problems by providing systems and methods to enable a mobile unit to maintain a first network connection with a central server and to control information flow on this connection using information received on an auxiliary channel. In one example, a mobile unit travels along a road and is exposed to a plurality of locally broadcast packets as the mobile unit enters into a local broadcast domain. A local broadcast domain includes the range of a transmitter that broadcasts data packets to mobile units within this range. When a packet of interest is received, information is automatically transferred via the first network connection and a web page or related application information is thereby accessed. Instead of the user needing to click upon a hyperlink to access a web site, a packet filter is configured to selectively pass packets according to a predefined criterion. When a packet passes through the packet filter, a web site is automatically accessed.
[0016] Because the received packet is transmitted from within a local broadcast domain, this packet carries with it geographically related information. For example, if a geographical web browser according to the present invention is currently set to a “movies” Internet site, when the mobile unit passes into an area with several movie theaters, the passed packet will include a pointer to the associated movie theaters' web pages. In some systems the web pages will be automatically downloaded into a buffer within the mobile unit, while in other systems a set of hyperlinks to these local theaters will appear.
[0017] In another aspect of the present invention, the mobile unit also maintains the network connection, but derives geographical information from a GPS receiver. The network connection preferably is an Internet connection or a connection to a central server such as a database server. GPS information is received and processed in the GPS receiver. Periodically, processed GPS information may be transmitted via the mobile network connection to the network server. When this processed GPS information is received, the network server is operative to control the flow of information to the mobile unit based upon the processed GPS information. In some embodiments the mobile unit maintains a list of local sites and sends information to the server based on a configuration parameter. This information may be specific to the requested areas of interest or it may contain a complete update to the mobile unit's database.
[0018] The mobile unit is thereby able to navigate the Internet based on the mobile unit's geographical position in addition to prior art methods employing mouse and keyboard inputs. When a virtual connection is being used, GPS information need only be transmitted at pre-specified intervals or upon the detection of pre-specified events. For example, a filter is preferably employed to cause the network connection to only be activated when the mobile unit enters a locality associated with a web site of interest. For example, a hungry user entering a new city is interested in seeing web pages for local restaurants. Based upon the GPS position indication a list of restaurants in surrounding localities is downloaded into a memory of the mobile unit. When the GPS receiver indicates the mobile unit is in a designated locality, web pages for those restaurants in the local area are downloaded or retrieved from memory and displayed.
[0019] The present invention provides a means for a user to “surf the web” or otherwise navigate a network application program based on geographically related information such as locally broadcast packets and GPS information. One or more filter parameters are used to screen information of interest to a user. A set of information deemed to be of interest to a user is called an “information class.”
[0020] The present invention also enables a road-navigation or traffic management system. For example, the user maintains a virtual connection to a central server that provides real-time best-route information through a navigation or traffic management web page. A plurality of sensors measures road conditions based on vehicle speeds as measured by sensors such as laser or infrared continuity sensors dispersed along the roadways. Additionally, special traffic data is monitored, or manually entered, including weather advisories, accident locations and effects and special event locations and effects. The central server thereby keeps track of road conditions and is able to display such information and to assign “costs” to route segments. The mobile unit stays virtually connected to the navigation web page and is updated with digital maps indicating the best current route leading from the mobile unit's current position to a selected destination.
BRIEF DESCRIPTION OF THE FIGURES
[0021] The various novel features of the present invention are illustrated in the figures listed below and described in the detailed description that follows.
[0022] FIG. 1 is a block diagram representing an embodiment of a system involving a mobile unit passing through a locality and maintaining a network connection.
[0023] FIG. 2 is a block diagram illustrating the architecture of a mobile unit designed in accordance with the present invention.
[0024] FIG. 3 is a flow chart illustrating a method of processing carried out in a mobile unit to provide a geographically controlled client-side application program.
[0025] FIG. 4 is a flow chart illustrating a method of processing carried out by a network server to provide a geographically controlled server-side application program.
[0026] FIG. 5 a is a flow chart illustrating a method of processing carried out by a system comprising a mobile unit, a local broadcast domain entity and optionally a network server to support a geographically controlled client-side application program in the mobile unit.
[0027] FIG. 5 b is a flow chart illustrating a method of processing carried out by a system comprising a mobile unit, a local broadcast domain entity and optionally a network server to provide customized information to the mobile unit.
[0028] FIG. 6 is a flow chart illustrating a method of processing carried out between a mobile unit and a network server to provide road navigation and traffic management information to the mobile unit.
[0029] FIG. 7 is a block diagram representing an embodiment of the invention applied to traffic management applications.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] FIG. 1 is a block diagram representing an illustrative embodiment 100 of a system configuration used to support the present invention. A vehicle 102 includes a mobile unit 105 . The mobile unit 105 may be designed similarly to the remote unit in the Dowling reference. The architecture of the mobile unit 105 is also discussed in more detail in connection with FIG. 2 .
[0031] The mobile unit 105 is connected to a first antenna 110 which is used to maintain a first network connection 112 . The first network connection 112 is preferably a wireless network connection and may be implemented in several ways. For example the wireless network connection may employ an air interface and protocol stack to interface with an IPDN, a CDPD network, a wideband CDMA data network, or a virtual session oriented network. The antenna 110 is operatively coupled to an air interface and switching module 115 . In many applications, the air interface and switching module 115 is provided by a telephone company which provides mobile communication services. In the illustrative embodiment 100 , the air interface and switching module 115 is coupled via a communications interface to a virtual session server 120 . The virtual session server 120 is discussed in more detail in the Dowling reference. In other embodiments, the virtual session server 120 may be replaced with any available network technology used to provide a network connection to a mobile unit via an air interface. The virtual session server 120 is preferably coupled to a network such as the Internet 122 . A network server 125 is coupled to the virtual session server 120 . The network server 125 may be co-located with and directly coupled to the virtual session server 120 as an application program 130 , or may be coupled across a network such as the Internet 122 as shown in the illustrative embodiment 100 . That is, in any of the embodiments as discussed herein, the network server 125 may be optionally implemented as the application program 130 .
[0032] A communication server 135 may also be coupled to the virtual session server 120 to provide the mobile unit 105 with a virtual communication presence at the virtual session server 120 . This allows calls and other communications received at the virtual session server 120 to be forwarded to the mobile unit 105 . The communication server 135 is most applicable in systems where the mobile unit 105 and the virtual session server 120 are entities within an enterprise, and the mobile unit 105 needs to maintain a virtual presence with the enterprise computing and communications resources. Details of this type of operation are described in the Dowling reference. The communications server 135 is optional and may be omitted in some embodiments of the invention.
[0033] The mobile unit 105 is also optionally coupled to a satellite antenna 140 . This antenna, though depicted as a dish antenna, may be implemented with other types of antennas. The satellite antenna 140 may be used to receive satellite communications information. The satellite antenna 140 may also be used to receive GPS transmissions. In some systems, the satellite antenna 140 may be used to both receive and transmit satellite communications data and receive GPS transmissions.
[0034] The mobile unit 105 is also optionally coupled to a local broadcast domain antenna 145 . The local broadcast domain antenna is coupled to receive locally broadcast transmissions from a local broadcast domain entity 150 . The transmission from the local broadcast domain entity 150 may emanate from a building, telephone pole, street light, store front, and the like. In terms of cellular communications technology, the local broadcast domain entity 150 is similar to a picocell level communication system. The local broadcast domain entity 150 may be optionally connected to a network such as the Internet 122 via a second connection 113 . In a preferred embodiment, the broadcast domain of the broadcast domain entity 150 is defined by the range of a low-power radio frequency channel. Depending on the system configuration, the range may vary from as low as 50 feet to as high as a few miles. In some embodiments, the low power radio channel is defined by a spread spectrum air interface such as the one used by cordless phones or PCS systems.
[0035] The illustrative embodiment 100 shows a mobile unit 105 with a full set of communication channels. In other embodiments, only a subset of these communication channels need be implemented. For example, in a simplest embodiment, only the local broadcast domain antenna 145 is implemented. This simple embodiment may be used to implement methods of processing as discussed in connection with FIGS. 3, 5 a , and 5 b . Some aspects of the present invention require the mobile unit 105 to include the network connection antenna 110 and at least one of the local broadcast domain antenna 145 or the satellite antenna 140 . In general, an “air-interface antenna” generically applies to any antenna used to maintain a network connection, receive satellite data, transmit local broadcast domain data, receive local broadcast domain data, or perform other related air-interface functions.
[0036] The illustrative embodiment 100 may also be altered in other ways. For example, while three distinctly protruding antennas 110 , 140 , 145 are illustrated, these antennas may be combined into one and may be built into the body of the vehicle so that no actual antennas will be visible as shown. Also, while the illustrative embodiment shows the mobile unit 105 connected into a vehicle, the mobile unit 105 may equally be implemented as a hand-held unit or in some other form convenient to the particular use desired. The present invention may be implemented as a dash-mounted vehicle computer or a hand-held unit such as a palm-pilot, a personal digital assistant or a laptop computer. Also, in some systems the antenna 110 may be used to implement both the network connection 112 as well as the connection to the local broadcast domain entity 150 . In some systems the local broadcast domain entity 150 may be implemented as a part of the same cell site as used to provide the network connection 112 . In this type of embodiment, the cell site provides mobile telecommunication services, network services, and local broadcast services within the same cell. Layered systems whereby a cell site provides mobile telecommunication services to a cell coverage and the local broadcast domain entity provides broadcast services within a picocell are also contemplated by the system 100 . FIG. 1 thus serves as a general background scenario to understand the context of the present invention. The operation of the illustrative embodiment 100 is discussed in more detail in connection with FIGS. 2-6 .
[0037] Referring now to FIG. 2 , an embodiment of the mobile unit 105 is shown. This embodiment includes the mobile network connection antenna 110 and the local broadcast domain antenna 145 . A variation of the mobile unit 105 will be discussed herein below whereby the local broadcast domain antenna 145 is replaced with the satellite antenna 140 . Still another variation of the mobile unit 105 will be discussed which only employs the local broadcast domain antenna 145 . Yet another variation involves a system where the antenna 110 is used for both the network connection 112 and to communicate with the local broadcast domain entity 150 . In such systems the local broadcast domain entity may be embodied by the same equipment used to provide the network connection 112 .
[0038] As illustrated in FIG. 2 , the mobile unit 105 includes the network connection antenna 110 which is coupled to a first link interface controller 200 . The first link interface controller 200 is preferably implemented as a cellular or PCS transceiver capable of transferring data traffic. The first link interface controller 200 provides a physical layer air interface to support the first network connection 112 .
[0039] The first link interface controller 200 is coupled to a network interface module 205 which preferably implements one or more software layers within a protocol stack and is able to receive and transmit packet data. Protocol stacks are well known in the art, as is the construction of network interface equipment to implement a network connection. The network interface module 205 preferably includes a virtual session layer software module. The virtual session layer software module directs a physical layer network connection to be established only when it is needed as discussed in the Dowling reference to reduce air-time costs. Other technologies and protocol stacks as implemented in CDPD, GSM, PCS and wideband CDMA data networking systems may alternatively be employed within the first link interface controller 200 and the network interface module 205 . Some of these technologies may be augmented with a virtual session server to establish and maintain virtual sessions to achieve the same effect as a constant connection but at a greatly reduced cost due to saving on otherwise wasted airtime.
[0040] The network interface module 205 is coupled to a user input-output device 210 . The user input-output device is commonly implemented as a display with a mouse and/or keyboard input. Some embodiments make use of other forms of input and/or output such as human speech. When human speech is used as an input, it is received via a microphone, digitized, and processed by a speech recognition circuit to produce a coded command signal representative of a user command.
[0041] The local broadcast domain antenna 145 is coupled to a second link interface controller 215 . The second link controller 215 provides an air interface to receive and possibly transmit data packets or other signals within a local broadcast domain. The second link interface controller 215 preferably includes radio frequency circuits used to receive a locally broadcast data packet. Some embodiments may receive locally broadcast data packets by means other than radio frequency. For example data may be locally broadcast using microwave or laser signals. In some embodiments, the second link controller 215 provides a physical layer radio connection to receive the locally broadcast data packet. One preferred embodiment implements the second link controller 215 as a spread spectrum transceiver in the 900 MHz range of frequencies. In an alternative embodiment, the second link controller 215 is coupled to the antenna 110 and the second antenna 145 is not used. In this embodiment, the local broadcast domain entity 150 may be co-located with the telecommunication cell's network equipment.
[0042] The second link controller 215 is coupled to a broadcast reception module 220 . The broadcast reception module preferably receives a baseband data signal from the second link controller 215 and performs framing operations to extract the broadcast information packet therefrom. The process of extracting a packet from a received bit stream is called formatting the data. In some applications the broadcast reception module also includes a transmit data path and the second link controller 215 is able to transmit data packets. In these embodiments, the broadcast reception module 220 is more properly termed a “broadcast transceiver module.”
[0043] The broadcast reception module 220 is coupled to provide the received and reconstructed data packet to the input of a packet filter 225 . The packet filter 225 is preferably coupled to receive a packet-filter parameter from the network interface module 205 and/or the user input-output device 210 . Coupling to the network interface module 205 allows the use of web pages to set the parameters for certain types of filters with minimal user intervention. The output of the packet filter 225 is coupled to provide an input to the network interface module 205 . In embodiments involving a GPS receiver, the packet filter 225 operates as a control module and performs comparisons of GPS coordinate information with pre-specified boundary information.
[0044] A physical processing circuit as used to implement the mobile unit 105 may be implemented in a variety of ways. The preferred way to implement the mobile unit 105 is using a bus-oriented processor architecture whereby a central processing unit is coupled to a memory via a bus. Likewise, the bus couples the central processing unit to peripheral devices such as the user input-output device 210 and the first and second link controllers 200 and 215 . The modules 205 , 220 , and 225 are thereby implemented in software and are controlled by a control program (not shown). Using this standard computer architectural approach, a timer may be used to generate interrupts at timed intervals in order to control the sampling of inputs and the processing performed by the central processor unit. The mobile unit 105 may also be implemented, for example, using custom or semi-custom logic blocks configured within an application specific circuit.
[0045] The mobile unit 105 is operative to maintain the first network connection 112 via the network connection antenna 110 . Preferably, the first network connection 112 comprises a virtual session or another type of intermittently used data network protocol such as the protocol employed by a CDPD network. The mobile unit 105 preferably moves about in a geographic region, for example carried by the vehicle 102 moving about in a city. As the mobile unit 105 enters the vicinity of the local broadcast domain entity 150 , a radio frequency signal is coupled onto the local broadcast domain antenna 145 . The local broadcast domain entity 150 is operative to transmit a broadcast-data packet. The second link controller 215 is operative to extract an information signal from the local broadcast domain antenna 145 , and to supply the information signal to the broadcast reception module 220 . The information signal is preferably supplied as a baseband bit stream to the broadcast reception module 220 . The broadcast reception module 220 is operative to extract framing-related data bits from the information signal. The framing bits and possibly other bits such as network layer packet bits are then used to also extract the broadcast-data packet.
[0046] The broadcast-data packet is next routed from the broadcast reception module 220 into the input of the packet filter 225 . The packet filter 225 is operative to selectively pass the broadcast-data packet if it meets a criterion encoded into one or more packet-filter parameters. The packet-filter parameters may be derived from information supplied from either the network interface module 205 and/or the user input-output module 210 . The packet filter parameter typically includes one or more packet-header bit masks. If the header of the broadcast-data packet matches the bit mask, the packet is passed through the packet filter. If the header of the broadcast-data packet does not match the bit mask of the packet-filter parameter, the packet is rejected and no output packet is produced at the packet filter output. In this way, the packet filter selectively passes the broadcast packet, passing it if it matches the mask and rejecting it otherwise. The set of information deemed to be of interest to the user that will pass through the packet filter is called an “information class.” Alternatively, the broadcast-data packet may contain keywords. The keywords are compared to a list of keywords provided from either the network interface module 205 and/or the user input-output device 210 . If the keyword in the keyword list of the broadcast-data packet matches a keyword list, the packet is passed through the packet filter. If no match is found, the packet is rejected.
[0047] A packet filter parameter is similar to a network address in that a particular network entity will receive a packet if information contained therein (such as a network address) matches a criterion and reject it otherwise. However, a packet filter differs from a network address in that a packet may be filtered based on other criteria as well. For example a packet filter may be constructed to reject packets sent from a particular network address, or to pass packets only marked to contain specific types of information. Hence packet filters allow information to be selectively received based upon other criteria beside network addresses.
[0048] The output of the packet filter is coupled to the network interface module 205 . The output of the packet filter includes any broadcast-data packet that passes through the packet filter. The packet filter output is then used to control information flow on the first network connection 112 . For example, the vehicle 102 has recently entered a new city at lunchtime and the user input-output module is manipulated by a user to navigate to a web page for restaurants. This may be done using standard techniques by entering a network address such as a URL, by entering keywords into a search engine or by clicking upon a bookmark in a web browser display. When the user connects to the web page for restaurants, a packet filter mask is downloaded from the web page for restaurants and loaded into the packet filter. Next the network connection is placed in an inactive state whereby the restaurant page is displayed with no physical network connection being needed. The restaurant web page is displayed until the vehicle enters the range of the local broadcast domain entity 150 which broadcasts possibly a complete packet stream comprising a plurality of different types of broadcast-data packets. Only the broadcast-data packets relating to restaurants are allowed to pass through the packet filter 225 . These data packets are then passed to the network interface module 205 which sends one or more application request packets to the network server 125 . The network server 125 then preferably downloads a set of web pages containing the menus and other information related to the restaurants associated with the received broadcast-data packets. This downloading occurs over the network connection antenna 110 .
[0049] Note the above system allows a user to log into a web page using known methods. Subsequently the system is operative to navigate to selected web sites, such as those associated with local restaurants, based on the physical location of the mobile unit 105 . As the mobile unit 105 enters a new local broadcast domain, a new set of associated web pages will be downloaded. Hence the user need not click on links to find an Internet site but rather drive about geographically to navigate the Internet.
[0050] When multiple web pages are downloaded, the browser is preferably configured with a “next” button that advances a displayed image to the next downloaded web page. The “next” button is different from the “forward” button on a conventional web browser. When the “forward” button is selected, the conventional browser goes to a previously viewed web page from which the “back” button was clicked. In the present invention, the “next” button navigates to the next entry in a list of pages that were downloaded because they met the packet-filter criterion but were not yet viewed. Alternatively, the browser could be configured to present a “pick list” menu from which the user can select a hyperlink to an associated set of information.
[0051] The foregoing discussion represents a preferred mode of operation, but other preferred modes are also contemplated. For example, in an enterprise environment, a plurality of mobile units carried by vehicles is used by a service providing fleet based within a geographical area. An on-going problem relates to finding the location of the next customer. For example, before setting out for a destination, a user enters information via the input-output device 210 to establish a virtual session with a navigation web page. The user also enters information relating to a desired destination into the navigation web page. Alternatively, the user may enter information to access a scheduling web page from which a worklist generated by a scheduling system is presented, in which case location information may be downloaded via the network interface module 205 . The navigation web page then downloads a packet-filter parameter. The packet filter parameter includes a packet-header bit mask that is used to configure the packet filter 225 to selectively pass navigation data. When the navigation system is enabled, the current location of the vehicle is logged and a map is displayed on the user input-output device 210 . The displayed map preferably indicates a currently best available route to the destination. The best route is preferably determined by calculating a distance which takes into account current traffic loads, number of traffic lights, average speed along a road and the like. When the user enters the range of a new local broadcast domain entity 150 , a navigation packet is received and is selectively passed through the packet filter and a new location is logged. More details regarding how the present invention may be used in navigation applications is discussed in connection with FIG. 6 .
[0052] In another preferred mode of operation, the mobile unit 105 is modified to include the satellite antenna 140 in lieu of the local broadcast domain antenna 145 . In this embodiment, the second link controller 215 and the broadcast reception device 220 are a part of a GPS receiver system. The GPS receiver system provides a set of geographical positional information to the packet filter 225 . The packet filter 225 now operates as a control module 225 . The control module 225 is operative to perform a comparison of the mobile unit's geographical position to a control parameter, and when the comparison provides an affirmative result, the control module is operative to request a signal comprising image information such as web pages to be transmitted. The control parameter preferably includes an interest designator indicative of an information class. The interest designator, like the packet mask indicates the user's current interest, such as restaurants. For example, when the user enters a new locality as defined by a grid granularity, information related to the mobile unit 105 's location is uploaded via the first network connection 112 and the network server 125 downloads the set of restaurant web pages registered for the current locality. Preferably, the control module 225 is loaded with a list of web site designators within the scope of the interest designator. With each web site designator is a geographical coordinates mask. When the mobile unit's GPS coordinates are within the range of the web site's domain, either a stored web page is displayed or the virtual session is activated and the associated web pages are downloaded.
[0053] To implement this functionality, a memory module operative to hold a list is provided within the control module 225 . This memory module may include a storage unit such as a large memory or a disk in some embodiments. The list includes one or more entries. Each entry preferably includes a first field indicative of a set of application data available on the network server 125 and a second field indicative of a set of boundaries. When the mobile unit's GPS coordinates are within the set of boundaries, a geographical packet is sent to the network server 125 . Hence the same result as the previous embodiment is achieved in a different way.
[0054] In yet another embodiment of the current invention, the mobile unit's GPS coordinates are used to designate a geographical area of interest. Boundaries of the are set based upon a selected algorithm, such as a radius about the mobile unit's current location or political boundaries such as a state, county or city. All data for the designated area, including map data and business establishment or tourist attraction data, for example, would be downloaded without filtering to a memory device. As inquiries are made by the user or the system using previously described methods, data from this stored database would be filtered by the packet filter 225 based upon the inquiry parameters without the need to re-establish a connection to the internet pages.
[0055] An embodiment preferred for low cost systems does not involve the first network connection 112 , so it does not include the network connection antenna 110 nor the first link controller 200 . In this system, the local broadcast domain entity 150 broadcasts a packet stream containing application data as opposed to pointers to application data. For example, the local broadcast domain entity 150 transmits an HTTP (Hypertext Transfer Protocol) packet stream that includes the web pages themselves. As in the foregoing systems involving locally broadcast packets, the packet filter is configured to selectively pass received packets according to a filter criterion as determined by a packet header bit mask. When the packet filter 225 selectively passes the received packet stream, only the desired web pages are loaded into the browser and optionally displayed. The network connection 112 is not needed and no airtime costs are incurred. Like the previous embodiments, if the packet filter 225 passes packets relating to more than one web page, the web pages are loaded into a buffer that the user preferably navigates using the aforementioned “next” button or pick list.
[0056] Note the foregoing low cost system implements a form of a selective “electronic sign.” The user selects an area of interest and information related to this area of interest is allowed to be displayed on the user input-output device 210 . In some systems of this nature, the second link controller 215 may also be used to transmit an application-request packet such as an HTTP packet transmitted in response to a user clicking a mouse upon a hyperlink. In such systems, the mobile user transmits a request packet indicating its interest to the local broadcast domain entity 150 . The local broadcast domain entity 150 then supplies the desired information relating to locally available resources. In other embodiments the application-request packet is forwarded to the network server 125 via the second network connection 113 . Down-stream application data is then passed to the mobile unit 105 from the network server 125 via the second network connection 113 . While the above discussion focused on a web browser application, other types of user interfaces and applications may be equivalently employed. For example, the display of the user input-output device 210 may be made of a simple LED array or a text-only LCD display. Other display options include projection displays and heads-up displays. The displays themselves can be reconfigurable and in some instances, such as is the case of touch-screen displays, would form the whole or a part of the human-machine interface. In this case the application program is operative to simply display a text message instead of a web-page image.
[0057] Another example of an electronic sign is an electronic real estate sign. When the vehicle 102 drives up in front of a property with a “for sale” sign, a set of data such as multiple listing information is transmitted to the mobile unit 105 . In some systems a full set of photographs may be displayed within the vehicle 102 . In one such example, the electronic real estate sign transmits information packets containing price and other information. A simple radio frequency transmitter placed within a window of the house may be used as the local broadcast domain entity 150 . In systems where the mobile unit 105 includes the network connection antenna 110 , a low cost transmitter may be used to broadcast an HTTP address packet so the full set of graphical data relating to the property may be downloaded to the mobile unit via the network connection 112 . Additional filtering could be employed based upon client interests (e.g. price range, size of property desired, etc.) compared to data transmitted from the web page or from the broadcast domain entity 150 .
[0058] Referring now to FIG. 3 , a method 300 of processing 105 is illustrated in flow chart form. The method 300 is carried out by an application program such as a geographical web browser running on the mobile unit 105 . The method 300 is designed to control the mobile unit 105 as configured according to FIG. 2 . The method 300 represents a client-side method used to communicate and interact with a server-side method as discussed in connection with FIG. 4 . When the mobile unit 105 is implemented in alternate embodiments, the method 300 is modified as well. These modifications are discussed after the following discussion relating to the mobile unit 105 as configured according to FIG. 2 .
[0059] In a first step 305 , a set of network application data is accessed. Application data may include, for example, web pages or database information. Application data is transmitted as application data packets using an application layer protocol such as HTTP. The application data is preferably downloaded from the network server 125 into the mobile unit 105 and then displayed on the user input-output device 210 . Typically, the network application data involves web pages provided in hypertext mark-up language (HTML) but other forms of network application data may be equivalently used. In many cases, the network application data includes a packet-filter parameter. In some embodiments, to limit airtime, the first step 305 accesses the set of network application data from a memory or other form of storage unit accessible to the mobile unit 105 . Control next passes to a second step 310 whereby information related to the network application data is displayed. In a preferred embodiment, the second step 310 involves displaying a web page on a web browser display screen that is a part of the user input-output device 210 . Operational data such as the packet-filter parameter need not be displayed in the step.
[0060] Control next passes from the second step 310 based on a first decision 315 . In the first decision 315 , a check is made to see whether a new packet-filter configuration parameter has been received. The packet-filter parameter either enters the system as a part of the network application data, is input via the user input-output device 210 , or is loaded from a memory within the mobile unit 105 . If the packet-filter needs to be reconfigured, control next passes to a third step 320 . In the third step 320 the packet-filter parameter is loaded into the packet filter 225 . If the network application data was accessed from the network connection, the packet filter parameter is coupled into the packet filter 225 via the coupling from the network interface device 205 . If the network application data was accessed from the user input-output device 210 , the packet filter parameter is coupled into the packet filter 225 via the coupling from the user input-output device 210 . As mentioned above, in some cases the parameter may be stored in a memory and loaded into the packet filter 225 via a coupling from the memory (not shown).
[0061] If the first decision 315 evaluates negatively, or after the packet filter has been configured in the third step 320 , control next passes to set of decisions that implement a wait-for-input control flow. In the embodiment shown, control passes to a second decision 325 where a check is made to see whether a user input has been detected. If a user input has been detected, control passes back to the first step 305 where the user information is processed and possibly packetize for transmission via the first network connection 112 . In the first step 305 , new information may be accessed and the aforementioned steps are repeated. If the second decision 325 is negative, control passes to a third decision 330 . In the third decision 330 , a check is made to determine if a broadcast packet has been received. If the third decision 330 evaluates to the affirmative, control next passes to a fourth decision 335 whereby the received packet's header or other associated information is checked against the packet filter's bit mask, one or more keywords, or other form of interest designator as configured in the third step 320 . If the fourth decision 335 evaluates to the affirmative, control passes back to the first step 305 . In the first step 305 information derived from the packet filter output is preferably uploaded via the first network connection 112 and used to access a new set of network application data such as web pages. If the third decision 330 evaluates to the negative, control loops back to continue to check for a valid user input or packet filter output. If the fourth decision 335 evaluates to the negative, control also loops back to continue to check for a valid user input or packet filter output.
[0062] In the method 300 , the decisions 325 , 330 and 335 are shown to be implemented as a sequence of binary tests. A variety of equivalent control flows may be employed to implement these decisions. For example, these three decisions may be implemented such that a processor enters a wait loop and waits for an interrupt from a user I/O device or from the packet filter.
[0063] The method 300 implements a geographically controlled web browser when implemented by the remote unit 105 which moves about as illustrated in FIG. 1 . For example, the first step 305 is operative to transmit one or more hypertext transfer protocol (HTTP) request packets via the first network connection 112 . The first step 305 is also operative to download web page data so that it can be displayed in the second step 310 on the display of the user input-output module 210 . If the first network connection 112 is coupled to the network server 125 , and the network server is configured to process inputs from a geographical web browser, the server will typically download a packet-filter parameter to the geographical web browser. This packet-filter parameter tells the geographical web browser which packets to send via the first network connection 112 to the network server 125 . If a packet-filter parameter is sent by the network server 125 or otherwise made locally available, the third step 320 is operative to configure the packet filter. Now as the mobile unit 105 moves from one broadcast domain to the next, only selected packets will pass through the packet filter and thereby navigate through a set of web pages to be displayed on the display screen of the mobile unit 105 . Alternatively, the user may provide navigation commands and navigate the web browser using conventional methods such as keyboard entries, voice commands, or mouse clicks.
[0064] A geographical web browser has an added advantage of providing a new means for advertising locally available items such as products and services. The user interested in a certain product or service logs into a geographically controlled web site and configures the packet filter to display information related to a user's needs. In one example the mobile unit 105 enters a new city and the user is interested in finding a mall with a particular clothing store within. As the user drives along, a web page comes up and provides directions to the shopping mall and also optionally provides an inside map of the mall to include directions to the desired store. This form of advertising helps both the consumer and the storeowners. Similarly, if the mobile unit 105 is connected to a road-navigation site, new map pages may be periodically downloaded based upon the mobile unit 105 's current position. If a user is using a hand-held unit, a similar type of scenario applies within the shopping mall, for example. A geographical web browser practicing the method 300 may also be used in systems where the local broadcast domain 150 is supplied by the same telecommunications cell site as used for the network connection 112 .
[0065] The method 300 operates with some modifications in systems when the mobile unit 105 uses the satellite antenna 140 and employs the GPS receiver in the broadcast reception module 220 . In such systems, the packet filter 225 does not filter packets but rather generates packets from a table based on a filter parameter and the calculated GPS positioning coordinates. The network server 125 or a memory preferably provides a set of potential pointers to web pages based on the user's current interest as defined by the web page to which the mobile unit 105 is connected. When the mobile unit crosses a boundary and enters a region within a locality, if any web page pointers are loaded for that locality and meet the packet-filter criterion, this has the same effect as if the decisions 330 and 335 were both affirmative. The comparison may be performed by subtracting from a set of reference coordinates a set of coordinates representative of the geographical location of the mobile unit and testing to see whether the difference is below a threshold. In some case the comparison may be made referenced to a man-made boundary such as a city limit or a cell coverage boundary. A “geographical packet” may be thereby generated to send a request for web pages or related application data to be downloaded. A “geographical packet” is a type of request packet sent by a geographical web browser to request application data such as web pages to be downloaded based on geographically related events. Instead of navigating an application by mouse-clicking on an icon or a hyperlink, a mobile unit automatically responds to positional and/or locally broadcast information packets. In some cases web pages may be stored locally and accessed locally using caching techniques to minimize the network transactions.
[0066] The method also operates with some modifications in situations where the mobile unit 105 does not include a network antenna 110 and thereby does not maintain the first network connection 112 . In this case the difference is the packet stream received at the antenna 145 includes the web pages themselves. The packet filter operates similarly and only accepts web pages that match the packet-filter criterion.
[0067] Referring now to FIG. 4 , a method 400 practiced by the network server 125 is illustrated in flow chart form. The method 400 is a server-side method that interacts with a client-side method such as the method 300 . Recall the network server 125 may also be implemented as the application program 130 . The method 400 is designed to provide the server side of a client-server application layer communication protocol. In this system the method 300 represents the client side of the connection and is practiced by the mobile unit 105 . The method 300 communicates client-side data packets to the network server 125 that responds with server-side data packets as it practices the method 400 .
[0068] In a first step 405 , initial communications are performed with a client such as the mobile unit 105 practicing the method 300 . For example, in a web browser application, the first step 405 involves receiving one or more HTTP request-packets and responding with packets comprising web-page data. Next control passes based on a decision 410 that checks to see whether one or more packet-filter parameters need to be downloaded to the client. If the decision 410 evaluates affirmatively, control passes to a second step 415 whereby the one or more packet-filter parameters are transmitted to the client. After the second step 415 , control next passes to a third step 420 . If the decision 410 evaluates negatively, control bypasses the second step 415 and passes directly to the third step 420 . In the third step 420 , a standardly generated or a geographically generated data application packet is received at the network server 125 . For example, a standardly generated application packet may be an HTTP packet transmitted by the method 300 after the user has clicked on an Internet link. As used herein, this type of packet is also called a “standard-request packet.” A geographically generated HTTP request packet references a page to which there is not necessarily a link. Instead of selecting a link, the HTTP request is generated in the first step 305 of the method 300 after the decision 335 indicates a packet has passed through the packet filter and thereby web pages need to be downloaded. A packet generated as such is one type of “geographical packet.” Another type of “geographical packet” is a request packet generated when a GPS receiver identifies the mobile unit 105 has passes into a locality and a request needs to be sent to the network server 125 as previously discussed.
[0069] Control next passes to a fourth step 425 whereby one or more application packets are transmitted in response to the request received in the third step 420 . Typically, the application packets transmitted in the fourth step 425 include information relating to one or more new web pages being downloaded from the network server 125 to the mobile unit 105 via the first network connection 112 . In some systems it is desirable to download a plurality of web pages into a cache within the mobile unit 105 . The user then preferably uses the “next” button in the geographical web browser to access the plurality of downloaded pages.
[0070] Control next passes out of the fourth step 425 based upon a second decision 430 . The second decision 430 checks to see whether the user has selected a link directing control away from the network server 125 . If the second decision 430 evaluates affirmatively, control passes to a fifth step 435 whereby the method is exited. If the second decision 430 evaluates negatively, control passes back to the third step 420 to await more standardly or geographically generated application packets.
[0071] Referring now to FIG. 5 a , a method 500 of processing within a communication system is illustrated. In a first step 505 , the local broadcast domain entity 150 is operative to transmit a low power broadcast packet that is then received by the mobile unit 105 . The mobile unit 105 selectively passes the received packet according to the packet-filter parameter as configured in the third step 320 of the method 300 . Control next passes to a second step 507 . In the second step 507 , a set of application data such as web pages are supplied by the network server 125 via the first network connection 112 to the mobile unit 105 . Depending on the system configuration, this step may also be performed by the local broadcast domain entity 150 so that the web pages or other application data is received via the local broadcast antenna 145 . In such systems, the web pages may be stored within the local broadcast domain entity 150 itself, or may pass through the local broadcast domain entity 150 after having been downloaded from the network server 125 via the second network connection 113 . Control next passes to a third step 509 practiced by the remote unit 105 whereby a set of application data such as web pages is displayed on the user input-output device 210 .
[0072] Referring now to FIG. 5 b , a method 510 of processing practiced by the mobile unit 105 , the local broadcast domain entity 150 and optionally the network server 125 is illustrated in flow chart form. In the method 510 , the mobile unit 105 and the local broadcast domain entity 150 engage in cooperative two-way communications. In a first step 515 , the mobile unit 105 transmits a user-interest packet via the local broadcast domain antenna 145 to the local broadcast domain entity 150 . In this method, the local broadcast domain entity 150 includes both a transmitter and a receiver, i.e., a transceiver. Also, the second link controller 215 also includes a transceiver capable of both transmitting and receiving within the local broadcast domain. As discussed hereinafter, the user-interest packet may be encrypted using a scheme such as public key encryption. If an encrypted user-interest packet is used, the system may employ challenge-and-reply authentication to thereby restrict access to information
[0073] Control next passes to a second step 520 . While the first step 515 is practiced by the mobile unit 105 , the second step 520 is practiced by the local broadcast domain entity 150 . In the second step 520 , the user-interest packet transmitted by the mobile unit 105 in the first step 515 is received by the local broadcast domain entity 150 . Control next passes to a third step 525 practiced by the local broadcast domain entity 150 in response to the first step 515 . In the third step 525 , the user-information packet received in the second step 520 is processed. This step involves extracting the user-information packet from a signal transmitted from the antenna 145 and received by the local broadcast domain entity 150 . Once received, the third step 525 involves feeding the user-information packet to a software module for evaluation. The software module checks the received user-interest packet to determine whether or not the local broadcast domain entity 150 can supply information related to a service desired by the user. The software module checks the user-interest packet and makes a decision 530 . If the local broadcast domain entity 150 cannot supply information related to a service desired by the mobile unit 105 as indicated by the user-interest packet, control transfers back to the first step 515 . In this case the local broadcast domain entity performs no action and awaits another user-interest packet to be transmitted. In some systems, the local broadcast domain entity 150 may also practice the method 500 while waiting for the next user-interest packet.
[0074] The user-interest packet is a packet identifying a specific user interest. For example, the user within the vehicle 102 has a toothache and enters the domain of the local broadcast domain entity 150 . The user is thereby interested in finding a dentist. The user enters information via the user input-output device 210 either by mouse click, keyboard entry, or voice commands indicative of this interest. The mobile unit 105 then broadcasts this information via the antenna 145 into the broadcast domain to be received by the local broadcast domain entity 150 . If a local dentist is registered with the local broadcast domain entity 150 , the decision 530 evaluates affirmatively and a packet relating a locally available dentist will be transmitted back to the mobile unit 150 as discussed below.
[0075] In another example the mobile unit 105 is implemented as a palm-pilot or personal digital assistant computer. A user carrying the palm-pilot version of the mobile unit 105 enters a shopping mall and is looking for a silver plated picture frame under fifty dollars. Information to this effect is entered by the user as discussed above and a user-interest packet is transmitted according to the first step 515 . The local broadcast domain entity 150 is preferably controlled by the shopping mall authorities or a contracted advertising company. The steps 520 and 525 then are performed to determine which stores carry the item of interest. If any of the stores within the shopping mall carry the item of interest, the decision 530 evaluates affirmatively and a packet will be transmitted back to the mobile unit 150 as discussed below.
[0076] If the decision 530 evaluates affirmatively, control next passes to a fourth step 535 . In the fourth step 535 a reply packet is transmitted back to the mobile unit 105 in response to the user-interest packet transmitted in the first step 510 . In systems employing challenge and password authentication procedures, an exchange of packets may be required between the mobile unit 105 and the local broadcast domain entity 150 before the fourth step 535 is performed. Control next passes to a fifth step 540 whereby application data such as web pages relating to the topic of the user-interest packet is supplied to the mobile unit 105 . Depending on the system configuration, the fifth step 540 may be performed by the local broadcast domain entity 150 so that the application data is received via the local broadcast antenna 145 . In other systems, the fifth step 540 is performed by the network server 125 which downloads the application data to the mobile unit 105 via the first network connection 112 . Control next passes to a sixth step 545 practiced by the remote unit 105 whereby information related to the application data such as web pages is displayed on the user input-output device 210 .
[0077] In restricted access systems, transmissions of the method 510 may be encrypted and electronic challenge and reply authentication may be used. Challenge and reply authentication involves providing a digital signature so that electronic eavesdroppers cannot gain access to a password. Public key encryption methods are preferably used to allow information to be disseminated using the method 510 to authorized mobile units only.
[0078] In systems involving multiple users the local broadcast domain entity must receive packets possibly from multiple different mobile units 105 . One way to handle this type of situation is to use a method known as carrier sense multiple access. The mobile units transmit burst data packets infrequently and at random intervals so the channel is clear most of the time. If two mobile units attempt to transmit simultaneously, a data collision occurs and an error detection algorithm involving check-bits is employed to determine the validity of a received data packet. If the received data packet includes errors, it is dropped. The two mobile units attempt to retransmit their packets at random time delays and in all probability are able to get then through on their second try. Other multiple access techniques may also be used but are not considered further herein because they are already well known in the art. These multiple access techniques include frequency division multiple access, time division multiple access and code division multiple access.
[0079] Referring now to FIG. 6 , a method 600 to assist in road navigation is illustrated in flow chart form. The method 600 may also be practiced in off-road situations such as shopping malls when the mobile unit 105 is implemented, for example, as a palm-pilot. In a first step 605 , the mobile unit 105 transmits a set of information related to the mobile unit's desired destination to a server such as the network server 125 . This information may be transmitted via the first network connection 112 or may be passed through the local broadcast domain entity 150 and to the network server 125 using the second network connection 113 .
[0080] Control next passes to a second step 610 whereby the information transmitted in the first step 605 is received at a navigation server. The navigation server may be implemented, for example as the application program 130 , or the network server 125 . Within building environments such as a shopping mall, a picocell architecture may be employed so that the Internet 122 is actually implemented as an intranet. For the purposes of description, an embodiment whereby the navigation server is implemented within the network server 125 will be described. Control next passes to a third step 615 . In the third step 615 a set of navigation information such as directions or a digital map is transmitted from the navigation server back to the mobile unit 105 . Control next passes to a fourth step 620 where the information transmitted to the mobile unit 105 in the third step 615 is displayed on the user input-output device 210 . This step often involves displaying an image with a digital map marking the best current route to the desired destination as defined in the first step 605 .
[0081] Control next passes to a fifth step 625 . The fifth step 625 may be executed after a timer has timed out, a local broadcast packet has passed through the packet filter 225 , or a user input has been entered via the user input-output device 210 . Once fifth step 625 indicates new navigational information is needed, control passes to a sixth step 630 . In the sixth step 630 new location information is received at the mobile unit 105 . This location information may be obtained using a GPS receiver, or by packet filtering local broadcast domain packets. In the navigation application, the packet filter is set to pass navigation packets that indicate the mobile unit 105 's geographical location.
[0082] Control next passes to a seventh step 635 where the mobile unit 105 's location information is uploaded to the navigation server. This step may be performed in a variety of ways. For example, the mobile unit 105 may activate a virtual session and send the location information via the first network connection 112 . Alternatively, the mobile unit 105 may transmit a request packet to the local broadcast entity 150 which then transmits the packet via the second network connection 113 . After the seventh step 635 , control passes back to the second step 610 where the navigation server once again receives a current-location packet from the mobile unit 105 and the foregoing steps are then repeated.
[0083] It should be noted the navigation server preferably selects a best route when transmitting route information to the mobile unit 105 in the third step 615 . The best route information is preferably calculated based on traffic conditions and distance. For example, a set of one or more sensors is associated with local broadcast domain entity 150 . The sensors measure traffic conditions using, for example, laser continuity sensors to measure vehicle speeds. The sensor information is forwarded back to the local broadcast domain entity 150 via wireless, wireline, or optical links. The sensor information is uploaded via the second network connection 113 to the network server 125 which acts as the navigation server for the system. The navigation server preferably collects data from a plurality of local broadcast domains in order to keep up-to-date information about road conditions and routes over a wide geographical coverage. The navigation server thereby calculates the best route of travel for the mobile unit 105 for its destination and includes this information transmitted in the third step 615 .
[0084] Referring now to FIG. 7 , a block diagram of system for navigation and traffic management 700 is illustrated. A vehicle 102 includes a mobile unit 105 , and is connected to a desired destination, 702 through a plurality of roadways, or routes 704 , 706 and 708 . Dispersed along the roadways, is a plurality of geographically dispersed sensors, 710 . In some instances, these geographically dispersed sensors may be deployed in a mobile unit such as the helicopter, 712 , shown in FIG. 7 . These sensors are connected to a central server 714 through wireline links 716 and wireless links 718 . In some cases, the sensors are combined in intermediate nodes, 720 . The intermediate nodes 720 are connected to the sensors through wireline links 722 and wireless links 724 . The intermediate nodes 720 are connected to the central server 714 through wireline links 726 and wireless links 728 . A fiber optic link 726 is a special form of a wireline link and is illustrated in FIG. 7 . The central server 714 is coupled to the mobile unit through wireless link 730 .
[0085] In FIG. 7 , the vehicle 102 is proceeding towards a destination, 702 . In the case of a commuter, the vehicle may be heading to work, in an office or a factory, or home. The vehicle could also be in transit between cities or boroughs. In many instances, the operator of the vehicle has a choice among routes, 704 , 706 , or 708 . For example and without limitation, route 704 may be a busy secondary road, route 706 may be a highway or freeway with controlled access, and route 708 may be a back road. As is well known to most drivers, it may be the case where the highway, 706 , may be the fastest unless there is congestion or an accident has occurred. The operator of the vehicle may desire to know the navigational route which will allow him to arrive in the shortest time, or encounter a minimum of traffic. The controlling authority of the roadways may similarly desire to regulate traffic, encouraging travel along alternate routes and at alternate times. The controlling authority of the roadways is thus motivated to share traffic patterns with the operator of the vehicle whose interests are generally aligned. Further inducement may be offered through a systems of road usage fees or tolls where off peak travel or secondary route travel is monetarily less expensive than peak or rush hour traffic, and travel along congested roads. It will be recognized that traffic congestion fluctuations are often unpredictable due to accidents and special events. The routes considered in this invention may not necessarily include all routes, and it is envisioned that early application of this system will limit itself to major highways and interstate freeways most prone to rush hour congestion. Heavily trafficked secondary roads will be added to the system next.
[0086] The invention disclosed herein teaches the use of sensors, 710 , which are used to measure the road conditions, including the amount and speed or traffic flow. By example and without limitation, 710 sensors may use infrared beam technology, pressure cables strung across the roadway, human observers, or electronic cameras such as CCD arrays. Further, any combination of technologies may be used. The sensors 710 may be statically mounted at an observation point, such as an intersection, or an entrance ramp, or the sensors 710 may be mounted in a mobile unit such as a traffic helicopter or a police car or other vehicle.
[0087] The data measured and collected by the sensors 710 are communicated in raw or processed fashion to the central server 714 . The communication links may generally be either wireless or wireline. Examples of wireline links include, without limitation, twisted pair wire, coaxial cable, plastic and glass fiber optics, and other transmission line media. Wireless links include, without limitation, RF, microwave and IR transmission between transmitting antennas and receiving antennas, or transmitting sources and receiving sources. The data collected by sensors 710 may be directly transmitted to the central server 714 , or the data may be relayed to the intermediate nodes 720 for simple multiplexing, packetizing, preprocessing and/or filtering before retransmission to the central server 714 .
[0088] At the central server 714 , the data is collected and analyzed. In a simple embodiment, information about traffic density and flow along different roadways may be organized and broadcast to the mobile unit 105 , to serve an announcement function similar to the existing traffic reports heard on metropolitan radio shows during rush hours. Alternatively, the analysis may entail calculating a preferred route for a vehicle 102 optimizing for distance weighted by road conditions. In yet a third embodiment, the data collected on traffic flow and road conditions may be used to set adaptive road tolls in order to use market forces to regulate the operator's choice of route. The concept of adaptive road tolls are tolls, tariffs or fees on a segment of a road or highway that change or adapt to demand. As road space becomes more in demand, the tolls preferably adjust to regulate the use of a given segment of road. The adaptive road tolls enable the use of an efficient free market mechanism to allocate the increasingly scarce resource of road space. The adaptive road tolls represent a usage fee and provide an improvement to fixed vehicle tariffs paid, for example, by county per year. The invention may be used to record and assess the adaptive road tolls through link 730 and central server 714 . Alternatively, payment may be made through existing technology such as the TollTag™ marketed by AmTech Corp.
[0089] The information collected and calculated by the central server, and in some cases, the intermediate nodes is relayed to the mobile unit 105 through a wireless link 730 . The wireless link 730 may be direct or through a plurality of local broadcast domain entities as disclosed above.
[0090] The discussion of FIG. 7 may be used to develop an alternative embodiment of the method 600 . This alternative embodiment provides a method for traffic management. Traffic management is a process whereby a controlling authority provides an incentive system to alter and control traffic flows. The alternate version of the method 600 operates as follows. The first 605 is the same as previously discussed. The second step 610 is augmented with the process of receiving information indicative of traffic conditions related to a plurality of roads and adaptively assigning a road usage toll to at least one of these roads based upon the received information. The step 615 is augmented by also electronically providing information relating to the adaptive road usage tolls to the mobile unit. The step 620 is augmented by also showing cost information relating to one or more routes. The digital map may show several routes, estimated travel times on each route, and a monetary cost for traveling on each route. In some systems, with or without adaptive tolls, the step 620 may also display information indicative of the estimated travel time associated with each route. By displaying estimated travel times and adaptive tolls, drivers can make an educated decision as to which route to select.
[0091] The steps 625 and 630 are optional in this alternative method and the step 635 may be practiced using a reflective means such as the TollTag™ marketed by AmTech Corp. That is, the step 635 may involve the controlling authority probing to determine the mobile unit's location instead of the mobile unit transmitting this information. Alternatively, the step 635 may involve the mobile unit automatically sending information related to its geographical position to continue to accept updated route information and to be charged accordingly. As such, the step 610 is also modified to identify electronically (to include optically, with or without probing) the mobile unit's choice of roadways and automatically charge the mobile unit's associated vehicle based upon the adaptive road usage toll. Instead of charging the vehicle for taking the best route, a credit can alternatively be applied against a taxation if the vehicle selects a less desirable route and thereby lessens a traffic loading on a congested roadway.
[0092] Although the present invention has been described with reference to specific embodiments, other embodiments may occur to those skilled in the art without deviating from the intended scope. It should be noted while the foregoing examples make use of a web browser application whereby application data involves HTTP packets representative of web pages, this is not required. Rather the present invention encompasses any application layer program that may send application layer packets to support other types of applications. Also, while the preferred embodiments employ various antennas such as the antennas 110 , 140 , and 145 , other types of transducers including ultrasonic and laser sensors may equivalently be used in some systems. Also, while the present disclosure focused on a mobile unit, geographically based web browsing may be used by stationary systems as well. For example a central movies site may automatically provide links to movies in a local area based on the access number used to connect to the network. Various modules have been described as being implemented in software but could equivalently be implemented in dedicated hardware. Also, while an embodiment where separate telecommunication cell and local broadcast domain entities exist, these may be merged. Likewise, packet filters may be set up to filter packets based on a bit mask to be compared to a packet header, or packet filters may compare keywords or other information to information contained within the data field of the packet itself. In any of the traffic management techniques, adaptive toll charges may be replaced with an adaptive credit system. Therefore, it is to be understood that the invention herein encompasses all such embodiments that do not depart from the spirit and scope of the invention as defined in the appended claims. | A geographical web browser allows a user to navigate a network application such as the Word Wide Web by physically navigating in geographical coordinates and roaming through coverage areas of cellular base stations, wireless LANs, microcells, and other such broadcast domains. A mobile unit communicates with a network server via an air interface that supports wireless packet data. A network server uses a set of user preferences to filter a set of server-side information in accordance with a user's interest. A content-selective information filter performs a network server-side search to identify content that matches the user's preferences and automatically downloads the information to the mobile unit based on a geographic event. | 8 |
BACKGROUND OF THE INVENTION
[0001] Modern large-scale commercial bakeries of the type utilized in the production of bread, sandwich buns, and similar dough products are frequently equipped with continuous proofing and baking apparatus. In the operation of a continuous proofer and/or oven, dough to be baked is received in bakery pans. The bakery pans are transported on grids which are supported on the links of a continuous chain. A drive mechanism actuates the chain to transport the bakery pans and the dough contained therein through a proofer wherein the dough is allowed to rise and/or through an oven wherein the dough is baked.
[0002] [0002]FIGS. 1, 2, and 3 illustrates a link 20 of the type comprising a prior art conveyor chain utilized in continuous proofing and baking apparatus. Each link 20 of the conveyor chain includes a first connection member 22 , a second connection member 24 , and a pair of spaced, parallel plates 26 . The first connection member 22 of a particular link 20 is connected to the second connection member 24 of the next preceding link in the chain by a pin 28 (FIG. 3) which facilitates pivotal movement between adjacent links in the nominally vertical plane. The plates 26 are connected to the first connection member 22 and to the second connection member 24 by pins 30 which facilitate relative pivotal movement between adjacent links in the nominally horizontal plane.
[0003] The first connection member 32 of each link 20 is provided with a pair of wheels 32 . The wheels 32 support the link 20 for movement along a conveyor track 36 (FIG. 3). A wheel 34 is positioned between the plates 26 . The wheel 34 functions to center the link 20 in the conveyor track 36 .
[0004] Conveyor chains of the type illustrated in FIGS. 1 - 3 have gained widespread acceptance in the commercial baking industry and other industries. Notwithstanding this fact, such conveyor chains incorporate various deficiencies. For example, the wheels 32 which support each link 20 for moving along the conveyor track comprise anti-friction bearings which require periodic lubrication. Lubricating the chain is time consuming and expensive, and is frequently overlooked by bakery operators. Lack of lubrication leads to bearing failure which, at a minimum, requires the conveyor to be taken out of service to facilitate replacement of the failed bearings. As will be appreciated by those skilled in the art, substantially more serious consequences can and do result from bearing failure which can require the replacement of multiple links of the conveyor chain, entire sections of the conveyor track, etc.
[0005] Various factors lead to improper conveyor chain maintenance and lubrication. One of the most important involves the demands made on commercial bakeries by their customers for continuous high level production leaving no time for maintenance and lubrication procedures. An equally important factor is the lack of technicians having the training and experience necessary to properly perform conveyor chain maintenance and lubrication procedures. When untrained and inexperienced personnel are employed to maintain and lubricate the conveyor chains used in continuous proofers and ovens, improper and inadequate maintenance and lubrication result.
[0006] A related problem attendant to the use of conveyor chains comprising links of the type shown in FIGS. 1 - 3 relates to the cleaning thereof. The lubricants which are used in the anti-friction bearings of the wheels 32 of the links 20 are incompatible with the use of water and detergents to clean the conveyor chain. It is therefore necessary to employ other, more costly, techniques in order to attain the level of cleanliness required in food manufacturing operations.
[0007] Even when proper lubrication and cleaning procedures are in place, the problems inherent in the use of the prior art chain are not resolved. Lubricant from the chain combines with debris from the dough products being baked to form a sludge which cannot be disposed of except pursuant to strict EPA guidelines. When the chain is used in an oven the high temperature environment causes the lubricant to thicken to the point that the bearings seize causing increased load on the conveyor drive system and increased chain and track wear.
[0008] The design of the link 20 illustrated in FIGS. 1 and 2 also involves difficulties in changing the pitch of the conveyor chain incorporating the link, that is, the distance between identical points on adjacent links. The inability to easily change the pitch of the conveyor chain in turn means that the conveyor chain cannot be readily customized to specific load profiles, for example, lengthening the pitch for light load applications and reducing the pitch for heavy load applications.
[0009] Yet another problem involves the fact that the wheels 34 positioned between the plates 26 do not restrain the links of the chain from bending and tipping. When tipping occurs, the wheels 34 act as can openers cutting slits into the side walls of the conveyor track. Tipping also tilts the grids supported on the conveyor chain which can cause displacement of the bakery pans carried by the grids.
SUMMARY OF THE INVENTION
[0010] The present invention comprises improvements in the design of conveyor chains adapted for use in conveyorized proofers, conveyorized ovens, and similar applications which overcome the foregoing and other difficulties long since associated with the prior art. In accordance with one feature of the invention, conveyor chains intended for use in baking operations are provided with bearings which do not require lubrication. For example, when used in proofers, the bearings of the conveyor chain may comprise sleeve bearings formed from plastic materials which are self-lubricating and adapted for utilization in high temperature environments of the type encountered in a bakery oven. Conveyor chains used in ovens may be equipped with self-lubricating graphite bearings of the type sold by Graphite Metallizing Corporation of Yonkers, N.Y., under the trademark GRAPHALLOY®. Alternatively, the conveyor chain may be provided with sealed self-lubricating anti-friction bearings suitable for high temperature applications.
[0011] The use of bearings which do not require lubrication in conveyor chains intended for bakery applications is advantageous for at least two reasons. First, by eliminating the lubrication function which heretofore has proven to be problematical, substantial cost savings are effected. Of equal importance is the elimination of conveyor chain failures stemming from improper lubrication. The elimination of the lubrication requirement also facilitates the cleaning of the conveyor track by simply attaching a scraper to the conveyor chain. The scraper pushes bakery debris along the track to an opening in the bottom wall thereof where the debris is accumulated for disposal as ordinary refuse.
[0012] Those skilled in the art will understand that some types of self-lubricating bearings useful in the practice of the present invention may initially having a higher coefficient of friction as compared with the anti-friction bearings currently in use. Depending on the geometries of the components, a higher coefficient of friction can result in higher loads imposed on the conveyor drive system. However, the coefficient of friction of the currently used anti-friction bearings tends to increase over time, particularly in the absence of proper lubrication. Thus, the use of self-lubricating bearings is advantageous in that the loading of the conveyor drive system remains substantially constant throughout the life of the conveyor.
[0013] Another feature of the invention comprises the use of compact carriages to support the bakery pan receiving grids. Adjacent carriages are connected one to the other by connection members which can comprise either connection rods or connecting cables. The compact carriage/connection member design is advantageous in that it is readily adapted to changes in pitch, whereby the conveyor chain in the present invention can be easily customized to a range of conveyor loading situations.
[0014] In accordance with the preferred embodiment of the invention, the conveyor chain is comprised of a plurality of identical links having spaced apart pairs of vertically disposed and horizontally disposed wheels. The diameters of the wheels are closely matched to the interior dimensions of the track whereby the wheels prevent the chain from bending or twisting. Another important feature is the fact that the chain is economical to manufacture and assemble.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A more complete understanding of the invention may be had by reference of the following Detailed Description when taken in conjunction with the accompanying Drawings, wherein:
[0016] [0016]FIG. 1 is an exploded perspective view of a link of a prior art conveyor chain;
[0017] [0017]FIG. 2 is a perspective view of the link of FIG. 1;
[0018] [0018]FIG. 3 is a top view of a conveyor chain comprising links of the type shown in FIGS. 1 and 2;
[0019] [0019]FIG. 4 is a side view of a conveyor chain comprising a first embodiment of the present invention in which certain parts have been broken away more clearly to illustrate certain features of the invention;
[0020] [0020]FIG. 5 is a view similar to FIG. 4 showing the conveyor chain of FIG. 4 operating in a vertically curved section of conveyor track;
[0021] [0021]FIG. 6 is a top view of the conveyor chain of FIG. 4 showing the conveyor chain operating in a horizontally curved section of conveyor track;
[0022] [0022]FIG. 7 is a transverse sectional view of the conveyor chain of FIG. 4;
[0023] [0023]FIG. 8 is an enlargement of a portion of FIG. 4;
[0024] [0024]FIG. 9 is an enlargement of a portion of FIG. 6;
[0025] [0025]FIG. 10 is a view similar to FIG. 4 showing a conveyor chain having a shorter pitch as compared with that of the conveyor chain of FIG. 4;
[0026] [0026]FIG. 11 is a side view similar to FIG. 4 showing a conveyor chain having a longer pitch as compared with that of the conveyor chain of FIG. 4;
[0027] [0027]FIG. 12 is a side view similar to FIG. 4 illustrating a conveyor chain comprising a second embodiment of the invention;
[0028] [0028]FIG. 13 is a side view similar to FIG. 4 illustrating a conveyor chain comprising a third embodiment of the invention;
[0029] [0029]FIG. 14 is a side view of a conveyor chain comprising a fourth and preferred embodiment of the invention in which certain parts have been broken away more clearly to illustrate certain features of the invention;
[0030] [0030]FIG. 15 is a side view of the conveyor chain of FIG. 14 showing the conveyor chain operating in a vertically curved section conveyor track;
[0031] [0031]FIG. 16 is a top view of the conveyor chain of FIG. 14 showing the conveyor chain operating in a horizontally curved section of conveyor track;
[0032] [0032]FIG. 17 is a transverse sectional view of the conveyor chain of FIG. 14;
[0033] [0033]FIG. 18 is an enlargement of a portion of FIG. 14;
[0034] [0034]FIG. 19 is a view similar to FIG. 14 illustrating a conveyor chain having a longer pitch as compared with that of the conveyor chain of FIG. 14;
[0035] [0035]FIG. 20 is a diagrammatic illustration of a conveyor chain drive mechanism useful in the practice of the invention;
[0036] [0036]FIG. 21 is a diagrammatic illustration of a conveyor chain drive mechanism comprising a variation of the conveyor chain drive mechanism of FIG. 20;
[0037] [0037]FIG. 22 is a diagrammatic illustration of the conveyor chain drive mechanism of FIG. 21 showing the utilization thereof in conjunction with a conveyor chain having a longer pitch as compared with that of the conveyor chain of FIG. 18;
[0038] [0038]FIG. 23 is an illustration similar to FIG. 18 showing a variation of the preferred embodiment of the invention; and
[0039] [0039]FIG. 24 is a diagrammatic illustration of a conveyor chain drive mechanism useful in conjunction with the apparatus of FIG. 23.
DETAILED DESCRIPTION
[0040] Referring now to the Drawings, and particularly to FIGS. 4, 5, 6 , 7 , 8 , and 9 thereof, there is shown a conveyor chain 50 comprising a first embodiment of the invention. The conveyor chain 50 comprises a plurality of identical compact carriages 52 which are connected end to end by a plurality of identical connection members 54 . The conveyor chain 50 operates in a conveyor track 56 comprising a solid bottom wall 58 ; opposed, solid side walls 60 ; and a top wall 62 having a center slot 64 formed therein.
[0041] Each of the compact carriages 52 comprises a unitary structure which may be manufactured from a variety of materials utilizing conventional manufacturing techniques. For example, the compact carriages 52 may be manufactured from steel and/or other metals by means of die casting, investment casting, or other well known manufacturing processes. Alternatively, the compact carriages 52 may be formed from various plastic materials suitable for high temperature applications, and may be manufactured utilizing conventional processes such as injection molding. Preferably, the material and the process used in the manufacture of compact carriages 52 are selected such that few if any machining operations are required in order to complete the manufacture thereof.
[0042] Each compact carriage 52 comprises a elongate body 74 having identical openings 76 formed in the opposite ends thereof. Each opening 76 receives a spherical bushing 78 which in turn receives the end portion of one of the connection members 54 . The spherical bushings 78 are retained in the openings 76 by pins 80 .
[0043] Axles 82 extend through the body 74 at points situated inwardly from the opening 76 . The axles 82 support pairs of wheels 84 which in turn support the conveyor chain 54 for movement along the track 56 . Bosses 86 extend upwardly from the body 74 and in turn support a grid (not shown) which receives and transports bakery pans having dough received therein along the length of the track 56 . The bosses 86 may be provided with drilled and tapped apertures 88 which received threaded fasteners to secure the grid thereto. Examples of grids which may be used in the practice of the invention are shown and described in U.S. Pat. Nos. 4,729,470, 4,760,911, and 4,836,360, all of which are owned by the assignee hereof and incorporated herein by reference.
[0044] Each of the bosses 86 may have a dimensionally reduced portion 90 at the upper end thereof. Top plates 92 are supported on the bosses 86 and receive the portions 90 therethrough. The top plates 92 function to prevent debris from entering the track 56 through the slot 64 .
[0045] Each compact carriage 52 is further provided with a pair of wheels 100 . The wheels 100 function to locate the compact carriage 52 relative to the side walls 60 of the track 56 . The wheels 100 are rotatably supported on a pin 102 extending through the body 74 of the compact carriage 52 . As is best shown in FIG. 7, the wheels 100 cooperate with the wheels 84 to completely prevent bending and tipping of the conveyor chain 50 .
[0046] Referring particularly to FIG. 9, the wheels 84 are secured to the axle 82 for rotation therewith. The axles 82 of conveyors intended for use in proofers may be supported by a self-lubricating plastic bearing 104 which may be of the type manufactured by Igus Spritzgussteile fur die Industrie GmbH (Igus) of Koln (Cologne), Germany and sold under the trademark IGLIDE®. In oven applications the self-lubricating bearings 104 may be of the type sold by Graphite Metallizing Corporation of Yonkers, N.Y., under the trademark GRAPHALLOY®. The bearings 104 do not require lubrication in order to rotatably support the axles 82 and the wheels 84 supported thereon. Therefore, by means of the present invention, the need for lubrication of the wheels which support the carriages 52 is eliminated as are the problems attended to the failure to provide required lubrication and difficulties associated with cleaning conveyor chains in which lubricating fluids are used. As is shown in FIG. 4, the wheels 84 may be rotatably supported by sealed self-lubricating anti-friction bearings 105 in lieu of the plastic bearings 104 .
[0047] Referring to FIG. 8, the wheels 100 are rotatably supported on the pin 102 . In conveyors used in proofers, self-lubricating plastic bearings 106 also manufactured by Igus are provided at the opposite ends of the pin 102 and in turn rotatably support the wheels 100 thereon. Conveyors for oven use may have bearings 106 of the type sold by Graphite Metallizing. Again, the use of self-lubricating bearings 106 to rotatably support the wheels 100 on the pin 104 eliminates the need for lubrication.
[0048] As is best shown in FIGS. 6 and 9, each connector member 54 has an eye 108 at each end thereof. Each eye 108 receives the spherical bushing 78 of one of the compact carriages 52 . In this manner, the eyes 108 of the connection members 54 and the spherical bushings 78 of the compact carriages 52 facilitate the movement of the conveyor chain 50 along inclined and curved portions of the track 56 . For example, FIG. 5 illustrates the movement of the conveyor chain 50 along a vertically curved portion 110 of the track 56 . FIG. 6 illustrates the movement of the conveyor chain 50 along a horizontally curved portion 112 of the track 56 . As will be appreciated by reference to FIGS. 5 and 6, the movement of the conveyor chain 50 along vertically and horizontally curved portions of the track 56 is accomplished without interference between the conveyor chain 50 and the track 56 .
[0049] [0049]FIG. 7 illustrates the relationship between the wheels 84 and 100 of the conveyor chain 50 and the track 56 . The wheels 84 travel along the bottom wall 58 of the track 56 and support the conveyor chain 50 of the movement through the track 56 . The wheels 100 serve to center the conveyor chain 50 in the track 56 and to prevent interference of the conveyor chain 50 with the track 56 as the conveyor chain 50 moves therethrough. Again, the wheels 84 and 100 cooperate to prevent bending and tipping of the conveyor chain 50 .
[0050] Referring to FIGS. 10 and 11, one of the advantages in the use of the conveyor chain in the present invention comprises the adaptability thereof to changes in pitch. Thus, in FIG. 10 the compact carriages 52 are connected end to end by connection members 54 ′ which are substantially shorter than the connection members 54 of the embodiment of the invention illustrated in FIGS. 4, 5, and 6 . The use of the connection members 54 ′ in lieu of the connection members 54 results in a conveyor chain 50 having a substantially shorter pitch. The use of a conveyor chain having a shorter pitch is advantageous in those instances in which the conveyor chain is used to transport either heavier bakery pans or bakery pans carrying heavier loads as compared with the loading of a conveyor chain having a longer pitch.
[0051] Referring to FIG. 11, there is shown a conveyor chain 50 wherein the compact carriages 52 are connected end to end by connection members 54 ″ which are substantially longer than the connection members 54 of the conveyor chain 50 illustrated in FIGS. 4, 5, and 6 . The use of the longer connection members 54 ″ in the conveyor chain 50 of FIG. 9 results in the conveyor chain having a substantially longer pitch as compared with the pitch of the conveyor chain 50 shown in FIGS. 4, 5, and 6 . The use of a conveyor chain having a longer pitch is advantageous in those instances in which the conveyor chain is called upon to carry either lighter bakery pans or bakery pans carrying lighter loads as compared with the loading of the conveyor chain 50 of FIGS. 4, 5, and 6 .
[0052] Referring to FIG. 12, there is shown a conveyor chain 150 comprising a second embodiment of the invention. The conveyor chain 150 comprises a plurality of identical compact carriages 152 which are connected end to end by a plurality of identical connection members 154 . The conveyor chain 150 operates in a conveyor track 156 comprising a solid bottom wall 158 ; opposed, solid side walls 160 ; and a top wall 162 having a center slot formed therein.
[0053] Each of the compact carriages 152 comprises a unitary structure which may be manufactured from a variety of materials utilizing conventional manufacturing techniques. For example, the compact carriages 152 may be manufactured from steel and/or other metals by means of die casting, investment casting, or other well known manufacturing processes. Alternatively, the compact carriages 152 may be formed from various plastic materials adapted for high temperature applications, and may be manufactured utilizing conventional processes such as injection molding. Preferably, the materials and the process used in the manufacture of compact carriages 152 are selected such that few if any machining operations are required in order to complete the manufacture thereof.
[0054] Each compact carriage 152 comprises a elongate body 174 having identical openings 176 formed in the opposite ends thereof. Each opening 176 receives a spherical bushing 178 which in turn receives the end portion of one of the connection members 154 . The spherical bushings 178 are retained in the openings 176 by pins 180 .
[0055] Axles 182 extend through the body 174 at points situated inwardly from the opening 176 . The axles 182 support pairs of wheels 184 which center the conveyor chain 154 in its movement along the track 156 . The axles are extended downwardly to prevent excess tipping of the compact carriages. A boss 186 extends upwardly from the body 174 and in turn support a grid (not shown) which receives and transports bakery pans having dough received therein along the length of the track 176 . The boss 186 may be provided with a drilled and tapped aperture 188 which receives a threaded fastener to secure the grid thereto. Examples of grids which may be used in the practice of the invention are shown and described in U.S. Pat. Nos. 4,729,470, 4,760,911, and 4,836,360, all of which are owned by the assignee hereof and incorporated herein by reference.
[0056] Each boss 186 may have a dimensionally reduced portion 190 at the upper end thereof. A top plate 192 is supported on each boss 186 and receives the portion 190 therethrough. The top plates function to prevent debris from entering the track 156 through the slot in the top wall 162 .
[0057] Each compact carriage 152 is further provided with a pair of wheels 200 . The wheels 200 function to support the compact carriage 152 for movement along the bottom wall 158 of the track 156 . The wheels 200 are rotatably supported on a pin 202 extending through the body 174 of the compact carriage 152 .
[0058] The wheels 184 are secured to the axle 182 for rotation therewith. Each axle 182 is rotatably supported by a self-lubricating bearing 204 . The bearings 204 do not require lubrication in order to rotatably support the axles 182 and the wheels 184 supported thereon. Therefore, by means of the present invention, the need for lubrication of the wheels which support the carriages 152 is eliminated as are the problems attendant to the failure to provide required lubrication and difficulties associated with cleaning conveyor chains in which lubricating fluids are used.
[0059] Like the rotational support for the wheels 184 , the wheels 200 are secured to the pin 202 . A self-lubricating bearing 206 rotatably supports the pin 202 and the wheels 200 mounted thereon. Again, the use of the self-lubricating bearings 206 to rotatably support the wheels 200 and the pin 202 eliminates the need for lubrication.
[0060] Each connector member 154 has an eye 208 at each end thereof. Each eye 208 receives a spherical bushing 178 of one of the compact carriages 152 . In this manner, the eyes 208 of the connection members 154 and the spherical bushings 178 of the compact carriages 152 facilitate the movement of the conveyor chain 150 along vertically and horizontally curved portions of the track 156 .
[0061] Referring to FIG. 13, there is shown a conveyor chain 250 comprising a third embodiment of the invention. The conveyor chain 250 comprises a plurality of identical compact carriages 252 which are connected at equally spaced intervals along a wire rope 254 . The conveyor chain 250 operates in a conveyor track 256 comprising a solid bottom wall 258 ; opposed, solid side walls 260 ; and a top wall 262 having a center slot formed therein.
[0062] Each of the compact carriages 252 comprises a unitary structure which may be manufactured from a variety of materials utilizing conventional manufacturing techniques. For example, the compact carriages 252 may be manufactured from steel and/or other metals by means of die casting, investment casting, or other well known manufacturing processes. Alternatively, the compact carriages 252 may be formed from various plastic materials suitable for high temperature applications, and may be manufactured utilizing conventional processes such as injection molding. Preferably, the material and the process used in the manufacture of compact carriages 252 are selected such that few if any machining operations are required in order to complete the manufacture thereof.
[0063] Each compact carriage 252 comprises a elongate body 274 having an opening 276 extending axially therethrough. The opening 276 receives the wire rope 254 . Compression sleeves 278 mounted on the wire rope 254 locate and secure each compact carriage 252 thereon.
[0064] Axles 282 extend outwardly from the body 274 at points situated inwardly from ends thereof. The axles 282 support pairs of wheels 284 which center conveyor chain 254 for moving along the track 256 . A boss 286 extends upwardly from the body 274 and in turn supports a grid (not shown) which receives and transports bakery pans having dough received therein along the length of the track 276 . The boss 286 may be provided with a drilled and tapped aperture which receives a threaded fastener to secure the grid thereto. Examples of grids which may be used in the practice of the invention are shown and described in U.S. Pat. Nos. 4,729,470, 4,760,911, and 4,836,360, all of which are owned by the assignee hereof and incorporated herein by reference.
[0065] The boss 286 may have a dimensionally reduced portion at the upper end thereof. A top plate may be supported on the boss 280 and receive the dimensionally reduced portion therethrough. If used, the top plates function to prevent debris from entering the track 256 through the slot in the top wall 262 .
[0066] Each compact carriage 252 is further provided with a pair of wheels 300 . The wheels 300 function to support the compact carriage 52 for movement along the bottom wall of the track 256 . The wheels 300 are rotatably supported on pins 302 extending from the body 274 of the compact carriage 252 .
[0067] The wheels 284 are each rotatably supported by a self-lubricating bearing. The self-lubricating bearings do not require lubrication in order to rotatably support the wheels 284 . Therefore, by means of the present invention, the need for lubrication of the wheels which support the carriages 252 is eliminated as are the problems attended to the failure to provide required lubrication and difficulties associated cleaning conveyor chains in which lubricating fluids are used. The wheels 300 are also rotatably supported by self-lubricating bearings.
[0068] Referring to FIGS. 14, 15, 16 , 17 , and 18 , there is shown a conveyor chain 350 comprising a fourth and preferred embodiment of the invention. The conveyor chain 350 comprises a plurality of identical links 352 which are connected end to end to form the chain 350 . The conveyor chain 350 comprising the links 352 is adapted for movement along the length of a conveyor track 356 comprising a solid bottom wall 358 ; opposed, solid side walls 360 ; and a top wall 362 having a central slot formed therein.
[0069] Each component of the links 352 comprises a unitary structure which may be manufactured from a variety of materials utilizing conventional manufacturing techniques. For example, the links 352 may be manufactured from steel and/or other metals by means of die casting, investment casting, or other well known manufacturing processes. Alternatively, the links may be formed from various plastic materials adapted for high temperature applications, and may be manufactured utilizing conventional processes such as injection molding. Preferably, the material and the process used in the manufacture of links are selected such that few if any machining operations are required in order to complete the manufacture thereof.
[0070] Each link 352 comprises a first link portion 364 and a second link portion 366 . Each first link portion 364 is connected to its corresponding second link portion 366 by a pin 368 which facilitates relative pivotal movement between the link portions in the nominally vertical plane. Each pin 368 also has mounted thereon a pair of wheels 370 which support the link 352 for movement along the bottom wall 358 of the track 356 .
[0071] The second link portion 366 of each link 352 is connected to the first link portion 364 of the immediately following link 352 by a pin 372 . Thus, the pins 372 facilitate relative pivotal movement the links 352 of the conveyor chain 350 in the nominally horizontal plane. Each pin 372 also supports two wheels 374 which serve to center the conveyor chain 350 and the track 356 . As is best shown in FIG. 17, the diameters of the wheels 370 and 374 are closely matched to the interior dimensions of the track 356 whereby the wheels 370 and 374 completely prevent bending or tipping of the chain 350 .
[0072] The pins 368 and 372 of the links 352 facilitate the movement of the conveyor chain 350 along inclined and curved portions of the track 356 . For example, FIG. 15 illustrates the movement of the conveyor chain 350 along a vertically curved portion of the track 356 . FIG. 16 illustrates the movement of the conveyor chain 350 along a horizontally curved portion of the track 356 . As will be appreciated by reference to FIGS. 15 and 16, the movement of the conveyor chain 350 along inclined and curved portions of the track 356 is accomplished without interference between the conveyor chain 350 and the track 356 .
[0073] Referring particularly to FIGS. 14, 16, 17 , and 18 , the wheels 370 are rotatably supported on the pins 368 by self-lubricating bearings 376 . Likewise, the wheels 374 are rotatably supported on the pins 372 by self-lubricating bearings 378 . The use of the self-lubricating bearings 376 and 378 to rotatably support the wheels 370 and 374 , respectively, eliminates the need for lubrication. As is shown in FIG. 14, the wheels 370 and 374 may be supported by sealed self-lubricating anti-friction bearings 379 adapted for high temperature applications in lieu of the bearings 376 and 378 .
[0074] Each first portion 364 of each link 362 includes a boss 380 extending upwardly therefrom and through the slot in the top wall 362 of the track 356 . Each boss 380 supports a grid (not shown) which receives and transports bakery pans having dough received therein along the length of the track 356 . Each boss 380 may be provided with a drilled and tapped aperture 382 which receives a threaded fastener to secure the grid thereto. Examples of grids which may be used in the practice of the invention are shown and described in U.S. Pat. Nos. 4,729,470; 4,760,911; and 4,836,360, all of which are owned the assignee hereof and incorporated herein by reference.
[0075] Each boss 380 may have a dimensionally reduced portion 384 at the upper end thereof. Top plates 386 are supported on the bosses 380 and receive the portions 384 therethrough. The top plates function to prevent debris from entering the track 356 through the slot in the top wall 362 thereof.
[0076] Referring to FIG. 19, one of the advantages of the use of the conveyor chain in the present invention comprises the adaptability thereof to changes in pitch. Thus, in FIG. 19 there is shown a conveyor chain 350 having links 352 ′ which are substantially longer than the links 352 of the conveyor chain 350 illustrated in FIGS. 14, 15, and 16 . The use of the longer links 352 ′ in the conveyor chain of FIG. 19 results in the conveyor chain having a substantially longer pitch as compared with the pitch of the conveyor chain 350 shown in FIGS. 14, 15, and 16 . The use of a conveyor chain having a longer pitch is advantageous in those instances in which the conveyor chain is called upon to carry either lighter bakery pans or bakery pans carrying lighter loads as compared with the loading of the conveyor chain 350 of FIGS. 14, 15, and 16 .
[0077] Referring now to FIG. 20, there is shown a drive mechanism 400 useful in conjunction with all of the conveyor chains illustrated in FIGS. 4 through 19, inclusive, and described hereinabove in conjunction therewith. The drive mechanism 400 includes a drive chain 402 which is trained around an idler sprocket 404 , an idler sprocket 406 , and a drive sprocket 407 . The drive sprocket 407 is actuated by a suitable drive mechanism to cause the drive chain 402 to move around the course defined by the sprockets 404 and 406 .
[0078] A plurality of chain engaging members 408 are supported on the drive chain 402 for engagement therewith. Each chain engaging member 408 includes a forward roller 410 which is rotatably supported on a pin 412 secured in the drive chain 402 and a rearward roller 414 which follows the surface of a cam 416 extending adjacent to the path of the drive chain 402 .
[0079] Referring particularly to the portion of the cam 416 extending adjacent to the idler roller 406 , if the rollers 410 and 412 were both secured to the drive chain 402 , the chain engaging members 408 would accelerate during movement around the idler roller 406 . However, the means of the engagement of the roller 414 with the cam 416 , each chain engaging member 408 remains parallel to its corresponding surface on the conveyor chain until the chain engaging member 408 has moved downwardly far enough to disengage from the conveyor chain. In this manner operating power is applied to the conveyor chain evenly and without periodic intervals of acceleration as would otherwise be the case.
[0080] [0080]FIG. 21 illustrates an alternative drive mechanism 420 which may be utilized in the practice of the invention. The drive mechanism 420 includes a drive chain 422 which extends around a course defined by a drive sprocket 424 and two idler sprockets 426 and 428 .
[0081] The drive mechanism further includes a plurality of conveyor chain engaging members 430 each dimensioned to fully fill the space between adjacent links of a conveyor chain. In this manner the drive mechanism 420 may be utilized to apply a breaking force to the conveyor chain. This is accomplished by slowly reducing the operating power that is supplied to the drive sprocket 424 or by completely reversing the direction of operation of the drive sprocket 424 depending upon the requirements of particular circumstances.
[0082] Each conveyor chain engaging member 430 is secured to the drive chain 422 by a pin. Each conveyor chain engaging member 430 is provided with a forward roller 434 and a rearward roller 436 . The rearward roller 436 follows a cam which is substantially identical in shape and function to the cam 416 illustrated in FIG. 20. Thus, the rearward roller 436 causes the conveyor chain engaging member 430 to disengage from the conveyor chain without applying acceleration thereto.
[0083] The forward roller 434 of each conveyor chain engaging member 430 follows a track 438 . The movement of the forward roller 434 in the track 438 causes each conveyor chain engaging member 430 to enter into the space between adjacent links of the conveyor chain without applying either acceleration forces or deceleration forces thereto. Thus, the conveyor chain engaging member moves smoothly into the gap between adjacent links of the conveyor chain and into engagement with both of the adjacent links without applying forces thereto which otherwise would tend to change the speed of travel of the conveyor chain.
[0084] [0084]FIG. 22 illustrates the use of the drive mechanism 420 in those instances in which the pitch of the conveyor chain is too long for the conveyor engaging members 430 to fill the entire gap between adjacent links of the conveyor chain. In such instances a spacer 440 is mounted on each connection member of the conveyor chain at a suitable location between adjacent links thereof so as to receive the chain engaging member 430 between the spacer 440 and the link of the conveyor chain situated forwardly thereof. In this manner the drive mechanism 420 functions identically to the manner in which it functions as illustrated in FIG. 21 but without the necessity of employing conveyor engaging members which are unduly long.
[0085] Referring to FIGS. 23 and 24, there is shown a conveyor chain 450 comprising a variation of the conveyor chain 350 illustrated in FIGS. 14 through 18, inclusive, and described hereinabove in conjunction therewith. The conveyor chain 450 is identical to the conveyor chain 350 except that it comprises identical links 352 ′ each having upper and lower drive cams 452 and 454 secured thereto by fasteners 456 .
[0086] [0086]FIG. 24 illustrates a drive mechanism 460 useful in conjunction with the drive chain 450 . The drive mechanism 460 includes a drive motor 462 which actuates a drive sprocket 464 . A drive chain 466 is trained around the drive sprocket 464 and two idler sprockets 468 and 470 .
[0087] A drive chain cam 472 extends between the idler sprockets 468 and 470 . The drive chain 466 carries a plurality of drive forks 476 . Upon actuation by the drive motor 462 , the drive sprocket 464 actuates the drive chain 466 to move the drive forks 476 around a course extending from the drive sprocket 464 around the idler sprocket 468 , across the drive chain cam 472 , around the idler sprocket 470 , and back to the drive sprocket 464 .
[0088] As each drive fork 476 moves into engagement with the drive chain cam 472 it is gradually lifted into engagement with one of the drive cams 452 on one of the links 352 ′ of the conveyor chain 450 , being understood that an identical drive fork engages the drive cam 454 on the opposite side of the particular link 352 ′. As will be appreciated by those skilled in the art, the drive chain 466 and the conveyor chain 450 move at the same speed. Therefore, the drive forks of the conveyor chain 466 engage the drive cams of the conveyor chain 450 without applying any acceleration force or any deceleration to the conveyor chain 450 . Subsequently, the drive chain cam 472 gradually lowers each drive fork 476 out of engagement with the drive cam 452 with which it has been engaged. Again, the disengagement between the drive forks and the drive cams is accomplished without applying any acceleration force or deceleration force to the conveyor chain 450 .
[0089] Although preferred embodiments of the invention as illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention. | In one embodiment, a conveyor comprises identical carriages and apparatus for connecting the carriages end. The carriages each include first wheel pairs supported for a rotation about spaced apart parallel axes and a second wheel pair supported for rotation about a perpendicular axis. The first and second wheel pairs are rotatably supported by self-lubricated bearings. The connection apparatus may comprise either connection rods or a wire rope. In another embodiment, the conveyor comprises identical links each including first and second link portions. The link portions are pivotally interconnected by a first connecting pin which also supports a first pair of wheels. Adjacent links are interconnected by a second connecting pin which also supports a second wheel pair. The first and second wheel pairs are rotatably supported by self-lubricated bearings. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from United Kingdom Patent Application No. 1300927.9, filed on Jan. 18, 2013. The priority application is herein incorporated by reference in its entirety
BACKGROUND
Energy harvesting is the process of capturing and storing small amounts of energy for use in a variety of application. One of the most common types of energy harvesting involves the transfer of energy from small movements in a device into electricity. For example, many watches capture user movement to power the watch mechanism. Energy harvesting using electrets has been proposed by Juji Suzuki, in his article Energy Harvesting from Vibration Using Polymer Electret (SUZUKI, Y. Energy Harvesting from Vibration Polymer Electret. International Symposium on Micro-Nano Mechatronics and Human Science. November 2008, pages 180 to 183).
SUMMARY
A first aspect provides a device for the transmission of electromagnetic signals, the device comprising: a conductive element at least one inducer, for inducing charge in said conductive element; a transmission circuit, for generation and transmission of electromagnetic signals; wherein said conductive element and said at least one inducer are movable, with respect to each other, between a plurality of relative positions; in a first position of said relative positions, said at least one inducer is arranged to induce a charge in said conductive element; in a second position of said relative positions, said conductive element is arranged to discharge; the conductive element is arranged to couple with the transmission circuit, in said first position and/or said second position, such that charging and/or discharging of said conductive element causes the transmission circuit to generate and transmit an electromagnetic signal; and the device is arranged such that movement of said device causes relative movement of said conductive element and said at least one inducer between said plurality of relative positions.
A second aspect provides a method of transmitting an electromagnetic signal using a device comprising: a conductive element; at least one inducer, for inducing charge in said conductive element; and a transmission circuit, for generation and transmission of electromagnetic signals; wherein said conductive element and said at least one inducer are movable, with respect to each other, between a plurality of relative positions; the method comprising: moving the device in a first direction to cause the conductive element and at least one inducer to move relatively closer to one another, thereby causing said at least one inducer to induce a charge in the conductive element; and moving the device in a second direction to cause the conductive element and at least one inducer to move relatively apart from one another, thereby causing the conductive element to discharge; wherein said steps of charging and/or discharging occur through said transmission circuit and cause the transmission circuit to generate and transmit an electromagnetic signal.
Further features of embodiments are recited in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective diagram of a device in accordance with a first embodiment;
FIG. 2 is a side-view diagram of the device shown in FIG. 1 in operation;
FIG. 3 is a further side-view diagram of the device shown in FIG. 1 in operation;
FIG. 4 is a further side-view diagram of the device shown in FIG. 1 in operation;
FIG. 5 is a further side-view diagram of the device shown in FIG. 1 in operation;
FIG. 6 shows a device in accordance with a second embodiment;
FIG. 7 shows a device in accordance with a third embodiment; and
FIG. 8 shows a device in accordance with a fourth embodiment.
DETAILED DESCRIPTION
FIG. 1 is a simplified diagram of an RF (radio frequency) device 100 in accordance with an embodiment. The device 100 includes an electret 101 and a conductive plate 102 . The electret 101 and the conductive plate 102 are arranged in parallel. The conductive plate 102 is arranged to move between a first position in which it is in contact with the electret 101 and a second position in which it is separated from the elecret 101 . In FIG. 1 , the conductive plate is shown between the first and second positions. The device 100 also includes a first contact 103 , a second contact 104 and an antenna 105 . Both contacts 103 , 104 are coupled to the antenna 105 . The device 100 also includes a resonant circuit, which is not shown in FIG. 1 . The resonant circuit is also coupled to the antenna 105 . The device 100 further includes a ground plane 106 , to which the electret 101 and the resonant circuit are coupled.
When the device is physically shaken or moved, the conductive plate 102 moves between the first and second positions. The electret 101 is an insulating material with an implanted fixed charge. The electret 101 produces a strong electric field in the area through which the conductive plate 102 moves. As the conductive plate 102 moves, a charge is induced in the plate. In this sense, the conductive plate is an inducer. The conductive plate 102 discharges through the contacts 103 , 104 , causing the resonant circuit to resonate, and an RF signal to be transmitted from the antenna 105 . All of the energy used to generate the signal is derived from the movement of the device. No energy is drawn from the electret itself.
FIG. 2 is a more detailed diagram of the device 100 shown in FIG. 1 . All of the components shown in FIG. 1 are also shown in FIG. 2 . In addition, resonant circuit 107 is shown in FIG. 2 , coupled between the groundplane 106 and the antenna 105 . In FIG. 2 , the conductive plate 102 is shown to be moveable in a direction perpendicular to the plane of the electret 101 . However, in alternative embodiments, the conductive plate 102 may move side-to-side or rotate relative to the electret, as will be described in more detail below.
The electret 101 is positioned parallel and adjacent to the groundplane 106 . Here, the eletret 101 is positioned in contact with the groundplane 106 , and the groundplane 106 is a metal backplate. The electret 101 has an implanted negative charge. There is an induced positive charge in the groundplane 106 . This induced charge is a result of the electret charging process. In FIG. 2 , the first contact 103 is located close to the electret 101 . The second contact 104 is situated close to the conductive plate's second position. When the conductive plate 102 is in the first position, it makes contact with the first contact 103 and the electret 101 . When the conductive plate 102 is in the second position, it makes contact with the second contact 104 and is separated from the electret 101 .
As noted above, the device 100 is designed such that motion of the device results in the conductive plate 102 moving toward and away from the electret 101 . Initially, to a first order approximation, the entire electric field (E-field) is contained within the electret 101 . The E-field in the electret 101 is dependent on: the charge density, σ; the area, A; and the permittivity, ε.
E
=
σ
A
ɛ
(
1
)
The surface voltage of the electret 101 and the groundplane 106 is determined by the charge and the distance of separation between the electret 101 and the groundplane 106 .
V=E·d (2)
where d is the distance of separation.
FIG. 3 shows the device 100 when the conductive plate 102 is in the first position and is in contact with the elecret 101 and first contact 103 . Charge redistributes between the conductive plate 102 and the groundplane 106 as they have to be at the same potential. Current i flows through the resonant circuit 107 and the antenna 105 radiates energy. Assuming that conductive plate 102 and the groundplane 106 are equidistant from the charge in the electret, 50% of the charge is transferred onto the conductive plate 102 . It should be noted that the conductive plate 102 and the electret 101 do not need to make contact. For example, in this embodiment, the conductive plate 102 and the electret 101 may move close to the charged electret, and make contact with the groundplane 106 . Such an arrangement would also be effective at charging the conductive plate 102 .
If the direction of motion (of the device 100 ) is now reversed, the conductive plate 102 moves away from the electret 101 . The charge on the conductive plate 102 is captured as no circuit is made with the groundplane 106 . This is shown in FIG. 4 .
As the motion forces the conductive plate 102 and electret 101 apart, work is being done. The electric field between the conductive plate 102 and the electret 101 remains constant since the captured charge remains constant:
E
=
Q
ɛ
0
(
3
)
As described above, the electric field is constant but the separation (d) is increased. Therefore, the voltage on the conductive plate 102 increases since:
V=E·d (4)
In the second position, the conductive plate 102 contacts with the second contact 104 and makes a circuit with the groundplane 106 , as shown in FIG. 5 . To a first approximation, the charge reverts to the initial state with all the charge residing in the groundplane 106 . The current i that results flows through the resonant circuit and results in radiation from the antenna 105 .
The energy scavenging device 100 described above requires that a metal structure (the conductive plate 102 ) moves close to an electret (the electret 101 ) and that additional motion moves the now charged metal away from the electret. Once separated, the metal structure is connected to the groundplane discharging the metal structure. Accordingly, so long as these requirements are met, it is possible to design structures to scavenge energy from different types of motion, for example rotational and sliding motion.
FIG. 6 shows a device 200 that could be used to scavenge energy from rotational movement. Sectors of metal backed electret 201 A, 201 B, 201 C are aligned with a rotating metal element 202 made up of similar sectors 202 A, 202 B, 202 C. A commutator 203 is used to make and break the required connections. As the rotating element sectors 202 and electret sectors 201 align, a connection is made, thereby charging the rotating element, as shown in the left-hand diagram. The rotation continues and the voltage on the element 202 is increased as the distance between the charged electret 201 and the rotating metal 202 is increased, as shown in the centre-most diagram. When the rotation elements 202 are maximally misaligned with the electret 201 , the commutator 203 remakes the contact and the charge flows back to the starting condition. At each contact current flows through a resonant circuit resulting in energy being radiated from the attached antenna.
A thinner solution to that shown in FIGS. 1 to 5 , in which the conductive plate slides over the charged electret, is shown in FIG. 7 . The basic operating principle, however, remains the same. FIG. 7 shows an RF (radio frequency) device 300 in accordance with an embodiment. The device 300 includes an electret 301 and a conductive plate 302 . The electret 301 and the conductive plate 302 are arranged in parallel. The conductive plate 302 is arranged to move between a first position in which it may be in contact with the electret 301 (as noted above, the conductive plate may be in contact with the electret, but is not required to be in contact with the electret) and a second position in which it is separated from the elecret 301 . The device 300 also includes a first contact 303 , a second contact 304 and an antenna 305 . Both contacts 303 , 304 are coupled to the antenna 305 . The device 300 also includes a resonant circuit 307 . The resonant circuit is also coupled to the antenna 305 . The device 300 further includes a ground plane 306 , to which the electret 301 and the resonant circuit 307 are coupled. In use, the conductive plate slides from side-to-side. Other than the direction of movement, the device 300 operates in the same manner as that described above in connection with FIGS. 1 to 5 .
FIG. 8 is a more detailed diagram of an implementation of the device shown in FIGS. 1 to 5 . FIG. 8 shows a device 400 . The device 400 includes an electret coated aluminium plate 401 , which is equivalent to the electret 101 . The device 400 also includes the a disk 402 , which is equivalent to the conductive plate 102 . The disk 402 measures around 19 mm in diameter. The metal disk includes a copper spindle 403 . The copper spindle is axially mounted through the electret coated aluminium plate 401 .
The device 400 also includes an uncoated metal plate 404 . The uncoated metal plate 404 and the electret coated aluminium plate 401 are connected by four supporting arms 405 A-D. The electret coated aluminium plate 401 and the uncoated metal plate 404 are both the same size and shape. They are each square in shape, and have a nominal thickness. Each supporting arm 405 A-D is positioned towards a respective corner of each plate. Each plate has a spindle supporting hole 406 A, 406 B towards its centre. The spindle 403 is supported through these holes such that the disk 402 may move back and forth along the axis of the spindle 403 .
The device 400 also includes insulted contacts 407 A, 407 B. Insulated contact 407 A, is positioned on a side of the uncoated metal plate 404 opposite to the side of the electret 401 . Insulated contact 407 B is positioned on a side of the electret 401 opposite the side of the uncoated metal plate 404 . The disk 402 moves between two end positions. In a first position, the disk 402 contacts or moves adjacent to the electret 401 . In a second position, the disk 402 is positioned closer to the uncoated metal plate 404 . In the first position, the spindle 403 contacts with insulted conductor 407 B. In the second position, the spindle 403 contacts with insulated conductor 407 A.
The device 400 also includes a dipole antenna 408 . The dipole antenna includes a first arm 409 A and a second arm 409 B. The first arm 409 A is coupled at one end to the insulated contacts 407 A, 407 B. The second arm 409 B is coupled at one end to the electret 401 . A tuning coil 410 is coupled between the first arm 409 A and the second arm 409 B of antenna 408 .
In use, the disk 402 moves between the electret 401 and the uncoated metal plate 404 . Charge is induced into the disk 402 when it is positioned adjacent to the electret 401 . In that same position, current flows through the spindle 403 and causes the tuning coil 410 to resonate, and an RF signal is transmitted by the dipole antenna 408 . As the disk 402 moves away from electret 401 , it maintains a charge. This is then discharged through the spindle 403 when the disc 402 reaches the other discharge position, again causing the antenna to transmit an RF signal.
Embodiments provide a means of achieving low cost communications and tagging without the need for a power supply or batteries. The pulse characteristics make it ideal for finding the direction of a tag. There are many possible applications including: emergency beacons; telemetry equipment; low-cost tagging; movement detection; low-data communication links; and position fixing/identifying.
In the embodiment described in connection with FIGS. 1 to 5 , the conductive plate 102 is arranged to move and the electret is fixed. In an alternative embodiment, the conductive plate may be fixed, and the electret may be arranged to move.
In the embodiment described in connection with FIGS. 1 to 5 , the electret is described as having a negative charge, and the conductive plate accordingly takes a positive charge. In an alternative embodiment, the electret may be positively charged, and the conductive plate may take a negative charge.
In the embodiment described in connection with FIGS. 1 to 5 , only a single electret is described. In an alternative embodiment, the device includes two electrets. The conductive plate is arranged to move between the two plates. The electrets would be oppositely charged in such an arrangement. Twice the amount of work would be required to move the conductor between two electrets, with the result that twice the energy would be scavenged and transmitted.
In the embodiment described in connection with FIGS. 1 to 5 , the conductive plate approaches the electret, in order for charge to induced in the plate. In an alternative embodiment, no groundplane is required. In such an embodiment, static charge induction is used to charge the conductor.
In the embodiment described in connection with FIGS. 1 to 5 , the conductive plate discharges through the resonant circuit when the plate is in contact with the electret. In an alternative embodiment, the conductive plate does not discharge at this point. Instead, the conductive plate only discharges when it is at the second discharge position.
The above-described embodiments include a device which is suitable for RF transmission. It will be appreciated that such devices may also be arranged to operate at microwave frequencies.
It will be appreciated that the afore-mentioned description is not limiting. Variations are possible without departing from the spirit and scope set forth in the claims. While particular combinations of features have been set forth in the description and claims, it will be appreciated that other combinations are possible within the scope of the claims. | A device for the transmission of electromagnetic signals, the device comprising: a conductive element at least one inducer, for inducing charge in said conductive element; a transmission circuit, for generation and transmission of electromagnetic signals; wherein said conductive element and said at least one inducer are movable, with respect to each other, between a plurality of relative positions; in a first position of said relative positions, said at least one inducer is arranged to induce a charge in said conductive element; in a second position of said relative positions, said conductive element is arranged to discharge; the conductive element is arranged to couple with the transmission circuit, in said first position and/or said second position, such that charging and/or discharging of said conductive element causes the transmission circuit to generate and transmit an electromagnetic signal; and the device is arranged such that movement of said device causes relative movement of said conductive element and said at least one inducer between said plurality of relative positions. | 7 |
FIELD OF THE INVENTION
The present invention pertains to temperature monitoring systems for refrigeration units, and more particularly pertains to a freezer alarm system and apparatus that produces both audible and visible alarm indicators when a pre-set temperature value or range has been exceeded so that the refrigeration unit can be checked, serviced or replaced.
BACKGROUND OF THE INVENTION
Refrigeration units for storing items such as meat and frozen foods over long periods of time are an essential component of contemporary life. Refrigeration units have widespread applicability and are found in such places as: refrigerators, coolers, ice cream boxes and freezers used for storing domestic family food items; ice cream and frozen food coolers and freezers in grocery stores; freezers and walk-in coolers for storage of the many food items used by public restaurants, school cafeterias and workplace cafeterias, and fast food stores; ice makers in restaurants and hotels for continuously supplying ice to patrons and guests; upright freezers and coolers in hospitals and veterinary clinics for storing medicine and blood at precise temperatures; refrigeration rooms in slaughterhouses; and computer operation rooms for cooling and dissipating the heat produced by mainframe computers.
In the above applications, as well as many others, the various items must be maintained within the refrigeration unit at below freezing temperatures for considerable lengths of time. Should the refrigeration unit fail, and the failure remain undetected, the items stored therein will degrade and spoil and have to be thrown out. The hardship this works not just for commercial and industrial enterprises, but for ordinary homeowners could be considerable. For example, an elderly couple on a fixed income would store the bounty of a summer season in their freezer for use throughout the winter only to lose that surplus bounty because the freezer broke down unbeknownst to them; and upon discover of the break down, the items stored within would have long since spoiled and must therefore be discarded nullifying the patient work and preparation of many months. Another example of the considerable loss that would occur would be the case of a single parent having purchased a large quantity of meat and produce for storage and use as needed throughout the winter, only to lose those stored items upon a freezer failure that remains undiscovered for many days.
Compounding the problem that refrigeration units often fail is the fact that many refrigeration units are located in basements, garages, or other out of the way places that are infrequently visited and inspected. As a result, the refrigeration unit may fail, and the failure may not become known for days, weeks or even months thereafter; and thus the ability of the refrigeration unit to maintain freezing conditions within the freezer cavity for the general 24 hour period after the initial failure is of only marginal value. While some refrigeration units do include warning or alarm lights, the lights are often too small to be noticeable unless they are viewed up close.
The prior art discloses a number of alarm devices and systems for freezing units to meet and overcome the above problems relating to refrigeration unit failure.
Thus, the Boyd device (U.S. Pat. No. 4,144,532) discloses a food freezer alarm that includes a sealed container mountable within the freezer compartment wherein a phase change of material within the container, resulting from a temperature increase, causes a conductive member to engage contacts that close a switch and set off an alarm warning the owner of undesirably high temperatures within the compartment.
The Kelley patent (U.S. Pat. No. 4,169,357) discloses a refrigerator-monitoring device that includes a temperature sensitive switch that closes when the temperature rises above a preset level thereby actuating a visible alarm and an audible alarm.
The Prosky patent (U.S. Pat. No. 4,283,921) discloses a freezer case alarm system that includes a sensing element operatively connected to a microcomputer so that the freezer compartment can be monitored, and if the temperature exceeds a certain limit, a first and a second alarm condition are energized.
The Hallett et al. patent (U.S. Pat. No. 4,855,721) discloses a freezer alarm apparatus that includes a sensor mounted within the freezer compartment that communicates with an externally mounted control unit for actuating a LED when the temperature within the compartment exceeds a preset temperature.
The Vidaillac patent (U.S. Pat. No. 6,034,607) discloses an electronic temperature alarm system that monitors ambient freezer temperature by a thermoresistor and in which a sound alarm is triggered by a piezoelectric buzzer when the freezer temperature exceeds a predetermined value.
Nonetheless, the remains a need for a freezer alarm system that is easy to install and provides clear and distinct signaling, in several forms, for remedial action and problem correction when the freezer unit temperature has exceeded a predetermined value.
SUMMARY OF THE INVENTION
The present invention comprehends a freezer alarm system and apparatus for monitoring the temperature within the freezer cavity of a refrigeration unit and producing warning signals when the temperature exceeds a pre-set value. The freezer alarm system and apparatus includes a housing that is mountable to a wall adjacent the refrigeration unit, and the housing plugs into a standard wall receptacle. Extending from the housing is a capillary tube, and the capillary tube terminates with a temperature-sensing bulb that is placed within the freezer cavity. An adjustable thermostat is mounted on the housing and is in registration with the sensing bulb so that when the temperature within the freezer cavity exceeds a temperature set point on the thermostat, the thermostat actuates an audible buzzer alarm and a visual indicator light to warn the owner that the refrigeration unit needs checked and remedial or corrective action is required.
It is an objective of the present invention to provide a freezer alarm system and apparatus that can be easily and quickly installed in various types of refrigeration units.
It is another objective of the present invention to provide a freezer alarm system and apparatus that provides both audible and visual signaling so that refrigeration unit failure cannot be overlooked or missed.
It is yet another objective of the present invention to provide a freezer alarm system and apparatus that can be easily and quickly retrofitted to residential, commercial, and industrial refrigeration units.
It is still yet another objective of the present invention to provide a freezer alarm system and apparatus that provides the substantial savings to the owner or user by immediately alerting the owner or user that the freezer temperature has raised and that corrective action should be taken so that spoilage of the products therein can be avoided.
Yet another objective of the present invention is to provide a freezer alarm system and apparatus that includes a minimum number of mechanical parts and elements and is therefore easy to operate and reasonably priced, especially for individuals and families on fixed incomes.
These and other objects, features and advantages will become apparent to one skilled in the art upon a perusal of the following detailed description when read in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the freezer alarm system and apparatus of the present invention;
FIG. 2 is a front elevational view of the freezer alarm system and apparatus of the present invention illustrating the freezer alarm system and apparatus mounted on a wall for use with a floor-standing freezer;
FIG. 3 is a front elevational view of the freezer alarm system and apparatus of the present invention illustrating the freezer alarm system and apparatus mounted on a wall for use with a refrigerator;
FIG. 4 is a sectioned elevational of the freezer alarm system and apparatus of the present invention illustrating the disposition of the temperature sensor within the freezer cavity of the refrigeration unit; and
FIG. 5 is an electrical schematic of the freezer alarm system and apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Illustrated in FIGS. 1–5 is a freezer alarm system and apparatus 10 that is used to monitor the temperature in the freezer compartment 12 of a refrigeration unit 14 such as domestic, commercial and industrial refrigeration units that can include domestic refrigerators, freezers, icemakers, commercial freezers and coolers for meats, produce, and other food items, medical freezers in hospitals and veterinary clinics, and industrial refrigeration units for maintaining precision equipment in control and computer rooms at below freezing temperatures. The freezer alarm system and apparatus 10 is designed utilization with or retrofitting to all types of refrigeration units currently in domestic, commercial and industrial use.
As shown in FIGS. 1–5 , the freezer alarm system and apparatus 10 of the present invention includes a housing 16 that is mountable to a wall surface 18 adjacent the refrigeration unit 14 by any suitable means such as by brackets or hangers. Enclosed within the housing 16 is the electrical circuitry 20 for performing the various temperature-monitoring functions and for actuating the several alarm devices. It should be noted that many different electrical layouts and designs can be used, and the electrical circuitry shown in FIG. 5 is one representative design. The electrical circuitry 20 can be standard off the shelf items that may include transistors, resistors, diodes, and capacitors as needed for operating the alarm system and apparatus 10 . Extending from the housing 16 is an electrical cord 22 having a plug 24 for providing power to the freezer alarm system and apparatus 10 from a standard electrical wall outlet or receptacle 26 such as an 110 v receptacle.
In order to communicate temperature variations or changes occurring within the freezer compartment 12 of the refrigeration unit 14 to the alarm and alert features, the present invention utilizes a temperature-sensing bulb 28 interconnected to the housing 16 by an elongated, flexible capillary tube 30 . More specifically, the housing 16 includes a selectively adjustable thermostat 32 that can be manually preset to various temperature set points such as, for example, in one design the set points denoted by the numbers 20, 22, 24, 26, 28 30, 32, 34, and 36 degrees. The temperature-sensing bulb 28 senses temperature changes and variations within the freezer compartment 12 and conveys these changes and variations to the thermostat 32 so that the thermostat 32 can register when the temperature within the freezer unit 14 rises and exceeds the given temperature set point, value or temperature range. When the thermostat 32 registers the temperature rise, the normally open contacts or elements 34 of the thermostat 32 - close thereby completing the circuit and initiating actions to be hereinafter described.
As shown in FIGS. 1–5 , the freezer alarm system and apparatus 10 includes several signaling means that are actuated and powered for signaling the owner/user that the temperature set point has been exceeded and remedial or corrective action is required. Thus, mounted on the housing 16 is an audible buzzer alarm 36 for providing an audible alert to the owner/user that the refrigeration unit 14 needs checked because the temperature within the freezer compartment 12 has surpassed the preset value. The audible buzzer alarm 36 can include a volume control knob or dial that will be necessary if the freezer system and apparatus 10 includes remote alerts, i.e., signaling means that are positioned remote from the housing 16 and the refrigeration unit 14 . In addition, the freezer system and apparatus 10 includes a visually discernible alarm and signaling means in the form of an alert light or light bulb 38 mounted to an alarm socket 40 that is mounted preferably on the top panel of the housing 16 for maximum visibility. The light bulb 38 may be, for example, a 40-watt long lasting bulb, and will be activated simultaneous with the activation of the audible buzzer alarm 36 when the temperature within the freezer compartment 12 has exceeded the preset value. It should be noted that it is possible to configure the light bulb 38 for remote placement and luminary signaling. Thus, the present invention includes two complementary signaling means: the audible buzzer alarm 36 and the visually discernible light bulb 38 so that if the owner/user if not positioned to observe the light bulb 38 , he or she will be made aware of the potential refrigeration unit 14 problem by hearing the buzzer alarm 36 . Contrawise, if the owner/user is not in position to hear the buzzer alarm 36 , such as if he or she is mowing the lawn, then the light bulb 38 will be easily and readily visually discernible thereby alerting the owner/user that there is a potential problem with the refrigeration unit 14 that must be immediately attended to.
The freezer alarm system and apparatus 10 also includes several other features that enhance its usability. The alarm system and apparatus 10 includes a power on/off switch 42 mounted on the housing 16 for turning on the apparatus 10 and also for turning off the apparatus 10 during periods when the refrigeration unit 14 is being cleaned or serviced. In addition, the system and apparatus 10 includes at least one test switch or button 44 that can be actuated for testing the system and apparatus 10 to make sure the buzzer alarm 36 and the light bulb 38 will properly activate. Furthermore, the system and apparatus 10 can be configured so that the buzzer alarm 36 and the light bulb 38 stay on and active for a set amount of time to provide the owner/user with more time to react to the alarm conditions. While the thermostat 32 may normally be set at 32 degrees for activating the buzzer alarm 36 and the light bulb 38 , some owners/users may set the thermostat 32 lower where it is imperative to maintain the freezer compartment 12 temperature below 32 degrees such as for hospital and laboratory refrigeration units. Setting the thermostat 32 at a lower temperature will also give the owner/user more time to respond to alarm conditions so that corrective actions can be expedited and produce and food item spoilage and loss can be minimized.
In mounting the system and apparatus 10 to the refrigeration unit 14 , the general procedure would be to first locate and then mount the housing 16 adjacent the refrigeration unit 14 and the electrical receptacle 26 . The lid 46 or door of the refrigeration unit 14 should be raised, and held in the raised position so that the temperature-sensing bulb 28 can be placed within the freezer cavity or compartment 12 ; and, more particularly, the temperature-sensing bulb 28 should be placed in the corner of the freezer compartment 12 approximately 12 to 16 inches under the top level of the produce and food items contained therein. The lid 46 can then be gently closed; for further protection the capillary tube 30 can be passed through and insulating and protective sleeve or gasket 48 that is interposed between the lid 46 and the sidewalls of the refrigeration unit 14 . The temperature-sensing bulb 28 should be taped to the inside corner of the freezer compartment 12 to prevent it from freely dangling and being damaged during the placement and removal of produce and food items into and from the freezer compartment 12 . The plug 24 of the electrical cord 22 of the housing 16 can then be plugged into the appropriately rated wall receptacle 26 . The power on/off switch 42 can be turned on, and then the test switch 44 can be activated to ascertain that there is power to the apparatus 10 , and that the audible buzzer alarm 36 and the light bulb 38 are in proper working order. The thermostat 32 can then be adjusted and set at the desired temperature set point. The refrigeration unit 14 will then run normally until conditions inside the freezer compartment 12 causes the temperature to exceed the set point of the thermostat 32 thereby activating the electrical circuitry 20 to energize and activate the audible buzzer alarm 36 and the light bulb 38 for providing the sound and visual alert signals to the owner/user. Owner/user intervention will then be necessary to rectify the situation, to prevent the spoilage or complete loss of the produce and food items stored within the freezer compartment 12 , and to reset the thermostat 32 to the desired temperature set point after the corrective and remedial action has been completed.
A primary distinguishing feature of the freezer alarm system and apparatus 10 of the present invention is that it is not battery powered. The critical shortcoming of battery powered alarm systems is that if the user forgets to keep fresh batteries in the system, then when the system goes out the user may not be aware of this failure for days or even weeks. The present system and apparatus 10 alleviates this concern and worry. If the power to the system 10 should happen to go out, the user will immediately and automatically know that the temperature inside the freezer compartment 12 will start to rise. In order to confirm that power has been lost, the user should attempt to plug the system 10 into a separate circuit than the circuit user's pre-existing freezer is plugged into. This is to make certain that if the pre-existing freezer goes out and throws the circuit breaker in the process, the freezer alarm system 10 of the present invention will still be powered because it will be on a different circuit.
Although a preferred embodiment of the invention has been disclosed and described, it should be understood that numerous modifications, alterations, and variations may be made by one skilled in the art without departing from the scope of the invention as defined by the appended claims. | A freezer alarm system and apparatus for monitoring the temperature in the freezer compartment of a refrigeration unit includes a housing mountable on a wall adjacent the refrigeration unit for plugging into a wall outlet. A capillary tube extends from the housing and terminates with a temperature sensor that is mounted inside the refrigeration unit for sensing when the temperature increases therein past a given temperature preset by an adjustable thermostat located on the housing. When this event occurs contacts within the housing close thereby actuating an audible buzzer and a visible luminary alarm warning the owner that the temperature within the refrigeration unit has exceeded a safe pre-set level and that the refrigeration unit needs checked for remedial action. | 5 |
This is a continuation of application Ser. No. 09/305,506 filed May 5, 1999, which in turn is a continuation of application Ser. No. 08/798,031, filed Feb. 6, 1997, now U.S. Pat. No. 6,001,347, which in turn is a continuation of PCT/US96/04580, filed Apr. 1, 1996, published as WO 96/30036, which is a Continuation-In-Part of application Ser. No. 08/414,654, filed Mar. 31, 1995, now U.S. Pat. No. 5,650,386, and which claims benefit to application Ser. No. 60/003,111, filed Sep. 1, 1995, and application Ser. No. 60/017,902, filed Mar. 29, 1996. Each of these prior applications is hereby incorporated herein by reference, in its entirety.
FIELD OF THE INVENTION
The present invention relates to compounds for delivering active agents, and particularly biologically or chemically active agents such as, for example, bioactive peptides and the like. These compounds are used as carriers to facilitate the delivery of a cargo to a target. The carriers are modified amino acids and are well suited to form non-covalent mixtures with biologically-active agents for oral administration to animals. Methods for the preparation and for the administration of such compositions are also disclosed.
BACKGROUND OF THE INVENTION
Conventional means for delivering active agents are often severely limited by biological, chemical, and physical barriers. Typically, these barriers are imposed by the environment through which delivery occurs, the environment of the target for delivery, or the target itself.
Biologically or chemically active agents are particularly vulnerable to such barriers. For example in the delivery to animals of pharmacological and therapeutic agents, barriers are imposed by the body. Examples of physical barriers are the skin and various organ membranes that must be traversed before reaching a target. Chemical barriers include, but are not limited to, pH variations, lipid bi-layers, and degrading enzymes.
These barriers are of particular significance in the design of oral delivery systems. Oral delivery of many biologically or chemically active agents would be the route of choice for administration to animals if not for biological, chemical, and physica: barriers such as varying pH in the gastro-intestinal (GI) tract, powerful digestive enzymes, and active agent impermeable gastrointestinal membranes. Among the numerous agents which are not typically amenable to oral administration are biologically or chemically active peptides, such as calcitonin and insulin; polysaccharides, and in particular mucopolysaccharides including, but not limited to, heparin; heparinoids; antibiotics; and other organic substances. These agents are rapidly rendered ineffective or are destroyed in the gastro-intestinal tract by acid hydrolysis, enzymes, or the like.
Earlier methods for orally administering vulnerable pharmacological agents have relied on the co-administration of adjuvants (e.g., resorcinols and non-ionic surfactants such as polyoxyethylene oleyl ether and n-hexadecylpolyethylene ether) to increase artificially the permeability of the intestinal walls, as well as the co-administration of enzymatic inhibitors (e.g., pancreatic trypsin inhibitors, diisopropylfluorophosphate (DFF) and trasylol) to inhibit enzymatic degradation.
Liposomes have also been described as drug delivery systems for insulin and heparin. See, for example, U.S. Pat. No. 4,239,754; Patel et al. (1976), FEBS Letters , Vol. 62, pg. 60; and Hashimoto et al. (1979), Endocrinology Japan , Vol. 26, pg. 337.
However, broad spectrum use of such drug delivery systems is precluded because: (1) the systems require toxic amounts of adjuvants or inhibitors; (2) suitable low molecular weight cargos, i.e. active agents, are not available; (3) the systems exhibit poor stability and inadequate shelf life; (4) the systems are difficult to manufacture; (5) the systems fail to protect the active agent (cargo); (6) the systems adversely alter the active agent; or (7) the systems fail to allow or promote absorption of the active agent.
More recently, microspheres of artificial polymers of mixed amino acids (proteinoids) have been used to deliver pharmaceuticals. For example, U.S. Pat. No. 4,925,673 describes drug-containing proteinoid microsphere carriers as well as methods for their preparation arid use. These proteinoid microspheres are useful for the delivery of a number of active agents.
There is still a need in the art for simple, inexpensive delivery systems which are easily prepared and which can deliver a broad range of active agents.
SUMMARY OF THE INVENTION
Compositions which are useful in the delivery of active agents are provided. These compositions are include at least one active agent, and preferably a biologically or chemically active agent, and at least one of the following compounds I-CXXIII, or salts thereof.
I
II
III
IV
V
VI
VII
VIII
IX
X
XI
XII
XIII
XIV
XV
XVI
XVII
XVIII
XIX
XX
XXI
XXII
XXIII
XXIV
XXV
XXVI
XXVII
XXVIII
XXIX
XXX
XXXI
XXXII
XXIII
XXXIV
XXXV
XXXVI
A
Compound
n
m
X
XXXVII
0
0
4-Cl
XXXVIII
3
0
H
XXXIX
3
1
4-CH 3
XL
3
1
2-F
XLI
3
1
2-CH 3
XLII
3
0
3-CF 3
XLIII
3
4
H
XLIV
3
0
3-Cl
XLV
3
0
3-F
XLVI
3
0
3-CH 3
XLVII
0
0
2-CF 3
XLVIII
1
2
H
XLIX
3
2
2-F
L
3
0
3,4-OCH 2 O—
LI
3
0
2-COOH
LII
1
0
2-OH
LIII
3
0
2,6-dihydroxy
LIV
2
0
2-OH
LV
0
0
2,4-difluoro
LVI
2
0
2,6-dihydroxy
LVII
0
0
4-CF 3
LVIII
3
0
3-NMe 2
LIX
2
0
3-NMe 2
LX
3
0
2,6-dimethyl
LXI
3
0
2-NO 2
LXII
3
0
2-CF 3
LXIII
3
0
4-n-Pr
LXIV
3
0
2-NH 2
LXV
3
0
2-OCH 3
LXVI
3
0
3-NO 2
LXVII
3
0
3-NH 2
LXVIII
2
0
2-NO 2
LXIX
2
0
2-NH 2
LXX
3
0
2-OCF 3
LXXI
2
0
2-OCH 3
LXXII
2
0
2-OCF 3
B
Compound
n
X
LXXIII
3
4-CF 3
LXXIV
1
2-F
LXXV
1
4-CF 3
LXXVI
3
3,4-dimethoxy
LXXVII
0
3-OCH 3
LXXVIII
3
3-OCH 3
LXXIX
3
2,6-difluoro
LXXX
3
4-CH 3
LXXXI
1
4-OCH 3
LXXXII
2
2-F
LXXXIII
0
2-F
LXXXIV
2
4-OCH 3
LXXXV
0
2-OCH 3
LXXXVI
2
2-OCH 3
LXXXVII
0
4-CF 3
LXXXVIII
3
3-F
LXXXIX
3
2-OCH 3
C
Compound
n
m
X
XC
3
0
2-carboxycyclohexyl
XCI
3
3
cyclohexyl
XCII
3
0
2-adamantyl
XCIII
3
0
1-morpholino
D
Compound
m
XCIV
0
XCV
3
E
Compound
X
XCVI
OH
XCVII
═O
F
Compound
n
XCVIII
0
XCIX
2
C
CI
CII
CIII
CIV
CV
CVI
CVII
CVIII
CIX
CX
G
Compound
n
m
X
CXI
6
0
2-OH
CXII
7
3
H
CXIII
7
0
2-I
CXIV
7
0
2-Br
CXV
7
0
3-NO 2
CXVI
7
0
3-N(CH 3 ) 2
CXVII
7
0
2-NO 2
CXVIII
7
0
4-NO 2
CXIX
9
0
2-OH
H
Compound
X
CXX
1-morpholino
CXXI
O-t-Butyl
CXXII
CH(CH 2 Ph)NC(O)O-t-Bu
CXXIII
2-hydroxyphenyl
It has been discovered that organic acid compounds, and their salts, having an aromatic amide group, having a hydroxy group substituted in the ortho position on the aromatic ring, and a lipophilic chain with from about 4 carbon atoms to about 20 atoms in the chain are useful as carriers for the delivery of active agents. In a preferred form the lipophilic chain can have from 5 to 20 carbon atoms.
Compositions comprising the carrier compounds discussed above and active agents have been shown effective in delivering active agents to selected biological systems. These compositions include at least one active agent which is preferably a biologically or chemically active agent, and at least one carrier compound having the formula
2—HO—Ar—CONR 8 —R 7 —COOH
wherein Ar is a substituted or unsubstituted phenyl or naphthyl;
R 7 is selected from the group consisting of C 4 to C 20 alkyl, C 4 to C 20 alkenyl, phenyl, naphthyl, (C 1 to C 10 alkyl) phenyl, (C 1 to C 10 alkenyl) phenyl, (C 1 to C 10 alkyl) naphthyl, (C 1 to C 10 alkenyl) naphthyl, phenyl (C 1 to C 10 alkyl), phenyl (C 1 to C 10 alkenyl), naphthyl (C 1 to C 10 alkyl), and naphthyl (C 1 to C 10 alkenyl);
R 8 is selected from the group consisting of hydrogen, C 1 to C 4 alkyl, C 1 to C 4 alkenyl, hydroxy, and C 1 to C 4 alkoxy;
R 7 is optionally substituted with C 1 to C 4 alkyl, C 1 to C 4 alkenyl, C 1 to C 4 alkoxy, —OH, —SH and —CO 2 R 9 or any combination thereof;
R 9 is hydrogen, C 1 to C 4 alkyl or C 1 to C 4 alkenyl;
R 7 is optionally interrupted by oxygen, nitrogen, sulfur or any combination thereof;
With the proviso that the compounds are not substituted with an amino group in the position alpha to the acid group, or salts thereof.
The preferred R 6 groups are of C 4 to C 20 alkyl and C 4 to C 20 alkenyl. The most preferred R 6 groups are C 5 to C 20 alkyl and C 5 to C 20 alkenyl.
A preferred carrier compound can have the formula
wherein R 7 is defined above.
Further contemplated by the present invention are dosage unit forms that include these compositions.
Also contemplated is a method for preparing these compositions which comprises mixing at least one active agent with at least one compound as described above, and optionally, a dosing vehicle.
In an alternative embodiment, these non-toxic compounds are orally administered to animals as part of a delivery system by blending or mixing the compounds with an active agent prior to administration.
Further provided is a method for the preparation of a compound having the formula
Wherein Y is
or SO 2 ;
R 1 is C 3 -C 24 alkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkyne, cycloalkyl, or aromatic;
R 2 is hydrogen, C 1 -C 4 alkyl, or C 2 -C 4 alkenyl; and
R 3 is C 1 -C 7 alkyl, C 3 -C 10 cycloalkyl, aryl, thienyl, pyrrolo, or pyridyl, where R 3 is optionally substituted by-one or more C 1 -C 5 alkyl group, C 2 -C 4 alkenyl group, F, Cl, OH, SO 2 , COOH, or SO 3 H;
said method comprising
(a) racking in water and the presence of a base, a compound having the formula
with a compound having the formula
R 3 —Y—X, wherein
Y, R 1 , R 2 , and R 3 are as above and X is a leaving group.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphic illustration of the results of subcutaneous injection of rhGH composition in rats.
FIG. 2 is a graphic illustration of the results of Sublingual (SL), intranasal (IN), and intracolonic (IC) dosing of rhGH in rats.
FIG. 3 is a graphic illustration of the results of intracolonic dosing of delivery of heparin with compound XXXI carrier.
DETAILED DESCRIPTION OF THE INVENTION
The specific compositions of the present invention include an active agent and a modified amino acid. These compositions may be used to deliver various active agents through various biological, chemical, and physical barriers and are particularly suited for delivering active agents which are subject to environmental degradation. Thee compositions of the subject invention are particularly useful for delivering or administering biologically or chemically active agents to any animals such as birds; mammals, such as primates and particularly humans; and insects.
Other advantages of the present invention include the use of easy to prepare, inexpensive raw materials. The compositions and the formulation methods of the present invention are cost effective, simple to perform, and amenable to industrial scale up for commercial production.
Subcutaneous, sublingual, and intranasal coadministration of an active agent, such as recombinant human growth hormone (rhGH), and the delivery agents, and particularly proteins, described herein results in an increased bioavailability of the active agent compared to administration of the active agent alone. A similar result is obtained by coadministration of salmon calcitonin with the delivery agents, in rats. Data supporting these findings are presented in the examples.
Active Agents
Active agents suitable for use in the present invention include biologically or chemically active agents, chemically active agents, including, but not limited to, fragrances, as well as other active agents such as, for example, cosmetics.
Biologically or chemically active agents include, but are not limited to, pesticides, pharmacological agents, and therapeutic agents. For example, biologically or chemically active agents suitable for use in the present invention include, but are not limited to, peptides, and particularly small peptides; hormones, and particularly hormones which by themselves do not or only a fraction of the administered dose passes through the gastro-intestinal mucosa and/or are susceptible to chemical cleavage by acids and enzymes in the gastrointestinal tract; polysaccharides, and particularly mixtures of muco-polysaccharides; carbohydrates; lipids; or any combination thereof. Further examples include, but are not limited to, human growth hormones; bovine growth hormones; growth releasing hormones; growth hormone-releasing hormones; interferons; interleukin- 1; interleukin-II; insulin; heparin, and particularly low molecular weight heparin; calcitonin; erythropoietin; atrial naturetic factor; antigens; monoclonal antibodies; somatostatin; adrenocorticotropin, gonadotropin releasing hormone; oxytocin; vasopressin; cromolyn sodium (sodium or disodium chromoglycate); vancomycin; desferrioxamine (DFO); parathyroid hormone anti-microbials, including, but not limited to anti-fungal agents; or any combination thereof.
Modified Amino Acids
The terms modified amino acid, modified poly amino acid, and modified peptide are meant to include amino acids which have been modified, or poly amino acids and peptides in which at least one amino acid has been modified, by acylating or sulfonating at least one free amine group with an acylating or sulfonating agent which reacts with at least one of the free amine groups present.
Amino acids, poly amino acids, and peptides, in modified form, may be used to deliver active agents including, but not limited to, biologically or chemically active agents such as for example, pharmacological and therapeutic agents.
An amino acid is any carboxylic acid having at least one free amine group and includes naturally occurring and synthetic amino acids.
Poly amino acids are either peptides or two or more amino acids linked by a bond formed by other groups which can be linked, e.g. an ester, anhydride, or an anhydride linkage.
Peptides are two or more amino acids joined by a peptide bond. Peptides can vary in length from dipeptides with two amino acids to poly peptides with several hundred amino acids. See Chambers Biological Dictionary , editor Peter M. B. Walker, Cambridge, England: Chambers Cambridge, 1989, page 215. Special mention is made of di-peptides, tri-peptides, tetra-peptides, and penta-peptides.
Although compounds I-CXXIII above have been found to act as carriers for the oral delivery of biologically or chemically active agents, special mention is made of compounds I-XXXI above.
Modified amino acids are typically prepared by modifying the amino acid or an ester thereof. Many of these compounds are prepared by acylation or sulfonation with agents having the formula
X—Y—R 4
wherein: R 4 is the appropriate radical to yield the modification indicated in the final product,
Y is
or SO 2 , and X is a leaving group. Typical leaving groups include, but are not limited to, halogens such as, for example, chlorine, bromine, and iodine. Additionally, the corresponding anhydrides are modifying agents.
Many of the compounds of the present invention can be readily prepared from amino acids by methods within the skill of those in the art based upon the present disclosure. For example, compounds I-VII are derived from aminobutyric acid; Compounds VIII-X and XXXII-XXXV are derived from aminocaproic acid; and Compounds XI-XXVI and XXXVI are derived from aminocaprylic acid. For example, the modified amino acid compounds above may be prepared by reacting the single amino acid with the appropriate modifying agent which reacts with free amino moiety present in the amino acids to form amides. Protecting groups may be used to avoid unwanted side reactions as would be known to those skilled in the art.
The amino acid can be dissolved in aqueous alkaline solution of a metal hydroxide, e.g., sodium or potassium hydroxide, and heated at a temperature ranging between about 5° C. and about 70° C., preferably between about 10° C. and about 40° C., for a period ranging between about 1 hour and about 4 hours, preferably about 2.5 hours. The amount of alkali employed per equivalent of NH 2 groups in the amino acid generally ranges between about 1.25 and about 3 mmole, preferably between about 1.5 and about 2.25 mmole per equivalent of NH 2 . The pH of the solution generally ranges between about 8 and about 13, preferably ranging between about 10 and about 12.
Thereafter, the appropriate amino modifying agent is added to the amino acid solution while stirring. The temperature of the mixture is maintained at a temperature generally ranging between about 5° C. and about 70° C., preferably between about 10° C. and about 40° C., for a period ranging between about 1 and about 4 hours. The amount of amino modifying agent employed in relation to the quantity of amino acid is based on the moles of total free NH 2 in the amino acid. In general, the amino modifying agent is employed in an amount ranging between about 0.5 and about 2.5 mole equivalents, preferably between about 0.75 and about 1.25 equivalents, per molar equivalent of total NH 2 group in the amino acid.
The reaction is quenched by adjusting the pH of the mixture with a suitable acid, e.g., concentrated hydrochloric acid, until the pH reaches between about 2 and about 3. The mixture separates on standing at room temperature to form a transparent upper layer and a white or off-white precipitate. The upper layer is discarded, and the modified amino acid is collected from the lower layer by filtration or decantation. The crude modified amino acid is then dissolved in water at a pH ranging between about 9 and about 13, preferably between about 11 and about 13. Insoluble materials are removed by filtration and the filtrate is dried in vacuo. The yield of modified amino acid generally ranges between about 30 and about 60%, and usually about 45%.
If desired, amino acid esters, such as, for example benzyl, methyl, or ethyl esters of amino acid compounds, may be used to prepare the modified amino acids of the invention. The amino acid ester, dissolved in a suitable organic solvent such as dimethylformamide, pyridine, or tetrahydrofuran is reacted with the appropriate amino modifying agent at a temperature ranging between about 5° C. and about 70° C., preferably about 25° C., for a period ranging between about 7 and about 24 hours. The amount of amino modifying agent used relative to the amino acid ester is the same as described above for amino acids. This reaction may be carried out with or without a base such as, for example, triethylamine or diisopropylethylamine.
Thereafter, the reaction solvent is removed under negative pressure and the ester functionality is removed by hydrolyzing the modified amino acid ester with a suitable alkaline solution, e.g. 1 N sodium hydroxide, at a temperature ranging between about 50° C. and about 80° C., preferably about 70° C., for a period of time sufficient to hydrolyze off the ester group and form the modified amino acid having a free carboxyl group. The hydrolysis mixture is then cooled to room temperature and acidified, e.g. aqueous 25% hydrochloric acid solution, to a pH ranging between about 2 and about 2.5. The modified amino acid precipitates out of solution and is recovered by conventional means such as filtration or decantation. Benzyl esters may be removed by hydrogenation in an organic solvent using a transition metal catalyst.
The modified amino acid may be purified by recrystallization or by fractionation on solid column supports. Suitable recrystallization solvent systems include acetonitrile, methanol and tetrahydrofuran. Fractionation may be performed on a suitable solid column supports such as alumina, using methanolin-propanol mixtures as the mobile phase; reverse phase column supports using trifluoroacetic acid/acetonitrile mixtures as the mobile phase; and ion exchange chromatography using water as the mobile phase. When anion exchange chromatography is performed, preferably a subsequent 0-500 mM sodium chloride gradient is employed.
In an alternate method modified amino acids having the formula
wherein Y is
or SO 2 ;
R 1 is C 3 -C 24 alkyl, C 2 -C 20 alkenyl, C 2 -C 20 alkyne, cycloalkyl, or aromatic;
R 2 is hydrogen, C 1 -C 4 alkyl, or C 2 -C 4 alkenyl; and
R 3 is C 1 -C 7 alkyl, C 3 -C 10 cycloalkyl, aryl, thienyl, pyrrolo, or pyridyl, where R 3 is optionally substituted by one or more C 1 -C 5 alkyl group, C 2 -C 4 alkenyl group, F, Cl, OH, SO 2 , COOH or, SO 3 H; may be prepared by
(a) reacting in water and the presence of a base a compound having the formula
with a compound having the formula
R 3 —Y—X, wherein
Y, R 1 , R 2 , and R 3 are as above and X is a leaving group.
Compound CXXV can be prepared, for example by the method described in Olah et al., Synthesis , 537-538 (1979).
Compound XXXI was prepared as described in Scheme I from 10-undecen-1-ol, 1, by a three step procedure in an overall yield of 31%. Alkylation of phthalimide with alkanol, 1, under Mitsunobu conditions, followed by reaction with hydrazine gave 1-aminoundec-10-ene, 2, in 66% yield. The amine was derivatized with O-acety'salicyloyl chloride and the resulting alkene, 3, was oxidized to the acid using potassium permanganate. Removal of the acetate, followed by acid precipitation provided compound XXXI in 47% yield based on amine 2.
Delivery Systems
The compositions of the present invention may include one or more active agents.
In one embodiment, compounds I-CXXIII or poly amino acids or peptides that include at least one of these compounds may be used directly as a delivery carrier by simply mixing one or more compound, poly amino acid or peptide with the active agent prior to administration.
In an alternative embodiment, the compounds, poly amino acids, or peptide may be used to form microspheres containing the active agent. These compounds, poly amino acids, or peptides are particularly useful for the oral administration of certain biologically-active agents, e.g., small peptide hormones, which, by themselves, do not pass or only a fraction of the administered dose passes through the gastro-intestinal mucosa and/or are susceptible to chemical cleavage by acids and enzymes in the gastrointestinal tract.
If the modified amino acids, poly amino acids, or peptides are to be converted into microspheres, the mixture is optionally heated to a temperature ranging between about 20 and about 50° C., preferably about 40° C., until the modified amino acid(s) dissolve. The final solution contains between from about 1 mg and to about 2000 mg of compound, poly amino acid, or peptide per mL of solution, preferably between about 1 and about 500 mg per mL. The concentration of active agent in the final solution varies and is dependent on the required dosage for treatment. When necessary, the exact concentration can be determined by, for example, reverse phase HPLC analysis.
When the compounds, poly amino acids, or peptides are used to prepare microspheres, another useful procedure is as follows: Compounds, poly amino acids, or peptides are dissolved in deionized water at a concentration ranging between about 75 and about 200 mg/ml, preferably about 100 mg/ml at a temperature between about 25° C. and about 60° C. preferably about 40° C. Particulate matter remaining in the solution may be removed by conventional means such as filtration.
Thereafter, the compound, poly amino acid, or peptide solution, maintained at a temperature of about 40° C., is mixed 1:1 (V/V) with an aqueous acid solution (also at about 40° C.) having an acid concentration ranging between about 0.05 N and about 2 N, preferably about 1.7 N. The resulting mixture is further incubated at 40° C. for a period of time effective for microsphere formation, as observed by light microscopy. In practicing this invention, the preferred order of addition is to add the compound, poly amino acid, or peptide solution to the aqueous acid solution.
Suitable acids for microsphere formation include any acid which does not
(a) adversely effect the modified amino acids, poly amino acids, or peptides e.g., initiate or propagate chemical decomposition;
(b) interfere with microsphere formation;
(c) interfere with microsphere incorporation of the active agent cargo; and
(d) adversely interact with the active agent cargo.
Preferred acids for use in this aspect include acetic acid, citric acid, hydrochloric acid, phosphoric acid, malic acid and maleic acid.
A microsphere stabilizing additive may be incorporated into the aqueous acid solution or into the compound or cargo solution prior to the microsphere formation process. With some active agents the presence of such additives promotes the stability and/or dispersibility of the microspheres in solution.
The stabilizing additives may be employed at a concentration ranging between about 0.1 and 5% (w/v), preferably about 0.50% (w/v). Suitable, but non-limiting, examples of microsphere stabilizing additives include gum acacia, gelatin, methyl cellulose, polyethylene glycol, polypropylene glycol, carboxylic acids and salts thereof, and polylysine. The preferred stabilizing additives are gum acacia, gelatin and methyl cellulose.
Under the above conditions, the compound molecules, poly amino acids, or peptides form hollow or solid matrix type microspheres wherein the cargo is distributed in a carrier matrix or capsule type microspheres encapsulating liquid or solid cargo. If the compound, poly amino acid, or peptide microspheres are formed in the presence of a soluble material, e.g., a pharmaceutical agent in the aforementioned aqueous acid solution, this material will be encapsulated within the microspheres. In this way, one can encapsulate pharmacologically active materials such as peptides, proteins, and polysaccharides as well as charged organic molecules, e.g., antimicrobial agents, which normally have poor bioavailability by the oral route. The amount of pharmaceutical agent which may be incorporated by the microsphere is dependent on a number of factors which include the concentration of agent in the solution, as well as the affinity of the cargo for the carrier. The compound, poly amino acid, or peptide microspheres do not alter the physiological and biological properties of the active agent. Furthermore, the encapsulation process does not alter the pharmacological properties of the active agent. Any pharmacological agent can be incorporated within the microspheres. The system is particularly advantageous for delivering chemical or biological agents which otherwise would be destroyed or rendered less effective by conditions encountered within the body of the animal to which it is administered, before the microsphere reaches its target zone (i.e., the area in which the contents of the microsphere are to be released) and for delivering pharmacological agents which are poorly absorbed in the gastrointestinal tract. The target zones can vary depending upon the drug employed.
The particle size of the microsphere plays an important role in determining release of the active agent in the targeted area of the gastro-intestinal tract. The preferred microspheres have diameters between about ≦0.1 microns and about 10 microns, preferably between about 0.5 microns and about 5 microns. The microspheres are sufficiently small to release effectively the active agent at the targeted area within the gastrointestinal tract such as, for example, between the stomach and the jejunum. Small microspheres can also be administered parenterally by being suspended in an appropriate carrier fluid (e.g., isotonic saline) and injected directly into the circulatory system, intramuscularly or subcutaneously. The mode of administration selected will vary, of course, depending upon the requirement of the active agent being administered. Large amino acid microspheres (>50 microns) tend to be less effective as oral delivery systems.
The size of the microspheres formed by contacting compounds, poly amino acids, or peptides with water or an aqueous solution containing active agents can be controlled by manipulating a variety of physical or chemical parameters, such as the pH, osmolarity or ionic strength of the encapsulating solution, size of the ions in solution and by the choice of acid used in the encapsulating process.
The administration mixtures are prepared by mixing an aqueous solution of the carrier with an aqueous solution of the active ingredient, just prior to administration. Alternatively, the carrier and the biologically or chemically active ingredient can be admixed during the manufacturing process. The solutions may optionally contain additives such as phosphate buffer salts, citric acid, acetic acid, gelatin, and gum acacia.
Stabilizing additives may be incorporated into the carrier solution. With some drugs, the presence of such additives promotes the stability and dispersibility of the agent in solution.
The stabilizing additives may be employed at a concentration ranging between about 0.1 and 5% (W/V), preferably about 0.5% (W/V). Suitable, but non-limiting, examples of stabilizing additives include gum acacia, gelatin, methyl cellulose, polyethylene glycol, carboxylic acids and salts thereof, and polylysine. The preferred stabilizing additives are gum acacia, gelatin and methyl cellulose.
The amount of active agent is an amount effective to accomplish the purpose of the particular active agent. The amount in the composition typically is a pharmacologically or biologically effective amount. However, the amount can be less than a pharmacologically or biologically effective amount when the composition is used in a dosage unit form, such as a capsule, a tablet or a liquid, because the dosage unit form may contain a multiplicity of carrier/biologically or chemically active agent compositions or may contain a divided pharmacologically or biologically effective amount. The total effective amounts can then be administered in cumulative units containing, in total, pharmacologically or biologically or chemically active amounts of biologically or pharmacologically active agent.
The total amount of active agent, and particularly biologically or chemically active agent, to be used can be determined by those skilled in the art. However, it has surprisingly been found that with some biologically or chemically active agents, the use of the presently disclosed carriers provides extremely efficient delivery, particularly in oral, intranasal, sublingual, intraduodenal, or subcutaneous systems. Therefore, lower amounts of biologically or chemically active agent than those used in prior dosage unit forms or delivery systems can be administered to the subject, while still achieving the same blood levels and therapeutic effects.
The amount of carrier in the present composition is a delivery effective amount and can be determined for any particular carrier or biologically or chemically active agent by methods known to those skilled in the art.
Dosage unit forms can also include any of excipients; diluents; disintegrants; lubricants; plasticizers; colorants; and dosing vehicles, including, but not limited to water, 1,2-propane diol, ethanol, olive oil, or any combination thereof.
Administration of the present compositions or dosage unit forms preferably is oral or by intraduodenal injection.
The delivery compositions of the present invention may also include one or more enzyme inhibitors. Such enzyme inhibitors include, but are not limited to, compounds such as actinonin or epiactinonin and derivatives thereof. These compounds have the formulas below:
Derivatives of these compounds are disclosed in U.S. Pat. No. 5,206,384. Actinonin derivatives have the formula:
wherein R 5 is sulfoxymethyl or carboxyl or a substituted carboxy group selected from carboxamide, hydroxyaminocarbonyl and alkoxycarbonyl groups; and R 6 is hydroxyl, alkoxy, hydroxyamino or sulfoxyamino group. Other enzyme inhibitors include, but are not limited to, aprotinin (Trasylol) and Bowman-Birk inhibitor.
The compounds and compositions of the subject invention are useful for administering biologically or chemically active agents to any animals such as birds; mammals, such as primates and particularly humans; and insects. The system is particularly advantageous for delivering chemically or biologically or chemically active agents which would otherwise be destroyed or rendered less effective by conditions encountered before the active agent its target zone (i.e. the area in which the active agent of the delivery composition are to be released) and within the body of the animal to which they are administered. Particularly, the compounds and composition of the present invention are useful in orally administering active agents, especially those which are not ordinarily orally deliverable.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples illustrate the invention without limitation. All parts are given by weight unless otherwise indicated.
EXAMPLE 1
Compound XIX was prepared as follows:
A 3 L three-neck round bottom flask was fitted with an overhead mechanical stirrer and a thermometer, and the flask was cooled in an ice-bath. A solution of 8-aminocaprylic acid (100.0 g, 0.65 moles) in 2 M aqueous sodium hydroxide (1.4 L) was charged into the round bottom flask. The temperature of the solution was kept at about 5° C., and O-acetylsalicyloyl chloride (198.6 g, 0.76 moles, 1.2 equiv.) was added portionwise over 7 hours. The mixture was stirred at 5° C. for 12 hours to yield a yellow homogenous solution. The solution was acidified with 1 M hydrochloric acid to pH 6.8 and was extracted with ethyl acetate (2×600 mL). The pH of the aqueous layer was readjusted to 6.3 and was further extracted with ethyl acetate (2×600 mL). The organic layers were combined, dried over anhydrous sodium sulfate, filtered, and evaporated under reduced pressure. The residue was redissolved in a minimum volume of 2 M aqueous sodium hydroxide, and the pH of the solution was between 9.5 and 10. The mixture was acidified with stirring with 1 M hydrochloric acid to pH of about 6.2, and a solid was formed. The solid was filtered, washed with water (3×300 mL), and recrystallized from 55% methanol/water (v/v) to yield Compound XVIII as an off-white solid (99.7 g, 57%).
Properties are listed below.
Mp 116-117° C. 1 H NMR (300 MHz, DMSO-d 6 ) δ: 12.70 (1H; br s), 11.95 (1H, br s) 8.81 (1H, t), 7.82 (1H, m), 7.38 (1H, m), 6.84 (2H, m), 2.36 (2H, q), 2.18 (2H, t), 1.50 (4H, br m), 1.28 (6H, m), Anal. Calcd for C 15 H 21 NO 4 : C, 64.50; H, 7.58; I N, 5.02. Found: C, 64.26; H, 7.81; N, 4.93.
Similar procedures were used to prepare Compounds I, II, III, IV, VI, IX, X, XI, XII, XIII, XIV, XX, XXI, XXIII, XXVII, XXVIII, XXXIII, and XXXIV.
Properties are listed below.
Compound I:
1 H NMR (300MHZ, D 2 O): δ 1:5 (2H, m) 2.0
(2H, t) 2.3 (2H,t) 7.5 (2H, t) 7.6 (1H, m) 7.3
(2H, m)
Compound II:
1 H NMR (300MHz, D 2 O): δ 1.4 (8H, m) 1.7
(6H, m) 2.1 (2H,t) 1.25 (1H, m) 3.05 (2H, t)
Compound III:
1 H NMR (300MHz, DMSO-d 6 ): δ0.7 (3H, m)
0.9 (2H, m) 1.1 (3H,q) 1.6.(5H, m) 1.75 (2H,
q) 2.1 (2H, t) 3.0 (2h, q) 7.9 (1H, m)
Compound IV:
Anal. Calcd for C 11 H 13 NO 4 : C, 59.9, H, 5.87,
N, 6.27 Found: C, 58.89, H, 5.85, N, 6.07.
1 H NMR (300MHz, DMSO-d 6 ): δ 1.8 (2H, m)
2.3 (2H, t) 3.1 (2H,q) 6.9 (2H, t) 7.4 (1H, t)
7.8 (1h, d) 8.85 (1H, t) 12.0 (1H, s) 12.15
(1H, s)
Compound VI:
1 H NMR (300MHZ, D 2 O): δ 0.8 (2H, m) 1.1
(4H, m) 1.4 (2H,q) 1.6 (7H, m) 2.15 (4H, m)
3.1 (2H, t)
Compound IX:
1 H NMR (300MHz, DMSO-d 6 ): δ 0.9 (q, 3H),
1.2 (m, 7H), 1.3 (q, 2H), 1.5 (q, 3H), 1.9 (d,
2H), 2.0 (d, 1H), 2.2 (t, 2H), 3.0 (q, 3H), 7.7
(s, 1H)
Compound X:
1 H NMR (300MHZ, DMSO-d 6 ): δ 0.7(d, 2H),
0.9 (dd, 1H), 1.2-1.3 (m, 7H), 1.5 (q, 3H),
1.6-1.8 (m, 5H), 2.15 (t, 2H), 3.0 (m, 3H),
7.5 (s, 1H), 12.0 (s, 1H)
Compound XI:
Anal. Calcd for C 15 H 20 NO 3 Cl: C, 60.48, H,
6.78, N, 4.70 Found: C, 60.4, H, 6.68, N,
4.53. 1 H NMR (300MHz, DMSO-d 6 ): δ 1.28
(m, 6H) 1.48 (m, 4H) 2.19 (t, 2H) 3.19 (qt,
2H), 7.323-7.48 (m, 4H), 8.39(t, H), 12.09
(s, 1H)
Compound XII:
Anal. Calcd for C 17 H 22 NO 3 : C, 66.42, H,
7.23, N, 4.56 Found: C, 65.80, H, 7.17, N,
4.14. 1 H NMR (300MHz, DMSO-d 6 ): δ 1.25
(m, 6H) 1.43-1.49 (m, 4H) 2.18 (t, 2H) 3.15
(qt, 2H), 6.72 (d, 1H), 7.21-7.26 (m, 2H),
7.39 (t, 1H), 7.48 (d, 1H), 7.65 (t, 1H), 8.21
(t, 1H)
Compound XIII:
Anal. Calcd for C 15 H 19 NO 3 : C, 60.18, H,
6,41, N, 4.67 Found: C, 60.26, H, 6.53, N,
4.61. 1 H NMR (300MHz, DMSO-d 6 ): δ 1.28
(m, 6H), 1.45-1.52 (m, 4H), 2.19 (t, 2H),
2.22 (qt, 2H), 7.13 (m, 2H), 7.43-7.53 (m,
1H), 8.67 (t, 1H)12.03 (s, 1H)
Compound XIV:
Anal. Calcd for C 14 H 20 N 2 O 3 : • 0.66 H 2 O: C,
63.04, H, 7.91, N, 10.34 Found: C, 63.21,
7.59, 10.53 1 H NMR (300MHz, DMSO-d 6 ): δ
1.22-12.8 (m, 6H), 1.48-1.50 (m, 4H), 2.18
(t, 2H), 3.24 (qt, 2H), 7.48 (m, 1H), 8.15 (d,
1H), 8.63-8.69 (m, 2H), 8.97 (d, 1H)
Compound XX:
Anal. Calcd for C 15 H 20 NO 3 F: C, 60.09, H,
7.19, N, 4.98 Found: C, 63.82, H, 7.23, N,
4.94. 1 H NMR (300MHz, DMSO-d 6 ): δ 1.28
(m, 6H) 1.49 (m, 4H) 2.19 (t, 2H) 3.23 (qt,
2H), 7.24-7.30 (m, 2H), 7.49-7.60 (m, 2H),
11.99 (s, 1H)
Compound XXI:
Anal. Calcd for C 17 H 23 NO 4 : C, 66.85, H,
7.61, N, 4.58 Found: C, 66.81, R, 7.69, N,
4.37. 1 H NMR (300MHz, DMSO-d 6 ): δ 1.26
(m, 6H) 1.42-1.50 (m, 4) 2.18 (t, 2H) 3.13
(qt, 2H), 6.63 (d, 1H), 6.80 (t, 1H), 6.86 (d,
1H), 7.15 (t, 1H)1 7.39 (d, 1H), 7.60 (d, 1H),
8.03 (t, 1H), 9,95 (s, 1H), 12.12 (s, 1H)
Compound XXIII:
Anal. Calcd for C 15 H 27 NO 3 : C, 66.86, H,
10.22, N, 5.19 Found: C, 66.92, H, 10.72,
N, 5.14. 1 H NMR (300MHz, DMSO-d 6 ): δ
1.56-1.34 (m, 13H) 1.46 (t, 2H) 1.60-1.68
(m, 5H), 2.04 (t, 1H), 2.17 (t, 2H), 2.97 (qt,
2H), 7.62 (t, 1H), 11.98 (s, 1H)
Compound XXVII:
Anal. Calcd for C 18 H 27 NO 4 : C, 67.25, H,
8.48, N, 4.36 Found: C, 67.23, H, 8.57, N,
4.20. 1 H NMR (300MHz, DMSO-d 6 ): δ 1.22-
1.26 (m, 12H) 1.45-1.51 (m, 4H) 2.16 (t,
2H) 3.25 (qt, 2H), 6.85 (t, 2H), 7.37 (t, 1H),
7.81 (d, 1H), 8.79 (t, 1H), 11.95 (s, 1H),
12.72 (s, 1H)
Compound XXVIII:
1 H NMR (300MHz, DMSO-d 6 ): δ 1.26
(8H, br m), 1.49 (4H, m), 2.17 (2H, t),
3.26 (2H, m), 6.86 (2H, m), 7.37 (1H,
m), 7.83 (1H, m), 8.80 (1H, t), 11.95
(1H, s), 12.73 (1H, s).
Compound XXXIII:
1 H NMR (300MHz, DMSO-d 6 ): δ 1.2
(a, 2H), 1.3 (q, 2H), 1.3 (q, 2H), 1.5 (q,
2H), 2.2 (t, 2H), 3.0 (q, 2H), 3.5 (s, 2H),
7.3 (m, 5H), 8.0 (s, 1H)
Compound XXXIV:
Anal. Calcd for C 12 H 17 NO 4 : C, 62.23,
H 6.83, N, 5.57 Found: C, 61.93, H,
6.80, N, 5.56. 1 H NMR (300MHz,
DMSO-d 6 ): δ 1.24-1.34 (m, 2H) 1.49
1.57 (m, 4H) 2.19 (t, 2H) 3.26 (qt,
2H), 6.68 (t, 2H), 7.37 (s, 1H), 7.83 (d,
1H) 8.81 (t, 1H), 12.08 (s, 1H), 12.72 (s,
1H)
EXAMPLE 1A
An alternate synthesis of compound XIX was as follows:
A 5 L three-neck round bottom flask was fitted with a heating mantle, an overhead mechanical stirrer, an addition funnel, and a thermometer. The reaction was performed under an argon atmosphere. Hydroxylamine-O-sulfonic acid (196.7 g, 1.74 moles, 1.10 equiv.) and formic acid (1 L) were charged into the round bottom flask and stirred to form a white slurry. A solution of cyclooctanone (200.0 g 1.58 moles, 1.0 equiv.) in formic acid (600 mL) was added dropwise to the white slurry via the addition funnel. After the addition, the addition funnel was replaced by a reflux condenser, and the reaction was heated to reflux (internal temperature about 105° C.) for 1 hour to give a brown solution. After the solution was cooled to room temperature, it was poured into a mixture of saturated aqueous ammonium chloride (1.5 L) and water (1.5 L). The aqueous mixture was extracted with chloroform (3×1200 mL). The combined chloroform layers were transferred into a breaker, and saturated sodium bicarbonate (2 L) was added slowly. The chloroform layer was then separated, dried over anhydrous sodium sulfate, and evaporated under reduced pressure to afford a brown oil. The oil was placed in a 500 mL round bottom flask with a magnetic stirrer. The round bottom flask was placed in a silicon oil bath and was fitted with a short path vacuum distillation head equipped with a thermometer. A Cow-type receiver was connected to three 250 mL flasks. 2-Azacyclononanone (145 g, 65%, mp 64-69° C.) was obtained by vacuum distillation (fraction with head temperature range from 80 to 120° C. at pressures between 3.0 and 3.4 mmHg).
A 5 L three-neck round bottom flask was fitted with a heating mantle, an overhead mechanical stirrer, a reflux condenser, and a 29 thermometer. A suspension of 2-azacyclononanone (83 g, 0.59 moles, 1.0 equiv.) in 5 M aqueous sodium hydroxide (650 mL, 3.23 moles, 5.5 equiv.) was charged into the round bottom flask. The mixture was heated to reflux (internal temperature about 110° C.) for 4 hours to yield a clear yellow solution. The heating mantle and reflux condenser were removed. After the solution cooled to room temperature, it was diluted with water (650 mL) and cooled further in an ice bath. Finely ground O-acetylsalicyloyl chloride (114.7 g, 0.59 moles, 1.0 equiv.) was added portionwise to the solution with stirring and continued cooling over 1 hour. After an additional 30 minutes, the ice-bath was removed and stirring was continued at ambient temperature for 21 hours to give a brownish yellow solution. The stirred mixture was acidified with 2 M sulfuric acid (about 850 mL) to a pH of about 1, and a yellow solid was formed. The solid was collected by filtration and was dissolved in warm methanol (1.7 L). Activated charcoal (about 5 g) was added to the methanol, and the solution was stirred for 10 minutes. The activated charcoal was removed by filtration, and the charcoal residue was washed with additional 300 mL methanol. Water (2 L) was added to the combined filtrates (i.e. the 2 L methanol), and an off-white solid precipitated upon standing at 4° C. overnight. The crude product was filtered and was recrystallized from 65% methanol/water (v/v) to yield Compound XIX (69.1 g, 42%) as off-white solid.
Properties are listed below:
mp 116-117° C.; HPLC, 1 H NMR and Anal. Calcd for C 15 H 21 NO 4 : C, 64.50; H, 7.58; N, 5.02. Found: C, 64.26; H, 7.81; N, 4.93.
EXAMPLE 2
Compound XXXI was prepared as follows:
1-Aminoundec-10-ene. A mixture of 10-undecene-1-ol (5.00 g, 29.36 mmol, 1 equiv), triphenylphosphine (7.70 g, 29.36 mmol, 1 equiv) and phthalimide (4.32 g, 29.36 mmol, 1 equiv) in dry tetrahydrofuran (THF, 30 mL) was stirred vigorously under argon. Diethyl azodicarboxylate (DEAD, 5.11 g, 29.36 mmol, 1 equiv) was diluted with THF (12 mL) and added dropwise by syringe. After the addition, the reaction was stirred at room temperature for 4 hours. The solvent was evaporated under vacuum and ether (30 mL) was added to precipitate the triphenylphosphine oxide and hydrazine dicarboxylate which were removed by filtration. The precipitate was rinsed with ether (2×30 mL) and the combined filtrates were evaporated to afford a yellow solid. The yellow solid was triturated with warm hexanes (3×50 mL) and filtered. The combined hexanes were evaporated to give 1-phthalimidylundec-10-ene as a yellow wax.
The yellow wax was dissolved in an ethanolic solution (38 mL) of hydrazine hydrate (1.47 g, 1 equiv, 29.36 mmol). The mixture was heated at reflux for 2 hours. After the mixture was cooled to room temperature, concentrated hydrochloric acid (30 mL) was added and the solid was filtered through a sintered glass filter. The residue was washed with water (50 mL) and the combined filtrates were evaporated to provide a yellow solid. The yellow solid was redissolved in 1M NaOH (100 mL) and extracted with ether (2×50 mL). The ether was dried and evaporated to provide a yellow oil. The oil was purified by Kugelrohr distillation (ca. 0.1 mmHg, 100° C.) to provide 1-aminoundec-10-ene (2) as a light yellow oil (3.29 g, 66%).
Properties are listed below.
1 H NMR (300 mHz, DMSO-d 6 ); δ 1.23 (14H, br m), 1.99
(2H, m), 2.48 (2H, m), 4.94 (2H, m), 5.77 (1H, m).
1-(O-Acetylsalicyloylamino)undec-10-ene. O-Acetylsalicyloyl chloride (3.82 g, 19.25 mmol, 1 equiv) in THF (30 mL) was cooled in an ice bath. Triethylamine (1.95 g, 19.25 mmol, 1 equiv), followed by 1-aminoundec-10-ene (3.26 g, 19.25 mmol, 1 equiv) in THF (10 mL) were added via syringe. The ice bath was removed and the reaction was stirred at room temperature for 3.5 hours. After removal of the solvent, the residue was dissolved in EtOAc (50 mL) and washed with water (2×30 mL). The organic layer was dried and evaporated to afford 1-(O-acetylsalicyloylarnino)undec-10-ene as a colorless oil, in a quantitative yield, 6.59 g.
Properties are listed below.
1 H NMR (300 mHz, DMSO-d 6 : δ 1.26 (12H, br s), 1.47 (2H,m), 1.99(2H,m), 2.19 (3H,s), 3.15 (2H, q), 4.95 (2H, m), 5.78 (1H, m), 7.15 (1H, m), 7.30 (1H, m), 7.50 (2H, ml 8.24 (1H, t).
Compound XXXI
1-(O-Acetylsalicyloylamino)under-10-ene (6.59 g, 19.25 mmol, 1 equiv) in dichloromethane (108 mL) was added to a mixture of water (108 mL), sulfuric acid (9M, 13 mL), glacial acetic acid (2.16 mL) and methyltrialkyl(C 8 -C 10 )ammonium chloride (0.32 g) (Adogen® 464, available from Aldrich Chemical Co.). The mixture was stirred vigorously in an ice bath and potassium permanganate (9.13 g, 57.75 mmol, 3 equiv) was added in portions over 1.5 hours. After the addition, the ice bath was removed and the resultant purple solution was stirred at room temperature for 20 hours. The solution was cooled in an ice bath and sodium bisulfite (6.8 g) was added to dissipate the excess permanganate. The organic layer was separated and the aqueous layer was extracted with ethyl acetate (2×50 mL). The combined organic layers were washed with brine (50 mL), dried and evaporated. sodium hydroxide (2M, 50 mL; was added to the residue and stirred for 30 min. The solution was diluted with water (50 mL), washed with ether (50 mL) and acidified to pH 1 with 2M hydrochloric acid. A solid formed and was collected by filtration. Recrystallization of the solid from 65 % MeOH/H 2 O gave XXXI as a tan solid (2.78 g, 47% based on the amine).
Properties are listed below.
1 H NMR (300 mHz, DMSO-d 6 ): δ 1.24 (10H, br m), 1.51 (4H, m), 2.17 (2H, t), 3.27 (2H, m), 6.86 (2H, m), 7.37 (1H m), 7.82 (1H, m), 8.80 (1H, t), 11.95 (1H, s), 12.72 (1H, s).
EXAMPLE 3
Compound LXXXVI was prepared as follows:
A one liter three-neck round bottom flask was fitted with a magnetic stirrer and a condenser. A solution of 3-(4-aminophenyl)propionic acid (30 g, 0.182 moles) in methylene chloride (300 mL) was charged to the flask and trimethylsilyl chloride (46.2 mL, 0.364 moles) was added in one portion. The reaction mixture was refluxed for 1.5 hours, allowed to cool to room temperature, and then immersed in an ice/water bath. Triethylamine (76.2 mL, 0.546 moles) was added, followed by 2-methoxycinnamoyl chloride (35.8 g, 0.182 moles). The reaction mixture was allowed to warm to room temperature and then stirred for 48 hours. The solvent was removed by rotary evaporation and saturated sodium bicarbonate solution and ethyl acetate were added to the residue. The layers were separated, the aqueous layer was acidified to pH 1.4 with 2N aqueous sulfuric acid and extracted with ethyl acetate (2×400 mL). The combined organic extracts were concentrated in vacuo and the residue recrystallized from 50% (v/v) aqueous methanol to provide the product as a tan solid (48.57 g, 82%).
Properties are listed below.
1 H NMR (300MHz, DMSO-d 6 ): δ 12.1 (1H, br), 7,8 (1H, dd), 7.6 (3H, m), 7.4 (1H, m), 7.3 (2H, m), 7.1 (1H, d), 7.0 (1H, t), 6.9 (1H, d), 3.9 (3H, s), 2.8 (2H, t), 2.5 (4H, m). Anal. Calcd for C 19 H 19 NO 4 : C, 70.14; H, 5.88; N, 4.31. Found: C, 69.76; H, 5.91; N, 4.21.
EXAMPLE 4
Compound CXVII was prepared as follows:
A 3 L three-neck round bottom flask was fitted with an overhead mechanical stirrer and a thermometer. A solution of 8-aminocaprylic acid (10.0 g, 0.054 moles) in 2 M aqueous sodium hydroxide (1.4 L) was charged into the round bottom flask and O-nitrobenzoyl chloride (12.0 g, 0.065 moles, 1.2 equiv.) was added portionwise over 7 h. The mixture was stirred at 25 ° C. for 12 h to afford a yellow homogenous solution. The solution was acidified with 1 M hydrochloric acid to about pH 2, an oily residue separated and was decanted. The oil was dissolved in stirred water (300 mL) and cooled in and ice/water bath. The product precipitated as a white solid. The solid was filtered, washed with water (3×300 mL), and recrystallized from 55% acetonitrile/water (v/v) to provide Compound CXVII as an off-white solid (7.4 g, 47%). mp 89-92° C.
Properties are listed below.
1 H NMR (300 MHz, DMSO-d 6 ) δ: 12.0 (1H, s), 8.65 (1H, t), 8.0 (1H, dd), 7.8 (1H, m), 7.65 (1H, m), 7.5 (1H, m), 3.2 (2H, q), 2.2 (2H, t), 1.5 (4H, br m), 1.3 (6H, br m). Anal. Calcd for C 15 H 20 N 2 O 5 : C, 58.41: H, 6.54; N, 9.09. Found: C, 58.50; H, 6.71; N, 9.14.
The other compounds of the invention can be readily prepared by following the procedures described in Examples 1-4.
EXAMPLES 5-15
In Vivo Evaluation of Recombinant Growth Hormone in Rats
Dosing compositions were prepared by mixing the modified amino acids and recombinant human growth hormone (rhGH) as listed in Table 1 below in a phosphate buffer solution at a pH of about 7-8.
Rats were administered the dosing composition by sublingual, oral gavage, intraduodenal administration, or colonic administration. Delivery was evaluated by using an ELISA assay for rhGH from Medix Biotech, Inc. For intracolonic administration, a sample was prepared and dosed to fasted rats at 25 mg/kg of carrier in a buffered solution containing propylene glycol (0-50%) and 1 mg/kg rhGH.
Results are illustrated in Table 1 below.
Comparative Example 5A
rhGH (6 mg/ml) was administered by oral gavage to a rat, and delivery was evaluated according to the procedure of Example 5.
Results are illustrated in Table 1 below.
TABLE 1
In Viva Delivery of rhGH
Carrier
Drug
Method of
Mean Peak Serum
Dose
Dose
Administra-
Levels of rhGH
Example
Carrier
(mg/kg)
(mg/kg)
tion
(ng/mL)
5
I
500
6
oral
26.6 +/− 43.83
5A
none
0
6
oral
<10 +/− 10
6
V
500
6
oral
3.22 +/− 7.2
7
VI
500
6
oral
19.34 +/− 18.73
8
VIII
500
6
oral
73.41 +/− 70.3
9
IX
500
6
oral
28.70 +/− 41.7
10
XIII
25
1
colonic
109.52 +/− 36.1
11
XIX
200
3
oral
60.92 +/− 26.3
12
XIX
25
1
colonic
111.52 +/− 16.4
13
XIX
100
3
sublingual
119.14 +/− 65.6
14
XIX
25
1
intranasal
92.7 +/− 73.2
15
XXVII
25
1
colonic
73.72 +/− 4.9
EXAMPLES 16-27
In Vivo Evaluation of Recombinant Growth Hormone in Rats
Preparation of Dosing solutions.
The delivery agents were reconstituted with distilled water and adjusted to pH 7.2-8.0 with either aqueous hydrochloric acid or aqueous sodium hydroxide. A stock solution of rhGH was prepared by mixing rhGH, D-mannitol and glycine and dissolving this mixture in 2% glycerol/water. The stock solution was then added to the delivery agent solution. Several delivery agent to active agent ratios were studied.
In vivo experiments.
Male Sprague-Dawley rats weighing 200-250 g were fasted for 24 hours and administered ketamine (44 mg/kg) and chlorpromazine (1.5 mg/kg) 15 minutes prior to dosing. The rats were administered one of the dosing solutions described above by subcutaneous injection, intranasal instillation, or sublingual instillation. Blood samples were collected serially from the tail artery for serum calcium concentration determination or serum rhGH concentrations. The dose of rhGH administered in these experiments was 0.1 mg/kg.
Serum rhGH concentrations were quantified by an rhGH enzyme immunoassay test kit. The results are given in Table 2 and FIGS. 1 and 2.
In FIG. 2 the circles represent the response following SL dosing of an aqueous solution of compound CXXIII and rhGH. The squares represent the response following IN dosing of an aqueous solution of compound CXXIII and rhGH. The triangles represent the response following IC dosing of an aqueous solution of compound CXXIII and rhGH. The dose of compound CXXIII was 25 mg/kg and the dose of rhGH was 1 mg/kg.
Comparative Example 16A
rhGH (1 mg/kg) was administered by oral gavage to a rat, and delivery was evaluated according to the procecure of Example 1 6.
Results are illustrated in Table 2 below.
TABLE 2
Delivery Agent Enhancement of Recombinant Human Growth Hormone
(rhGH) Bioavailability Administered by Subcutaneous Administration.
Delivery Agent Dose
Peak Serum [rhGH]
Example
Deliver Ageny
(mg/kg)
(ng/mL)
16
CXXIII
1.0
22 ± 3
16A
None
0.0
4 ± 2
17
CXXIII
2.5
25 ± 5
18
CXXIII
25
30 ± 6
19
CX
2.5
16 ± 2
20
LVIII
1.0
29 ± 10
21
LXXXVI
1.0
22 ± 7
22
LXXXVI
2.5
23 ± 5
23
LXI
2.5
26 ± 5
24
CX
1.0
15 ± 3
25
CXV
1.0
25 ± 3
26
LXVI
1.0
33 ± 5
27
CIX
1.0
16 ± 3
EXAMPLES 28-33
In Vivo Evaluation of Interferon in Rats
Dosing compositions were prepared by mixing the modified amino acid compounds and interferon α2b as listed in Table 3 below in a Trizma® hydrochloride buffer solution (Tris-HCl) at a pH of about 7-8. Propylene glycol (0-25%) was added as a solubilizing agent, if necessary.
Rats were administered the dosing composition by oral gavage, intraduodenal administration, or intracolonic administration. Delivery was evaluated by use of an ELISA assay for human interferon a from Biosource, Inc.
Results of intracolonic administration are illustrated in Table 3 below.
Comparative Example 28A
Interferon a2b (250 μg/kg) was administered intracolonically to rats, and delivery was evaluated according to the procedure of Example 14.
Results are illustrated in Table 3 below.
TABLE 3
In Vivo Delivery of Interferon by Intracolonic Administration
Mean Peak Serum
Carrier Dose
Interferon Dose
Levels of Interferon
Example
Carrier
(mg/kg)
(μg/kg)
(pg/mL)
28
VII
100
250
5241 +/− 2205
28A
none
0
250
0
29
XI
100
250
1189 +/− 1373
30
XII
100
250
6955 +/− 2163
31
XIX
100
250
11193 +/− 8559
32
XXI
100
250
4238 +/− 2789
33
XXXIV
100
250
4853 +/− 5231
Results are illustrated in Table 4 below.
EXAMPLES 34-37
In Vivo Evaluation of Salmon Calcitonin in Rats
Dosing compositions were prepared by mixing the modified amino acids and salmon calcitonin as listed in Table 4 below. 400 mg of carrier were added to 2.9 mL of 25% aqueous propylene glycol. The resultant solution was stirred, and the pH was adjusted to 7.2 with sodium hydroxide (1.0 N). Water was added to bring the total volume to 2.0 mL.
The sample had a final carrier concentration of 200 mglmL. Calcitonin (10 μg) was added to the solution. The total calcitonin concentration was 2.5 μg/mL.
For each sample a group of fasted rats were anesthetized. The rats were administered the dosing composition by oral gavage, intracolonic instillation, or intraduodenal administration. Blood samples were collected serially from the tall artery. Serum calcium was determined by testing with a calcium Kit (Sigma Chemical Company, St. Louis, Mo., USA).
Results are illustrated in Table 4 below.
TABLE 4
In Vivo Delivery of Calcitonin
Carrier
Drug
Method of
Maximum Decrease
Exam-
Dose
Dose
Administra-
in Serum Calcium
ple
Carrier
(mg/kg)
(μg/kg)
tion
(% below baseline)
34
I
400
10
oral
35
V
400
10
oral
18.35 +/− 2.87
36
XIX
10
3
intracolonic
26.49 +/− 12.3
37
XIX
200
7.5
oral
25.48 +/− 4.7
EXAMPLES 38-43
In Vivo Evaluation of Salmon Calcitonin in Rats
Preparation of Dosing solution.
The delivery agents were reconstituted with distilled water and adjusted to pH 7.2-8.0 with either aqueous hydrochloric acid or aqueous sodium hydroxide. A stock solution of sCT was prepared by dissolving sCT in citric acid (0.085N). The stock solution was then added to the delivery agent solution. Several different delivery agent to active agent ratios were studied.
In vivo experiments.
Male Sprague-Dawley rats weighing 200-250 g were fasted for 24 hours and administered ketamine (44 mglkg) and chlorpromazine (1.5 mg/kg) 15 minutes prior to dosing. The rats were administered one of the dosing solutions described above by subcutaneous injection. Blood samples were collected serially from the tail artery for serum calcium concentration.
Serum calcium concentrations were quantified by the o-cresololphthalein complex one method (Sigma) using a UV/VIS spectrophotometer (Perkin Elmer). The results are given in Table 5.
EXAMPLES 38A
Salmon calcitonin was administered by oral gavage to rats, and delivery was evaluated according to the Procedure of Example 38. The results are given in Table 5 below.
TABLE 5
Delivery Agent Enhancement of Salmon Calcitonin (sCT, dosed
at 0.2 μg/kg) Bioavailability Administered
by Subcutaneous Administration.
Delivery Agent Dose
Percent Decrease in
Example
Deliver Ageny
(μg/kg)
Serum Calcium
38
CXXIII
2
17 ± 3
38A
None
0
17 ± 2
39
CXXIII
20
25 ± 4
40
CXXIII
200
25 ± 5
41
CXXIII
2000
26 ± 5
42
CXI
20
21 ± 4
43
CXIV
20
20 ± 3
EXAMPLES 44-50
In Vivo Evaluation of HeDarin in Rats
Dosing compositions were prepared by mixing the modified amino acids and heparin as listed in Table 4. In a test tube, 900 mg of carrier were dissolved in 3 mL of propylene glycol, and 0.299 g of sodium heparin was dissolved in 3 mL of water. The solutions were mixed by vortex. Sodium hydroxide (10M) was added to the resulting mixture until a solution was obtained. The pH was then adjusted to 7.4+/−0.5 with concentrated hydrochloric acid, and the final solution was sonicated at 40° C. for 30 minutes.
A group of fasted, conscious rats were administered the dosing compositions by oral gavage. Blood samples were collected by cardiac puncture following the administration of ketamine (44 mg/kg)., Heparin activity was determined by utilizing the activated partial thromboplastim time (APTT) according to the method of Henry, J. B., Clinical Diagnosis and Management by Laboratory Methods ; Philadelphia, Pa.; W B Saunders (1979).
Results are illustrated in table 6 below.
Comparative Example 44A
Heparin (100 mg/kg) was administered by oral gavage to rats, and heparin activity was determined according to the procedure of Example 44.
Results are illustrated in Table 6 below.
TABLE 6
In Vivo Delivery of Heparin by Oral Administration
Carrier Dose
Drug Dose
Mean Peak APTT
Example
Carrier
(mg/kg)
(mg/kg)
(sec)
44
II
300
100
25.45 +/− 2.8
44A
none
none
100
20.7 +/− 0.17
45
III
300
100
38.64 +/− 17
46
V
300
100
87.4 +/− 34.1
47
XII
300
100
49.53 +/− 17.1
48
XIX
300
100
119.99 +/− 56.3
49
XXXI
50
25
127.56 +/− 22.97
50
XXXI
50
10
50.85 +/− 9.1
EXAMPLE 51
The method of Example 44 was followed, substituting low molecular weight heparin for the heparin and varying the amounts of propylene glycol and water for solubilization as, necessary.
EXAMPLES 50-58
In vivo Evaluation of Parathyroid Hormone in Rats
Preparation of dosing solutions.
The delivery agents were reconstituted with distilled water and/or propylene glycol and adjusted to an apparent pH of 7.2-8.0 with either aqueous hydrochloric acid or aqueous sodium hydroxide. A stock solution of parathyroid hormone was prepared by dissolving parathyroid hormone in water. The parathyroid hormone solution was then added to the delivery agent solution. Several different delivery agent to active agent ratios, were studied.
In vivo experiments.
Male Sprague-Dawley rats weighing 200-250 g were fasted for 24 hours and administered ketamine (44 mg/kg) and chlorpromazine (1.5 mg/kg) 15 minutes prior to dosing. The rats were administered one of the dosing solutions described above by oral gavage or intracolonic instillation. Blood samples were collected serially from the tail artery for serum determination of parathyroid hormone concentration. Serum parathyroid hormone concentrations were quantified by a parathyroid hormone radioimmunoassay test kit.
In vivo Oral administration.
Oral administration of solutions containing parathyroid hormone (PTH) and the non-a-amino acid delivery agents was tested in vivo in rats. The result show a significant increase in the oral bioavailability of parathyroid hormone as compared to similar administration of the active agent alone. Data are presented in Table 7.
TABLE 7
Delivery Agent Enhancement of Parathyroid Hormone (PTH) Oral
Bioavailability.
Active
Peak
Carrier
Agent
Serum
Dose
Method of
Dose
[PTH]
Example
Carrier
mg/kg
Administration
(μg/kg)
(pg/mL)
51
CXXIII
100
intracolonic
25
130 ± 20
52
CXXIII
250
oral
100
75 ± 25
53
CXXIII
250
oral
25
20 ± 6
54
CVIII
100
intracolonic
25
115 ± 20
55
LXXXVI
100
intracolonic
25
40 ± 12
56
LVIII
100
intracolonic
25
145 ± 25
57
CXIV
100
intracolonic
25
65 ± 15
58
LXXXIX
100
intracolonic
25
70 ± 15
The above mentioned patents, applications, test methods, and publications are hereby incorporated by reference in their entirety.
Many variations of the present invention will suggest themselves to those skilled in the art in light of the above detailed description. All such obvious variations are within the full intended scope of the appended claims. | The present invention provides a compound having the formula
or a salt thereof which facilitates the delivery of active agents. Compositions and dosage unit forms comprising the compound of the present invention and at least one active agent, such as a peptide, mucopolysaccharide, carbohydrate, or a lipid, are also provided. Methods of administration and preparation of the compounds and compositions of the invention are provided as well. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a novel platinum catalyst composition useful for the so-called hydrosilylation.
2. Description of the Prior Art
The reaction for adding an organosilicon compound having a .tbd.SiH radical in its molecule to an organic compound having an unsaturated double bond is known as the so-called hydrosilylation, and has been utilized for the synthesis of new organosilicon compounds.
In the hydrosilylation employed for the synthesis of organosilicon compounds, a variety of platinum catalysts have generally been used. As the platinum catalysts for such use, there have been known, for example, platinum supported on activated carbon (U.S. Pat. No. 2,970,150), chloroplatinic acid (U.S. Pat. No. 2,823,218), a platinum-organic compound complex (U.S. Pat. No. 3,159,601), a platinum-organofunctional polysiloxane complex (Japanese Patent Publication (KOKOKU) No. 63-19218 (1988)), etc.
Though the known platinum catalysts have the merit of being rich in reactivity by virtue of good activity for addition reaction, their high activity would cause rearrangement of a terminal unsaturated double bond of the organic compound used as a reactant in the hydrosilylation. As a result of the rearrangement, isomeric raw materials with poor reactivity may remain as unreacted material in the reaction system, or isomers of the intended organosilicon compound may be by-produced in large quantities, leading to an unfavorably lower yield of the desired product. Further, the isomeric raw materials are difficult to reuse, even if recovered. Moreover, the byproduced isomers are very difficult to separate for purification from the intended organosilicon compound, due to the similarity in chemical structure.
SUMMARY OF THE INVENTION
It is accordingly an object of this invention to provide a platinum catalyst composition with which it is possible to obviate the aforementioned problems or inconveniences accompanying the hydrosilylation reaction, and a process for producing the platinum catalyst composition.
According to this invention, there is provided a platinum catalyst composition comprising a diolefin component represented by the following general formula:
CH.sub.2 ═CH--R--CH═CH.sub.2 (I)
wherein R represents a divalent saturated hydrocarbon radical of from 2 to 10 carbon atoms, and a platinum compound component having a platinum valence of 0, 2, 4 or an admixture of at least two of 0, 2 and 4.
The platinum catalyst composition is produced by reacting the diolefin represented by the above general formula (I) with the platinum compound having a platinum valence of 0, 2, 4 or an admixture of at least two of 0, 2 and 4.
The platinum catalyst composition of this invention is extremely useful for a hydrosilylation reaction between an organosilicon compound having a .tbd.SiH radical in its molecule and an olefin. When used for the hydrosilylation reaction, the platinum catalyst composition inhibits effectively the isomerization of the raw material olefin, thereby enabling the intended organosilicon compound to be obtained in a high yield.
DETAILED DESCRIPTION OF THE INVENTION
Diolefin
The diolefin used in this invention is an olefin which, as represented by the general formula (I):
CH.sub.2 ═CH--R--CH═CH.sub.2 (I)
(wherein R is as defined above), has double bonds at both ends of its molecular chain.
In the general formula (I), the radical R is a divalent saturated hydrocarbon radical of from 2 to 10 carbon atoms, for example, ethylene, propylene, butylene, hexylene, octylene, decylene, cyclohexylene, etc., which may be branched partially.
In this invention, diolefins in which the radical R is linear, such as 1,5-hexadiene, 1,7-octadiene, 1,9-decadiene, 1,11-dodecadiene, etc., are used particularly preferably, from the viewpoint of coordination with platinum and the isomerization-inhibitive effect. In this case, diolefins with a shorter chain, such as butadiene, pentadiene, etc., are unsuitable because of their poorer inhibitive effect on the isomerization, whereas diolefins with a longer chain, such as 1,14-pentadecadiene, are unsuitable because they are susceptible to solidification and, therefore, difficult to deal with. Further, cyclic diolefins such as cyclooctadiene are also too poor in the isomerization-inhibitive effect to attain the object of this invention. In any way, only the use of the diolefin represented by the aforementioned general formula (I) makes it possible to obtain a platinum catalyst composition capable of inhibiting effectively the isomerization which would otherwise occur at the time of the hydrosilylation reaction.
Platinum compound
The platinum compound used in combination with the above-mentioned diolefin in this invention is a platinum compound having a platinum valence of 0, 2, 4 or an admixture of at least two of 0, 2 and 4.
Representative, but not limitative, examples of the platinum compound include the followings:
platinum compounds with a platinum valence of 2, such as platinum halides represented by the formula PtX 2 where X represents a halogen atom, the same applying hereinbelow, e.g. platinum(II) chloride, platinic acids, e.g. tetrachloroplatinic(II) acid, alkali salts of platinic(II) acid, e.g. potassium tetrachloroplatinate(II), etc.;
platinum compounds with a platinum valence of 4, such as platinum halides represented by the formula PtX 4 , e.g. platinum(IV) chloride, platinic acids, e.g. hexachloroplatinic(IV) acid, alkali salts of platinic acid(IV), e.g. potassium hexachloroplatinate(IV) or sodium hexachloroplatinate(IV), etc.; and
platinum compounds with a platinum valence of 0, such as platinum complexes having a neutral ligand, e.g., Pt(PPh 3 - ) 4 where Ph represents the phenyl group.
The platinum compounds may be used singly or in combination of two or more.
The platinum compounds are, if necessary, dissolved in a solvent such as an alcohol, etc., before put to use.
Production of platinum catalyst composition
The platinum catalyst composition of this invention is produced by reacting the aforementioned specified diolefin and platinum compound with each other.
The reaction between the two components may be carried out by mixing both the components in a solvent system, in the same manner as in a method of preparing a Zeise's salt [Refer to Shin Jikken-Kaoaku Kohza (A New Course in Experimental Chemistry), vol. 12, 255, 1976, Maruzen Co., Ltd.].
The reaction temperature, which depends on the kinds of the diolefin and the platinum compound used, is in general preferably from 10 to 100° C, more preferably from 20° to 80° C., and most preferably from 40° to 80° C. The reaction may be normally carried out sufficiently for about 1 to 24 hours.
It is preferred that the diolefin be used in an amount of generally from 0.5 to 8 moles, more preferably from 2 to 6 moles, per mole in terms of platinum of the platinum compound.
In view of the expensiveness of platinum itself and in order to reduce errors associated with the addition of the reaction product as a catalyst, the platinum compound may be diluted with an alcohol or a hydrocarbon solvent so as to obtain an effective platinum component concentration on the order of several percent, before used for the reaction.
Furthermore, because side reactions may be caused by free chloride ions when a chlorine-containing platinum compound such as chloroplatinic acid is used as the platinum compound, it is desirable in such a case to neutralize the chlorine-containing platinum compound with a base such as sodium hydrogencarbonate, sodium carbonate, hydrazine, etc., before reacting the platinum compound with the diolefin, or to react the chlorine-containing platinum compound with the diolefin and then neutralize the reaction product by addition of the aforementioned base. In general, it is preferred to neutralize the chlorine-containing platinum compound prior to the reaction between the platinum compound and the diolefin.
The reaction product obtained as above is subjected to the usual purification treatments, such as filtration, extraction, etc., for removing the by-produced salts, such as sodium chloride, and the surplus neutralizer and the like therefrom, before used as the platinum catalyst composition.
Platinum catalyst composition
In the platinum catalyst composition obtained by the aforementioned method, the reaction product of the diolefin with the platinum compound is formed at least in a portion of the composition, and the presence of the reaction product is considered to be the origin of the effective catalytic action on the hydrosilylation reaction. The reaction product is presumed to comprise an olefin-platinum complex salt having a platinum atom as a central atom with which the double bonds of the diolefin are coordinated. The olefin-platinum complex salt is considered to have a chemical structure of, for example,
[PtZ.sub.2 ], [X.sub.4 PtZ.sub.2 ], [X.sub.2 PtZ.sub.2 PtX.sub.2 ],
[X.sub.4 PtZ], [X.sub.2 PtZ]
or the like, where Z represents the diolefin.
The platinum catalyst composition of this invention, comprising the diolefin component and the platinum compound component as mentioned above, is used after being diluted, if necessary, with an organic solvent so as to obtain a platinum concentration of from 0.1 to 5% by weight.
Hydrosilylation reaction
The platinum catalyst composition of this invention is used profitably as a catalyst for effective acceleration of the hydrosilylation reaction between an organosilicon compound having a .tbd.SiH radical in its molecule and an organic compound having an unsaturated bond at an end of the molecular chain thereof which is represented by, for example the following general formula:
CH.sub.2 ═CH--CH.sub.2 --R.sup.1 (II)
wherein R 1 represents a monovalent organic radical, or the general formula:
CH.sub.2 ═CH--CH.sub.2 --R.sup.2 --CH.sub.2 --CH═CH.sub.2 (III)
wherein R 2 represents a divalent saturated hydrocarbon radical of up to 8 carbon atoms or a single bond.
That is, the hydrosilylation reaction is the addition of the .tbd.SiH radical to the olefin linkage, and the addition reaction causes the synthesis of the organosilicon compound having a silyl radical which is represented by the following formula:
.tbd.Si--CH.sub.2 CH.sub.2 CH.sub.2 --R.sup.1 (IV)
.tbd.Si--CH.sub.2 CH.sub.2 CH.sub.2 --R.sup.2 --CH.sub.2 --CH═CH.sub.2 (V)
or
.tbd.Si--CH.sub.2 CH.sub.2 CH.sub.2 --R.sup.2 --CH.sub.2 CH.sub.2 CH.sub.2 --Si.tbd. (VI)
If the above reaction is carried out by use of a conventionally known platinum catalyst, part of the olefin or diolefin used as the starting material undergoes rearrangement of its terminal double bond, resulting in the formation of the isomers having low reactivity.
For instance, when the monoolefin of the formula (II) is used, part of the raw material olefin remains as an isomer in the unreacted state, as represented by the following reaction equation:
X.sub.3 Si--H+CH.sub.2 ═CH--CH.sub.2 --R.sup.1 →X.sub.3 Si--CH.sub.2 CH.sub.2 CH.sub.2 --R.sup.1 +CH.sub.3 --CH═CH--R.sup.1
so that the yield of the intended reaction product is extremely low. Furthermore, the isomer of the raw material olefin thus left unreacted is extremely poor in reactivity and is, therefore, difficult to reuse through recovery.
Also, when the diolefin of the formula (III) is used, part of the starting material diolefin is isomerized through rearrangement, as represented by the following reaction equation: ##STR1## in the case of using an excess of the diolefin, or by the following reaction equation: ##STR2## in the case of using an excess of the organosilicon compound. Consequently, large amounts of by-products are formed in addition to the intended compound, resulting in an extremely low yield of the intended compound. Moreover, where an excess of the diolefin is used, the principal product and the by-products formed are isomeric with each other; therefore, purification of the principal product by separation is difficult to achieve. In these cases, also, part of the raw material diolefin is left unreacted, in the form of isomers with low reactivity.
Thus, in carrying out the aforementioned hydrosilylation reaction by use of a conventionally known platinum catalyst, it has been impossible to obviate the above-mentioned problems or inconveniences, due to the isomerization of the olefin compound used as a starting material.
On the other hand, when the aforementioned platinum catalyst of this invention is applied to the hydrosilylation reaction, the isomerization of the starting material olefin compound is inhibited effectively, whereby the problems or inconveniences such as the lowered yield of the intended product, etc., are obviated effectively.
In the hydrosilylation reaction to which the platinum catalyst of this invention is applied, the organosilicon compound to be used is not particularly limited, insofar as it has at least one .tbd.SiH radical in its molecule. The usable organosilicon compounds can have any of structures ranging from a monomer which has only one Si atom in its molecule to an organopolysiloxane which has a multiplicity of Si atoms in its molecule.
Nonlimitative examples of the organic compound having an unsaturated bond at an end of its molecular chain include monoolefins such as 1-butene, 1-hexene, 1-octene, 1-decene, 1-octadecene, etc., epoxyolefines such as acryl glycidyl ether, etc., acrylolefins such as allyl methacrylate, allyl acrylate, etc., haloolefins such as acryl chloride, vinylbenzyl chloride, etc., dienes such as 1,5-hexadiene, 1,7-octadiene, 1,9-decadiene, 1,11-dodecadiene, 1,13-tetradecadiene, etc., and styrenes such as styrene, α-methylstyrene, etc. Among these organic compounds, those diolefins having unsaturated double bonds at both ends of the molecular chain thereof are particularly preferred.
The hydrosilylation reaction is generally carried out in an organic solvent at a temperature ranging from room temperature to 200° C., preferably from 30° to 150° C. In the reaction, the platinum catalyst composition of this invention is used in an amount of from 1×10 -5 to 1×10 -1 mol % (calculated as platinum) based on the organosilicon compound used as a reactant.
EXAMPLES
Example 1
A flask equipped with a cooling pipe, a thermometer, an agitator and a nitrogen gas inlet port was charged with 5.2 g (10 mmol) of hexachloroplatinic(IV) acid hexahydrate (H 2 PtCl 6 ·6H 2 O), to which 4.9 g (60 mmol) of 1,5-hexadiene and 26 g of ethanol (as solvent) were added to permit dissolution. To the contents of the flask, 6.7 g (80 mmol) of sodium hydrogencarbonate (NaHCO 3 ) was added slowly, upon which vigorous bubbling occurred.
After agitation was continued for a while and the bubbling ceased, the reaction system was maintained under a stream of nitrogen while the reaction was effected at 50° to 65° C. for 2 hours. The reaction mixture, initially yellowish orange in color, turned dark red upon the reaction.
After the reaction was over, the reaction mixture was cooled and filtered to remove by-produced sodium chloride and the surplus sodium hydrogencarbonate therefrom. The filtrate obtained was concentrated at 40° to 50° C. under a reduced pressure (100 torr or below) to remove the solvent. The residual liquid was diluted with toluene to obtain a total weight of 100 g, followed by filtration again to remove the remaining sodium chloride and sodium hydrogencarbonate.
The solution of the platinum-diolefin complex thus obtained was found, upon analysis, to have a platinum concentration of 1.43%.
The solution was diluted further with toluene to form a solution having a platinum concentration of 0.2%. This solution was name catalyst El.
Example 2
In the same manner as in Example 1, 5.2 g (10 mmol) of hexachloroplatinic(IV) acid hexahydrate was reacted with 8.3 g (60 mmol) of 1,9-decadiene, upon which the color of the reaction mixture changed from the initial yellowish orange to dark red.
After the reaction was over, the reaction mixture was treated in the same manner as in Example 1, to yield a toluene solution of a platinum-diolefin complex.
Upon analysis, the solution of the complex was found to have a platinum concentration of 0.78%.
The complex solution was diluted further with toluene to obtain a solution having a platinum concentration of 0.2%. This solution was named catalyst E2.
Example 3
By use of the same apparatus as used in Example 1, a mixture of 5.2 g (10 mmol) of hexachloroplatinic(IV) acid hexahydrate, 4.9 g (60 mmol) of 1,5-hexadiene and 26 g of ethanol (as solvent) was reacted under a stream of nitrogen at 50° to 65° C. for 2 hours. Then, the reaction mixture was cooled, and diluted with ethanol to obtain a total weight of 100 g.
The solution of the platinum-diolefin complex thus obtained was found, upon analysis, to have a platinum concentration of 2.11%.
The solution of the complex was diluted further with toluene to obtain a solution having a platinum concentration of 0.2%. This solution was named catalyst E3.
Example 4
By use of the same apparatus as used in Example 1, a mixture of 4.2 g (10 mmol) of potassium tetrachloroplatinate(II) (K 2 PtCl 4 ), 4.9 g (60 mmol) of 1,5-hexadiene and 16 g of ethanol (as solvent) was treated in the same manner as in Example 3, to obtain an ethanol solution of a platinum-diolefin complex.
The platinum concentration of the solution of the complex was analyzed to be 2.25%.
The complex solution was diluted further with toluene to obtain a solution having a platinum concentration of 0.2%. This solution was named catalyst E4.
Comparative Example 1
In the same manner as in Example 1, a mixture of 5.2 g (10 mmol) of hexachloroplatinic(IV) acid hexahydrate was reacted with 11.2 g (60 mmol) of 1,3-divinyl-1,1,3,3-tetramethyldisiloxane represented by the following formula: ##STR3## Upon the reaction, the color of the reaction mixture changed from the initial yellowish orange to dark red.
After the reaction was over, the reaction mixture was treated in the same manner as in Example 1, to yield a toluene solution of a platinum-siloxane complex.
Upon analysis, the platinum concentration of the solution of the complex was found be 0.63%.
The complex solution was diluted further with toluene to obtain a solution having a platinum concentration of 0.2%. This solution was named catalyst Cl.
Comparative Example 2
A toluene solution of a platinum-diolefin complex was obtained in the same manner as in Comparative Example 1 except that 6.5 g (60 mmol) of 1,5-cyclooctadiene was used in place of the 1,3-divinyl-1,1,3,3-tetramethyldisiloxane.
Upon analysis, the platinum concentration of the solution of the complex was found to be 0.75%.
The complex solution was diluted further with toluene to obtain a solution having a platinum concentration of 0.2%. This solution was named catalyst C2.
Comparative Example 3
Hexachloroplatinic(IV) acid hexahydrate was dissolved in each of n-butyl alcohol, sec-butyl alcohol, t-butyl alcohol and 2-ethylhexanol to prepare respective solutions having a platinum concentration of 2%. The solutions were diluted further with toluene to obtain solutions having a platinum concentration of 0.2%.
The solutions thus obtained were named catalysts C3, C4, C5 and C6, respectively.
Application Example
A flask equipped with a cooling pipe, a dropping funnel, a thermometer and an agitator was charged with 277 g (2 mol) of 1,9-decadiene and 250 g of toluene (as solvent), and the contents of the flask was heated to about 60° C. under a stream of nitrogen.
To such a system was added each of the catalysts E1 to E4 and catalysts Cl to C6 obtained in the above Examples and Comparative Examples, in an amount (calculated as platinum) of 50 μmol each, to prepare 10 kinds of reaction systems.
Into each of the reaction systems, 136 g (1 mol) of trichlorosilane (HSiCl 3 ) was added dropwise through a dropping funnel, upon which heat generation was observed.
After the dropwise addition, each of the reaction systems was reacted at 60° to 65° C. for 1 hour. For each of the reaction systems, the reaction product was analyzed by gas chromatography, and the rates of isomerization were calculated from the formulas given below. Furthermore, the rate of addition reaction was calculated according to the formula also given below, from the H 2 gas quantity determined by alkali hydrolysis of the SiH radical. The results are shown in Table 1. ##EQU1##
In the above formulas, the rate of isomerization A is the rate of isomerization of the addition product, and the rate of isomerization B is the rate of isomerization of decadiene.
Besides, the reaction in the Application Example is represented by the following formula: ##STR4##
TABLE 1______________________________________ Rate of addi- tion reaction Rate of isomerization (%)Catalyst (%) addition product decadiene______________________________________E1 98.3 1.0 (1)* 1.9 (1)*E2 99.5 0.7 (1) 1.4 (1)E3 96.5 1.5 (1) 2.2 (1)E4 93.7 2.1 (1) 4.5 (1)C1 98.6 16.9 (1) 47.9 (2)C2 95.2 15.4 (1) 30.3 (2)C3 96.5 67.7 (2) 68.9 (4)C4 86.0 21.0 (1) 38.1 (2)C5 48.5 13.7 (1) 20.4 (1)C6 73.0 17.2 (1) 31.6 (2)______________________________________ Remarks: *The parenthesized numerical values each represent the number of isomers formed by the isomerization reactions, exclusive of the unisomerized addition products and 1,9decadiene. | The platinum catalyst composition comprises a diolefin component represented by the following general formula:
CH.sub.2 ═CH--R--CH═CH.sub.2
wherein R is a divalent saturated hydrocarbon radical, and a platinum compound component. The platinum catalyst composition is extremely useful for hydrosilylation of an organosilicon compound having a .tbd.SiH radical with an olefin. When used for the hydrosilylation reaction, it inhibits effectively the isomerization of the starting material olefin, thereby enabling the intended organosilicon compound to be obtained in a high yield. | 1 |
PRIORITY CLAIM
[0001] Applicants and inventors claim priority, pursuant to 35 U.S.C. §119(d), with respect to U.S. Provisional Patent Application No. 62/219,195, filed 16 Sep. 2015.
BACKGROUND OF THE INVENTION
[0002] 1. Field of The Invention
[0003] The present invention relates to leather treatment and refurbishing.
[0004] 2. Background Information
[0005] Having leather upholstery is among the most expensive of options for home, automobile, aircraft and other seating. Leather is also among the least understood of materials with respect to proper care, preservation and restoration.
[0006] For most upholstery materials, one can purchase a bottle or can of a substance that is applied to the upholstery for cleaning and/or providing stain resistance to the material. Instructions typically provide for some agitation of the substance after application, and later removal by wiping or vacuum of some kind. Unfortunately, leather cleaning and preservation, and much less restoration is achievable in this manner. Many Products that are suitable for fibrous or synthetic leather materials are at best ineffective, and often worse are destructive to authentic leather.
[0007] Particularly in the high-end automobile and aircraft industries, visibly worn leather upholstery is often replaced at many thousands of dollars of expense. Even in the high-end automobile realm, vehicles are even prematurely retired (traded in or otherwise sold) simply because the appearance of the vehicle is not to the standards of its owner because of Warren Al” leather seating.
[0008] While the use of currently available “leather creams” and the like may prolong the useful life of leather upholstery, conventional use of such products do virtually nothing to restore previously neglected leather upholstery, nor to the fullest extent possible through application of the hereafter described processes, extend leather upholstery life anywhere near its potential. Further still, when re-dying of the previously died and extensively used leather materials is involved, currently practiced methods produce aesthetically unacceptable results (uneven, or “splotchy” tint and contrast).
SUMMARY OF THE INVENTION
[0009] In view of the foregoing, the present inventor here discloses and claims an improved leather treatment process for preserving and restoring previously used and degraded leather materials.
[0010] Application of the herein described process results in leather surfaces that are of a texture, suppleness, and (when died) coloration that more resembles new leather material than is achievable through use of any presently practiced processes or methods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] This patent application and resulting patent includes no drawings, as such are not needed to satisfy enablement requirements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] As mentioned previously, the process described herein is principally intended for use with previously used and degraded leather materials, but can be used periodically to preserve them from further such degradation.
[0013] The present process involves several steps that will be outlined below.
[0014] Step 1 (Leather cleaning): A user first cleans the leather (to the extent possible) of any dirt, sweat, body oil (proteins) or any other contaminates. This may be accomplished through use of a commercially available, all-purpose degreaser; mild dish soap and warm water, denatured alcohol, rubbing alcohol, mineral spirits, citrus cleaner, tri-prep cleaner, or any form of leather cleaner.
[0015] One should not over-saturate the leather with the chosen cleaner or cleaner/water mixture. Further, if more than one cleaning step is needed, one should allow the leather to dry between cleaning steps, as the removal (or not) of soiling will not (for most leather materials) be readily apparent until or unless the leather has dried.
[0016] In the one or more cleaning steps, cleaning solutions should be applied using such as a lint-free or microfiber towel, sponge(s), or a soft-bristled brush. The cleaning solutions should be applied to the entire area to be restored, in a circular motion to ensure the area is cleaned thoroughly and evenly.
[0017] Step 2 (Leather Preparation): Preparing leather for restoration involves abrading the leather. The necessity of this step relates to certain characteristics of leather that distinguish it from other, non-hide-based cover materials—that of having natural pores through which restorative substantives and dies must pass for an optimally successful restoration. Over the course of use, these pores are distorted and most often occluded through blockage or distortion. The abrading restores access to pore lumens as is needed, again, for an optimal restoration of degraded leather, or even of leather that, though not materially degraded, is to be dyed, or re-dyed.
[0018] The abrading steps involves the use of sandpaper with grit ranging from 80 to 3000. One can also use scouring pads, such as SCOTCH BRITE® brand pads.
[0019] One can hand-sand the leather, or use such as a random orbital sander. In either case, this abrading step should proceed no further than to provide a uniform exposure to the “raw” leather beneath the original patina of the material. Excessive abrading may breach the fabric entirely, and/or create unnecessarily thin areas that are prone to ripping upon later use.
[0020] If, in order to achieve the just-described state (such as when the leather is excessively cracked, deeply stained, or for some other reason) one initially uses a lower grit, more abrasive sand paper), one should later use one or a more progressively higher grit sand papers to achieve a tactilely smooth surface.
[0021] Once the preparation stage is complete, a user should wipe or vacuum the to-be-stored area to remove any dust and any other contaminants, and thereafter ensure that the surfaces are fully dry before proceeding.
[0022] Step 3 (Masking): One should next (if not already done) mask any seat piping, and plastic trim near the to-be-stored materials, principally to prevent accidental staining from the to-be-used dye.
[0023] Step 4: (Dying): After selecting and preparing a leather dye of the desired color and tint, apply the dye using the dye manufacturer's prescribed method of application. In most instances, dye may be rubbed and massaged into the leather using a lint free or microfiber towel or similar lint and remnant-free sponge or material, or may be applied through use of an automotive paint gun, air brush tool, or aerosol device.
[0024] Once again, for optimal results, one must ensure that the leather the dry between any successive applications of dye.
[0025] If, upon drying, one determines that an area did not “take” the dye to the extent of other, adjacent areas, such is usually an indication that the original patina was not adequately removed and the hide pores opened up sufficiently. Any such areas may be re-treated as in the above second step. This step can be repeated multiple times, and may also be involved in adequately remediating stains.
[0026] Step 5 (Conditioning the Leather): Once a desired color and tint is achieved through Step 4, and after ensuring that the upholstery has (once again) fully dried, one conditions the leather using a commercially available “leather dressing” or other leather-specific conditioning produce. As with other steps in the present process, it is once again recommended that one use a lint free towel, micro fiber towel, sponge or foam applicator for this step, and apply using a circular, massage-like motion. Conditioner should be applied in multiple steps (allowing to dry between each such application) until the leather material no longer perceptibly absorbs any more conditioner.
[0027] Step 6 (Sealing/Water-Proofing/Top-coating): Use of a leather-specific sealer/water proofing completes the restoration process. To avoid staining or distorting the coloring, or displacing the previously-applied conditioning substances, one should use small amounts of the sealer/water proofer at any given time, and evenly massage it into the leather. One should use the same kinds of lint-free, remnant-free application materials as described above for other steps. One may apply this last substance in several light coats, allowing the leather to fully absorb the material, and fully dry between each such application.
[0028] Following Step 6, the leather will be (to the greatest degree possible, based on its prior condition) fully restored, sealed, and water-proofed, and will provided substantially extended life, both in durability and aesthetic appearance than is achievable through any presently-employed method or process in the upholstery preservation and restoration trade.
[0029] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention. | A process for preserving and restoring leather upholstery through steps involving use of cleaning, dye, conditioning and sealing materials, and, prior to dying or conditioning, abrading the material, in part, for restoring access to hide pores for optimizing the hide's degree and uniformity of acceptance of dye(s) and conditioner(s). | 2 |
FIELD OF THE INVENTION
The present invention relates to an apparatus for and a method of cutting a web of sheet material, such as reconstituted tobacco sheet, and more particularly to an apparatus for cutting a web of sheet material into a cut product having a desired length and width and a method of making cut filler from a sheet of reconstituted tobacco.
BACKGROUND OF THE INVENTION
In the cigarette making art, small particles of tobacco and tobacco fines resulting from the handling of tobacco leaf and the manufacture of cigarettes and other tobacco products are recycled into a web or sheet product known as reconstituted tobacco, for example, by conventional paper making processes. The webs or sheets are then cut into smaller pieces then shredded into strips useful as cut filler in the cigarette making process. Similarly, in other arts, such as plastic molding, a web of plastic sheet material may be cut into smaller pieces or chips for subsequent processing.
Typically, if the web to be cut into smaller pieces has a width greater than the desired dimensions of the final cut product, the web is slit longitudinally in the direction of travel of the web with one or more knives or cutters and is then cut transversely to the direction of travel. Alternatively, the web may be initially cut transversely across the web width to form elongated strips which are then cut into two or more strips of shorter lengths.
European Patent Publication No. 0124255 discloses one known apparatus and method of the former type for shredding a sheet material in which a longitudinally pre-slit web of reconstituted tobacco or blended leaf tobacco is fed off the end of a support table past a serrated ledger blade supported at the edge of the table. A complementary serrated blade fixed to a rotating cylinder strikes the projecting sheet portion extending past the ledger blade, penetrates the sheet and separates the projecting portion of the sheet by tearing. According to this cutter design, a clearance is maintained between the fixed ledger blade and the moving blade so that there is no interference between the blades. The absence of interference is said to be advantageous to solve the problems of blade wear, noise and blade adjustment owing to sagging of the rotating shaft of the cutter. Because the sheet material is longitudinally pre-slit, the transverse cutting or tearing of the projecting portion results in a cut product having a length equal to the spacing between the pre-slits and a width proportional to cutter speed and the feed rate of the sheet, i.e., equal to the distance the web of sheet material is advanced between successive cuts or tears by the moving blade or blades.
U.S. Pat. No. 2,335,515 to Jehle discloses a cutting method and apparatus with a fixed and a movable cutter which is used to cut a sheet of plastic material into small pieces or chips suitable for a plastic molding process. According to this patent, the movable cutter is made up of a plurality of toothed cutters arranged axially on a rotating shaft in two sets with the cutters of the first set alternating with the cutters of the second set and the teeth of the first set being circumferentially offset or staggered with the teeth of the second set. With this arrangement, rotation of the movable cutter and advancement of the sheet will cause one row of the first set of teeth to cut pieces from the sheet having a length equal to the transverse width of the teeth of the first set, then one row of the second set of teeth to cut pieces from the sheet having a length equal to the transverse width of the teeth of the second set, then the second row of the first set of teeth to cut pieces from the sheet and so on. Thus, each set of cutter teeth cuts alternate pieces from the sheet so that two rows of cutter teeth must cut the sheet to cut off pieces equal in length to one entire sheet width.
It would be desirable to provide a sheet cutting apparatus and method having a movable cutter blade that is capable of coacting with a fixed cutter blade to substantially simultaneously cut the entire width of a web of sheet material both longitudinally as well as transversely into cut pieces of desired dimensions so that pre-slitting of the sheet is unnecessary. It would also be desirable to provide a cutting apparatus having blades that are substantially self-sharpening and are characterized by substantially reduced blade wear.
SUMMARY THE INVENTION
The present invention is directed to a method of and an apparatus for cutting a web of sheet material into cut pieces having predetermined lengths and widths. According to the apparatus aspects of the invention, the sheet cutting apparatus comprises a fixed ledger blade mounted in a ledger block having a platen over which the web of sheet material is advanced by a feed roll. One or more movable cutter blades is fixed to a rotatable drum or shaft for coacting with the ledger blade to cut off a portion of the sheet projecting beyond the ledger blade in the direction of advancement of the sheet. Coaction between the cutter blade and the ledger blade substantially simultaneously cuts the projecting portion of the sheet transversely across the entire width of the sheet and longitudinally in one or more cuts in the direction of travel of the sheet.
In a first embodiment of the invention, the cut product is in the form of narrow, rectangular strips or pieces of sheet material. If the sheet material is a web of reconstituted tobacco, the strips or pieces may be used as cut filler along or in combination with cut filler made from tobacco leaf. In such case, the width of the cut filler strips may be about 1/32 inch and the length may range from about 1/2 inch to about 1 inch or more. The width of the cut strip is determined by the relationship between the rate of feed or advancement of the sheet, the rotational speed of the cutter drum or shaft and the number of cutter blades mounted to the rotatable drum or shaft.
The movable cutter blade is formed with a plurality of short, longitudinally-extending knife edges transversely spaced from one another a dimension or dimensions equal to the desired length or lengths of the cut pieces, e.g., 1/2 inch to 1 inch. Concave, generally cylindrically- or elliptically-shaped surfaces are formed between each knife edge so that the cutting face of the blade has an undulating or wave-like appearance. Each time the cutter blade or blades coact with the ledger blade a narrow strip is cut from the entire width of the web and that strip is substantially simultaneously cut by the knife edges into shorter lengths corresponding to the spacing between the knife edges.
The ledger blade is preferably made of a soft or mild steel and the cutter blade or blades is preferably made of a harder steel such as CPM 10 V. Because of the difference in hardness of the blades the ledger blade is a "sacrificial blade" and must be periodically adjusted by advancing the same toward the cutter blade so that the blades are essentially self-sharpening. It has been advantageously found with this arrangement that blade wear is relatively small, e.g., on the order of about 0.0001 inch per week, so that sharpness of the blades may be maintained by a relatively simple periodic adjustment of the ledger blade.
In a second embodiment of the invention, the ledger blade and the cutter blade or blades are provided with a complementary zigzag or sawtooth pattern or configuration. At spaced transverse intervals across the ledger and cutter blades, the sawtooth pattern is interrupted by complementary straight blade portions on the ledger and cutter blades extending at a slight angle to the longitudinal direction of feed of the web of sheet material. These blade portions coact with each other to cut the zigzag strip into lengths corresponding to the spacing between the complementary straight blade portions. This construction of the zigzag blades according to the invention is operative to cut a zigzag strip across the entire width of the web of sheet material and to simultaneously cut off the zigzag strip at spaced transverse intervals corresponding to the spacing between the straight blade portions. The ledger blade and cutting blades are made of the same materials as the corresponding blades of the first embodiment of the invention.
The straight blade portions are arranged at a slight angular inclination (about 1°) relative to the longitudinal movement of the web and to the axis of adjustment of the ledger blade. This slight angular offset from the adjustment axis is necessary to maintain the self-sharpening effect that would otherwise be absent if the straight blade portions of the ledger blade were adjustable parallel to the straight blade portions of the cutting blades. Each successive straight blade portion on the cutter blades is preferably arranged at an opposite angular inclination to the preceding straight blade portion so as to balance the transverse forces between the ledger blade and cutting blades when they coact with one another. If the angular inclination of all the straight blade portions were in the same direction, the transverse force between the blades would be substantial and could adversely affect the self-sharpening and cutting characteristics of the coacting blades.
According to a third embodiment of the invention, the ledger blade and the cutting blade or blades are provided with a complementary scalloped configuration similar to a sine wave pattern. Like the second embodiment of the invention, the scalloped pattern is interrupted at spaced transverse intervals by straight blade portions extending at a slight inclination to the direction of feed of the web or the adjustment direction of the ledger blade. These straight blade portions function in the same manner and are self-sharpening in the same way as the straight blade portions of the second embodiment.
Advantageously, the zigzag shape of the strips of the second embodiment and the scalloped shape of the strips of the third embodiment have an improved filling capacity when used as cut filler in a cigarette as compared with the narrow rectangular strips of the first embodiment. When used as cut filler, the zigzag and scalloped strips preferably have a width of about 1/2 inch to 1/16 inch, a length of about 3/4 inch to 11/2 inch and a peak-to-peak dimension of about 3/16 inch to 1/4 inch.
According to the method aspects of the present invention, the cutting method comprises the step of rotating at least one cutting blade to coact with a stationary ledger blade to substantially simultaneously cut a web of sheet material both transversely and longitudinally into cut strips or pieces, especially to form cut filler from a sheet of reconstituted tobacco.
With the foregoing and other advantages and features of the invention that will become hereinafter apparent, the nature of the invention may be more clearly understood by reference to the following detailed description of the invention, the appended claims and to the several views illustrated in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the sheet cutting apparatus of the invention;
FIG. 2 is a fragmentary side elevation detail of the cutting apparatus of FIG. 1 showing the coaction of the cutting blades;
FIG. 3 is a fragmentary detail in perspective showing the cutting surfaces of the movable cutter blade of the cutting apparatus of the invention;
FIGS. 4(a)-(c) are fragmentary top plan views of a web of sheet material showing the progression of the cuts made by the cutter blade of FIG. 3;
FIG. 5 is a fragmentary side elevation view of another embodiment of the cutting apparatus of the present invention;
FIG. 6 is an enlarged cross-sectional detail of the cutting apparatus of FIG. 5 showing the coaction of the cutting blades;
FIG. 7 is a fragmentary top plan view of the cutter blades of a second embodiment of the invention;
FIG. 8 is a top view of a cut zigzag strip or piece formed by the blades of the second embodiment of the invention;
FIG. 9 is an enlarged detail of the movable cutter blade shown in FIG. 7;
FIG. 10 is a fragmentary top plan view of a cutter blade of a third embodiment of the invention; and
FIG. 11 is a top view of a cut scalloped strip formed by the blades of the third embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now in detail to the drawings, there is illustrated in FIG. 1 a first embodiment of the sheet cutting apparatus of the invention which is designated generally by reference numeral 10. Only so much of the apparatus 10 is shown in FIG. 1 as is necessary for a complete understanding of the present invention, it being understood that other components of the apparatus, such as drive and control means for the rotatable elements and the like are necessary for operation of the apparatus.
Cutting apparatus 10 comprises a fixed cutter component 12 and a movable cutter component 14 for cutting a web W of sheet material, such as reconstituted tobacco sheet or the like, advanced from a roll 16 by a feed roller 18 in a longitudinal direction shown by arrow 20. Fixed cutter component 12 comprises a ledger block 22 on which a ledger blade 24 is mounted at an inclination in the range of about 15°-20° and rigidly clamped in place by a platen 26 fixed to the ledger block 22 by bolts (not shown) extending through openings (not shown) in the ledger blade. A plurality of ledger blade adjustment screws 28 are threadably mounted in the ledger block 22 for adjusting the ledger blade 24 in the direction shown by the arrow 30 in FIG. 2.
Movable cutter blade 14 comprises a drum 32 mounted for rotation on a shaft (not shown) for rotation in the counter-clockwise direction shown by the arrow 34. Rigidly mounted in slots the periphery of drum 32 are a plurality of cutter blades 36, four blades being shown in the FIG. 1 embodiment. While four blades 36 are shown, it will be understood that a greater or lesser number of cutter blades may be used. Typically, one to twenty-four blades are used. If the web W is reconstituted tobacco sheet, it typically would have a width of about two feet and the width of the fixed and movable cutter components 12, 14 would have a width at least the width of the web W.
Now referring to FIGS. 2 and 3, the coaction of the ledger and cutter blades 24, 36 will be described. As the web W is advanced over platen 26 by feed roll 18 in the direction 20, a portion P of the web will be projected past the uppermost edge 25 of the ledger blade 24. Cutter blade 36 has a rake angle A which may be about 5°. The underside or cutting face 38 of cutter blade 36 is shown in FIG. 3 and is formed with a plurality of knife edges 40 extending in the direction of travel 20 of the web W, i.e., perpendicular to the rotational axis of the cutter drum 32. Between knife edges 40 cutter face 38 is provided with concave surfaces 42 which may have a generally circular, elliptical, or other curvilinear shape in cross-section. The cutter face 38 thus defines a wave-like or undulating edge 39 on the front face 41 of the cutter blade 36. The spacing S between the knife edges 40 defines the lengths of the pieces cut from the projecting portion P of the web W as explained hereinafter.
Referring again to FIG. 2, rotation of drum 32 in the counterclockwise direction 34 causes the knife edges 40 of cutter blade 36 to engage the top surface of the projecting portion P of the web. Continued rotation of the drum 32 causes each of the knife edges 40 to slit or cut through the projecting portion P in the longitudinal direction of feed of the web shown by arrow 20. When the outermost tips 37 of the knife edges 40 move past the uppermost edge 25 of ledger blade 24, the coaction between such edge 25 and the undulating edge 39 of the front face 41 of the cutter blade 36 gradually cuts slits in the web in each transverse direction from the knife edges 40 until the deepest points 43 (FIG. 3) of the concave surfaces 42 or undulating edge 39 move past the uppermost edge 25 of the ledger blade 24 at which time the slits join together to cut off projecting portion P from the web W.
The above-described cutting sequence is best illustrated with reference to FIGS. 4(a)-(c). Referring first to FIG. 4(a), the web W having front edge 54 is shown at the point in time when the knife edges 40 of the cutter blade 36 have slit or at least partially slit the projecting portion P of the web along lines 44 (shown partially cut by dashed lines) which are spaced apart a distance corresponding to spacing S in FIG. 3. The tips 37 of the knife edges 40 have penetrated the web at points 46 and have moved past the uppermost edge 25 of the ledger blade 24 to a point where the coaction between edges 39 and 25 have initiated transverse slits 48, 50 propagating in opposite directions from points 46. Continued counterclockwise rotation of the cutter blade 36 relative to the ledger blade 24 as shown in FIG. 4(b) causes the knife edges 40 to slit completely through the projecting portion P as shown by solid line slits 44' and further causes coaction between edges 25 and 39 to propagate the transverse slits 48, 50 toward one another from points 46. Finally, as shown in FIG. 4(c) the transverse slits 48, 50 join one another to cut off the projecting portion P from the web along continuous slit 52 when the points 43 on the undulating edge 39 pass or coact with edge 25 thereby cutting the projecting portion P into a plurality of individual cut pieces F defined by slits 52 and 44' and front edge 54 and having a width w corresponding to the width of projecting portion P and a length l corresponding to the spacing S (FIG. 3) between knife edges 40. It will be appreciated that the width w of the cut pieces F may be varied by changing the feed rate of the web, the rotational speed of the drum 32 or the number of blades 36 on the drum or a combination of any of those changes.
The cutter blade 36 is preferably made of a hard steel, such as CPM 10 V steel, and the ledger blade is made of a soft or mild steel. Because the cutter blade is made of a harder steel than the ledger blade, the ledger blade is a "sacrificial" blade that will be maintained sharp by periodic adjustment of the ledger blade toward the cutter blade in the direction of arrow 30 (FIG. 2). As shown in FIG. 2, the end face 27 of the ledger blade 24 has a large radius from top to bottom equal to the radius of the tips 37 of the cutter blade 36 from the rotational axis of drum 32. The rake angle A, which is preferably about 5°, prevents interference between the end face 41 of the cutter blade 36 and the end face 27 of the ledger blade 24 that might otherwise cause substantial blade wear. The thickness of the cutter blade 36 and ledger blade 24 is preferably in the range of about 1/16 inch to about 1/8 inch but may be of greater or lesser thickness.
FIG. 5 illustrates another embodiment of a cutting apparatus 60 constructed according to the invention which comprises a fixed blade component 62 and a movable blade component 64. The fixed blade component 62 comprises a ledger block 66 having a ledger blade 68 mounted to the top surface thereof for slidable movement toward the movable blade component. Ledger blade 68 may be mounted for slidable movement in any suitable manner such as by a sliding block 70 bolted to the ledger blade 68 and keyed for sliding movement along a guideway 72 in the ledger block 66. Ledger blade 68 forms a platen over which a web W of sheet material, such as reconstituted tobacco sheet, is fed by means of a feed roll 74. The ledger blade 68 is adjustable in a horizontal plane toward the movable blade component 64 in the direction shown by arrow 76 by a plurality of adjustment screws 78 (only one shown). When the ledger blade 68 is properly adjusted, it may be bolted rigidly to the ledger block 66 by bolts (not shown).
The movable blade component 64 comprises a drum 80 rotatable in the direction of arrow 81 and having one or more cutter blades 82 rigidly affixed in slots in the periphery of drum 80. Cutter blades 82 preferably engage the ledger blade 68 at an angle. As shown in FIG. 5, this angular relationship may be accomplished by offsetting the rotational axis of the drum a distance D from the plane of the upper surface of the ledger blade 68. Alternatively, the upper surface of ledger blade 68 and the rotational axis of drum 80 may be in a common horizontal plane and the cutter blades 82 may be offset parallel to and clockwise from that plane, e.g., a distance D. In another possible arrangement, the cutter blades 82 may be affixed to the drum 80 at an angle to a radial line from the drum axis. The embodiment of the cutting apparatus 60 shown in FIG. 5 is especially useful for forming the zigzag or scalloped strips shown in FIGS. 8 and 11 as will be described hereinafter.
Referring now to FIGS. 6-8 which illustrate the zigzag pattern blades, and especially FIG. 6, the ledger blade 68 and cutter blade 82 are shown in enlarged detail in a cross-section taken along line E--E of FIG. 7. In FIG. 7 the blades 68, 82 have been spaced apart to show the entire blade surfaces, it being understood that in the position shown in FIG. 6 the blade 82 is in interengaging relationship with the blade 68. When the zigzag tips 84 of blade 82 engage the mating uppermost points 86 of the ledger blade 68, blade 82 is angularly offset at an angle B from the plane of the ledger blade 68. The zigzag face 88 of the cutter blade 82 is provided with a rake angle C greater than angle B to insure that there is no interference between zigzag face 88 and the zigzag face 90 of the ledger blade 68 as blade 82 rotates past blade 68. The straight complementary blade portions 85, 87 and 89, 91 are operative to cut longitudinal slits in the web which define the ends of each zigzag piece cut from the projecting portion of the web.
As in the first embodiment, the cutter blade 82 is made of a hard steel and the ledger blade 68 is a "sacrificial" blade made of a soft or mild steel. Thus, the lowermost zigzag edge of the cutter blade 82 cuts or shapes the zigzag face 90 of the ledger blade and maintains it in a sharpened condition. To accommodate the minimal wear between the blades, the ledger blade 68 is adjustable in the direction of arrow 76 by means of adjustment screws 78 (FIG. 5).
The blades 68, 82 shown in FIG. 7 when used in the apparatus 60 of FIG. 5 are operative to cut the zigzag strips 92 shown in FIG. 8 from the web W. The width X of the strips 92 as measured in the direction of web travel is, as in the first embodiment, a function of the feed rate of the web W and the rotational speed and number of cutter blades 82. The length y of the strips 92 is determined by the spacing between the complementary straight blade portions 85, 87 and 89, 91 (FIG. 7) which coact to cut longitudinal slits in the web W defining the ends 94, 96, respectively, of the strip 92.
The complementary straight blade portions 85, 87 and 89, 91 are preferably disposed at a slight angle of about 1° to the longitudinal direction of adjustment of the ledger blade 68 so that the straight blade portions are self-sharpening. It will be appreciated that if the straight blade portions are oriented parallel to the adjustment direction, the straight blade portions 85, 89 of the cutter blade 82 will not be operative to sharpen the straight blade portions 87, 91 of the sacrificial ledger blade 68. Preferably, the blade portions 85, 87 are arranged at a small angular inclination opposite to that of the straight blade portions 89, 91 so that the transverse force generated between the blade portions 85, 87 when those portions coact will be counterbalanced by the transverse force generated between the blade portions 89, 91 when those portions coact. It should be apparent that the number of coacting straight portions 85, 87 of the blades should be equal to the number of oppositely inclined coacting straight blade portions 89, 91 to exactly counterbalance the transverse forces between the blades 68, 82.
FIG. 9 illustrates in enlarged detail the small inclination angle I of straight blade portion 85 of cutter blade 82 which is necessary to sharpen the straight blade portion 87 of the ledger blade 68. Preferably, the angle I is about 1°.
FIG. 10 illustrates the cutter blade 100 of a third embodiment of the invention in which the blade pattern is scalloped or generally sinusoidal in shape. The blade 100 can be used in the apparatus 60 of FIG. 5 with a complementary shaped ledger blade (not shown). In cross-section taken longitudinally through one of the peaks 102 of the blade 100, the coacting cutter blade 100 and its ledger blade (not shown) will have essentially the same cross-sectional appearance as that shown in FIG. 6. Similarly, the straight blade portions 104, 106 have the same form, inclination and function as the straight blade portions 85, 89 respectively, of the blade 82 of the second embodiment. As also shown in FIG. 10, the straight blade portions 104, 106 are oppositely inclined to counter-balance the transverse forces caused by coaction of the complementary straight blade portions of the blade 100 and its ledger blade.
FIG. 11 shows one of the plurality of strips 108 that is cut from a projecting portion of the web W by a single cut by the cutter blade 100 in which the length m of the strip 108 is determined by the spacing between blade portions 104 and 106, and the width n is determined as in the second embodiment by the feed rate of the web W and the rotational speed and number of cutter blades. The third embodiment of the invention differs from the second embodiment only in the blade pattern and shape of the cut strip.
Although only preferred embodiments are specifically illustrated and described herein, it will be appreciated that many modifications and variations of the present invention are possible in light of the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention. | A sheet cutting apparatus and a method of cutting tobacco sheet into cut filler are disclosed. The apparatus comprises a fixed ledger blade and a rotatable cutter blade coacting with the ledger blade to simultaneously cut the tobacco sheet transversely and longitudinally into cut pieces useful as cut filler in a cigarette making process. The cut pieces may have a rectangular, zigzag or scalloped shape according to different embodiments of the invention. | 8 |
CROSS REFERENCE TO OTHER APPLICATIONS
[0001] The present application is related to a patent application entitled “Frequency shifting based interference cancellation device and method” (Attorney Docket No. 4424-P04911US0) filed concurrently herewith. The entire disclosure of the foregoing application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The field of the present invention relates to an interference signal cancellation device, used for example, in a receiver used in a base transceiver station (BTS) of a mobile communications network. The field of the present invention further relates to a method for interference cancellation on a disturbed signal comprising an interference signal. The field of the present invention also relates to a computer program product enabling a foundry to carry out the manufacture of an interference cancellation device, and to a computer program product enabling a processor to carry out the method for interference cancellation.
BACKGROUND OF THE INVENTION
[0003] In a “classic” design of radio communication systems the transmitter and the receiver comprise hardware to ensure a certain degree of selectivity in the frequency band. The hardware can be filters, oscillators, mixers or other components. The dedicated hardware allows the transmitter or the receiver to be tuned to a relatively narrow frequency range, often termed “channel”.
[0004] A more modern concept is the so-called “software-defined radio system”. In the software-defined radio system, components that have typically been implemented in hardware (e.g. mixers, filters, amplifiers, modulators/demodulators, detectors etc.) are instead implemented using software. The software-defined radio system became interesting from a commercial point of view when digital circuits with sufficient calculating power became available at reasonable prices. The software-defined radio system makes it possible to use relatively generic electronic components because significant parts of the way a signal is processed can be defined in software. Thus, the software-defined radio system can be, in principle, updated to support new radio protocols or modifications in existing radio protocols.
[0005] Software-defined radio systems make use of analogue-to-digital converters or digital-to-analogue converters. The analogue-to-digital converters and the digital-to-analogue converters usually have a limited bandwidth, a limited frequency range and a limited dynamic range. Due to these limitations, the analogue-to-digital converter may not be able to process an incoming analogue signal in the intended manner, such as extracting a wanted signal at a specific frequency within a wideband analogue signal. This inability of the analogue-to-digital converter may be due to an insufficient signal-to-noise ratio or a strong blocker within the frequency range that is observed by the analogue-to-digital converter.
[0006] Mobile communications networks are still constantly developing with the aim to increase the volume of data that can be transmitted in a certain geographic region and within a certain time. This effort may lead to constantly evolving mobile communications standards so that the software-defined radio system appears to be a good choice for an operator of the mobile communications network. Base transceiver stations (BTS) operated by the mobile network operator can be updated and adapted to a number of future mobile communications standards. A well known standard for mobile communications networks is the GSM standard (Global System for Mobile Communications). The GSM standard has been in use for commercial applications since the early 1990's and continues to be used, at least in some regions. Other standards that may succeed the GSM standard are for example the UMTS and the LTE (Long Term Evolution) standards. The mobile communications standard may define certain tests that the equipment operating under this particular mobile communications standard needs to pass. For example, the specification of the GSM standard contains a blocker test for a GSM receiver. A blocker is a strong interfering signal of which the frequency is close to, or even within, the frequency range of the wanted signal. The GSM specification requires the signal blocker at −16 dBm or −25 dBm to be handled. At a level of −16 dBm a noise figure of 9 dB is permitted. This allows an attenuator to be switched in to reduce the blocker level. In the other case the blocker level is reduced to −25 dBm and the relaxation of using an attenuator is no longer permitted.
[0007] U.S. Pat. No. 4,739,518 issued to Beckley et al. describes a receiver interference suppression system. A received signal is distributed to two single paths, one of which provides a constant amplitude signal and the other of which provides a limited signal. The constant amplitude and the limited signals combine through a subtraction operation resulting in a significant attenuation of the interfering signal while causing only a small attenuation of a desired signal. The receiver interference suppressions system taught in U.S. Pat. No. 4,739,518 uses a limiter which typically creates broad band interference due to its severe non-linearity when limiting. In frequency modulation (FM) receivers, to which U.S. Pat. No. 4,739,518 relates, a broad band interference may be acceptable, since the carriers and blockers in a FM transmission system are typically constant-envelope and hence no loss of signal fidelity occurs when passing through a limiter. For a couple of transmission techniques other than FM the use of the limiter would create the same problem that the receiver interference suppression system is trying to solve, namely that of overload/non-linearity in the receive path, due to the presence of a strong interferer, causing distortion which masks a weak wanted signal and can also cause distortion of the wanted signal itself. This will result in a degradation of the error vector magnitude of the signal, for example, thereby making the signal difficult or impossible to demodulate. The teachings of the entire disclosure of U.S. Pat. No. 4,739,518 are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0008] It would be desirable to have a structure for cancelling a blocker or interference signal wherein such an interference cancellation structure would add no or only little broad band interference to the processed signal. It would also be desirable that such an interference cancellation structure works with a subsequent analogue-to-digital converter. To address at least one of these concerns and/or possible other concerns an interference signal cancellation device is proposed. The interference signal cancellation device comprises a signal splitter, a delay element and a signal combiner. The signal splitter distributes a disturbed signal to a first signal path and a second signal path. The first signal path and the second signal path have substantially linear behaviour. The delay element is located in the first signal path or the second signal path. In the alternative, both the first signal path and the second signal path could comprise an individual delay element. The delay element introduces a relative delay between a first signal in the first signal path and a second signal in the second signal path. The signal combiner combines the first signal and the second signal. An interference signal within the disturbed signal is substantially reduced within the signal combiner due to the relative delay difference between the two paths.
[0009] Under the assumption that the relative delay is chosen in correspondence to a main frequency of the interference signal, portions of the interference signal in the first signal path and the second signal path are substantially reduced out in the signal combiner due to a destructive superposition. The remainder of the disturbed signal, such as a wanted signal, is relatively unaffected by the introduced relative delay and the action of the signal combiner because the main frequency of the interference signal is different from a frequency of the wanted signal.
[0010] The interference signal cancellation device can be used in connection with a software-defined radio system, because the substantially linear behaviour of the first signal path and the second signal path prevents excessive intermodulation. Thus, the frequency range covered by the disturbed signal is not or at least only to a small extent, enlarged, diminished or shifted. This preservation of the covered frequency range usually reduces problems in a subsequent analogue-to-digital converter, such as increased noise level. A non-linearity in the first signal path and/or the second signal path would typically lead to a degradation of the error vector magnitude of the signal. A consequence of a high error vector magnitude is often a high received bit-error rate. Reducing or eliminating the non-linearities in the first signal path and the second signal path avoids these problems.
[0011] The delay element does not necessarily have to be a dedicated delay element but could be an element that is present anyway in the first signal path or the second signal path. For example, most types of filter introduce a delay. It is also possible to use a combination of a dedicated delay element and an element that is present in the first signal path or the second signal path and also introduces a delay.
[0012] At least one of the first signal path and the second signal path may comprise a filter. In a wideband signal it is possible that the relative delay causes a destructive superposition not only for the interference signal, but also at other frequencies. Depending on the application, it may not be desirable to cancel portions of the wideband signal at those frequencies where destructive superposition occurs. For example, it could be that a payload signal of another channel happens to be at a frequency that is affected by destructive superposition due to the relative delay. The filter in at least one of the first signal path and the second signal path is able to prevent such destructive superposition.
[0013] It would be desirable that the first signal and/or the second signal can be adjusted in amplitude and/or phase so that an interference signal portion present in the first signal and an interference signal portion present in the second signal can be matched for the best possible destructive superposition. This concern and/or possibly other concerns are addressed by at least one of the first signal path and the second signal path comprising at least one of a gain controller and a phase controller. The gain controller may be provided for adjusting an amplitude of at least one of the first signal and the second signal. The phase controller may be provided for adjusting a phase of at least one of the first signal and the second signal.
[0014] As an alternative to a gain controller and a phase controller the at least one of the first signal path and the second signal path may contain a vector modulator for adjusting at least one of: the amplitude of the first signal, the phase of the first signal, the amplitude of the second signal, and the phase of the second signal.
[0015] At least one of the first signal path and the second signal path may comprise an amplifier. Among other purposes, the amplifier may be useful to compensate for an attenuation of the first signal or the second signal. The attenuation of the first signal or the second signal might be caused by elements within the first signal path or the second signal path, respectively, such as the filter, the gain controller, the phase controller or the delay element.
[0016] It would be desirable that the interference signal cancellation device can be adjusted to cancel (or reduce) interference signals occurring at different frequencies. This aspect and/or possibly other aspects are addressed by the delay element having an adjustable delay.
[0017] The interference signal cancellation device may further comprise a cancellation controller. At least one of the first signal path and the second signal path may comprise at least one of a gain controller and a phase controller (or alternatively a vector modulator) for adjusting at least one of an amplitude of the first signal, a phase of the first signal, an amplitude of the second signal, and a phase of the second signal. The cancellation controller may be adapted to control the adjusting of at least one of the amplitude of the first signal, the phase of the first signal, the amplitude of the second signal, and the phase of the second signal. The function of the gain controller and of the phase controller has already been discussed above. Besides the delay element, the cancellation controller also controls the gain controller and/or the phase controller in the first signal path and/or the second signal path. In an alternative embodiment, it is possible that the delay element has a fixed delay and that the cancellation controller controls the phase controller in order to match the interference signal portion in the first signal path and the interference signal portion in the second signal path to achieve the desired destructive superposition.
[0018] It would be desirable that in a receiver structure having a plurality of similar or identical receive paths, such as in a receiver structure connected to an antenna array, interference signal cancellation could be achieved for all of the receive paths and with little structural overhead. This aspect and/or possible other aspects are addressed by the cancellation controller controlling a plurality of at least one of gain controllers and phase controllers, each one of the gain controllers or phase controllers being part of an individual receive path in a group of similar or identical receive paths. For example, if the group of similar or identical receive paths is connected to the antenna array, the relative phase of the interference signal within the individual receive path depends on the location of the interference signal source relative to the antenna array. The same is true for the phase of the wanted signal within the individual receive path and a location of the source of the wanted signal relative to the antenna array. The proposed arrangement allows an adjustment of the interference signal's amplitude and phase independent from any gain and phase adjustments for the desired signal.
[0019] The above-mentioned aspects may also be addressed by the interference signal cancellation device being adapted for a plurality of similar or identical receive paths, wherein the interference cancellation device further comprises an interference signal splitter and additional signal combiners in each one of the plurality of receive paths. The interference signal splitter may be adapted to distribute the first signal to the plurality of additional signal combiners. The additional signal combiners may be adapted to combine the distributed first signals with distributed second signals, each of the distributed second signals relayed by one of the plurality of receive paths, respectively.
[0020] The delay element may introduce a portion of the relative delay, wherein that portion introduced by the delay element is common for several or even all receive paths among the plurality of receive paths. The delay element may be regarded as “shared” between several or all receive paths. With a shared delay element the number of delay elements can be reduced possibly to a single delay element.
[0021] The interference signal cancellation device may further comprise a plurality of at least one of gain controllers and phase controllers acting on the distributed first signal.
[0022] The interference signal may be an in-band blocker or an out-band blocker.
[0023] The present disclosure further provides a method for interference cancellation on a disturbed signal comprising an interference signal. The method comprises splitting the disturbed signal into a first signal and a second signal, time delaying at least one of the first signal and the second signal by a relative delay between the first signal and the second signal, and combining the first signal and the second signal for substantially reducing the interference signal within the disturbed signal due to the introduced delay. The first signal and the second signal undergo substantially only linear processing between splitting and combining.
[0024] The method may further comprise identifying an interference signal by at least one of frequency, amplitude and phase, and adjusting the delay between the first signal and the second signal so as to optimize the cancelling (or reduction) of the interference signal.
[0025] The action of identifying an interference signal may comprise determining whether the disturbed signal causes an overload.
[0026] The present disclosure further provides a computer program product embodied on a computer-readable medium and the computer-readable medium comprising executable instructions for the manufacture of an interference cancellation device as described herein.
[0027] The present disclosure also provides a computer program product comprising instructions that enable a processor to carry out the method as described herein.
[0028] As far as technically meaningful, the technical features disclosed herein may be combined in any manner. The interference signal cancellation device and the method for interference cancellation may be implemented in software, in hardware, or as a combination of both software and hardware.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 shows a receiver arrangement with an interference signal cancellation device according to a first possible configuration.
[0030] FIG. 2 shows a receiver arrangement with an interference signal cancellation device according to a second possible configuration.
[0031] FIG. 3 shows a receiver arrangement with an interference signal cancellation device according to a third possible configuration.
[0032] FIG. 4 shows a receiver arrangement with two interference signal cancellation devices.
[0033] FIG. 5 shows a multi-receiver arrangement with a plurality of interference signal cancellation devices.
[0034] FIG. 6 shows a multi-receiver arrangement with a common interference signal cancellation device.
[0035] FIG. 7 shows a flowchart of one possible algorithm for the identification of an in-band-blocker.
[0036] FIG. 8 illustrates the form of the cancellation characteristic and its effect on the blocker signal and on a wanted signal.
DETAILED DESCRIPTION OF THE INVENTION
[0037] The invention will now be described on the basis of the drawings. It will be understood that the embodiments and aspects of the invention described herein are only examples and do not limit the protective scope of the claims in any way. The invention is defined by the claims and their equivalents. It will be understood that features of one aspect can be combined with a feature of a different aspect or aspects.
[0038] FIG. 1 shows a receiver arrangement or a receive path that may be used in a base-station of a mobile communications network. A signal from a remote transmitter is received at an antenna 101 . The antenna 101 is connected to a duplex filter 102 that separates a transmission path from the receive path in the frequency domain. Instead of a duplex filter, other techniques may be used, such as a circulator or time multiplexing. The signal arriving from the transmission path is illustrated as the input to the upper part of the duplex filter 102 . The lower part of the duplex filter 102 filters the part of the spectrum that is reserved for a receive band of the base-station in a mobile communications network. The duplex filter 102 is connected to a low noise amplifier (LNA) 103 that amplifies the filtered antenna signal to a level at which further signal processing may be performed. The output of the low noise amplifier 103 is connected to a signal splitter 104 . The signal splitter 104 distributes the signal received from the LNA 103 to a first signal path and a second signal path. The first signal path comprises a delay element 105 and a bandpass filter 106 . The second signal path (blocker cancellation path) comprises a buffer amplifier 110 and a gain/phase controller 111 . An alternative to the gain/phase controller 110 is a vector modulator. The upper signal path in FIG. 1 may be regarded as a main receive path and the lower signal path may be regarded as a blocker cancellation path. In the blocker cancellation path the signal undergoes some buffer amplification in the buffer amplifier 110 to overcome the losses in the gain/phase controller 111 . The signal in the main receive path, meanwhile, has undergone receive-bandpass filtering in the bandpass filter 106 and, if required, a further time delay in the delay element 105 . Depending on the circumstances, the time delay introduced by the bandpass filter 106 might already be sufficient for the purposes of interference signal cancellation so that the bandpass filter 106 , in this case, also assumes the role of the delay element 105 . The first signal path and the second signal path are both connected to a signal combiner 107 in which the signal in the second signal path is subtracted from or added to the signal in the first signal path. Due to the time delay in the first signal processing path the two signals arriving at the signal combiner 107 will have experienced very different path delays so that the cancellation achieved can be assumed to be narrow band. The cancellation can be tuned by the gain/phase controller 111 to cancel the blocker leaving the wanted signals relatively untouched. Leaving the wanted signals relatively untouched while significantly reducing the blocker is assumed to be possible due to the achieved narrow band cancellation, even if the blocker signal is spaced only a few megahertz away from the wanted signals.
[0039] An output of the signal combiner 107 is connected to an analogue-to-digital converter 108 which is assumed to be of a delta-sigma type in FIG. 1 . Other types of analogue-to-digital converters may be used, as will be illustrated and explained below. The delta-sigma modulator 108 in the receiver arrangement shown in FIG. 1 converts an analogue signal received from the signal combiner 107 to a digital signal that may be processed by a digital signal processor (DSP) 109 . Another function of the delta-sigma modulator 108 may be a frequency translation from a radio frequency (RF) of the analogue signal to a base band frequency or an intermediate frequency (IF) of the digital signal. In a software-defined radio system the DSP 109 may now perform any necessary action to extract one or several payload signals from a digitised signal generated by the delta-sigma modulator 108 . The DSP 109 may output the payload signal in the form of an in-phase component I and a quadrature component Q. The DSP 109 may also perform one or several functions relative to the interference signal cancellation achieved by the interference signal cancellation device. For example, the quality of the cancellation process can be assessed by the DSP 109 , based upon the level of residual blocker signal remaining in the converted received signal. The DSP 109 can then adjust the gain and phase controllers, as required, improving or optimizing cancellation of the blocker. This function of the DSP 109 is performed by a portion 112 of the DSP 109 or a module in the programming of the DSP 109 .
[0040] As a variation to the configuration of the interference signal cancellation device illustrated in FIG. 1 , the time delay element could also be located in the lower path. In this position, the value of the time delay would take account of the delay in the receive bandpass filter 106 so that a relative delay between the first signal and the second signal corresponds to the required delay for achieving cancellation of the blocker signal.
[0041] FIG. 2 shows a similar arrangement to that of FIG. 1 , except that in this case a conventional analogue-to-digital converter 208 is assumed together with a single-stage of analogue down conversion and a digital input to the DSP 109 at an intermediary frequency IF. Elements in FIG. 2 that are substantially identical or equivalent to corresponding elements illustrated in FIG. 1 bear the same reference numerals and will normally not be explained again. This also applies to the other figures.
[0042] The first signal path in FIG. 2 comprises a mixer 205 , for example a down conversation mixer. Likewise, the second signal path comprises a mixer 204 . Both mixers 204 and 205 receive a local oscillator signal from a local oscillator 201 . The first signal path now comprises an IF bandpass filter 206 instead of the bandpass filter 106 . The second signal path comprises also an IF bandpass filter 207 . The IF bandpass filters 206 and 207 are relatively wideband. The basic operation of the receiver arrangement shown in FIG. 2 is the same as that described in connection with FIG. 1 , with the exception that subtraction occurs at the intermediary frequency (IF), prior to analogue-to-digital conversion,
[0043] FIG. 3 shows an alternative arrangement to that of FIG. 2 . In this case, the cancellation process occurs at radio frequency (RF), prior to the down conversion and filtering operations. The output of the signal combiner 107 is connected to a mixer 305 that performs a down conversion from the radio frequency to the intermediary frequency. The mixer 305 receives a local oscillator signal from a local oscillator 301 . Performing the interference signal cancellation directly at radio frequency may make it possible to use a carrier wave component of the interference signal in the cancellation process. Typically, a carrier wave is relatively periodic so that a good cancellation performance may be expected.
[0044] FIG. 4 shows a receiver arrangement with a first interference signal cancellation device and a second interference cancellation device to cancel two different interference signals or blockers. The configuration of each interference signal cancellation device is similar to the configuration shown in FIG. 3 . An additional blocker cancellation path comprising the second interference cancellation device is connected to the signal splitter 104 . The additional blocker cancellation path comprises a buffer amplifier 410 and a gain/phase controller 411 . The gain/phase controller 411 receives control signals from the cancellation controller 112 so that the additional blocker cancellation path can be adjusted to cancel a further blocker.
[0045] The principle shown in FIG. 4 may be extended to a configuration with a plurality of blocker cancellation paths to cancel a corresponding number of blockers or interference signals. In other words, the signal splitter 104 may distribute the signal received from the LNA 103 to a plurality of blocker cancellation paths.
[0046] It is also possible to duplicate or multiply the configurations of the interference cancellation device shown in FIGS. 1 , 2 , 5 , and 6 in a manner analogous to the configuration shown in FIG. 4 .
[0047] FIG. 5 extends the principles of FIG. 1 to a multi-receiver arrangement, such as that found in an antenna-embedded radio system. The multi-receiver arrangement is connected to the antenna array having n antenna elements 101 . Each one of the antenna elements 101 is connected to an individual one of the plurality of receive paths via a plurality of duplex filters 102 . Accordingly, the multi-receiver arrangement comprises n receive paths. Each receive path comprises an interference signal cancellation device as illustrated in FIG. 1 and as described in the context relative thereto. The different interference signal cancellation devices in the different receive paths may need to be adjusted in amplitude and phase in an individual manner, because a location of a source of the interference signal relative to the antenna array may have an influence on the amplitude and the phase relation of the interference signal. Some properties of the interference signal are, however, the same for all interference signal cancellation devices, such as the frequency of the interference signal. The digital signal processor 109 can perform a combined analysis of all signals received from the plurality of delta-sigma modulators 108 to determine whether the interference signal has been sufficiently cancelled in the various receive paths. The DSP 109 may further determine improved adjustments that are valid for all interference signal cancellation devices.
[0048] FIG. 6 shows another multi-receiver arrangement in which the interference signal cancellation device implements a “single-extraction/multiple-cancellation “scheme of the teachings disclosed herein. The identification or extraction of the interference signal is performed only once within the n′th receive path. As in FIG. 1 , the signal splitter 104 distributes the signal to a first signal path and a second signal path. In contrast to the configuration shown in FIG. 1 , the delay element 105 is now in the second signal path, because in this manner only a single delay element 105 is necessary, instead of n delay elements. An output of the delay element 105 in the second signal path is connected to a signal splitter 605 that distributes the second signal to a plurality of gain/phase controllers within the various receive paths. According to a gain setting and a phase setting of a corresponding one gain/phase controller within the plurality of gain/phase controllers the second signals are adjusted individually on a per-receive path basis, in order to achieve good cancellation in each of the plurality of receive paths. The adjustment of the plurality of gain settings and phase settings is performed by the cancellation controller 112 within the DSP 109 .
[0049] The fact that at least a portion of the elements does not need to be duplicated on a per-receive path basis saves cost, size and weight. Once interference has been identified, the interference signal's location in the frequency spectrum can be used to control the individual gain/phase controllers for subtraction of the interference signal from each receive path.
[0050] In some configurations it may be possible to process the amplitude of the blocker only once, since it may be equal for all antenna elements—only the phase-shift element may require replication for each receiver. In this case, an amplitude controller may be placed in the common part of the interference signal cancellation device, e.g. between the time delay element 105 and the signal splitter 605 . It may also be possible to omit the amplitude controller and to use the buffer amplifier 110 to adjust the amplitude.
[0051] FIG. 7 illustrates one possible algorithm for the identification of an in-band blocker. The algorithm may be performed, for example, by the DSP 109 and the cancellation controller 112 . At block 701 the algorithm begins. At block 702 the wanted signal(s) and the blocker signal(s) are received from the analogue-to-digital converter(s). At a decision point 703 it is determined, whether the analogue-to-digital converter(s) is/are overloaded. An in-band blocker that does not overload the analogue-to-digital converter is not a problem to the system, as this can be dealt with using the usual receiver digital filtering, for example performed by the software-defined radio system. Thus, in the case in which the analogue-to-digital converter (ADC) is not overloaded the algorithm continues with block 704 in order to process the received signals and to send the I/Q data to appropriate equipment within the base-station and/or the mobile communications network. In the other case the ADC is overloaded and the algorithm initiates, at block 705 , a search for the largest signal, as this is likely to be the blocker signal.
[0052] This search for the blocker signal could take many forms, such as a Fast Fourier Transformation (FFT), plus identification of the largest value and identification of its corresponding frequency bin; a scan utilizing a digital local oscillator and digital filter, to search for the largest peak etc. Once the largest signal has been found, a quick assessment can be made, at block 706 , to ascertain whether or not it is likely to be the blocker signal (e.g. whether the largest signal is in the owning-operator's frequency allocation for the product's site—if so, the largest signal is unlikely to be the blocker signal). If the largest signal is not the blocker signal the algorithm goes on to block 707 and signals a receiver overload condition to a failure management system of the base-station, for example. If, in the contrary case, the largest signal is indeed identified as the blocker signal, then the algorithm continues with block 709 to adjust the gain and the phase controls in one direction. It is, in principle, also possible to adjust the delay value to provide anti-phase cancellation.
[0053] The effect of this gain/phase variation is checked at a decision point 710 . If the blocker signal could be reduced then it can be assumed that the gain/phase variation in said one direction leads to better cancellation of the blocker signal. In the contrary case it might be that a best possible minimum of level of a residual blocker signal has already been reached. This is checked at a decision point 711 . The algorithm ends at a block 712 , if the blocker signal is already low enough. The algorithm continues at a block 613 if the blocker signal is not yet low enough. At a block 713 it is attempted to vary the gain/phase controls in another direction. Again, it is checked whether the gain/phase variation had a positive effect on the cancellation performance, at a decision point 714 . If the blocker signal could be reduced, then the method returns to a block 713 in order to perform further variation of the gain and/or the phase in said other direction. In the other case, the algorithm goes on at a decision point 715 where it is determined whether the blocker signal is already low enough. If the blocker signal is low enough, the algorithm ends at block 716 . In the contrary case, the algorithm jumps back to the block 709 to attempt another variation of the gain and/or the phase controls in said one direction. The algorithm will run periodically to check whether the blocker has reduced in level or disappeared or whether a new blocker has appeared and will act accordingly, as just described.
[0054] Diagram a in FIG. 8 illustrates the form of the cancellation characteristic which results from an intentional delay mismatch in a cancellation process. The width of the notch is determined by the number of cycles of delaying mismatch—the greater the number of cycles the narrower the notch width.
[0055] Diagram b in FIG. 8 shows the impact of this notch upon the blocker signal and a wanted signal: the blocker signal is significantly attenuated (40-50 dB is realistic for a narrow band, e.g. GSM blocker) and the wanted signal remains virtually untouched. A GSM blocker test according to the specifications takes place with a blocker offset of at least 1 MHz from the wanted carrier (3 MHz for the more stringent requirements). This distance in the frequency between the wanted signal and the blocker signal allows a realistic notch width to have a significant impact upon the blocker signal, but little or no impact upon the wanted signal. The mathematical derivation of the time delay required for a given level of cancellation, at a given frequency offset from “perfect” cancellation, can be found in the text book “High Linearity RF Amplifier Design “by P. B. Kenington, Boston, USA: Artech House, 2000, ISBN 1580531431, Chapter 5, the entire disclosure of which is incorporated herein by reference.
[0056] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example, and not limitation. It will be apparent to persons skilled in the relevant arts that various changes in form and detail can be made therein without departing from the scope of the invention. In addition to using hardware (e.g., within or coupled to a central processing unit (“CPU”), micro processor, micro controller, digital signal processor, processor core, system on chip (“SOC”) or any other device), implementations may also be embodied in software (e.g. computer readable code, program code, and/or instructions disposed in any form, such as source, object or machine language) disposed for example in a computer useable (e.g. readable) medium configured to store the software. Such software can enable, for example, the function, fabrication, modelling, simulation, description and/or testing of the apparatus and methods describe herein. For example, this can be accomplished through the use of general program languages (e.g., C, C++), hardware description languages (HDL) including Verilog HDL, VHDL, and so on, or other available programs. Such software can be disposed in any known computer useable medium such as semiconductor, magnetic disc, or optical disc (e.g., CD-ROM, DVD-ROM, etc.). The software can also be disposed as a computer data signal embodied in a computer useable (e.g. readable) transmission medium (e.g., carrier wave or any other medium including digital, optical, analogue-based medium). Embodiments of the present invention may include methods of providing the apparatus described herein by providing software describing the apparatus and subsequently transmitting the software as a computer data signal over a communication network including the internet and intranets.
[0057] It is understood that the apparatus and method describe herein may be included in a semiconductor intellectual property core, such as a micro processor core (e.g., embodied in HDL) and transformed to hardware in the production of integrated sequels. Additionally, the apparatus and methods described herein may be embodied as a combination of hardware and software. Thus, the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | An interference signal cancellation device comprises a signal splitter, a delay element and a signal combiner. The signal splitter distributes a disturbed signal to a first signal path and a second signal path. The delay element is situated in at least one of the first signal path and the second signal path for introducing a relative delay between a first signal in the first signal path and a second signal in the second signal path. The signal combiner combines the first signal and the second signal. An interference signal within the disturbed signal is substantially reduced within the signal combiner. A method for interference signal cancellation is also proposed. Furthermore, a computer program product with instructions for the manufacture and a computer program product enabling a processor to carry out the method for interference signal cancellation are also proposed. | 7 |
This application is a continuation of international PCT application Ser. No. PCT/EP02/05479, filed May 17, 2002, which was published in English as WO 02/094584 A1 on Nov. 28, 2002, and which is incorporated by reference.
BACKGROUND
The present invention relates to tires. More particularly it relates to a tire having a rim protector acting as an anchorage point for at least one carcass-type reinforcement structure.
The reinforcement of tire carcasses is currently formed by one or more plies (conventionally termed “carcass plies” from the manufacturing process in the form of semi-finished products as plies), provided with cord reinforcements which are usually radial. The anchoring or support of these plies or reinforcements is effected conventionally by turning up a portion of the ply around a bead wire disposed in the bead of the tire.
Furthermore, there are currently tires which do not have the traditional turning-up of the carcass ply around a bead wire, nor even a bead wire in the traditional sense of this element. For example, the specification EP 0 582 196 describes a means of contriving a carcass-type reinforcement structure in the beads, by disposing adjacent to the reinforcement structure circumferential filaments, the whole being embedded in a rubber anchoring or bonding mix, preferably with a high modulus of elasticity. Various arrangements are proposed in this specification. The specification further refers to tires manufactured without the aid of semi-finished products in the form of plies. For example, the cords of the various reinforcement structures are applied directly to the adjacent layers of rubber mixes, the whole being applied by successive layers on to a core having a form whereby it is possible to obtain directly a profile related to the final profile of the tire being manufactured. Thus, in this case, rather than “carcass plies” in the conventional sense, more specifically “carcass-type reinforcements” are found.
The anchoring of the reinforcement structure or carcass ply (if the tire is assembled with various semi-finished products, including a carcass ply) is of particular importance in order to ensure durability of the tire. The realisation of durable and reliable anchorage often involves using a large area of the bead and using high-quality materials, which is therefore costly. The presence of cord windings or a bead wire further implies a large mass.
Furthermore, the specifications of motor vehicle manufacturers on the one hand and standards in force in the various countries on the other mean that, for a tire of a given dimension, one finds a rim also of given dimensions. These technical standards mean that it is more difficult to get away from the usual compromise of the conventional anchoring found in tires of known types. The manufacturers of tires therefore generally use other architectural elements than beads and anchorings in order to optimise the features of the product.
SUMMARY OF INVENTION
Thus the invention proposes a tire comprising at least one carcass-type reinforcement structure anchored on each side of the tire in a bead whose base is intended to be mounted on a rim seat, each bead extending radially outwardly by a sidewall, the sidewalls radially outwardly joining a tread, the carcass-type reinforcement structure extending circumferentially from the bead to the sidewall, and a crown reinforcement, each of the beads further comprising a main anchoring zone for supporting the reinforcement structure, the tire comprising, in a position that is radially outward from the anchoring zone, a rim protector provided with a rubber projection extending axially outwardly from the sidewall and comprising at least one secondary anchoring zone comprising a plurality of circumferential cord windings, the windings cooperating with an adjacent portion of a secondary reinforcement structure via a rubber anchoring mix.
As its name indicates, the rim protector provides a bearing point extending axially beyond the rim: in the case of impact or friction against an attacking element, e.g. a pavement, the rim protector prevents contact with the rim. In this case, slight deterioration of the rim protector, such as a scratch or graze which is generally barely visible and above all has no effect on the lifespan of the tire, is preferred to deterioration of the rim, which would often be more easily visible.
Furthermore, the presence of the secondary anchoring zone in the rim protector helps to lend rigidity thereto in order to improve its strength and durability.
Furthermore, the use of the rim protector in order to provide therein a secondary anchoring zone makes it possible to optimise the use of the rim protector as such. Thus there is benefit to be gained from the available space in the rim protector, freeing the bead, which thus benefits from a larger available volume for disposing the various constituent elements. Since anchoring is distributed between the bead and the rim protector, new architectural or design possibilities are opened up, for example permitting the use of the restricted space of the bead in an optimum manner. Thus, for example, the presence of the secondary anchoring zone at the rim protector helps greatly to improve the behaviour of the tires, in particular resistance to drift.
Furthermore, the use of alignments or windings of cord in cooperation with a rubber anchoring mix, preferably with a high modulus of elasticity, and preferably in cooperation also with an adjacent portion of reinforcement structure, helps to separate rigidities. Therefore, it is thus possible to increase the transverse rigidity whilst keeping the radial rigidity unchanged.
The secondary reinforcement structure is preferably a structure portion extending from the rim protector to a portion of the sidewall located radially outwardly. According to a preferred embodiment of the invention, the secondary structure cooperates with the first reinforcement structure.
According to a first advantageous embodiment of the invention, the secondary reinforcement structure extends from one sidewall of the tire to the other along a meridian path substantially adjacent to the first carcass-type reinforcement structure. The tire therefore comprises two reinforcement structures.
In a second advantageous embodiment of the invention, the secondary reinforcement structure consists of a plurality of sections of carcass-type reinforcement structure of limited circumferential length, whose axial position is apart from the two other adjacent circumferential sections from the sidewall to the rim protector. These may be portions of the main reinforcement structure of which certain portions are uncoupled starting from a certain position along the sidewall, which is radially exterior to the rim protector, in order to extend radially inwardly and axially outwardly from the point of separation towards the secondary anchoring zone. The tire is thus formed of a circumferential alternation between uncoupled zones on one hand, and non-uncoupled or single-structure zones up to their anchoring in the bead on the other.
The main anchoring zone may advantageously be realised in particular according to two main types of structure: first of all, it comprises a plurality of circumferential windings cooperating with the adjacent reinforcement structure portion via a rubber anchoring mix. According to the second type, it comprises a bead wire about which a carcass-type structure portion is at least partially wound or turned.
According to an advantageous embodiment of the invention, the rubber mix of the secondary anchoring zone is similar to that of the main anchoring zone. The conception and manufacture of the tire are therefore simplified. Homogeneity of certain properties is also obtained.
According to an advantageous example, at least one of the anchoring zones comprises or is generally formed of a rubber mix with a high modulus of elasticity. This mix may for example be provided on only one side of the cord alignments. A high modulus helps to effect optimum anchoring. By way of non-limiting example, the modulus of elasticity of such a mix may reach or even exceed 15 Mpa, and even in some cases reach or exceed 40 Mpa.
According to a further advantageous embodiment the rubber anchoring mix extends along the reinforcement structure from the primary anchoring zone to the secondary anchoring zone.
The cord alignments of the second zone are advantageously of a similar kind to those of the primary zone.
According to an advantageous modification, the secondary zone comprises plural types of cord. These may be metal, textile or of a hybrid type.
Whether the main or secondary anchoring zone is involved, a winding or alignment may comprise one single or plural cords. The cord alignments may also be arranged and manufactured in various ways. For example, one alignment may be advantageously formed of a single cord wound (substantially at zero degrees) in a spiral in plural turns, preferably from the smallest diameter to the largest. It may also be formed of a plurality of concentric cords placed one inside another, so that rings of progressively increasing diameters are superimposed one on another. It is not necessary to add a rubber mix in order to effect impregnation of the cord or circumferential windings of cord. The cords may also be discontinuous along the circumference.
According to another advantageous example, some cords are of a substantially elastic type. The elastic cords are arranged preferably in the radially outer portion of the mechanical bonding means. This type of cord affords behaviour which is adapted to possible compression zones tending to form during operation, e.g. when the sidewall is pushed inwards. The probability of formation of such zones is higher the further one goes from the bead, radially outwardly.
By using different types of cord having different properties or materials, each has a very specific place whereby it is possible to optimise the features of the bottom zone of the tire.
Some or all of the cords of the alignment are advantageously non-metal, preferably of a textile type, such as cords with a base of aramide, aromatic polyester, or other types of cord with lower moduli of elasticity such as cords with a base of PET, nylon, rayon, etc. These cords advantageously have a lower modulus of elasticity than that of the metal cords of the anchoring zone.
BRIEF DESCRIPTION OF DRAWINGS
All the details of realisation are given in the following description with reference to FIGS. 1 to 3 , which show:
FIG. 1 , a radial section showing essentially a sidewall and a bead of a first embodiment of a tire according to the invention;
FIG. 2 , a radial section showing essentially a sidewall and a bead of a second embodiment of a tire according to the invention;
FIG. 3 , is a radial section showing essentially a sidewall and a bead of a modification with respect to the embodiment of FIG. 1 ; and
FIG. 4 , a radial section showing a modification of the reinforcement structure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
For reference, “radially upward” or “radially upper” or “radially outward” here means towards the larger radii.
In the present specification, the term “cord” designates very generally both single filaments and multiple filaments or assemblies such as cables, yarns or even any other type of equivalent assembly, whatever the material and processing of these cords, for example surface treatment or coating or pre-coating with glue to promote adhesion to the rubber.
A carcass-type reinforcement structure will be known as radial since its cords are arranged at 90°, but also, according to current terminology, at an angle close to 90°.
By “features of the cord”, its dimensions, composition, mechanical properties (in particular its modulus), chemical properties etc. are intended.
FIG. 1 shows the lower zone, in particular the bead 1 of a first embodiment of the tire according to the invention. The bead 1 has an axially outer portion 2 provided and shaped so as to be placed against the flange of a rim. The upper portion, or radially outer part of the portion 2 forms a portion 5 adapted to the hook of the rim. This portion is often curved axially outwards, as is shown in FIGS. 1 and 2 . The portion 2 ends radially and axially on the inside with a bead seat 4 adapted to be placed against a rim seat. The bead also has an axially inner portion 3 extending substantially radially from the seat 4 to the sidewall 6 . A rubber sidewall mix 62 , advantageously of a lower modulus than the anchoring mix 60 , is provided along the sidewalls.
A zone 25 of protective mix, whose modulus of elasticity is lower than that of the mix of the anchoring zone, is advantageously provided along the outer contour of the bead, e.g. in order to promote contact with the rim and to protect the anchoring zone.
The tire further comprises a carcass-type reinforcement structure 10 comprised of a main reinforcement structure 10 ′ and a secondary reinforcement structure 11 . Both reinforcement structures 10 ′ 11 are provided with reinforcements advantageously configured in a substantially radial arrangement. This structure can be contrived to be continuous from one bead to the other, passing through the sidewalls and the crown of the tire, or again it may comprise two or more parts arranged for example along the sidewalls without covering the entire crown.
In order to position the reinforcement cords as precisely as possible, it is most advantageous to pre-fabricate the tire on a rigid support, e.g. a rigid core imposing on the tire the shape of its inner cavity. All the components of the tire are applied to this core in the order required by the final architecture, without the need to modify the tire profile during fabrication.
Circumferential cords 21 , preferably arranged in the form of batches 22 , form an arrangement of anchoring cords, provided in each of the beads. These cords are preferably metal, and possibly brass-coated. In each batch, the cords are advantageously substantially concentric and superimposed.
In order to effect perfect anchoring of the reinforcement structure, a composite layered bead is formed. Inside the bead 1 , between the cord alignments of the reinforcement structure, cords 21 are provided which are oriented circumferentially. These are disposed in a batch 22 as in the Figures, or in plural adjacent batches or in bundles, or in any other judicious arrangement, according to the type of tire and/or the features desired.
The radially inner end portions of the main reinforcement structure 10 ′ cooperate with the cord windings. Thus anchoring of these portions in the beads is obtained. In order to promote this anchoring, the space between the circumferential cords and the reinforcement structure is occupied by a rubber bonding or anchoring mix 60 . The use of plural mixes having different features defining different zones may also be provided, the combinations of mixes and resulting arrangements being virtually unlimited. It is however advantageous to provide the presence of a mix with a high modulus of elasticity in the intersection zone between the cord arrangement and the reinforcement structure, thus forming a main anchoring zone 20 . By way of non-limiting example, the modulus of elasticity of such a mix may reach or even exceed 15 Mpa, and even in some cases reach or exceed 40 Mpa.
The arrangements of circumferential cords may be contrived and manufactured in various ways. For example, a batch may advantageously consist of a single cord wound (substantially at zero degrees) in a spiral in plural radially spaced turns, preferably from the smallest diameter to the largest. A batch may also be formed of a plurality of concentric cords placed one inside another, so that radially spaced rings of progressively increasing diameters are superimposed one on another. It is not necessary to add a rubber mix in order to effect impregnation of the cord reinforcement or circumferential windings of cord.
In the example in FIG. 1 , on each side of the reinforcement structure the bead comprises an arrangement of anchoring cords formed of juxtaposed batches of cords disposed on either side of the main reinforcement structure 10 ′. They are advantageously disposed immediately next to the reinforcement structural. The structure shown in FIG. 1 is particularly simplified and simple to realise. Some stresses of the reinforcement structure are transmitted to the windings at zero degrees via the mix 60 .
The tire further comprises a rim protector 70 . This consists of a circumferential rubber strip which is axially exterior to the sidewall and is located substantially radially outward from the bead 1 . This rim protector acts as a protection by preventing any contact between the rim disposed on this wheel and any external object or obstacle capable of damaging the rim. This is a highly useful element for vehicles equipped with rims composed of alloy, such as aluminium. They furthermore greatly improve the appearance of the vehicle.
The tire further comprises a secondary anchoring zone 30 . This zone is intended to cooperate with a carcass-type secondary reinforcement structure 11 . The features of this secondary zone are advantageously similar to those previously described for the main zone 20 . This zone 30 is at least partially disposed in the rim protector 70 .
In the various examples illustrated in the Figures, the secondary anchoring zone takes the form of at least one cord batch 31 disposed near or immediately next to the secondary reinforcement structure portion 11 .
The batch 31 may advantageously be formed of a single cord wound in a spiral, preferably from the smallest diameter to the largest. A batch may also be formed of plural concentric cords placed one inside another. In FIG. 1 , the alignment is disposed substantially at zero degrees.
The arrangement 30 of cords 31 may extend substantially radially towards the sidewall and even along a portion thereof.
The number of windings, the radial spacing, and the radial position of the arrangement may vary infinitely. These features are defined according to the qualities desired, particularly in the lower zone and the zone of the sidewall of the tire, such as rigidity, wear-resistance, durability, etc. For example, the arrangement 30 of cords 31 extends substantially radially from the base of the reinforcement structure 11 .
The cords are preferably metal. Various modifications advantageously provide cords of a textile composition, such as aramide, nylon, PET, PEN, or hybrid for example.
According to the invention, the use of cord alignments or windings 31 in cooperation with a rubber anchoring mix 60 , preferably with a high modulus of elasticity, and preferably in cooperation also with an adjacent portion of reinforcement structure, contributes to the durability of the anchoring.
The secondary reinforcement structure 11 of the tire may take various forms, according to the particular case. Preferably, the structure portion extends from the rim protector to a portion of the sidewall located radially outwardly. According to a first advantageous example, the secondary reinforcement structure 11 extends from one sidewall of the tire to the other along a meridian path substantially adjacent to that of the first carcass-type reinforcement structure. In such a case, the two reinforcement structures of the tire are side-by-side along a portion of their path, then, at a certain radial position along the sidewall, the secondary structure 11 separates from the main structure 10 ′ and extends towards the rim protector 70 , where its end portion is anchored in the secondary anchoring zone 30 .
According to another advantageous embodiment, shown in FIG. 4 . the secondary reinforcement structure 11 a consists of a plurality of carcass-type reinforcement structures of limited circumferential length, whose axial position separates from the two other adjacent integral circumferential portions 10 a from the sidewall towards the rim protector. In this example, the circumference of the tire is subdivided into main zones where some portions 10 a of a single reinforcement structure 100 are anchored in the bead, and other secondary zones where the structure 100 separates to form the secondary structure 11 a , the structure 11 a being then anchored in the rim protector. These main and secondary zones are preferably disposed alternatingly along the tire circumference. This example therefore gives rise to a circumferential alternation of zones where the structure now separates from the sidewall at a given point in order to form the main and secondary reinforcement structures 10 a and 11 a , respectively, and now the structure 10 a extends towards the bead until it is anchored therein.
In the first of these two embodiments (FIGS. 1 - 3 ), the tire has two reinforcement structures, one anchored in the beads, the other anchored in the rim protector. In the second embodiment (FIG. 4 ), the structure 11 a extends from the rim protector and joins the structure 10 a at a certain radial position along the sidewall in order to form, starting from this point of imbrication, one single structure 100 extending preferably as far as a symmetrical point of disimbrication in the other sidewall. In this case, the secondary reinforcement structure 11 a cooperates with the main reinforcement structure 10 a.
In the embodiment shown in FIG. 2 , the main anchoring zone 20 comprises a bead wire 80 , about which a portion of the carcass-type reinforcement structure 10 is at least partially wound. This produces a turned-up portion 81 , the whole preferably in a rubber anchoring mix 82 of known type.
FIG. 3 shows a modification of the embodiment of FIG. 1 , wherein a plurality of circumferential windings 90 extend between the bead of one part and the zone where the structures 10 ′ and 11 converge. In a first radially inner portion, the windings are immersed in a rubber anchoring mix 60 , whereas in a radially outer zone, the windings 90 are disposed in a sidewall mix 62 , whose modulus of elasticity is advantageously lower than that of the anchoring mix 60 . | Tire, comprising at least one carcass-type reinforcement structure extending circumferentially from the bead to the sidewall and a crown reinforcement, each of the beads further comprising a main anchoring zone for supporting the reinforcement structure, the tire comprising a rim protector provided by a rubber projection extending axially outwardly relative to the sidewall and comprising at least one secondary anchoring zone comprising a plurality of circumferential cord windings, the windings cooperating with an adjacent portion of a secondary reinforcement structure via a rubber anchoring mix. Since anchoring is distributed between the bead and the rim protector, new architectural or design possibilities are opened up, for example permitting the use of the restricted space of the bead in an optimum manner. Thus, for example, the presence of the secondary anchoring zone at the rim protector helps greatly to improve the behavior of the tires, in particular resistance to drift. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 204,103, filed Nov. 5, 1980, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the treatment of oil wells, gas wells, injection wells and similar boreholes. In one aspect it relates to a method of stimulating the productivity of hydrocarbon-bearing formations by hydraulic fracturing techniques. In a more specific aspect, it relates to a method of preventing the overdisplacement of propping agent particles into a subterranean formation during the hydraulic fracturing treatment.
2. Description of the Prior Art
A common technique for stimulating the productivity or injectivity of subterranean formations is a treatment known as hydraulic fracturing. In this treatment, a fluid is injected down the well and into the formation at a high pressure and rate to cause the formation to fail in tension, thereby creating a crack (fracture) in the formation. The earth stresses are normally such that the fracture is vertical, extending in opposite directions from the well. The fracture can be extended several hundred feet into the formation depending upon the volume and properties of treating fluid. The fracture is normally propped open by means of particles known as propping agents. The propping agent is carried down the well and into the formation as a suspension in the fracturing fluid. As the fracturing fluid bleeds off into the formation, the propping agent is deposited in the fracture. Upon the release of the fluid pressure, the fracture walls close upon the propping agent. The propping agent thus prevents the fracture from completely closing, thereby creating a highly conductive channel in the formation. If properly performed, the hydraulic fracturing treatment can increase productivity of a well several fold.
A problem associated with the placement of the propping agent in a fracture is that of overdisplacement. As pointed out in SPE Paper 3030 "Stresses and Displacements Around Hydraulic Fractured Wells" published by the Society of Petroleum Engineers of the AIME in 1970, the closure stress of a fracture at the mouth in the near wellbore region can affect productivity. If the fracture is not completely filled with propping agent in the near wellbore region, the productivity will be greatly reduced. Studies have shown that the stress level in this region causes the fracture to close upon incomplete fracture fill-up, thereby reducing the effectiveness of the treatment.
On the other hand, if too large a volume of propping agent is used, the process will settle in the wellbore and could cover the well perforations and reduce well productivity.
The normal technique for preventing overdisplacement of the slurry (propping agent particles suspended in the fracturing fluid) is to carefully monitor the volume of fluid pumped into the well so that upon injection of the proper volume of displacement fluid, the pumping operations are terminated. The proper displacement volume is based upon tubular volume calculations. However, the instruments, including flowmeters, tank strapping techniques, etc., used to measure the total volume of displacement fluid are not precise. Because of the inherent inaccuracies in these instruments, the monitoring technique frequently results in underdisplacement or overdisplacement of propping agent into the fractures.
SUMMARY OF THE INVENTION
The present invention provides for a simple technique which positively prevents the overdisplacement or underdisplacement of propping agent. It has been discovered that by incorporating ball sealers of controlled density in a trailing end portion of a fluid carrying the propping agent to the fracture, the ball sealers upon reaching the perforated interval will seat on and close the perforations thereby preventing overdisplacement. In a preferred embodiment, wherein a displacement fluid is used to flush the fracturing fluid through the well tubulars, ball sealers are selected to have a density less than or equal to that of the fracturing fluid but greater than that of the displacing fluid. In another embodiment, wherein the same fracturing fluid is used as the displacing fluid, the ball sealers are selected to have a density less than that of the slurry but greater than that of the fracturing fluid. During transport in the first embodiment the ball sealers will be maintained at the interface (or transition region) between the fracturing fluid and the displacement fluid. If the fracturing fluid and the displacement fluid are the same, the ball sealers will be maintained at the slurry/displacement fluid transition region.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic showing the relative position of the ball sealers at the transition region between a fracturing fluid and the displacement fluid during transport down the well tubulars.
FIG. 2 is a schematic similar to FIG. 1 showing the ball sealers being transported at the transition region between a slurry and displacement fluid.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is specifically adapted for use in hydraulic fracturing of oil wells, gas wells or water wells. With reference to FIG. 1, such wells are normally provided with casing 10 which extends from the surface through a hydrocarbon-bearing formation 11. The casing, cemented in place, is provided with a plurality of perforations 12 which penetrate the casing 10 and the cement sheath 15 surrounding the casing. The perforations provide flow paths for fluids to flow into the casing 10.
In order to stimulate the productivity of the well, the formation 11 is frequently fractured. This is accomplished by injecting a fracturing fluid down the casing 10 through the perforations 12 and into the formation 11. (In fracturing operations, the fluid is usually injected through a tubular string positioned inside the casing. For purposes of describing this invention, however, it is not necessary to illustrate the tubing.) The injection is conducted at such a rate and pressure to cause the formation to fracture forming radially outwardly extending fractures. Once the fracture is initiated, a carrier fluid is used to transport propping agent particles such as sand, glass beads, or ceramic proppants into the fracture. The terms "fracturing fluid" and "carrier fluid" are used interchangeably herein. The propping agent particles are illustrated as dots 13 in the drawing. The slurry of carrier fluid and propping agent is flushed down the casing (or the tubing, if used) and into the perforations 12 by means of a displacement fluid. As mentioned previously, it is important to avoid overdisplacement of the propping agent deeply into the fracture and away from the near wellbore region.
In accordance with this invention, ball sealers illustrated as 14 are incorporated in the trailing portion of the carrier fluid. The density of the balls is controlled to prevent settling in the carrier fluid or slurry. Ball sealers have long been used as diverting agents, but have not been used to prevent overdisplacement of propping agent particles in the manner described herein. Ball sealers are generally spherical having a diameter ranging from about 5/8 inches (1.59 cm) to about 11/8 inches (2.86 cm). They may be composed of resinous material such as nylon or syntactic foam and may have deformable covers of plastic or elastomer to aid in the sealing of perforations. The density of ball sealers normally range from about 0.8 to about 1.9 g/cm 3 . A particularly suitable ball sealer for use in the present invention is a rubber-coated syntactic foam ball sealer described in U.S. Pat. No. 4,102,401.
The ball sealers for a particular application will depend upon the fluid system used in the treatment. The density of the ball sealers is selected to prevent settling in the slurry. In treatments using a displacing fluid lighter than the fracturing fluid, the sealers may have a density less than or equal to the fracturing fluid but greater than the displacing fluid. In treatments wherein the densities of the fracturing fluid and displacing fluid are about the same, the density of the ball sealers should be less or equal to that of the slurry but greater than that of the fracturing fluid.
The fracturing fluid may be any of those presently used including water-based, oil-based, and emulsion fluids having densities between 6.5 pounds per gallon (777.9 gm/l) and 10.0 pounds per gallon (1197 gm/l). The displacement fluid frequently is a gas or a hydrocarbon liquid such as diesel or lease crude to facilitate establishing initial production following treatment. However, water or the fracturing fluid itself may also be used as the displacing fluid.
Any propping agent may be used. Sand is by far the most common, but glass beads, resin particles, and ceramic proppants are frequently used proppants. The particle size normally ranges from 10 mesh to 80 mesh with 20-40 mesh being the most common. The concentration of the particles in the carrier fluid also may vary within a relatively broad range. For a normal fracturing treatment the overall average of "sand" concentration is usually between 1 to 3 pounds per gallon (119.7 to 359 gm/l); however during the treatment sand concentration is often in the 3 to 5 pounds per gallon (359 to 598.4 gm/l) range, and at times it is 6 pounds per gallon (718.1 gm/l) and above.
The following laboratory test demonstrates that ball sealers heavier than a fluid will exhibit buoyancy in a sand suspension of that fluid.
A 4-foot (121.9 cm) section of 2-inch (5.1 cm) lucite tube closed at one end was filled with water having a density of 8.3 pounds per gallon (993.4 gm/l) and 20-40 mesh sand was added to provide a concentration equivalent to 8.7 pounds per gallon (1041.2 gm/l). Syntactic foam-cored and nylon-cored ball sealers, having densities of 1.0 and 1.1 g/cm 3 , respectively, were then introduced into the tube. The top of the tube was closed. The tube was agitated to disperse the sand and the ball sealers. When the agitation was stopped the balls tended to rise to the top of the slurry where the ball sealers remained in the upper portion of the slurry as the sand settled within the tube.
In carrying out the treatment according to the present invention, the fracturing operation may be performed in the conventional manner employing the desired amounts of fracturing fluid and proppant. Normally a pad volume is used to initiate the fracture and the carrier fluid is used to transport the propping agent into the fracture. During the final stages of blending in the propping agent into the slurry at the surface, a plurality of ball sealers (usually in excess of the number of perforations of the wells) are incorporated in batch form into the slurry along with the propping agent or immediately following the propping agent. If a displacing fluid is used, it normally will have a density equal to or less than that of the fracturing fluid. If the density is less, the ball sealers will be selected to have a density intermediate that of the fracturing fluid and displacement fluid. The ball sealers will thus tend to collect at the interface or transition region as shown in FIG. 1. If the density of the fracturing equal to that of the displacing fluid or if the fracturing fluid itself is used as the displacing fluid, as shown in FIG. 2, the ball sealers will be selected to have a density slightly greater than that of the fracturing fluid. As demonstrated in the laboratory experiment described above, these ball sealers will not settle in the slurry but will remain in the trailing end portion thereof.
Injectors are available for placing the ball sealers in the stream at the proper time. Ideally, the ball sealers may be positioned in a by-pass type injection line which may be activated at the proper time by directing the flow through the injector line, causing all of the balls to the introduced into the well at once.
During transport down the well, the ball sealers will remain in the trailing fluid portion of the treating fluid. As the trailing fluid portion of the carrier fluid approaches the perforations, the ball sealers will seat on the perforations closing off the flow therethrough. Since the balls by design are to remain in the trailing fluid portion, the sealing will occur before the displacement fluid can overdisplace the propping agent. As more and more balls seat on the perforations, monitoring of the surface pumping pressure will indicate a pumping pressure increase, signaling that termination of the pumping of the treating fluid and other aspects of the treating operation should be made. Ideally, all of the perforations will be sealed because an excess number of the balls is used. However, because some of the perforations may not be receiving fluid, it is possible that a small number of the perforations may not be sealed. This, however, should be of no consequence because over displacement would not be a problem in these perforations.
As can be seen by the foregoing description, the invention provides a simple but positive method for preventing the overdisplacement or underdisplacement of propping agent. While an embodiment and application of this invention has been shown and described, it will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein described. The invention, therefore, is not to be restricted except as is necessary by the prior art and by the spirit of the appended claims. | A method of preventing overdisplacement of propping agent particles during well treatments to hydraulically induce a fracture in a subterranean formation wherein buoyant or neutrally buoyant ball sealers are incorporated in the trailing end portion of the fracturing fluid. The ball sealers seat on at least some of the well perforations in final stages of particle injection thereby causing the surface pumping pressure to increase, signalling the end of the treating operation. This minimizes proppant overdisplacement and provides for a fully packed fracture in the near wellbore region. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a semiconductor device and a method for producing thereof, and more particularly to an insulating film used for a semiconductor device and a producing method thereof.
DESCRIPTION OF THE PRIOR ART
Recently, with high integrating of DRAMs, it has been intended to reduce a cell size and a capacitor area. In order to ensure sufficient capacitance, a stacked capacitor or a trench stacked capacitor having a large capacitor area and α-ray resistance and small interference between capacitors is used. However, in a 64 Mbit DRAM, a cell area is estimated to be 1.5 μm 2 , and, even when such a capacitor structure as mentioned above is used, less than 50 Å (angstrom) of oxide equivalent thickness as a insulating film is required. In order to satisfy this requirement, the reduction in the thickness of the insulating film composed of SiO 2 and SiO 2 and Si 3 N 4 and a device application research of a high dielectric film have been positively examined.
Recently, in the application of the insulating film composed of SiO 2 and Si 3 N 4 , it has been reported that a uniform SiO 2 /Si 3 N 4 two layer dielectric film was fabricated by the thermal oxidation of silicon nitride film deposited on silicon electrodes by LPCVD method. In the reported paper entitled "Reliability of ON film Trench Capacitor" in the technical report (SDM88-43) OF THE Electronic Information and Communication Society of Japan, the high reliability of this film can be shown.
Further, when a high dielectric film and a strong dielectric film are applied to a storage capacitor, a non-oxidation electrode such as Pt is used as the bottom electrode in order to prevent the formation of a low dielectric rate layer on the electrode surface. An actual example of this is reported in the paper entitled "Formation of PZT films by MOCVD", Solid State Devices and Materials, 1991, pp. 192-194.
It is possible to form the uniform insulating film having the oxide equivalent thickness of approximately 50 Å by the SiO 2 /Si 3 N 4 two layer film fabricated by the thermal oxidation of the silicon nitride film directly formed on the silicon electrode by the LPCVD method. However, when making a thin film having an oxide equivalent thickness of approximately 40 Å, the leakage current is increased and consequently it becomes difficult to perform the device application. About this fact, there is a reported paper entitled "Inter-Poly SiO 2 /Si 3 N 4 Capacitor Films 5 nm Thick for Deep Submicron LSIs", Solid State Devices and Materials, 1988, pp. 173-176. Further, even when the leakage current is low at room temperature, the leakage current can be increased at a device operation temperature of 120 ° C.
Further, although a method of applying the non-oxidation electrode such as Pt to the bottom electrode is used when the high dielectric film and the strong dielectric film are applied to the capacitor, a processing of the electrode is very difficult.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an insulating film structure and its producing method in order to remove the aforementioned demerits of the prior art, and to realize an insulating film with low leakage current and low temperature dependence of leakage current.
It is another object of the present invention to remove the aforementioned demerits of the prior art, and to provide a preventing method of the oxidation of the electrode surface in the formation of the insulating film including an oxide film, such as the high dielectric film.
In accordance with one aspect of the present invention, there is provided a semiconductor device, comprising: a lower electrode; an upper electrode; and an insulating film interposed between the lower electrode and the upper electrode, the lower electrode, the insulating film and the upper electrode constituting a capacitor, the insulating film being a multi-layer insulating film including a silicon nitride film and a silicon oxide film alternately stacked in at least four layers.
In accordance with another aspect of the present invention, there is provided a method of producing a semiconductor device inciuding an insulating film having at least a silicon nitride film, comprising the steps of: forming a silicon nitride film on a substrate; and performing an oxidation treatment of the substrate having the silicon nitride film in an oxygen atmosphere positively excluding hydrogen and water to form a thin oxide film on the silicon nitride film.
In accordance with still another aspect of the present invention, there is provided a producing method of a semiconductor device, comprising the steps of: forming a silicon nitride film on a silicon electrode; and forming an insulating film including an oxide of high dielectric on the silicon nitride for preventing oxidation of the silicon electrode.
The present inventor has found that, in case that a silicon nitride film having a small oxygen concentration is oxidized in oxygen ambient in which hydrogen and water are not positively added,, even when the oxidation treatment is carried out for 5 hours at 800° C., an oxide film can not be formed on the silicon nitride film in thickness of more than 20 Å and a uniform and thin film can be formed. Since this process can uniformly form the extremely thin oxide film on the nitride film, it is very much effective for reduction of the defects of an insulating film. Further, in this process, an SiO 2 /Si 3 N 4 two-layer film having a thickness of approximately 20 Å can be readily formed.
Further, the oxide film as a barrier of holes and the nitride film as a barrier of electrons are alternately laminated in four layers to form the four-layer dielectric film of the oxide equivalent thickness of approximately 40 Å. As a result of its electric measurement, the following effects can be confirmed.
(1) When the silicon oxide film with a small hole mobility and the silicon nitride film with a small electron mobility are alternately laminated in at least four layers, the current component such as the electrons or holes flowing in this structure is limitted by the layer with the smaller mobility.
Hence, a carrier mobility for contributing the Poole-Frenkel conduction as a leakage current component of the nitride film is started to fall and the Poole-Frenkel component is reduced to reduce the leakage current. As described in (1), by laminating insulating films in at least four layers, a trap level for contributing the Poole-Frenkel conduction becomes shallow, and thus the temperature dependence of the leakage current is reduced.
As described above, the present inventor has found that, in case that the silicon nitride film having the small oxygen concentration is oxidized in oxygen ambient in which the hydrogen and the water are not positively added, even when the oxidation treatment is carried out for 5 hours at 800 ° C., the oxide film can not be formed on the nitride film in thickness of more than 20 Å and the uniform and thin film can be formed. Hence, by forming a silicon nitride film between a silicon electrode and an insulating material containing a kind of an oxide, a formation of an oxide film on the silicon electrode can be prevented. By using this process, there is no need to use the electrode which is difficult to process such as Pt as a high dielectric film electrode.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, features and advantages of the present invention will become more apparent from the consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which:
FIGS. 1 to 8 are cross sectional views showing the steps of a producing method of an insulating film according to the present invention;
FIGS. 9a and 9b are graphical representations showing leakage current characteristics of ONON four-layer structure insulating films according to the present invention;
FIG. 10 is a graphical representation showing a temperature dependence of a leakage current of the ONON four-layer structure insulating film according to the present invention;
FIG. 11 is a graphical representation showing an breakdown voltage distribution characteristic of the ONON four-layer structure insulating film according to the present invention;
FIG. 12 is a graphical representation showing an electric field dependence of a 50% time to breakdown of the ONON four-layer structure insulating film according to the present invention;
FIGS. 13 to 16 are cross sectional views showing the steps of a producing method of another insulating film according to the present invention;
FIG. 17 is a graphical representation showing a leakage current characteristic of another ONON four-layer structure insulating film different from one prepared by a silicon oxide film method according to the present invention;
FIG. 18 is a graphical representation showing an breakdown voltage distribution characteristic of another ONON four-layer structure insulating film according to the present invention; and
FIG. 19 is a graphical representation showing an electric field dependence of 50% time to breakdown of another ONON four-layer structure insulating film according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference characters designate like or corresponding parts throughout the views and thus the repeated description thereof can be omitted for brevity, the first embodiment of a present invention, that is, a producing method of a multi-layer insulating film according to the present invention with respect to a stacked capacity electrode having a simple cubic structure will now be described in connection with FIGS. 1 to 8.
First, as shown in FIG. 1, an oxide film 2 is formed on a silicon (Si) substrate 1 and a resist 3 is coated on the oxide film 2 to carry out a patterning of the resist 3. In FIG. 2, by using the dry etching, the oxide film 2 is etched. Then, a polysilicon 4 doped with phosphor is deposited in thickness of 2000 Å on the surface of the etched substrate 1 by using a Si 2 H 6 gas (150 cc/min) and a 4% of PH 3 +a 96% of He gas (480 cc/min) at 0.2 Torr by LPCVD method. On the polysilicon film 4, a resist 5 is applied to make a patterning of the resist 5, as shown in FIG. 3, and by using the patterned resist 5 as a mask, the polysilicon film 4 is dry-etched to form a lower electrode, as shown in FIG. 4.
After removing the resist 5, an HF processing is applied to the substrate to remove a native oxide and then flowing an ammonia gas in a flow amount of 1000 cc/min into a lamp heating apparatus, the substrate is thermally treated for 30 seconds at 850 ° C. to form a silicon nitride film 6 having a thickness of 15 Å on the silicon electrode, as shown in FIG. 5. In this embodiment, although the thermal nitridation is used, any silicon nitride film formed by any method can be used. Next, in an oxidation furnace, an oxidation treatment of the substrate is performed for 10 minutes at 800 ° C. under a condition of an oxygen flow amount of 10000 cc/min to form a uniform silicon oxide film 7 with a thickness of approximately 10 Å over the silicon nitride film 8, as shown in FIG. 6.
Then, on the SiO 2 /Si 3 N 4 two layer film, a silicon nitride film 8 is deposited with a thickness of 30 Å by LPCVD method. Next, an oxidation treatment of the substrate is performed for 30 minutes at 800 ° C. under conditions of an oxygen flow amount of 5 l/min and a hydrogen flow amount of 5 l/min to form a uniform silicon oxide film 9 with a thickness of about 10 Å, as shown in FIG. 7.
Then, a polysilicon doped with phosphor as an upper electrode 10 is deposited in thickness of 2000 Å over the silicon oxide film 9 by using the Si 2 H 6 gas (150 cc/min) and the 4% of PH 3 +the 96% of He gas (480 cc/min) at 0.2 Torr by the LPCVD method, and an electrode processing is carried out to form the upper electrode 10, as shown in FIG. 8.
As described above, a SiO 2 /Si 3 N 4 /SiO 2 /Si 3 N 4 (ONON) four-layer film with oxide equivalent thickness of 45 Å is formed. For making a comparison, a SiO 2 /Si 3 N 4 (ON) two-layer film with oxide equivalent thickness of 45 Å is also formed by the following method. That is, after a thermal nitridation of a silicon eletrode, a silicon nitride film is deposited thereon by the LPCVD method to obtain a silicon nitride film with a total thickness of 60 Å. Then, an oxidation treatment is performed for 30 minutes at 800° C. under conditions of an oxygen flow amount of 5 l/min and a hydrogen flow amount of 5 l/min to form an ON two-layer film.
FIGS. 9a and 9b show a leakage current charactristics of the ONON four-layer film of oxide equivalent thickness of 45 Å, as shown by solid curves, in comparison with the ON two-layer film with an equal film thickness, as shown by broken curves. From FIGS. 9a and 9b, it is readily understood that by forming the four-layer film, the leakage current can be reduced. Also, the leakage current reduction is remarkably occurred in a positive gate bias. Hence, when this is used for a memory, an average storage charge holding time is increased at least 5 times, and thus a DRAM refresh cycle can be elongated.
FIG. 10 shows the temperature dependence of the leakage current of the ONON four-layer film. Concerning the ON two-layer film, with the increase of the temperature, the leakage current increases. However, as to the ONON four-layer film, the leakage current hardly increases up to 120° C. and starts to increase beyond 120° C. The leakage current density at 120 ° C. reaches to 1×10 -8 A/cm 2 when the positive and negative biases are +1.60 V and -1.26 V, respectively, in the ONON four-layer film in comparison with +1.13 V and -1.21 V, respectively, in the ON two-layer film.
FIG. 11 shows a breakdown voltage distribution of the ONON four-layer film with oxide equivalent thickness of 45 Å, formed in a pattern including 25000 numbers of 2 μm square stack capacitors. In this case, it is readily understood that, even when the ONON four-layer film is actually applied to a stacked capacitor, a problem such as an initial failure will not be caused.
FIG. 12 shows electric field dependence of a 50% breakdown (T50) of the ONON four-layer film with time to oxide equivalent thickness of 45 Å, obtained by constant voltage TDDB (time dependent dielectric breakdown) measurement. From this, it is readily understood that the ONON four-layer film has a life of at least 10 years at a DRAM operation voltage of 1.5 V and has high reliability with device applicability.
The second embodiment of the present invention, that is, a similar producing method of a insulating film according to the present invention to the first producing method described above with respect to a simple plane structure will now be described in connection with FIGS. 13 to 16.
First, as shown in FIG. 13, a silicon oxide film 12 is formed on a silicon substrate 11 to perform an LOGOS device isolation. Then, an HF processing is applied to the substrate to remove native oxide film, and then flowing an ammonia gas in a flow amount of 1000 cc/min into a lamp heating apparatus, the substrate is thermally treated for 30 seconds at 850 ° C. to form a silicon nitride film 16 having a thickness of 15 Å on the surface of the substrate, as shown in FIG. 14. Next, in order to form a SrTiO 3 film 22 having a dielectric constant of 200 on the surface of the substrate, the substrate is put into a vapor deposition chamber and the chamber is evacuated. At this time, an ultimate vacuum is 1×10 -7 torr. In this state, the substrate is heated to 600 ° C. and an oxygen gas is flown in so that a total pressure may be 1×10 -3 Torr. Next, Ti and Sr are deposited on the Si.sub. 3 N 4 film 16 to form the SrTiO 3 film 22 having a thickness of 1000 Å thereon. At this time, Ti is evaporated by using an electron gun and Sr is evaporated by heating a K-cell to 370° C. In this case, since there exists a high density of oxygen defects in the SrTiO 3 film 22 after this process, the specimen is introduced into an oxidation furnace and an oxidation treatment is executed for 30 minutes at 700° C., as shown in FIG. 15. In this embodiment, the silicon nitride film 16 can effectively act as a protective layer for preventing the silicon substrate electrode from the oxidation in the oxygen atmosphere during the deposition of the SrTiO 3 film 22 and in a oxidation treatment after the formation of the SrTiO 3 film 22. Next, an upper electrode 20 of a TiN electrode is formed over the SrTiO 3 film 22 by sputtering, as shown in FIG. 16.
Then, the third embodiment of the present invention, that is, another producing method of an ONON four-layer insulating film will now be described and its electric characteristics are shown in FIGS. 17 to 19.
First, in the same manner as the first embodiment described above, a lower silicon electrode is formed. Then, after RCA cleaning of a specimen is carried out, a native oxide film is removed from the specimen by an HF diluted to 1/100 with deionized water, and then flowing an ammonia gas in a flow amount of 2000 cc/min into a lamp heating apparatus, the substrate is thermally treated for 60 seconds at 850 ° C. to form a silicon nitride film having a thickness of 17 Å on the silicon electrode. In this embodiment, although the thermal nitridation is used for forming the silicon nitride film, any silicon nitride film produced by any method can be used. Next, a silicon oxide film having a thickness of 10 Å is deposited on the silicon nitride film by the LPCVD method. This deposition is performed under conditions of a SiH 4 flow amount of 100 cc/min, an N 2 O flow amount of 1000 cc/min at 800 ° C. Then, a silicon nitride film having a thickness of 20 Å and a silicon oxide film having a thickness of 10 Å are successively formed on the surface of the specimen in the same manner as described above to obtain a SiO 2 /Si 3 N 4 /SiO 2 /Si 3 N 4 four-layer structure film with oxide equivalent thickness of 45 Å.
Then, in the same manner as the first embodiment described above, by depositing a polysilicon doped with phosphor on the four-layer film to carry out an electrode processing to form a stacked capacitor. The electric characteristics of this film are shown as follows.
FIG. 17 shows a leakage current densities of the ONON four-layer film prepared by the LPCVD method (indicated by a broken curve) in the third embodiment in comparison with the one prepared by the thermal oxidation method (indicated by a solid curve) in the first embodiment. It is readily understood that the leakage current of the four-layer film in which the silicon oxide film is formed by the LPCVD method is smaller than the other one. This can be considered that, when the silicon oxide film is formed by the thermal oxidation, the oxygen is also introduced into the silicon nitride film and thus the dielectric constant of the silicon nitride film is reduced to reduce an actual film thickness. In this embodiment, there is no problem in the breakdown voltage distribution characteristic of this film, as shown in FIG. 18, and the long period reliability (at least 10 years at 1.5 V), as shown in FIG. 19.
Next, the fourth embodiment of the present invention, that is, a further producing method of a multi-layer insulating film according to the present invention will now be described.
First, in the same manner as the first embodiment described above, a lower silicon electrode is formed. Then, after RCA cleaning of a specimen is carried out, a native oxide film is removed from the specimen by an HF diluted to 1/100 with deionized water, and the specimen is put into a UHV-CVD apparatus. In this UHV-CVD apparatus, a base pressure is 1×10 -11 Torr and a source gas is irradiated onto the substrate in the beam form. Also, a multi-layer film formation can be possible at 1×10 -3 Torr by a CVD method.
After a wafer is introduced via a load lock chamber, the NH 3 in a flow amount of 20 cc/min and the SiH 4 in a flow amount 1 cc/min are irradiated onto the substrate at a substrate temperature of 700° C. to form a silicon nitride film of a thickness of 20 Å. Then, the temperature is raised to 800 ° C. and the N 2 O in a flow amount of 40 cc/min and the SiH 4 in a flow amount of 1 cc/min are irradiated to the substrate to form a silicon oxide film of a thickness of 10 Å on the silicon nitride film. Next, a silicon nitride film having a thickness of 20 Å and a silicon oxide film having a thickness of 10 Å are successively formed on the surface of the specimen in the same manner as described above to obtain a SiO 2 /Si 3 N 4 /SiO 2 /Si 3 N 4 four-layer structure film. In this embodiment, an oxide equivalent thickness of this film is 40 Å.
In this embodiment, a multi-layer film can be formed without exposing to the air during the formation of multi layer film, and hence a clean interface can be obtained without receiving the influence by forming the native oxide film and contaminating materials. Further, the present invention is effective for thinning of a capacitor dielectric film.
As described above, according to the present invention, by forming a four-layer film composed of a silicon oxide film and a silicon nitride film alternately formed, a leakage current can be reduced and its temperature dependence can be also reduced. Further, there is no problem of an initial failure and a long period reliability to exhibit high reliability. Also, by using thermal oxidation method to form a oxide layer, a thin silicon oxide film can be formed on a silicon nitride film with good controllability. Further, according to a present producing method of an insulating film, there in no need to use a hard processing material such as Pt for a high dielectric film electrode.
While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by those embodiments but only by the appended claims. It is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention. | A thermal oxidation method for producing a semiconductor device having a capacitor insulating film structure capable of making a thin film having a small leakage current and small temperature dependence of the leakage current. In the insulating film, a silicon nitride film with a small electron mobility and a silicon oxide film with a small hole mobility are alternately laminated in order of the nitride film/oxide film/nitride film/oxide film from a lower electrode side. A current component such as electrons flowing in this insulating film structure is limited by the layer with the smaller mobility to reduce the leakage current. An oxide film thickness of approximately several Å can thus be strictly controlled. By forming the silicon nitride film between the high dielectric oxide film and the electrode, the reaction of the silicon electrode and the high dielectric oxide film can be prevented. | 8 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a control system for controlling an implement attached to an agricultural tractor, and, particularly, to a control system that will allow for variations in prevailing slip-pull data at progressively increasing implement draft levels.
[0002] The term, “tractor”, is meant to include any vehicle capable of propelling a ground or soil engaging implement for the purpose of processing the ground or soil, or objects (e.g. crops, forage, shellfish) lying on or in the ground or soil. Typically a tractor is a four wheel drive vehicle having a hitch for attachment of an implement behind the vehicle. It is also well known for tractors to push implements, such as furrow presses. The typical configuration of a tractor includes an operator cab mounted at the rear of the vehicle, and a forward-mounted engine and transmission system. However it is also known to provide a multi purpose vehicle, that may function as a tractor, having a forward mounted cab and underslung engine and transmission systems beneath a load carrying deck. Other forms of tractors include two wheeled, two wheel drive devices and tracked vehicles that may be coupled to pull or push implements. The instant invention relates to and embraces within its scope all such tractors.
[0003] Tractor/implement combinations are widely used in various processes in agriculture. One of the most common of these is plowing, in which a plow is towed behind a tractor. However, tractors may be used for a great variety of other operations such as spraying, furrow pressing, harrowing, raking, seeding and a number of specialized operations such as arise, for example, in vineyards and estuaries, in which specially designed ground-engaging implements are used. Consequently, “implement” as used herein includes but is not limited to plows, harrows, furrow presses, rakes, seed drills, and indeed virtually any article that may be attached to or operated by a tractor and that has the effect of increasing the energy demand of the tractor by virtue of engagement of the implement with the ground or soil or with objects thereon or therein.
[0004] Electronic control of the subsystems of tractors is becoming more and more common. For example European Patent Application No. 0838141 (the entire disclosure of which is incorporated herein by reference) discloses an integrated control system for tractors (designated by the trade mark “TICS” that is the subject of Community Trade Mark registration no. 1532696), by means of which a programmed microprocessor (or series of microprocessors) maximizes the work rate of a tractor, e.g. during plowing operations, by comparing the implement draft force against a steady state reference model, and performing implement working width and transmission ratio adjustments in order to maintain a maximal work rate while also maintaining a predetermined implement working depth.
[0005] There are four readily identifiable subsystems of a tractor/implement combination operating under the control of arrangement such as the aforementioned TICS. The subsystems influence the performance of the combination. They are the tractor engine; the tractor transmission; the implement; and the tire/soil interface. As disclosed in the aforementioned European Patent Application No. 0838141, it has in practice proved impossible successfully to carry out tractor/implement control using a dynamic reference model. The arrangement of the control system in European Patent Application No. 0838141 therefore includes a steady state reference model. In the use of such a model it is necessary for the control software to process accurately generated data on the influence of variables on the behavior and/or performance of the tractor/implement combination.
[0006] It is readily possible to obtain real-time data on the engine torque and governor setting, through use of sensors. One suitable form of engine torque sensor is disclosed, for example, in European Patent Application No. 0741286. It is also a straightforward matter to detect, using known transducers, the selected transmission ratio and generate a signal corresponding thereto for use by the control software. Prediction of the horizontally acting load resulting from engagement of the implement with the soil, or with other objects as noted above, is also possible. The method disclosed in European Patent Application No. 0838141 includes for this purpose an assessment of the prevailing soil strength value (or an equivalent thereto in the event of the implement engaging a medium other than soil) during calibration of apparatus included on the tractor/implement combination.
[0007] Heretofore, however, there has been no proposal for providing real-time information on the effect of the prevailing tire/soil interface on the performance of a tractor/implement combination. When a wheeled tractor propels an implement either by towing it or by pushing it, a degree of so-called “wheel slip” arises. Wheel slip, that is expressed as a percentage value, varies in dependence on numerous factors including the traction factors or conditions, that in turn depend on the soil type and density, the soil moisture conditions, and the presence at the soil surface of e.g. crop residues; and vehicle factors, including the tire size, the tire condition, the ballasting (weight distribution) of the tractor, and whether the tractor is a two wheel drive (2WD) or four wheel drive (4WD) vehicle.
[0008] The tire size and condition (that determine the area of the tire surface in contact with the soil) do not in practice vary during e.g. a plowing operation. Similarly the vehicle ballasting is, in Northern Europe at least, likely to be invariant during e.g. a plowing operation. This is because in Northern Europe the only factor that is likely to cause variations in the vehicle ballasting is the gradual depletion of fuel in the tanks of the tractor. This mass change is insignificant compared with the mass of the tractor. In North America it is known to inject nitrous ammonia during soil tilling operations. The nitrous ammonia is typically stored in a tank at the front of the tractor. Reduction of the level of nitrous ammonia during tilling may (depending on the mass of nitrous ammonia dispensed) have a noticeable effect on the ballasting of the tractor.
[0009] For a given tractor and implement combination it is possible to derive a so-called “slip-pull” curve that is a plot of the percentage wheel slip (y-axis) against the horizontally acting load resulting (referred to as the draft, in kN, when the tractor tows an implement) from engagement of the implement (x-axis). The term “slip-pull” is used even when the tractor is arranged to push rather than tow an implement.
[0010] In the past the possibility of variations in slip-pull characteristics have been largely ignored in the software responsible for predicting the performance of a tractor/implement combination. Instead it has been the practice simply to employ a one-dimensional lookup table, stored in a memory forming part of the control apparatus, that represents an idealized slip-pull curve of use of a tractor/implement combination in a “sandy loam stubble” (SLS) soil. This approach was generally acceptable for the following reasons:
[0011] (a) The SLS slip-pull curve is fairly conservative. Pull that can be generated at a given slip level (for the same tire size and vehicle mass) is dependent on inherent soil strength and the frictional nature of the surface. Hence while a sandy soil will return similar slip-pull characteristics over a wide range of moisture contents (until its bearing capacity is eventually reduced); a clay-based soil is inherently stronger and can therefore generate greater traction. However the range of moisture contents over which this can be achieved is narrower, increasing moisture causing a rapid increase in wheel slip. Consequently in the majority of field conditions in which plowing would be contemplated, the SLS curve returns an acceptable estimate (or possible underestimate) of the pull levels that can be generated at any given slip.
[0012] (b) Additionally a tire-soil traction system is a relatively stable, forgiving system at the slip levels which TICS tries to operate for maximum field efficiency (11-14% slip). At times (in dry, good traction conditions), the traction interface may have appeared under-loaded (8-10% slip), but this is often a result of a compromise between available engine power, implement-imposed draft and vehicle ballasting and tire size.
[0013] Despite the generally acceptability of the single SLS slip-pull curve as discussed, a need has arisen for greater robustness of the control. This need has arisen principally from use of tractor/implement combinations in soils that do not closely match the SLS soil on which the stored SLS slip-pull curve is based; and use of a mis-matched tractor and implement combination.
SUMMARY OF THE INVENTION
[0014] It is, therefore, an object of the present invention to provide a method of controlling an implement attached to a tractor that solves the aforementioned problems of prior art control systems.
[0015] It is a feature of this invention that the method of controlling a tractor/implement combination can be utilized with an implement that is not adjustable.
[0016] It is an advantage of this invention that the method of controlling the combination of a tractor and attached implement advantageously improves the robustness and accuracy of control of the tractor/implement combination.
[0017] It is another object of this invention to provide a method of controlling the combination of a tractor and attached implement that is suitable for use with a tractor/implement combination in which one or more features of the implement are adjustable so as to vary the horizontally acting loading (pull) experienced by the tractor.
[0018] It is another feature of this invention that the method includes selection of a transmission ratio that is known to be suitable for the tractor/implement combination and for the task under consideration.
[0019] It is still another feature of this invention that an experienced tractor operator will know that in carrying out some tasks only a limited range of the tractor transmission ratios is suitable, so that the method advantageously embraces within its scope selecting the transmission ratio selected from the group of suitable ratios for the task in question.
[0020] It is another advantage of this invention that the predetermined engine governor setting will be used as the setting corresponding to maximum speed of the tractor engine in the selected transmission ratio.
[0021] It is another advantage of this invention that the method of controlling the tractor/implement combination provides a convenient datum setting, although other governor settings may if desired be selected.
[0022] It is still another feature of this invention that the step of adjusting one or more settings of the implement, when carried out, includes increasing the working depth of a depth-adjustable implement.
[0023] It is still another advantage of this invention that the step of adjusting implement settings, when carried out repeatedly, sequentially increases the draft experienced at the tractor/implement hitch, thereby permitting the calibration method to be carried out over a range of loadings.
[0024] It is yet another feature of this invention that the step of adjusting one or more settings of the implement may include increasing the width of a width-adjustable implement.
[0025] It is yet another advantage of this invention that the step of increasing the width of a width adjustable implement, when carried out repeatedly, also sequentially increases the loading of the tractor.
[0026] It is still another feature of this invention to adjust the implement depth to a predetermined value before adjustment of the element width of the implement commences.
[0027] This preferred order of the method steps is advantageous because under some soil conditions and with some tractor/implement combinations, it is possible, through adjustment of the implement depth alone, to achieve a degree of wheel slip that exceeds the normal working range. Under such circumstances there is no need additionally to increase the width of the implement in order to provide a full range of test loadings for the tractor/implement combination. This is preferable because tractor operators generally prefer to maintain a constant furrow width when plowing a field.
[0028] Nonetheless, within the scope of the invention it is possible to permit further adjustment of the implement depth after commencement of the adjustment of the implement width. This possibility allows numerous options for increasing the tractor wheel slip to a predetermined threshold value.
[0029] Preferably the predetermined wheel slip threshold value is 28%. Once the horizontally acting load on the tractor is sufficient, through practicing of the method of the invention, to cause this degree of wheel slip the tractor is operating well outside its normal, efficient range. Currently therefore there is therefore no requirement to obtain further data after a 28% wheel slip value has been reached.
[0030] It is still another object of this invention to provide a method of controlling a tractor/implement combination that includes the step of comparing the stored values with reference data includes the sub steps of:
[0031] (a) determining from the stored values a reference value of the horizontally acting load corresponding to a predetermined reference wheel slip value; and
[0032] (b) mapping the reference value of the horizontally acting load onto a series of reference data to enable selection of a set of the reference data.
[0033] More specifically the substep of determining the stored values includes the further substep of:
[0034] (c) determining the value of the horizontally acting load at the reference wheel slip value, by interpolation between two or more said values that are stored in a memory device.
[0035] It is yet another object of this invention to provide a method of controlling the combination of a tractor and attached implement that incorporates reference data including a plurality of characteristic wheel slip/horizontally acting load (slip-pull) curves; and the step of selecting a set of reference data includes the sub-step of:
[0036] (a) selecting a said curve by identifying the curve, from the plurality, that approximates most accurately to the reference value of the horizontally acting load at the reference wheel slip value.
[0037] These features advantageously allow for straightforward manipulation of the recorded data and their comparison with pre-existing slip-pull curves. The use of a plurality of slip-pull curves greatly increases the accuracy of the model, compared with the prior art arrangement that used only a single such curve.
[0038] In all probability the reference value of the horizontally acting load at the reference wheel slip value, that in a preferred embodiment is 25% wheel slip, does not lie exactly on one of the slip-pull curves. Therefore, it is a further object of this invention to provide a method of controlling a tractor/implement combination that includes the addition of positive and negative tolerances to respective values represented by the reference curves at the said reference wheel slip value. In other words, the method includes effectively “broadening” the curves at least at the reference wheel slip value, so that any given reference horizontally acting load value at the reference wheel slip value will intersect one of the curves.
[0039] To ensure robustness of this technique, the modulus of the positive tolerance added to each said reference value is greater than the modulus of the negative tolerance added thereto. For this reason it is also desirable that the sum of the modulus of the said positive tolerance added to a first said referenced curve and the modulus of the said negative tolerance added to the next successive reference curve along a line representing the said reference wheel slip value is equal to the distance along the said line by which the said first and second reference curves are separated one from another.
[0040] The foregoing features ensure that the “broadening” of the reference slip-pull curve is sufficient that any reference horizontally acting load value likely to be recorded during practicing of the method will intersect one of the curves.
[0041] It is yet another feature of this invention that the ratio of the modulus of the positive tolerance to the modulus of the negative tolerance is 3:2.
[0042] It is still another feature of this invention that the reference curves are stored as a two-dimensional lookup table in a memory.
[0043] It is a further feature of this invention that the method of controlling a tractor/implement combination can include the following optional steps:
[0044] (a) detecting whether, during step (i), the tractor engine speed is less than a predetermined minimum; and
[0045] (b) detecting whether, during step (i), the tractor wheel slip exceeds a predetermined initial wheel slip maximum.
[0046] In either case it is possible, as a result of such detection, as necessary to initiate a further control action. For example it is possible for the method to include the transmission of a message to a cab-mounted display device, to the effect that an engine stall is imminent by virtue of the calibration run being attempted in too high a transmission ratio or for a similar reason; or a message indicating that the draft loading caused by the implement is causing too high a degree of wheel slip for the calibration meaningfully to be carried out.
[0047] According to a second aspect of the invention there is provided a method of controlling a tractor/implement combination including the steps of:
[0048] (a) carrying out a method as defined herein; and
[0049] (b) carrying out a control action using the resulting selected set of reference data.
[0050] The control action may, for example, include operation of a software program of the kind described in European Patent Application No. 0838141, using the resulting, selected set of reference data as an input thereto.
[0051] These and other objects, features and advantages are accomplished according to the instant invention by providing a method of controlling the combination of a tractor and an attached implement includes the calibration of a tractor/implement combination to allow for variations in prevailing slip-pull data at progressively increasing implement draft levels. The recorded data is then interpolated at a reference slip value and compared with a series of reference slip-pull curves. The slip-pull curve approximately most closely to the recorded pull value at the reference slip value is then selected for subsequent use in a control algorithm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] The advantages of this invention will become apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings, wherein:
[0053] [0053]FIG. 1 is a schematic representation of a tractor/implement combination incorporating the principles of the instant invention;
[0054] [0054]FIG. 2 is a flow chart showing the steps of a first aspect of the method of the invention;
[0055] [0055]FIG. 3 is a graph illustrating a technique, according to the invention, for broadening stored reference slip-pull curves so as to ensure their intersection by recorded load values; and
[0056] [0056]FIG. 4 is a graph depicting a technique, according to the invention, of selecting a reference slip-pull curve for use in a subsequently carried out control method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0057] Referring to the drawings, there is shown an agricultural tractor denoted by the reference numeral 10 . In common with such vehicles in use nowadays, tractor 10 has a plurality of driven, ground engaging members in the form of front 11 and rear 12 pairs of driven wheels, although as noted herein other kinds of tractors, including those that do not include four driven wheels and/or a rear mounted operator cab, are within the scope of the invention. As an example of another kind of tractor there are known vehicles in which one or both the pairs of driven wheels are substituted by sets of caterpillar tracks. Such tractors are within the scope of the invention. Tractor 10 also has an engine (not shown in the drawings), a transmission system including a gearbox, transfer box and appropriate differentials for the driven wheels; an operator cab 13 and a three point hitch 15 at the rear of the vehicle between the rear wheels for attachment of an adjustable implement, which in the embodiment shown is a plow 60 .
[0058] Thus the tractor/implement combination 10 may be regarded as comprising a plurality of controllable sub-systems, each of which influences the performance of the tractor in dependence on the prevailing conditions. The sub-systems include the engine (adjustable in one of two ways, i.e. by means of a throttle setting or by means of an engine governor setting, depending on the engine type); the transmission (adjustable by virtue of selection of gear ratios); the three point hitch 15 ; and the plow 60 adjustable in a manner described below by adjustment of one or more actuators.
[0059] The tractor/implement combination 10 includes a plurality of slave controllers for the sub-systems, in the form of microprocessors 40 , 41 , 42 , 43 and 48 . External hydraulics control subsystem 40 controls the flow of hydraulic fluid to actuators, located externally of the tractor, that draw hydraulic power from the on-board hydraulic circuit of the tractor.
[0060] Certain parameters of the engine performance are controlled by means of an engine management system including microprocessor 41 that optimizes engine performance in dependence on the throttle or engine governor settings input either by the tractor operator using suitable control members indicated schematically at 21 , or from a programmable controller constituted as a further microprocessor also signified schematically by numeral 21 (described in greater detail in European Patent Application No. 0838141, the description of which is incorporated herein), located in the cab of the FIG. 1 vehicle. The engine management system operates by adjusting various parameters, such as the metering volume of a fuel injection system, the timing of the fuel injection system, the boost pressure of a turbocharger (if present), the opening of engine valves and the opening of portions of the vehicle exhaust system, via suitable powered actuators such as solenoids.
[0061] Tractor 10 includes a semi-automatic transmission system in which the transmission ratio selected is determined by a slave controller in the form of microprocessor 42 acting on one or more solenoids to engage and disengage gear sets of the gearbox and/or gears of the transfer box, in dependence on the settings of a plurality of gear levers in the operator's cab 13 or in dependence on signals from microprocessor 21 .
[0062] The FIG. 1 embodiment includes hitch microprocessor 43 and plow control microprocessor 48 . Microprocessor (slave controller) 43 controls the positions (i.e. the heights) of the elements of the implement (three point) hitch 15 . Again, the microprocessor 43 controls a number of actuators such as solenoids in dependence on the settings of control levers etc in the operator's cab 13 , on signals received from a further microprocessor 21 , or, during carrying out of the method of the aforementioned European Patent Application No. 0838141 in dependence on its own programming.
[0063] Microprocessor 48 is in the embodiment shown in FIG. 1 operatively connected to actuators, e.g. respective hydraulic actuators, for adjusting the width of the plow; for inverting the plow at the end of each furrow; and for setting the plow working depth. Microprocessor 48 operates in dependence on signals received from microprocessor 21 ; from lever settings in cab 13 ; or according to its own programming. The plow adjustment actuators are known per se and are optional features of the tractor/implement combination.
[0064] [0064]FIG. 1 also shows optional sensors 48 a , 48 b and 48 c (illustrated schematically) whose purpose is the detection of the condition of the various plow adjustment actuators. Sensor 48 a detects the state of a plow turnover actuator and hence indicates the orientation of the plow. Sensors 48 b and 48 c respectively detect the working depth and working width of the plow 60 .
[0065] The microprocessors preferably are interconnected via a vehicle CAN-BUS 49 , an extension 49 a of which connects microprocessor 48 (and sensors 48 a - 48 c ) via a node 49 b . Cab 13 has mounted thereon an optional GPS position sensor 14 also connected to the CAN-BUS and hence to the microprocessors.
[0066] Plow 60 is in the exemplary embodiment shown a semi-mounted implement. The implement-mounted actuators are described in more detail below. By “semi-mounted” is meant an implement the working depth of the front part 60 a of which is adjusted by adjusting the height of the tractor implement hitch; and the height of a second part 60 b , to the rear of part 60 a , by an actuator 51 on the implement itself. The use of a towed, semi-mounted implement is not essential for carrying out the method of the first aspect of the invention which, as noted above, is suitable for controlling tractor/implement combinations including a wide variety of implements that need not be towed behind the tractor.
[0067] As shown in FIG. 1, part way along its length plow 60 includes a mid-axle mounted wheel 52 , relative to the location of which the rear portion 60 b of plow 60 is pivotable. Actuator 51 operates under the control of microprocessor 40 to effect such pivoting of plow rear portion 60 b , in dependence on a control algorithm.
[0068] [0068]FIG. 2 shows, in flow chart form, a method according to the invention of calibrating a tractor/implement combination according to prevailing slip-pull conditions. Following start of the procedure, as exemplified at block 70 that includes various software initializing subroutines, the tractor operator carries out the operations identified at block 71 . These are the selection of a transmission gear that the operator knows is acceptable for the contemplated operation; the commencement of e.g. plowing and, assuming that the width of the implement carrying the selected task is adjustable, reducing the implement width as necessary to the minimum possible value.
[0069] Subsequently block 72 indicates two actions that are necessary, in the preferred form of the invention, for initializing the calibration routine proper. These are the acceleration of the engine to the full throttle setting; and the maintenance of the implement working depth (as necessary) at an initial setting. These and subsequent steps of the method of the invention occur automatically in the preferred embodiment. The steps subsequent to block 72 constitute the calibration routine of the method of the invention.
[0070] At the next block, 73 , the software decides, following a stabilization delay that in the preferred embodiment is 6 seconds, whether there is a danger of the engine stalling. This is determined by an assessment of the measured engine speed. If this is less than a predetermined threshold value (1675 rpm in the preferred embodiment) the software routine aborts (blocks 74 , 76 and 77 ).
[0071] Block 74 is an “engine overload” block that might, for example, send via the operator interface display 21 a message to the effect that the engine is about to stall. The engine overload and/or abort routine steps ( 74 , 76 ) could, in preferred embodiments, initiate subroutines that cause shifting of the transmission ratio and/or raising of the implement, as necessary, to avoid an engine stall condition.
[0072] Assuming that the tractor/implement combination and the soil conditions are such that there is no danger of an engine stall, the software next determines (block 78 ) whether the initial slip resulting from engagement of the implement with the soil at a high level is within acceptable limits. If either the slip exceeds 20% or the horizontally acting loading (draft force) measured at the link pin 48 a exceeds a predetermined value (99 kN in the preferred embodiment) the routine terminates by implementation of the actions represented by blocks 79 , 76 and 77 . In other embodiments of the invention the draft force need not be measured at the link pin. It may be measured e.g. at a flywheel torque sensor as described above or at another location.
[0073] Block 79 is similar to block 74 in that it optionally generates an error message that is displayed via the device 21 and indicates that the initial slip experienced at the tractor wheels is at too high a value to enable the acquisition of meaningful data. This may be the result of the tractor operator attempting to pull too large an implement for the soil conditions engine torque, tire type and so on. If this is the case there are a limited number of remedial actions that the software can carry out. Nonetheless one of these might, for example, involve raising part or all of the plow by means of operation of the actuators 51 , 53 .
[0074] Assuming that the initial slip conditions are within acceptable limits, the tractor advances (block 81 ) across the field and acquires horizontally acting load (draft) and (wheel) slip data. From the acquired data the software calculates the average draft and average slip values. Following further checks (blocks 82 and 83 ) of the likelihood of a stall condition and of the slip and draft values exceeding predetermined threshold values, the software next assesses (block 84 ) whether the implement working depth is greater (higher) than a predetermined lower limit value.
[0075] The lower limit value corresponds to the lowest working depth of the implement. Assuming that there remains room for downward adjustment of the implement 60 , at block 86 the software causes lowering of the forward end of the implement by, in the preferred embodiment, a 3% decrement. The lowering action may be achieved e.g. by means of operation of the actuator indicated at numeral 53 ; or by rotation of the three point hitch rock shaft as indicated in block 86 , to lower the implement.
[0076] Following a further, short stabilization delay represented at block 87 , the software routine then loops back to block 81 from which point the method repeats in order to provide for a further data acquisition run. If on the subsequent iteration the determination at block 83 indicates that the prevailing slip value exceeds (in the preferred embodiment) 28% and/or the measured draft force exceeds 99 kN the software terminates the calibration routine as indicated by blocks 88 , 89 and 91 .
[0077] Block 88 includes the optional transmission of a message to operator interface 21 indicating successful termination of the calibration. If on the other hand following one or more iterations of the loop represented by reference numeral 92 the determination at block 83 indicates that the slip and/or draft values are less than the preferred threshold values, the control routine passes again to block 84 at which there is an assessment of whether the implement working depth exceeds a predetermined lowermost value.
[0078] If the answer to this determination is affirmative, at block 93 the software determines whether the implement is at its maximum operating width (assuming the implement width to be adjustable). If it is not possible further to increase the implement width, as indicated at blocks 94 , 96 and 97 the calibration routine terminates. Block 94 includes the transmission of a message via interface 21 to indicate that it is impossible using the tractor and implement combination selected to achieve the desired horizontally acting load to allow completion of the calibration routine.
[0079] If, on the other hand, there remains scope for increasing the implement width, as indicated at blocks 98 and 99 the width is increased and, optionally, the working depth of the implement is further incremented. Following a further stabilization delay represented at block 99 , the software loops back to block 81 and the data acquisition step takes place once again. The software loops in the manner indicated, until (preferably) the data acquisition is complete.
[0080] For the avoidance of doubt, other implement adjustment regimes are possible. For example the implement need not be either width-adjustable or a semi-mounted plow as shown. Under such circumstances the method steps constituting Block 93 could be altered appropriately. In the specific embodiment of the semi-mounted plow shown, the described adjustment regime allows easily controlled, incremental changes in the implement draft force value.
[0081] As best indicated in FIG. 4, that shows lines 101 , 102 , 103 illustrating the intersection of three exemplary sets of acquired data with reference slip-pull curves, the calibration method includes for any given set of acquired data, an assessment of which of a plurality of reference slip-pull curves 104 , 106 , 107 , 108 , 109 is most closely applicable to the field conditions prevailing during the calibration routine. The assessment technique involves a determination of the recorded draft (horizontally acting load) value at a predetermined level, 111 , of slip that in the preferred embodiment is for example 25%.
[0082] As signified in FIG. 4, the intersection lines (e.g. 101 ) of some of the sets of recorded data intersect one of the reference slip-pull curves (i.e. curve 107 in the example) at the 25% wheel slip value. However, the remaining sets of recorded data do not intersect any of the curves at the 25% slip-pull reference value. For this reason it is desirable in practice to broaden the slip-pull curves as exemplified in FIG. 3, so that each of the sets of recorded data definitely intersects one of the slip-pull curves at the preferred 25% wheel slip value level.
[0083] The broadening of the slip-pull curves is achieved by adding positive and negative tolerances to either side of the reference curves at the 25% wheel slip value. The positive tolerances added are in the preferred embodiment 50% greater than the negative tolerances, as indicated by the percentage values in FIG. 3. The effect of broadening the slip-pull curves at the 25% wheel slip value is to ensure that each line 101 , 102 , 103 etc. intersects one and only one of the reference curves at that slip value.
[0084] The chosen biasing of the positive and negative tolerances is to a degree a matter of design choice. The embodiment shown is likely to allocate each set of recorded data to a slip-pull curve having a lower, rather than a higher, average draft characteristic. The slip-pull curves themselves may be generated in any of several ways.
[0085] In the preferred embodiment curve 107 constitutes actual, recorded slip-pull data corresponding to a sandy clay loam stubble soil at a known moisture content, etc. The remaining curves 104 , 106 , 108 and 109 are factored versions of curve 107 , such that over the range of slip values the curve gradients are similar but the overall draft values are higher or lower, as appropriate. Depending on which of the “broadened” slip-pull curves the recorded set of data intersects at the 25% (or other value) slip, the selected curve is then employed as a reference value for example in a control operation such as the operation of a TICS-type software control program. For the avoidance of doubt, the number of reference slip-pull curves may be varied within the scope of the invention. Also it is not necessarily the case that the said curves are simply factored versions of the same expression as represented by curve 107 . For example each of the reference curves may represent recorded rather than simulated data.
[0086] It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown. | A method of controlling the combination of a tractor and an attached implement includes the calibration of a tractor/implement combination to allow for variations in prevailing slip-pull data at progressively increasing implement draft levels. The recorded data is then interpolated at a reference slip value and compared with a series of reference slip-pull curves. The slip-pull curve approximately most closely to the recorded pull value at the reference slip value is then selected for subsequent use in a control algorithm. | 0 |
This is a division of application Ser. No. 291,967, filed Dec. 30, 1988 now U.S. Pat. No. 5,037,902.
FIELD OF THE INVENTION
Applicants teach about unique combinations of select imide containing polymers that contain an isopropylidene group which are miscible with biphenyl containing polysulfones, and processes for using such combinations. These blends are suitable for printed wiring board substrates, flexible printed circuit boards, electrical connectors and other fabricated articles requiring high heat and chemical resistance, and good dimensional and hydrolytic stability. They are particularly suitable for use as matrix resins in thermoplastic continuous fiber composites.
BACKGROUND OF THE INVENTION
Applicants have directed their attention to making miscible blends of polymers having utility as composite matrices for advanced composite aerospace uses and for use as general purpose injection molding resins. Rather than directing attention to miscible thermoplastic blends, the prior art has been directed to blends of thermoplastics without regard to whether or not they are miscible.
U.S. Pat. No. 4,293,670 to Robeson et al describes molding compositions of blends of poly(aryl ether) resin and a polyetherimide resin. The poly(aryl ether) resin is taught to be a linear, thermoplastic polyarylene polyether wherein the arylene units are interspersed with ether, sulfone or ketone linkages. Particular formulae of polyetherimides are taught in the reference. A molding composition comprising blends of these materials is claimed and exemplified in the reference.
U.S. Pat. No. 4,713,426 describes blends of a biphenyl containing poly(aryl ether sulfone) and a poly(aryl ether ketone). The reference teaches that these blends have limited miscibility and excellent mechanical compatibility. According to the reference, these blends possess, in an article molded therefrom, a good balance of properties including higher modulus, impact resistance, solvent resistance and resistance to environmental stress cracking. As taught, the poly(aryl ether ketones) are used because they offer an exceptional balance of properties, namely, high melting point, excellent thermal stability, excellent hydrolytic stability, high stiffness and strength, good toughness, and excellent solvent and environmental stress rupture resistance. The reference specifically teaches that the results indicate that a low level of miscibility is observed in these blends as the glass transition temperature of the poly(aryl ether sulfone) is slightly decreased. However, the blend contains separate glass transition temperatures for each of the components of the blends.
U.S. Pat. No. 4,684,674 to Brooks teaches another blend. Specifically, the reference teaches polyamide-imidephthalamide copolymers and polyamide-imide copolymers containing aromatic sulfone polymers. However, the blends are two-phase and exemplified by two glass transition temperatures, one for each of the components of the blend. The reference teaches that a completely miscible system exhibits a single glass transition temperature (T g ) while immiscible blends have two T g 's, each at the temperature of one of the components. The reference specifically teaches that the polyamideimide/polyethersulfone blends taught in the reference show no evidence of a system which is miscible.
World Patent Application No. WO 8604-079A describes blends of phenylindane containing polyimides with polyetherimides, polysulfones, polyarylether ketones, polycarbonates, polyarylates or polyphenylene oxides. The compositions are claimed to be useful as adhesives, coatings or matrix resins in carbon fiber reinforced composites.
In the field of miscibility or compatibility of polymer blends, the prior art has found predictability to be unattainable, even though considerable work on the matter has been done. According to the authorities:
(A) "It is well known that compatible polymer blends are rare". Wang and Cooper, Journal of Polymer Science, Polymer Physics Edition, Vol. 21, p. 11 (1983).
(B) "Miscibility in polymer--polymer blends is a subject of widespread theoretical as well as practical interest currently. In the past decade or so, the number of blend systems that are known to be miscible has increased considerably. Moreover, a number of systems have been found that exhibit upper and lower critical solution temperatures, i.e., complete miscibility only in limited temperature ranges. Modern thermodynamic theories have had limited success to date in predicting miscibility behavior in detail. These limitations have spawned a degree of pessimism regarding the likelihood that any practical theory can be developed that can accommodate the real complexities that nature has bestowed on polymer-polymer interactions." Kambour, Bendler, Bopp, Macromolecules, 16, 753 (1983).
(C) "The vast majority of polymer pairs form two-phase blends after mixing as can be surmised from the small entropy of mixing for very large molecules. These blends are generally characterized by opacity, distinct thermal transitions, and poor mechanical properties. However, special precautions in the preparation of two-phase blends can yield composites with superior mechanical properties. These materials play a major role in the polymer industry, in several instances commanding a larger market than either of the pure components." Olabisi, Robeson, and Shaw, Polymer--Polymer Miscibility, Academic Press, New York, N.Y., p. 7 (1979).
(D) "It is well known that, regarding the mixing of thermoplastic polymers, incompatibility is the rule and miscibility and even partial miscibility is the exception. Since most thermoplastic polymers are immiscible in other thermoplastic polymers, the discovery of a homogeneous mixture or partially miscible mixture of two or more thermoplastic polymers, is, indeed, inherently unpredictable with any degree of certainty; for example, see P. J. Flory, Principles of Polymer Chemistry, Cornell University Press, 1953, Chapter 13, p. 555." Younes, U.S. Pat. No. 4,371,672.
(E) "The study of polymer blends has assumed an ever increasing importance in recent years and the resulting research effort has led to the discovery of a number of miscible polymer combinations. Complete miscibility is an unusual property in binary polymer mixtures which normally tend to form phase-separated systems. Much of the work has been of a qualitative nature, however, and variables such as molecular weight and conditions of blend preparation have often been overlooked. The criteria for establishing miscibility are also varied and may not always all be applicable to particular systems." Saeki, Cowie and McEwen, Polymer, vol. 25, p. 60 (January 1983).
Thus, miscible or compatible polymer blends are not common. The criteria for determining whether or not two polymers are miscible are now well established. According to Olabisi, et al., Polymer--Polymer Miscibility, supra p. 120:
"The most commonly used method for establishing miscibility in polymer--polymer blends or partial phase mixing in such blends is through determination of the glass transition (or transitions) in the blend versus those of the unblended constituents. A miscible polymer blend will exhibit a single glass transition between the Tg's of the components with a sharpness of the transition similar to that of the components. In cases of borderline miscibility, broadening of the transition will occur. With cases of limited miscibility, two separate transitions between those of the constituents may result, depicting a component 1-rich phase and a component 2-rich phase. In cases where strong specific interactions occur, the Tg may go through a maximum as a function of the concentration. The basic limitation of the utility of glass transition determinations in ascertaining polymer--polymer miscibility exists with blends composed of components which have equal or similar (20° C. difference) Tg's, whereby resolution by the techniques to be discussed of two Tg's is not possible."
W. J. MacKnight et al., in Polymer Blends, D. R. Paul and S. Newman, p. 188, Academic press, New York, N.Y. (1978) state:
"Perhaps the most unambiguous criterion of polymer compatibility is the detection of a single glass transition whose temperature is intermediate between those corresponding to the two component polymers."
In this passage, it is clear that by compatibility the authors mean miscibility, i.e., single phase behavior. See, for example, the discussion in Chapter 1 by D. R. Paul in the same work. The above references and related application are hereby incorporated by reference.
However, the miscible blends disclosed in this application are one phase based on them having a single glass transition temperature giving the resulting blends improved chemical resistance compared to the immiscible multiphase blends having similar constituents. Further, the miscible blends show improved thermal and optical performance over immiscible blends. This is attributable to discovering that select imide containing polymers having an isopropylidene group are miscible with biphenyl containing polysulfones. Herein, the term "polyimide" refers to polymers containing the following linkage: ##STR1## or mer unit.
SUMMARY OF THE INVENTION
This invention relates to a miscible blend of a poly(aryl sulfone) and a polyimide or amide-imide comprising: (a) poly(aryl sulfone) containing the following unit: ##STR2## and (b) polyimide or amide-imide containing the following unit: ##STR3##
This invention also relates to a process for producing a miscible blend of biphenyl containing poly(aryl sulfone), and isopropylidene and imide containing polymer comprising adding the monomers used to form the latter polymer to the poly(aryl sulfone) in a vented extruder.
This invention further relates to a polyimide of the following formula:
DETAILED DESCRIPTION OF THE INVENTION
Applicants disclose a method of improving the flow of polyimides (PI) and amide-imides (PAI) while at the same time improving the chemical resistance of poly(aryl sulfones) (PAS) by alloying the two polymers together. A major factor limiting the applicability of the alloying approach is that the majority of polymer alloys are not miscible. That is, the alloys are two-phase; and the continuous phase is usually the lower viscosity component. Thus, immiscible blends will likely be a poly(aryl sulfone) filled with the polyimide or amide-imide component as inclusions. Such a morphology generally results in an improvement in flow (e.g. reduced viscosity). However, the chemical resistance of such an alloy will be closer to that of the continuous phase than to the inclusions and may be expected to be poor. Additionally, in the event the T g s of the two components are significantly different, the upper use temperature of the alloy will not be significantly higher than that of the lower T g constituent. In the case of continuous fiber composites wherein the alloy is the matrix resin, the reason for this is that a high matrix modulus is necessary to prevent buckling of carbon fibers when a composite is loaded in compression. An immiscible blend has two T g s (usually near those of the constituents); and at each T g , the matrix modulus drops significantly. If such a blend is used as the composite matrix, then the useful temperature range of the composite is limited to the lower T g .
It has been discovered unexpectedly that a select group of poly(aryl sulfones) is miscible with a select group of polyimides and amide-imides. The poly(aryl sulfone) must contain biphenyl linkages while the polyimides or amide-imides must contain isopropylidene linkages. These blends show markedly improved chemical resistance and a single T g intermediate to those of the constituents resulting from their miscible character. Thus, the upper use temperature of the alloy may be significantly improved over that of the lower T g constituent. Further, by reducing the T g of the higher T g constituent, it is typically more processable. As a consequence of this, these alloys can be used as injection moldable thermoplastic materials having improved flow and toughness characteristics as well as better chemical resistance.
The components of the miscible blend of imide containing polymers with poly(aryl sulfones) will be discussed below. Also to be discussed is the need or criticality of the mixture to exhibit a negative miscibility factor.
The poly(aryl sulfone)s which are suitable for use in the invention contain at least one biphenyl unit in the structure. The presence of the biphenyl unit in the poly(aryl sulfone) is critical to obtain miscibility between the poly(aryl sulfone) and the polyimide.
Poly(aryl sulfone) polymers are characterized by inherently high heat distortion temperatures, excellent dimensional stability, creep resistance, low loss AC dielectric properties, and high mechanical strength as shown below.
TYPICAL PROPERTIES OF POLY(ARYL SULFONE) RESINS
______________________________________Property Units Typical Range______________________________________Tensile Strength psi 12,500-15,000Elongation to Break % >40Tensile Modulus psi 300-400,000Flexural Strength psi 13,000-20,000Heat Deflection Temperature °C. 170-250Density gm/cc 1.2-1.4AC DielectricsDielectric Constant60 HZ -- 3.0-4.01 KHZ -- 3.0-4.01 MHZ -- 3.0-3.5Dissipation Factor60 Hz -- 0.0005-0.0051 KHZ -- 0.0005-0.0031 MHZ -- 0.004-0.01Dielectric Strength1/8" specimen Volts/mil 350-550______________________________________
Poly(aryl sulfone) polymers are easily processed utilizing standard injection molding machinery and practice. Prior to molding, resins should be dried to obtain optimum performance in a dehumidified hopper drier or circulating air oven.
The rheological characteristics of poly(aryl sulfone) polymers provide excellent flow for filling thin and intricate wall sections typically encountered in injection molding. The polymers process readily at stock temperatures in the 550°-750° F. range. Mold temperatures of 150°-400° F. are typically used.
The poly(aryl sulfone) may be random or may have an ordered structure. The poly(aryl sulfone)s, which are suitable for use in this invention, contain at least one biphenyl unit in the repeat unit. The preferred biphenyl containing poly(aryl sulfone) contains the repeating unit: ##STR5## where X 1 and X 2 are independently --O--, ##STR6## --SO 2 --, --NHCO--, CH 3 -- ##STR7## or a direct bond with the proviso that at least one of X 1 or X 2 is a direct bond, and R, S and T are independently 0 or 1; with the proviso that at least one of R or S is 1.
The preferred poly(aryl sulfones) include those having the following reoccurring units: ##STR8##
Examples of commercially available biphenyl containing poly(aryl sulfones) are the polymers known as Radel R and Radel C sold by Amoco Performance Products, Inc. of Ridgefield, Conn.
The poly(aryl sulfone)s are produced by methods well known in the art such as those described in U.S. Pat. Nos. 3,634,355; 4,008,203; 4,108,837 and 4,175,175, hereby incorporated by reference.
The preferred method of preparation, herein referred to as method A, involves the reaction of a dihydric phenol with a dihalobenzenoid compound in substantially equal molar amounts in a mixture of alkali metal carbonates and an aprotic solvent. The ratio of reactive halogen groups in the dihalobenzenoid compound to hydroxyl groups in the dihydric phenol is preferably from 0.98 to 1.02. Preferred dihalobenzenoid compounds include 4,4'dichlorodiphenylsulfone (DCDPS) and 4,4'-Bis[(4-chlorophenylsulfonyl)] 1,1'-biphenyl (BCPSB). Preferred dihydric phenols include 4,4'-dihydroxybiphenyl (BP), 4,4'-dihydroxydiphenylsulfone (Bis-S), 1,4-dihydroxybenzene (HQ), and Bis(4-hydroxyphenyl) 1-methylethylidene (Bis A).
The poly(aryl sulfones) are prepared by contacting substantially equimolar amount of the dihydric phenols and dihalobenzenoid compounds with from about 0.5 to 1.0 mole of an alkali metal carbonate per mole of hydroxyl group in a solvent mixture comprising a solvent which forms an azeotrope with water to maintain the reaction medium at substantially anhydrous conditions during polymerization.
The reaction of the mixture is kept at from about 120° to about 180° C. for about 1 to 5 hours, then raised and kept at about 200° to 250° C. for about 1 to 10 hours. The reaction is carried out in an inert atmosphere, e.g., nitrogen, at atmospheric pressure. The poly(aryl sulfone) may be recovered by conventional techniques such as coagulation, solvent evaporation, and the like. The resultant polymers have reduced viscosities in the range from 0.4 to 1.5 dl/g, as measured in N-methylpyrolidone at 25° C.
The other component of the blend is a polyimide or amide-imide that contains an isopropylidene group. The isopropylidene group is critical to the miscibility of the blend constituents of this invention. Polyimides or amide-imides are characterized by the presence of the phthalimide structure in the polymer backbone: ##STR9##
Polyimides are very rigid polymers which sometimes lack the inherent toughness needed to compete in those uses which require elevated temperature resistance and good impact strength. The lack of matrix toughness can cause problems when molding thick cross-sectional parts. The art has been looking for improvements in the impact resistance and toughness of these polymers but it is essential that the additive not significantly impair their thermal and strength properties, particularly their heat deflection temperature, tensile strengths, and chemical resistances.
The polyimides which are suitable for use in this invention comprise those containing the following repeating units: ##STR10## wherein X 3 , X 4 , X 5 and X 6 are independently ##STR11## --SO 2 --, --NHCO--, ##STR12## or a direct bond with the proviso that at least one is isopropylidene; and U, V and W are independently 0 or 1 with the proviso that at least one of U or V is 1.
The polyamide-imides which are suitable for use in this invention comprise those containing the following repeating units: ##STR13## wherein X 4 , X 5 , X 6 , U, V and W are as defined above.
The preferred polyimides comprise those having the following recurring units: ##STR14## wherein X 7 can be ##STR15## --O-- or a direct bond.
The preferred polyamide-imides also comprise those having the following recurring units: ##STR16##
The polyimides of this invention may be made by methods well known in the art such as those described in U.S. Pat. No. 4,713,438, hereby incorporated by reference. They are preferably prepared by the reaction of a dianhydride (or mixture of dianhydrides) with a diamine (or mixture of diamines) in substantially equimolar amounts in a solvent followed by chemical dehydration of the intermediate poly(amide-acid), hereafter referred to as Method B. Preferred dianhydrides include 1,2,4,5-benzene tetracarboxylic anhydride (PMDA), bis(4-phthalic anhydride) 1-methylethylidene (IPAN), 3,3',4,4'-biphenyltetracarboxylic anhydride (BPDA), 3,3',4,4'-diphenylether tetracarboxylic anhydride (OPAN) and 3,3',4,4'-benzophenone tetracarboxylic anhydride (BTDA). Preferred diamines include 4,4'-(1-methylethylidene)bisaniline (BAA), 4,4'-[1,4-phenylene bis (1-methyl ethylidene)] bisaniline (BAP), bis(4-amino phenoxy-4-phenyl) 1-methylethylidene (BAPP), 4,4'-diaminodiphenylether (OBA), and 1,3-diaminobenzene (MPD).
The solvents useful in the solution polymerization process for synthesizing the polyamide-acid compositions are the organic solvents whose functional groups do not react with either of the reactants (the diamines or the dianhydrides) to any appreciable extent. In addition to being inert to the system, and preferably, being a solvent for the polyamide-acid, the organic solvent must be a solvent for at least one of the reactants, preferably for both of the reactants. The normally liquid organic solvents of the N,N-dialkylcarboxylamide class are useful as solvents in the process. The preferred solvents are the lower molecular weight members of this class, particularly N,N-dimethylformamide and N,N-diethylacetamide. Other useful solvents are N,N-diethylformamide, N,N-diethylacetamide, N,N-dimethylmethoxyacetamide, N-methyl caprolactam, and the like. Other solvents which may be used include dimethylsulfoxide, N-methyl-2-pyrrolidone, tetramethyl urea, pyridine, dimethylsulfone, hexamethyl-phosphoramide, tetramethylene sulfone, formamide, N-methyl-formamide, butyrolactone and phenols such as m-cresol. The solvents can be used alone, in combinations, or in combination with poorer solvents such as benzene, benzonitrile, dioxane, xylene, toluene and cyclohexane.
Another group of solvents that are very useful for the preparation of polyimides as well as of poly(amide-imides) are the diaryl sulfones and diaryl ketones; they may be used alone or in combination with other solvents such as the hydrocarbons, chlorinated hydrocarbons, etc. Typical representatives are diphenyl sulfone and benzophenone. These solvents are of interest because they allow for the use of high temperatures and are, therefore, adequate in cases where the amine reaction reactivity is low; or in cases where low solubility of the polymer is encountered. In both instances, use of higher reaction temperatures may be necessary. Also, the thermal cyclization of the poly(amide-acids) to the corresponding polyimides can be performed in the same solvent by simply increasing the temperature to the required level. The same is feasible with phenolic solvents such as the cresols; the diaryl sulfones and ketones have the added advantage of low toxicity, however.
For most combinations of diamines and dianhydrides falling within the definition given above, it is possible to form compositions of 100% poly(amide-acid) by conducting the reaction below 100° C. However, temperatures up to 175° C. and higher may be tolerated to provide shapeable compositions.
The degree of polymerization of the poly(amide-acid) is subject to deliberate control. The use of equal molar amounts of the reactants under the prescribed conditions provides poly(amide-acids) of high molecular weight. The use of either reactant in large excess limits the extent of polymerization. In addition to using an excess of one reactant to limit the molecular weight of the poly(amide-acid), a chain terminating agent such as phthalic anhydride may be used to "cap" the ends of the polymer chains. Typical useful capping agents are less than 5 wt. % of monoanhydrides or monoamines such as phthalic anhydride, aniline, p-methylaniline, and the amine and anhydride shown below: ##STR17##
In the preparation of the poly(amide-acid), it is desired that the molecular weight be such that the inherent viscosity of the polymer is at least 0.1, preferably 0.3-1.5. The inherent viscosity is measured at 25° C. at a concentration of 0.5% by weight of the polymer in a suitable solvent such as N-methylpyrolidone.
The quantity of organic solvent used in the process need only be sufficient to dissolve enough of one reactant, preferably the diamine, to initiate the reaction of the diamine and the dianhydride. It has been found that the most successful results are obtained when the solvent represents at least 60% of the final solution. That is, the solution should contain 0.05-40% of the polymeric component.
The second step of the process is performed by treating the poly(amide-acid) with a dehydrating agent, alone or in combination with a tertiary amine, such as acetic anhydride or an acetic anhydride-pyridine mixture. The ratio of acetic anhydride to pyridine can vary from just above zero to infinite mixtures.
In addition to acetic anhydride, lower fatty acid anhydrides and aromatic monobasic acid anhydrides may be used. The lower fatty acid anhydrides include propionic, butyric, valeric, and the like.
The aromatic monobasic acid anhydrides include the anhydride of benzoic acid and those of the following acids: o-, m-, and p-toluic acids; m- and p-ethyl benzoic acids; p-propyl benzoic acid; p-isopropyl benzoic acid; anisic acid: o-, m- and p-nitro benzoic acids; o-, m-, and p-halo benzoic acids; the various dibromo and dichloro benzoic acids; the tribromo and trichloro benzoic acids; and the like.
Tertiary amines having approximately the same activity as the preferred pyridine can be used in the process. These include isoquinoline, 3,4-lutidine, 3,5-lutidine, 4-methyl pyridine, 3-methyl pyridine, 4-isopropyl pyridine, N,N-dimethyl benzyl amine, 4-benzyl pyridine, and N,N-dimethyl dodecyl amine. These amines are generally used from 0.3 to equimolar amounts with that of the anhydride converting agent. Trimethyl amine and triethylene diamines are much more reactive, and therefore are generally used in still smaller amounts. On the other hand, the following operable amines are less reactive than pyridine: 2-ethylpyridine, 2-methyl pyridine, triethyl amine, N-ethyl morpholine, N-methyl morpholine, diethyl cyclohexylamine, N,N-dimethyl cyclohexylamine, 4-benzoyl pyridine, 2,4-lutidine, 2,6-lutidine and 2,4,6-collidine, and are generally used in larger amounts.
Dehydration of the poly(amide-acid) to form the polyimide, that is imidization, can also be performed by heating the poly(amide-acid) solution to temperatures at or above 200° C. at reflux to remove the water which is a by-product of the reaction. Additionally, a catalyst, such as p-toluenesulfonic acid, and/or an azcotrophing agent, such as monochlorobenzene, can be added to assist the thermal imidization.
A novel class of solvents for the polymerization of polyimides is the poly(arylsulfone)s of the present invention. The combination of the diamines and dianhydride can be added to the molten poly(arylsulfone) at temperatures between 200° and 400° C.; preferably between 300° and 380° C. While not generally considered solvents for the poly(amide-acid) intermediates, these poly(arylsulfones) are by virtue of being miscible true solvents for the polyimides of this invention. However, because the reaction between the aromatic amine and anhydride end groups takes place at such high temperatures, the amide-acid intermediate is never formed and thus the poly(arylsulfone) performs all of the desired functions of a good solvent including solubilization of the reaction product. Because of the relatively high viscosity of the resulting solution, the reaction can be best accomplished in an extruder or other device capable of conveying viscous polymer solutions. Such devices are known in the art and are described in any good text on polymer processing such as J. L. Throne, "Plastics Process Engineering, " Marcel Dekker, New York, 1979 hereby incorporated by reference. The extruder or other device should preferably be vented to provide for the removal of the by products (water) of the reaction. This process has several advantages. Firstly, because the processing takes place above 200° C., imidization occurs spontaneously and not in a separate step after the formation of the poly(amide acid). Secondly, the solvent (i.e., the poly(arylsulfone)) does not have to be removed via a recovery step after the polymerization is complete. Lastly, the blend is formed in situ and not during a subsequent compounding step. The elimination of these three intermediate steps results in considerably better economics.
The resulting polyimides of the instant invention can be homopolymers, random copolymers, and block copolymers. They have reduced viscosities as measured in N-methylpyrolidone at concentrations of 0.5% by weight at 25° C. between 0.1 and 1.5 dl/g and higher.
The polyamide-imides of this invention may be made by methods well known in the art such as those described in U.S. Pat. No. 4,713,438.
The preparation of the poly(amide-imides) is preferably performed using reactions that are similar to those discussed for the preparation of the polyimides. This method of preparation will be referred to as Method C. Typically a tricarboxylic acid monoanhydride or derivative thereof is reacted with a diamine (or mixture of diamines) as shown below and as described in, for example, Japanese Patent Application Nos. 61/126,136 and 61/126,137, hereby incorporated by reference. ##STR18##
Preferred tricarboxylic acid monoanhydride derivatives include 1,2,4-benzenetricarboxylic anhydride and 1,2,4-benzenetricarboxylic anhydride acid chloride. The preferred diamines include those described for the polyimides.
Typical aprotic solvents which are the same as those used for polyimides, e.g., N,N-dimethylacetamide or N-methylpyrrolidone, and the like are useful. In another embodiment, these polymers can be prepared via the reaction of diisocyanate and tricarboxylic acid monoanhydride. The reaction is base-catalyzed. See for example, Japanese Patent Application No. 61/14,218, hereby incorporated by reference. It is illustrated below: ##STR19##
Experimental details are generally the same as those described for the corresponding preparation of the polyimides.
The resulting polyamide-imides of the instant invention can be homopolymers, random copolymers, and block copolymers. They have reduced viscosities as measured in N-methylpyrrolidone at concentrations of 0.5% by weight at 25° C. between 0.1 and 1.5 dl/g and higher.
Not all blends containing the components mentioned above are miscible. However, a novel way has been determined to select those that are miscible with each other. It has been determined that the miscibility factor for the components must be negative for the components to be miscible and to form a polymer with a single glass transition temperature.
As mentioned previously, polymer miscibility cannot be predicted. There is recent evidence that once several examples are found where polymers of a class 1 are miscible with polymers of a class 2, then the phase behavior of blends of polymers of class 1 and polymers of class 2 can be correlated with structure. The net result is that a mathematical inequality can be written which correctly predicts when other polymers chosen from class 1 and class 2 are miscible. There is evidence that the miscibility of two polymers composed of several different types of mer units can be correlated by an equation of the type:
F.sub.c >.sub.i.sup.Σ.sub.j>i.sup.Σ (φ.sub.i.sup.1 φ.sub.j.sup.2 +φ.sub.i.sup.2 φ.sub.j.sup.1 -φ.sub.i.sup.1 φ.sub.j.sup.1 -φ.sub.i.sup.2.sub.j.sup.2)B.sub.ij (1)
where F c is a small positive number (or zero), the φ i k are related to the number of mers of type i in polymer K, and the B ij represents the interaction energy between mers of type i and j. A mer is a small substructual component of a polymer repeat unit. For example, in Paul, et al., Polymer 25, pp. 487-494 (1984), hereby incorporated by reference, the miscibility of the polyhydroxy ether of bisphenol A is successfully correlated with a series of aliphatic polyesters using (equation 10 in the above reference).
O>B.sub.13 φ.sub.1 '+B.sub.23 φ.sub.2 '-B.sub.12 φ.sub.1 'φ.sub.2 ' (2)
Equation (2) is equivalent to equation (1) if the following change of notation is made:
F c =O
φ' 1 =φ 1 1
φ 2 ' =φ 2 1
φ 3 2 =1
and all other φ i K =0.
In this case, the φ i K are taken to be the volume fraction mer i in polymer K. The B ij were essentially taken as adjustable parameters representing the enthalpy of interaction between group i and j. Paul and coworkers considered the polymer blend system to be made up of three groups, or mers:
(i) --CH 2 -- and
(ii) ##STR20## which make up the aliphatic polyesters, and (iii) ##STR21## which makes up the polyhydroxy ether.
Kambour, et al, Macromolecules, 16 pp. 753-757 (1983) used a similar equation to correlate the miscibility of poly(styrene-co-bromostyrene) with poly(xylenyl co-bromoxylenyl-ether), hereby incorporated by reference. In the case where polymer 1 contained only mers of type i and polymer 2 contained mers of type j and k, the condition of miscibility that is arrived at is (see equation 4 on page 756 of the above cited work):
X.sub.AB.sup.C >(1-λ.sub.c)X.sub.ij +λ.sub.c (X.sub.ik)-λ.sub.c (1-λ.sub.c)X.sub.kj (3)
Note the mistake in the third term of equation 4 in Kambour, et al, which is corrected in equation (3) above. Equation (3) is seen to be identical with equation (1) if the following change of notation is made:
F c =X AB c
X c =φ j 2
(1-X c )=φ k 2
φ i l =1
All other φ i k =0.
X ij =B ij for all i l j.
In this instance, Kambour has taken the φ i k to be the mole fraction mer i in polymer K. Again the B ij were taken to be adjustable parameters.
There is a precedent, then, for correlating miscibility using equation (1). We have seen that the φ i k may be interpreted as volume fractions or mole fractions. Prausnitz, et al, in the Properties of Gases and Liquids, Third Edition, published by McGraw Hill Book Co., New York, N.Y. (1977), hereby incorporated by reference, recommend the use of molecular area fractions in equations similar to equation (1) (See Chapter 8 in Prausnitz, et al). They recommend the use of the group contribution method developed by A. Bondi in the Physical Properties of Molecular Liquids, Crystals and Glasses Chapter 14, published by John Wiley and Sons, New York, N.Y. (1968), hereby incorporated by reference, for the estimation of the surface area of mer units.
It has been found that when poly(aryl sulfones) are miscible with imide containing polymers, the miscible blend comprises separately made biphenyl containing polysulfones with isopropylidene based polyimides or amide-imides formed into an intimate moldable mixture by physical methods such as melt extrusion.
Miscible combinations have been correlated for poly(aryl sulfone) and polyimide or amide-imide alloys. It is highly probable that they will be miscible if the Miscibility Factor (MF) defined by the following equation is less than 0.05: ##EQU1## where φ k l is the area fraction mer K in polymer l (l=1(PAES), 2(PI, PAI)). The mers are chosen from the list in Table I where their estimated molar surface areas are also given. The miscibility factor in Equation (4) may be thought of as a function of the composition of the PAES, designated by φ 1 1 , φ 2 1 , φ 3 1 , . . . φ m 1 , and the PI or PAI, by φ 1 2 , φ 2 2 , φ 3 2 , . . . φ n 2 .
If this function is less than 0.05, polymers 1 and 2 will be completely miscible. If this function is greater than 0.05, then polymers 1 and 2 will be for all practical purposes immiscible. Of course, when this function is near 0.05 then polymer 1 and 2 are likely to be partially miscible. The quantity φ k l may be calculated if the mole fractions of the various mers in polymer l are known. If X i is the mole fraction mer i in polymer l, then ##EQU2## where A i is the molar surface area of mer i (given in Table I) and the sum is over all types of mers which are given in Table I.
The blends of this invention are at least partially miscible. Preferably, the blends of this invention are miscible in all proportions. Preferably, the blends contain from about 2 to about 98, more preferably, the blends contain from about 15 to about 85 weight % of the poly(aryl sulfone), the balance being the polyimide or amide-imide constituent. The individual concentrations are readily chosen by those skilled in the art.
The blends of this invention are prepared by conventional mixing methods. For example, the polymer components are mixed with each other and any other optional ingredients in powder or granular form in an extruder. The mixture is extruded into strands. The strands are chopped into pellets; the pellets are molded into the desired article.
Additives which may be used with the thermoplastic alloy include reinforcing and/or non-reinforcing fillers such as wollastonite, asbestos, talc, alumina, clay, mica, glass beads, fumed silica, gypsum, graphite powder, molydenum disulfide and the like; and reinforcement fibers such as aramid, boron, carbon, graphite, and glass. Glass fiber is the most widely used reinforcement in the form of chopped strands, ribbon, yarn, filaments, or woven mats. Mixtures of reinforcing and non-reinforcing fillers may be used, such as a mixture of glass fibers and talc or wollastonite. These reinforcing agents are used in amounts of from about 10 to about 80 weight percent, whereas the non-reinforcing fillers are used in amounts of up to 50 weight percent. Other additives include stabilizers, pigments, flame retardants, plasticizers, processing aids, coupling agents, lubricants, mold release agents, and the like. These additives are used in amounts which achieve the desired result. A particularly useful additive, especially when either of the blend constituents contains a carbonyl linkage, is a hydrate such as those described in U.S. patent application Ser. No. 07/291,966, filed Dec. 30, 1988, now U.S. Pat. No. 4,963,627, entitled Injection Moldable Blends of Poly(Etherketones) and Poly Amide-Imides to Smyser et al.
EXAMPLES
The following examples serve to give specific illustrations of the practice of this invention but are not intended to limit the scope of this invention. They are exemplary, not exclusive. The examples show the unexpected discovery noted above. Table II compiles the polymers used in the following blending experiments along with their structures in terms of φ 1 k , φ 2 k . . . φ 7 k .
EXAMPLE 1
A 50/50 blend of PAES-I (Radel R5000 obtained from Amoco Performance Products, RV=0.56 dl/g as measured in 0.5% N-methylpyrolidone (NMP) solution at 25° C.) and PAI-I, as defined in Table II, (I.V.=0.90 dl/g as measured in 0.5% NMP solution at 25° C.) are melt mixed in a Brabender mixing head at 360° C. and 50 RPM for five minutes. The blend is compression molded into a 4×4×0.02 inch plaque at about 350° C. The molded plaque is observed to be transparent with low haze. The plaque is tested for tensile strength, 1% secant modulus and elongation at break according to a procedure similar to ASTM D-638. The pendulum impact strength of the plaque is also measured.
Pendulum impact strength is measured as follows. A steel pendulum is used, cylindrical in shape with a diameter of 0.83 inch and weighing 1.562 pounds. The striking piece, mounted almost at the top of the pendulum, is a cylinder 0.3 inch in diameter. Film specimens, 4 inches long, 0.125 inch wide and about 1 to 30 mils thick are clamped between the jaws of the tester so that the jaws are spaced one inch apart. The 0.125 inch width of the film is mounted vertically. The pendulum is raised to a constant height to deliver 1.13 foot pounds at the specimen. When the pendulum is released, the cylindrical striking piece hits the specimen with its flat end, breaks the film, and travels to a measured height beyond. The difference in the recovery height (i.e., the difference in the potential energy of the pendulum at the maximum point of the upswing), represents the energy absorbed by the specimen during the rupture. The impact strength, expressed in foot-pounds per cubic inch, is obtained by dividing the pendulum energy loss by the volume of the specimen.
The modulus-temperature and resilience-temperature relationship for the blend is determined using an Instron testing device equipped with a sample chamber capable of being heated to 400° C. at 1.6° C./min. From this information, the (Tg or Tgs) of the blend is (are) extracted as the minimum (minima) in the resilience-temperature curve at a strain rate of 0.2 inches/minute. See the discussion in Olabisi et al, Polymer--Polymer Miscibility, pp. 126-127, Academic Press, New York (1979), for a discussion of the modulus-resilience method. The results of the testing are shown in Table III.
TABLE I______________________________________MERS Surface AreaIndex (cm.sup.2 /mole) Structure of Mer______________________________________1 4.96 × 10.sup.9 ##STR22##2 7.02 × 10.sup.9 ##STR23##3 8.84 × 10.sup.9 ##STR24##4 4.6 × 10.sup.9 ##STR25##5 6.02 × 10.sup.9 ##STR26##6 7.06 × 10.sup.9 ##STR27##7 7.01 × 10.sup.9 ##STR28##______________________________________
TABLE II__________________________________________________________________________POLYMERS USED IN BLENDING EXPERIMENTS__________________________________________________________________________ Poly(aryl sulfones) Dihalobenzenoid Dihydric Method of Composition of Resultant Poly(aryl sulfone)PAES Compound(s) Mole % Phenol(s) Mole % Preparation φ.sub.1.sup.1 φ.sub.2.sup.1 φ.sub.3.sup.1 φ.sub.4.sup.1 φ.sub.5.sup.1 φ.sub.6.sup.1 φ.sub.7.sup.1__________________________________________________________________________I DCDPS 100 BP 100 A 0.46 0.33 0 0.21 0 0 0II DCDPS 100 BisS 100 A 0.41 0.59 0 0 0 0 0III DCDPS 100 BisA 100 A 0.39 0.27 0.34 0 0 0 0IV DCDPS 100 HQ 80 A 0.56 0.39 0 0.05 0 0 0 BP 20V BCPSB 100 HQ 50 A 0.32 0.46 0 0.22 0 0 0 BP 50VI DCDPS 100 BisS 75 A 0.45 0.55 0 0 0 0 0 HQ 25VII BCPSB 100 BP 100 A 0.30 0.42 0 0.28 0 0 0__________________________________________________________________________Triacid anhydrideacid chloride or Polyamide-imidesdianhydride or Method of Composition of Resultant Polyamide-imide diacid Chloride Mole % Diamine Mole % Preparation φ.sub.1.sup.2 φ.sub.2.sup.2 φ.sub.3.sup.2 φ.sub.4.sup.2 φ.sub.5.sup.2 φ.sub.6.sup.2 φ.sub.7.sup.2__________________________________________________________________________I 4-TMAC* 100 BAP 100 C 0 0 0.56 0 0 0.22 0.22II 4-TMAC 65 BAPP 100 C 0.30 0 0.27 0 0 0.29 0.14 PMDA 35III 4-TMAC 100 BAA 100 C 0 0 0.38 0 0 0.31 0.31IV 4-TMAC 100 BAPP 100 C 0.30 0 0.28 0 0 0.21 0.21V 4-TMAC 100 OBA 70 C 0.20 0 0 0 0 0.40 0.40 MPD 30VI 4-TMAC 50 MPD 100 C 0 0 0 0 0 0.25 0.75 IAC** 50__________________________________________________________________________ Polyimides Method of Composition of Resultant PolyimidePI Dianhydride Mole % Diamine Mole % Preparation φ.sub.1.sup.2 φ.sub.2.sup.2 φ.sub.3.sup.2 φ.sub.4.sup.2 φ.sub.5.sup.2 φ.sub.6.sup.2 φ.sub.7.sup.2__________________________________________________________________________I IPAN 100 BAA 100 B 0 0 0.56 0 0 0.44 0II IPAN 100 BAP 100 B 0 0 0.65 0 0 0.35 0III IPAN 100 OBA 100 B 0.18 0 0.32 0 0 0.50 0IV IPAN 100 MPD 100 B 0 0 0.39 0 0 0.61 0V BPDA 100 BAA 100 B 0 0 0.32 0.17 0 0.51 0VI BPDA 100 BAP 100 B 0 0 0.48 0.13 0 0.39 0VII BTDA 100 BAA 100 B 0 0 0.30 0 0.21 0.49 0VIII BTDA 100 BAP 100 B 0 0 0.47 0 0.16 0.37 0__________________________________________________________________________ *Trimethylacetamide **Isophthalic acid chloride
EXAMPLE 2 (COMPARATIVE)
Example 1 is repeated except PAES-II (Victrex PES-200P obtained from ICI Americas RV=0.5 dl/g as measured in 0.5% NMP solution at 25° C.) is substituted for PAES-I and the composition is 60/40 PAES-II/PAI-I. The molded plaque is translucent with noticeable haze. The results of the testing are given in Table III.
EXAMPLE 3 (COMPARATIVE)
A 50/50 blend of PAES-III (Udel P-1700 obtained from Amoco Performance Products, RV=0.5 dl/g as measured in 0.5% CHCl 3 solution at 23° C.) and PAI-I is made by dissolving 3 grams of each in NMP to make a 10% solution. It is coagulated into an 80/20 water/methanol mixture and filtered. The filtrate is reslurried in water and boiled for 5 hours, refiltered, and dried. The dry cake is compression molded as in Example 1. Its Tgs are determined as in Example 1 and are given in Table III.
CONTROLS A, B, C AND D
PAES-I, PAES-II, PAES-III, and PAI-I are compression molded at about 350° C. The moldings are tested as in Example 1. The results of the testing are given in Table III.
As can be seen, the blend of PAES-I and PAI-I is miscible by virtue of its intermediate single Tg and transparency. Conversely, blends of PAES-II or PAES-III with PAI-I are seen to be immiscible as two Tgs are detected and by virtue of the poor optical properties of the blends.
EXAMPLE 4
A 50/50 blend of PAES-I and PAI-II (I.V.=0.25 dl/g as measured in 0.5% NMP solution at 25° C.) is melt homogenized in a Brabender mixing head at 360° C. and 50 rpm. The blend is molded and tested as in Example 1 with the exception that the Tg is determined using a Polymer Laboratories DMTA operating in tensile mode at 10 Hz and scanning at 5° C./min. The Tg is taken as the maximum in the tan δ curve. The results are given in Table III. The molding is transparent with little haze.
EXAMPLE 5 (COMPARATIVE)
A 50/50 blend of PAES-III and PAI-II is melt homogenized in a Brabender mixing head at 360° C. and 50 rpm. The blend is molded and tested as in Example 4. The results are given in Table III. The molding is translucent with significant haze.
EXAMPLE 6 (COMPARATIVE)
A 50/50 blend of PAES-IV (RV=0.92 as measured in a 1% NMP solution at 25° C.) and PAI-II is melt homogenized in a Brabender mixing head at 360° C. and 50 rpm. The blend is molded and tested as in Example 4. The results are given in Table III. The molding is translucent with considerable haze.
CONTROLS E AND F
PAI-II (I.V.=0.79 dl/g as measured in 0.5% NMP solution at 25° C.; same as used in Example 4, except solid state advanced to a higher MW) and PAES-IV are compression molded into 4×4×0.20 inch plaques at 360° C. and tested as in Example 4. The results are given in Table III.
TABLE III__________________________________________________________________________BLEND PROPERTIES Pendulum Tensile Impact Strength Elongation Modulus Strength Tg(s)Example Component I Component II (psi) (%) (ksi) (ft-lb/in.sup.3) (°C.)__________________________________________________________________________1 50% PAES-I 50% PAI-I 11,400 16 236 121 2422 60% PAES-II 40% PAI-I 12,700 8.4 275 72 232, 2783 50% PAES-III 50% PAI-I -- -- -- -- 185, 265Control A 100% PAES-I -- 9,920 75 230 184 223Control B 100% PAES-II -- 12,000 26 245 116 229Control C 100% PAES-III -- 9,710 40 234 152 185Control D 100% PAI-I -- 14,300 13 289 97 2704 50% PAES-I 50% PAI-II 11,200 17 255 238 2355 50% PAES-III 50% PAI-II -- -- -- -- 184, 2366 50% PAES-IV 50% PAI-II -- -- -- -- 215, 260Control E 100% PAI-II -- -- -- -- -- 245Control F 100% PAES-IV -- -- -- -- -- 210__________________________________________________________________________
EXAMPLE 7
A 50/50 blend of PAES-I and PI-I (RV=0.60 dl/g as measured in 0.5% NMP solution at 25° C.) is made by dissolving 2.5 grams of each in dimethylacetamide (DMAC) at 25° C. to make a 20% solution. It is coagulated in a Waring blender filled with a methyl alcohol/water mixture. The resultant coagulant is filtered and dried overnight under vacuum at 200° C. The next morning it is compression molded into a 2×2×0.010 inch plaque at 360° C. The Tg of the plaque is measured using a Polymer Laboratories DMTA operating in the tensile mode at 1 Hz and scanning at 3° C./min. The HDT of the blend at 264 psi is estimated as the temperature where the modulus of the blend dropped to 100,000 psi as suggested by M. T. Takemori in the SPE Proceeding of ANTEC, pp. 216-219 (Apr. 24-27, 1978), hereby incorporated by reference. Results of the testing are given in Table IV.
EXAMPLE 8
A 50/50 blend of PAES-V (RV=0.57 dl/g as measured in a 1% NMP solution at 25° C.) and PI-I is made and tested as in Example 7. The results are given in Table IV.
EXAMPLE 9 (COMPARATIVE)
A 50/50 blend of PAES-VI (Radel A 400 obtained from Amoco Performance Products, RV=0.48 dl/g as measured in 1.0% NMP solution at 25° C.) is made and tested as in Example 7. The results are given in Table IV.
CONTROLS A, G, H, I
PI-I and PAES-I, V and VI are compression molded into 4×4×0.02 inch plaques at 360°-380° C. The moldings are tested as in Example 7 and the results are given in Table IV.
One of the advantages of a miscible blend as opposed to an immiscible blend (in addition to transparency) is demonstrated in the last column of Table IV. PAES-I and PAES-VI have similar Tgs and HDTs, yet the former is miscible with PI-I while the latter is not. A 50/50 blend with PI-I increases the HDT of PAES-I by 32° C. to 246° C. while it increases the HDT of PAES-VI by only 8° C. to 224° C. A significant improvement in the HDT of PAES-V, which is also miscible with PI-I, is observed on blending.
TABLE IV______________________________________BLEND PROPERTIES Tg(s) HDT*Example Component I Component II (°C.) (°C.)______________________________________7 50% PAES-I 50% PI-1 259 2468 50% PAES-V 50% PI-1 283 2639 50% PAES-VI 50% PI-I 227, 277 224Control A 100% PAES-I -- 223 214Control G 100% PI-I -- 292 281Control H 100% PAES-V -- 263 240Control I 100% PAES-VI -- 225 216______________________________________ *Estimated at 264 psi.
EXAMPLES 10 THROUGH 35
The phase behavior of the blends of Examples 1 through 9 are summarized in Table V. Further, the phase behavior of several additional 50/50 blends of various poly(aryl sulfones) with various polyimides and amide-imides are also summarized in Table V as Examples 10 through 35. The blends are made by the same methods used to prepare Examples 1 through 9, except where noted. The blends are compression molded and the Tg(s) of the moldings are determined by a) modulus/resilience, b) DMTA or c) DSC. The blends are judged to be miscible (immiscible) on the basis of one (two) Tg(s) existing between (similar to) those of the constituents. Only poly(aryl sulfones) containing biphenyl linkages are found to be miscible with polyimides or amide-imides. Thus, biphenyl linkages in the poly(aryl sulfone) appear to be necessary. Further, the polyimides or amide imides all contain an isopropylidene group. Imide groups in conjunction with isopropylidene groups also appear to be necessary as no polyamide or amide-imide not containing an isopropylidene linkage is found to be miscible with a poly(aryl sulfone).
The required proportions of biphenyl linkages in the PAES and isopropylidene linkages in the PI or PAI are determined by Equation 4. If the Miscibility Factor is less than 0.05 then the blend will very likely be miscible in all proportions. If the Miscibility Factor is very near 0.05, a borderline case exists and the blend may be miscible or immiscible, or most likely partially miscible. Finally, if the Miscibility Factor is greater than 0.05 then the blend will very likely be immiscible and not within the scope of this invention.
The last column in Table V gives the value of the Miscibility Factor calculated for the particular polymer combination given in columns 2 and 4. As can be seen, the Miscibility Factor is less than or equal to 0.05 in every miscible example. Likewise, the Miscibility Factor is greater than or equal to 0.05 in every immiscible example. Note that when the Miscibility Factor is equal to 0.05, then the Example may be miscible (Example 18), immiscible (Example 32) or partially miscible (Example 16). Thus the deviation of the Miscibility Factor from the value of 0.05 is a measure of the blend compatibility.
TABLE V__________________________________________________________________________Observed Phase Behavior of 50/50 Blends of Various Poly(aryl sulfones)with Various Polyimides and Polyamide-imides Biphenyl Imide Group in Containing Method of Observed Miscibility FactorExamplePAES Compound Repeat Unit Compound Forming Blend Phase Behavior of Equation__________________________________________________________________________ 4 1 PAES-I YES PAI-I 2 Miscible -0.01 2 PAES-II NO PAI-I 2 Immiscible 0.07 3 PAES-III NO PAI-I 1 Immiscible 0.21 4 PAES-I YES PAI-II 2 Miscible 0.04 5 PAES-III NO PAI-II 2 Immiscible 0.39 6 PAES-IV SOME PAI-II 2 Immiscible 0.12 7 PAES-I YES PI-I 4 Miscible -0.21 8 PAES-V YES PI-I 4 Miscible -0.14 9 PAES-VI NO PI-I 4 Immiscible 0.1210 PAES-VI NO PAI-III 1 Immiscible 0.2711 PAES-II NO PAI-III 1 Immiscible 0.2712 PAES-I YES PAI-III 1 Immiscible 0.2913 PAES-III NO PAI-III 1 Immiscible 0.7014 PAES-VI NO PAI-II 2 Immiscible 0.2115 PAES-II NO PAI-II 2 Immiscible 0.2316 PAES-V YES PAI-II 2 Partially Miscible* 0.0517 PAES-VIII YES PAI-II 1 Miscible 0.0118 PAES-V YES PAI-IV 2 Miscible 0.0519 PAES-VI NO PAI-V 2 Immiscible 1.0420 PAES-II NO PAI-V 2 Immiscible 1.0221 PAES-VI NO PAI-VI 2 Immiscible 1.7222 PAES-II NO PAI-VI 2 Immiscible 1.6523 PAES-I YES PI-V 2 Immiscible 0.1724 PAES-V YES PI-V 2 Immiscible 0.2325 PAES-II NO PI-VI 2 Immiscible 0.2926 PAES-I YES PI-VI 2 Miscible -0.0827 PAES-III NO PI-VI 2 Immiscible 0.2928 PAES-I YES PI-IV 2 Immiscible 0.0529 PAES-I YES PI-VIII 2 Miscible -0.1330 PAES-V YES PI-VIII 2 Miscible -0.0631 PAES-II NO PI-II 2 Immiscible 0.1432 PAES-III NO PI-II 3 Immiscible 0.0533 PAES-II NO PI-I 3 Immiscible 0.1634 PAES-I YES PI-III 2 Miscible 0.0135 PAES-VIII YES PI-III 1 Miscible 0.00__________________________________________________________________________ Methods of Forming the Blends 1 = Solution Blend as in Example 3 2 = Melt blend made in Brabender as in Example 1 3 = Solution Blend as in Exmaple 3 Except methylene chloride was used as the solvent instead of Nmethyl pyrolidone 4 = Solution Blend as in Example 7 *Blend determined to be partially miscible by transmission and scanning electron microscopy. Electron dispersion spectroscopy was used to contras the poly(aryl sulfone) rich phase. Tgs of the constituents were too close together to determine phase behavior by mechanical or calorimetric methods.
EXAMPLE 36
A 50/50 blend of PAES-I (RADEL R5000 obtained from Amoco Performance Products, Inc.) and PAI-II (I.V.=0.30 dl/g as measured in 0.5% NMP solution at 25° C.) is made in a one inch single screw (L/D=36) extruder at about 350° C. The extrudate is chopped into pellets, dried to remove absorbed moisture and injection molded at about 340° C. into ASTM test specimens. The molded blend is tested as shown in Table VI.
EXAMPLE 37 (COMPARATIVE)
A 50/50 blend of PAES-II (Victrex 200P obtained from I.C.I. Americas, Inc.) and PAI-II (same as in Example 36) is made and tested as described in Example 36. The results are given in Table VI.
CONTROLS J AND K
Pellets of the PAES-I and PAES-II of Examples 36 and 37 are injection molded and tested in Example 36. The results are given in Table VI.
All of the polyimides, polyamide-imides and poly(aryl sulfones) discussed up to this point are made by conventional solution techniques. The following is an example of a polyimide made in an extruder using a poly(aryl sulfone) as the solvent.
EXAMPLE 38
A 60/40 blend of PAES-I and PI-VI is made in the following manner. A dry mixture of:
______________________________________53.85% BAP44.70% BPDA1.39% Phthalic Anhydride100.00%______________________________________
is thoroughly homogenized. Forty percent of this mixture is added to 60% of the PAES-I of Example 36 and extruded in a single screw one inch diameter (L/D=36) Killion extruder. The extruder has seven zones, including the die, and two vents. The equally spaced seven zones from the rear to the die of the extruder have the following temperatures: cold, 570° F., 570° F., 670° F., 670° F. and 670° F.
Under the above conditions, the mixture is extruded at about 2 pounds/hour chopped into pellets and then reextruded a second time. The second time through the zone temperatures are all raised to 700° F., otherwise conditions are the same. The extrudate is chopped, diced, and injection molded at about 700° F. into a 300° F. mold. The resulting ASTM test specimens are used to determine the properties given in Table VI.
EXAMPLE 39
A 60/40 blend of PAES-II and PI-VI is made in the following manner. A dry mixture of:
______________________________________53.85% BAP44.70% BPDA1.39% phthalic Anhydride100.00%______________________________________
is thoroughly homogenized. Forty percent of this mixture is added to 60% PAES-II of Example 37 and extruded under identical conditions given in Example 38. The resulting pellets are injection molded and tested as shown in Table VI.
Examples 36 through 39 clearly depict the advantages of miscible blends over immiscible blends. For example, consider heat distortion temperature (HDT). PAES-I and PAES-II have similar Tgs and heat distortion temperatures (214° C. for PAES-I and 224° C. for PAES-II). Blending each with PAI-II to make a 50% blend resulted in the increase in HDT depicted in Table VII. Likewise, a blend of each with PI-VI to make a 40% blend resulted in the increase in HDT also shown in Table VII. Recall that PAES-I is miscible with both PAI-II and PI-VI (See Table V, Examples 4 and 26) while PAES-II is immiscible with both (See Table V, Examples 15 and 25). Thus, it is seen that miscibility resulted in a substantial increase in HDT while immiscibility resulted in very little.
Comparing Examples 36 to 37 and 38 to 39, it is also seen that miscibility produced a substantial benefit in toughness. The miscible blends (Examples 36 and 38) have significantly higher elongations at break, tensile impact strengths, and unnotched Izods than their immiscible counterparts (Examples 37 and 39) even though these values for the two controls (J and K) are almost identical.
The improvement in environmental stress rupture resistance (chemical) is also dramatic. Tensile bars of controls J and K and Examples 36 and 37 are loaded in flexure to an outer fiber stress of 3000 psi. Methylethylketone (MEK) is applied to the surfaces. MEK is a common ingredient of paint thinners. The times required for the bars to rupture are given in Table VIII. Note that both controls are rapidly attacked by MEK and that the immiscible blend is not significantly better. The miscible blend of PAES-I and PAI-II, however, is unaffected by MEK for an extended period of time.
TABLE VI__________________________________________________________________________ Example 36 Example 37 Example 38 Example 39 ASTM Control J Control K 50% PAES-I 50% PAES-II 60% PAES-I 60% PAES-IIComposition Test Method PAES I PAES II 50% PAI-II 50% PAI-II 40% PI-VI 40% PI-VI__________________________________________________________________________Tensile Strength D-638 10,700 12,000 11,500 12,400 12,600 10,800(psi)Elongation (%) D-638 84 112 41 10 11 3.5Tensile Modulus D-638 344 398 412 452 423 452(ksi)Tensile Impact D-1822 144 137 111 88 57 19(ft-lb/in.sup.2)Heat Deflection* D-648 214 224 224 223 230 225Temperature@ 264 psi(°C.)Unnotched Izod D-256 No Break No Break No Break 63 35 11@ 1/8"(ft-lb/in)__________________________________________________________________________ *Samples annealed at 200° C. for 4 hours prior to testing.
TABLE VII__________________________________________________________________________EFFECT OF MISCIBILITY ON HDT Example Example 36 Example 37 Example 38 Example 39 (Miscible) (Immiscible) (Miscible) (Immiscible) 50% PAI-II 40% PI-VIComposition 50% PAES-I 50% PAES-II 60% PAES-I 60% PAES-II__________________________________________________________________________Increase in 10 -1 16 +1HDT °C. overPAES Component__________________________________________________________________________
TABLE VIII__________________________________________________________________________CHEMICAL RESISTANCE Control J Control K Example 36 Example 37__________________________________________________________________________Composition PAES-I PAES-II 50% PAES-I 50% PAES-II 50% PAI-II 50% PAI-IIMEK at 23° C. Rupture Immediate No effect Immediateand 3000 psi after 5 min. Rupture after 24 hrs. Rupture__________________________________________________________________________
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. | A method for the preparation of miscible blends comprising biphenyl-containing poly(aryl sulfones) and polyimides is disclosed. The process comprises adding the monomeric polycarboxylic acid and aromatic diamine components of the polyimide to a suitable polyaryl sulfone in a vented extruder and melt-processing the resulting mixture, thereby polymerizing the monomers to form the polyimide component of the blend. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present application relates to temperature controlled railroad freight cars, and particularly to railroad freight car body structures incorporating air duct arrangements for circulation of air from a refrigeration or heating unit to various locations within a body of such a car while maximizing available cargo space.
[0002] Temperature controlled railroad boxcars are well known, and have long used mechanical refrigeration and heating units mounted on an end wall, primarily to deliver chilled air to the interior of the car. For simplicity, the term refrigeration unit will be used herein to refer to refrigeration units, heating units, or units capable of both heating and cooling. Air from a refrigeration unit is typically forced into one end of an upper plenum extending longitudinally overhead, near the roof of the car, to deliver the conditioned air throughout the car to maintain a desired temperature throughout the cargo space in the car body. Such plenums in the past have intruded down into otherwise useable cargo space more than is desired, in order to assure sufficient air flow throughout the car body. This downward projection has also made the plenum vulnerable to damage from lift trucks moving cargo within such cars.
[0003] Typically, an air circulation pattern in such a temperature-controlled car includes flow of air down from the upper plenum onto and along the sides of the cargo and the end wall of the car that is remote from the refrigeration and heating unit. Air returns along the floor to a return air intake plenum leading back up along the near end wall to the refrigeration unit.
[0004] As railroad car sizes have increased it has become increasingly difficult to ensure even distribution of air throughout a railroad freight car, as needed in order to avoid uneven cooling that could damage parts of a sensitive cargo. A factor contributing to such difficulty is the desire to provide as much useable cargo space as possible within a boxcar whose size is limited by clearance along rights-of-way where the car is intended to be used.
[0005] Another factor in the design of such railcars is the need to avoid excessive car weight, which would limit the weight of cargo that could be carried and add to the cost of fuel used in hauling the car.
[0006] In view of these factors, it is desired to provide the necessary air circulation flow and distribution through an upper plenum that is no larger than necessary, so that it takes as little as possible of the potential cargo space within a refrigerated boxcar body, is out of the way of lift truck uprights and the like, and is not unnecessarily heavy.
[0007] Along with larger cars has come the desire to use larger lift trucks to quickly load and unload such cars. Lift trucks now in such use are rated at up to 60,000 lb (27240 kilograms) per axle. It is therefore also desired to provide for such a car a floor structure that provides sufficient strength and aids efficient air circulation and thermal conduction to or from the cargo, and yet does not contribute excessive weight to the car.
SUMMARY OF THE INVENTION
[0008] The present invention provides an answer to the aforementioned need for improved distribution of conditioned air within the cargo space of a temperature-controlled railroad freight car, as defined by the claims which follow.
[0009] In particular, in one preferred embodiment of the present invention an air outlet port from a refrigeration unit extends through an opening in an end wall of a railroad freight car body at a distance beneath a ceiling height and is interconnected with an inflow end of an upper plenum extending closely along the ceiling toward an opposite end wall of the car body. A diverter extends slopingly upward, from a location near a lower side of the air outlet port of the refrigeration unit, into the inflow end of the plenum, smoothly directing a flow of air from the outlet port of the refrigeration unit into the inflow end of the upper plenum. The diverter preferably includes an upper shoulder located at the inflow end of the upper plenum, defining a most constricted part of a path for the flow of air from the refrigeration unit, and an inner margin portion of the diverter extends away from the shoulder at a gently sloping angle, allowing the flow of air to expand slightly as it enters into the inflow end of the plenum.
[0010] In a preferred embodiment of the invention, an upper deflector is also included and provides a smoothly curved concave surface defining part of the path for the flow of air. The upper deflector extends from an end wall of the car, adjacent the inlet opening, to an upper interior surface of the upper plenum, and also contributes to smooth flow of air from the refrigeration unit into the plenum.
[0011] Smooth flow of air from the refrigeration unit into the upper plenum, combined with a smooth substantially unobstructed interior shape of the upper plenum, contributes to continued smooth flow of air throughout the upper plenum over the length of the temperature-controlled car, even in a car considerably longer than previously known refrigerated cars.
[0012] The foregoing and other features of the present invention will be more readily understood upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] FIG. 1 is a side elevational view of a temperature controlled railroad boxcar which includes one preferred embodiment of the present invention.
[0014] FIG. 2 is a side elevational view of a portion near a first end of the car shown in FIG. 1 , with the near side cut away to expose the interior of the car, showing a part of a pattern of flow of air from the refrigeration unit to the cargo space within the car and back to the refrigeration unit.
[0015] FIG. 3 is a side elevational view of a portion near the other end of the car shown in FIG. 1 , with the near side cut away to expose the interior of the car, showing another part of the pattern of flow of air from the refrigeration unit to the cargo space within the car and back to the refrigeration unit.
[0016] FIG. 4 is a sectional view toward a first, or “A” end of the car, taken along line 4 - 4 of FIG. 1 .
[0017] FIG. 5 is a sectional view toward a second, or “B” end of the car, taken along line 5 - 5 of FIG. 1 .
[0018] FIG. 6 is an isometric view from a point above and to one side of the car shown in FIG. 1 , and looking toward the “A” end of the car, showing a preferred arrangement of a plenum adjacent the ceiling of the car and an air discharge port for a refrigeration unit carried on the “A” end of the car.
[0019] FIG. 7 is a view of a portion of FIG. 2 at an enlarged scale, showing details of the inflow end of the upper plenum and associated structures.
[0020] FIG. 8 is a partially cutaway sectional view, taken along line 8 - 8 in FIG. 1 , showing a portion of the floor, subfloor, and subframe structures of the car.
[0021] FIG. 9 is a view of a detail of FIG. 8 at an enlarged scale, showing construction of an end wall and a side wall.
[0022] FIG. 10 is a sectional view, at an enlarged scale, taken along line 10 - 10 in FIG. 8 , showing a portion of the structure of the subfloor and floor of the temperature-controlled car.
[0023] FIG. 11 a is a sectional view taken along 11 - 11 in FIG. 8 at an enlarged scale, showing the construction of the floor and subfloor of the car.
[0024] FIG. 11 b is a detail view at an enlarged scale of a portion of FIG. 11 a , showing an area of intersection of a subfloor portion with a side wall of the car.
[0025] FIG. 12 is an exploded view, at an enlarged scale, of portions of the extruded aluminum floor shown in FIG. 11 .
[0026] FIG. 13 is a partially cutaway top plan view of a longitudinally central portion of the car, showing provision for gaining access to the tubular structure of the floor for cleaning and repair.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Referring now to FIGS. 1-8 of the drawings which form a part of the disclosure herein, a temperature-controlled railroad freight car 20 has an underframe structure 22 which may include a center sill 24 , a pair of side sills 26 , and a pair of body bolsters 28 each supported by a wheeled truck 30 . Cross-bearers 32 extend from the center sill to each of the side sills 26 , and crossties 34 , of lighter construction, extend similarly at spaced-apart locations between those of the body bolsters 28 and cross-bearers 32 . Longitudinal stringers 36 are spaced apart between the side sills 26 and center sill 24 and are carried by the bolsters 28 , cross-bearers 32 and crossties 34 , assisting in supporting a subfloor 38 and a floor 40 that rests on the subfloor 38 . An end sill 41 is located at each end of the car body, interconnecting the opposite side sills 26 that extend the entire length of the car between the end sills.
[0028] Side walls 42 and end walls 44 and 46 are supported by the underframe and extend upwardly above the floor 40 to a roof 48 . The subfloor 38 , end walls 44 , 46 , side walls 42 , and roof 48 are of a thermally insulating construction. The floor 40 , inner faces of the side walls and end walls, a ceiling 50 , and an upper plenum 52 suspended beneath the ceiling 50 , define an enclosed cargo space 53 . Doorway openings 54 are provided in the side walls 42 , and may be closed by conventional insulated doors 56 . Construction of the side walls 42 and floor 40 may be largely conventional, in connection with one aspect of the car 20 .
[0029] Preferably, as may be seen with reference also to FIGS. 2, 3 , 4 and 5 , the roof 48 of the car may be of composite construction, including a skin sheet 57 of corrugated sheet steel, for example 13 gauge steel panels pressed to the desired shape and welded together, and which is preferably cambered to promote runoff of precipitation. A layer 58 of thermal insulation material such as a closed cell plastic foam is fastened to the skin sheet 57 and may have a depth 60 of about six inches (7.6 cm), below which smooth ceiling panels 62 of fiber reinforced plastic are located.
[0030] In a preferred embodiment of the temperature-controlled railcar 20 , the roof 48 is manufactured as an assembly of composite materials that can be placed atop and fastened to the end walls 44 , 46 and side walls 42 as a single module during the process of assembling the car 20 . A fiber-reinforced polymeric resin liner including the substantially flat ceiling panels 62 of fiber reinforced plastic is attached to the skin 57 to form an enclosed space between the skin 57 and the liner. That space is filled with poured-in-place urethane foam insulation and cured, with the roof 48 assembly held in a suitable press to maintain the required shape.
[0031] A refrigeration unit 64 is mounted on the outer side of the end wall 44 at an “A” end of the car, and a fuel tank 66 for the refrigeration unit 64 may be supported by the underframe 22 of the car beneath the refrigeration unit.
[0032] A refrigeration unit opening 68 is provided in the “A” end wall 44 to receive an inwardly directed portion of the refrigeration unit 64 and to permit air from within the cargo space 53 to enter into the refrigeration unit 64 through a lower portion of the refrigeration unit opening 68 , to be chilled or heated as may be needed, and to allow the refrigerated (or heated) air from the refrigeration unit 64 to be delivered into the car for distribution as necessary within the cargo space 53 . The top 70 of the refrigeration unit opening 68 is spaced downward a distance 72 such as 1 inch (2.5 cm) beneath the height of the ceiling 50 . The refrigeration unit opening 68 may have a height 74 of 46 inches (116.8 cm), for example, in order to accommodate any of various commercially available refrigeration units.
[0033] An upper, or air inlet opening portion 76 of the refrigeration unit opening 68 extends down to the structure of the top 78 of a return air plenum 80 extending up from the floor 40 along the interior of the end wall 44 . Air can return through the return air plenum 80 to the supply air opening 82 or intake of the refrigeration unit 64 . The upper or air inlet opening portion 76 of the refrigeration unit opening 68 , above the top 78 of the return air plenum 80 , receives the air outlet port 84 of the refrigeration unit, from which a flow of air proceeds toward the interior of the cargo space 53 within the car body 20 . The air outlet port 84 is defined by the refrigeration unit 64 and may have, for example, a height 86 of 4⅞ inches (11.9 cm) and a width 88 of 30 13/16 inches (78.1 cm) in a refrigeration unit available from the Carrier Corporation.
[0034] A general pattern of air circulation is shown by the arrows 89 in FIGS. 2, 3 , 6 , and 7 . The upper plenum 52 extends along the underside of the ceiling 50 from a location adjacent the “A” end wall 44 of the car toward the opposite, or “B”, end wall 46 of the car. Bottom panels 90 and side panels 92 of the upper plenum 52 are perforated, beginning from a point a predetermined distance 94 , such as 8 feet, from the “A” end wall and thence along the length 96 of the upper plenum 52 to a location near the “B” end wall 46 . Perforations may be circular holes 1 inch (2.5 cm) in diameter arranged in line with center-to-center spacings 99 of 6 inches (15.2 cm) in the side panels 92 , as shown in FIG. 2 , in one preferred embodiment. In the plenum bottom panel 90 , the holes 97 may be arranged in staggered transversely extending rows with holes spaced apart by a distance 99 ′ of about 14¾ inches (37.5 cm) in a row and with rows spaced apart by a distance 99 ″ of about 18 inches (45.7 cm), as shown in FIG. 6 , to allow air to escape from the upper plenum 52 in an evenly distributed fashion.
[0035] A conduit 98 extends downwardly along the interior side of the “B” end wall 46 toward the floor 40 , and passageways 100 are defined longitudinally through the floor 40 toward the “A” end beneath cargo (not shown) that may be resting on the floor 40 , to complete a circulation route for air, collecting and leading the flow of air back toward the “A” end of the car body after it has absorbed heat from the cargo and from the ceiling 50 , walls 42 , 44 , and 46 , and floor 40 . The return flow of air through the floor 40 makes that air available near the “A” end of the car 20 to be drawn into the refrigeration unit 64 and again chilled for circulation again within the cargo space. Air which has escaped from the upper plenum 52 through the perforations described above flows over the upper surfaces and along the side surfaces of cargo contained in the cargo space 53 , and is then conducted forward within the car, along the floor 40 and at least partially through the air passageways 100 , toward the “A” end. The return air plenum 80 receives the forward-flowing air from the passageways 100 , or through openings 101 in the sides of the return air plenum 80 , and conducts it into the supply air, or intake, opening 82 of the refrigeration unit.
[0036] The ceiling 50 is preferably adhesively attached to the underside of the roof 48 as an integral part thereof, and is preferably constructed of generally flat horizontal panels 62 of fiber reinforced polymeric resin, which can be amply stiff, are of lighter weight than previously utilized metal ceiling panels, and can be interconnected with each other in smooth joints, providing a generally smooth and flat ceiling surface as the upper interior surface of the upper plenum 52 .
[0037] The bottom panels 90 of the upper plenum 52 are similarly flat and located parallel with the ceiling panels 62 , providing a wide plenum with smooth interior surfaces and a smaller height than that of similarly located plenums in previously known cars. The height 102 of the upper plenum 52 is preferably less than 4 inches (10.2 cm) and more preferably is about 3 15/16 inches (10.0 cm), while the width 104 of the upper plenum 52 is preferably relatively great, to spread the flow of air over the width of the cargo space, and may, for example, be about 88 13/16 inches (225.6 cm).
[0038] In a preferred embodiment of the upper plenum 52 , the bottom panels 90 of the plenum are of a stiff fiber reinforced resin sheet material having a nominal thickness of 0.075 inch (0.19 cm) and the sides 92 of the upper plenum 52 are of easily flexible urethane resin sheet material adhesively attached to the ceiling 50 and the plenum bottom panels 90 . A central support web or a plurality of small support strips 106 of similar flexible material may be used to support the median portions of the plenum bottom panels 90 , although the plenum bottom panels 90 are preferably rigid enough to be largely self supporting and remain substantially flat and parallel with the ceiling 50 . The flexibility of the plenum sides 92 and support strips 106 permits the bottom panels 90 simply to move up if bumped by a lift truck or cargo during loading or unloading of the car, and to move back down into place undamaged when the offending item has been removed. The car 20 may be constructed to provide an interior height of 11 feet, 9 inches (3.58 m) between the floor 40 and the upper plenum 52 , while remaining within the limitations of AAR Plate F and providing acceptable thermal insulation.
[0039] The conduit 98 defined along the “B” end wall 46 for downward flow of air has a cross sectional area which is smaller than that of the interior of the upper plenum. While the conduit 98 , as shown in FIG. 5 , extends across most of the width 148 of the “B” end wall 46 , a vertical conduit wall 107 is spaced apart from the interior surface of the insulated “B” end wall of the car by a distance 108 of, for example, only 1½ inches (38 mm), which is about one-third the height 102 of the upper plenum 52 mentioned previously. The flow of air down through the conduit 98 along the interior face of the “B” end wall 46 is thus comparatively restricted, generating some back pressure against the flow of air through the upper plenum 52 and requiring some of the flow of air into the upper plenum 52 to flow out of the upper plenum 52 through the perforations in the sides 92 and bottom panels 90 of the upper plenum.
[0040] Nevertheless, in order for the air to be distributed as evenly as is necessary throughout the interior of the cargo space 53 within the car 20 , it is desired for the flow of air through the upper plenum 52 to proceed unimpeded and smoothly toward the “B” end of the car.
[0041] Because of the location of the air outlet port 84 in the refrigeration unit 64 , the top of the air outlet port 84 is spaced downward from the top 70 of the refrigeration unit opening 68 in the “A” end wall 44 of the car body by a distance 109 of about 2 inches (5.1 cm). Because the height 86 of the air outlet port 84 of the refrigeration unit 64 is greater than the height 102 of the upper plenum 52 , the bottom 110 of the air outlet portion 84 is thus located at a distance below the ceiling 50 and also below the plenum bottom panel 90 . In order to promote the desired smooth flow through the interior of the upper plenum 52 , the flow of air from the air outlet port 84 through the end wall 44 at the “A” end of the car 20 must be diverted upward to the inflow end 112 of the upper plenum 52 , but diversion must be accomplished without causing turbulence that would interfere with the flow of air through the interior of the upper plenum 52 toward the opposite, or “B”, end of the car 20 . Accordingly, a diverter 114 is mounted atop a transverse structural member 116 that extends across the width of the interior of the car at the top of the return air plenum 80 at the “A” end, as may be seen in FIGS. 4, 6 , and 7 .
[0042] A preferred embodiment of the diverter 114 includes a narrow base flange 118 mounted upon and attached to the transverse structural member 116 and extending away from the “A” end wall 44 . An upwardly sloped front face portion 120 extends from the base flange 118 toward the ceiling 50 and away from the interior face of the end wall 44 at the “A” end, at an angle 121 preferably in the range of 40°-60° and most preferably equal to about 45° to the plenum bottom panel 90 . An uppermost portion of the diverter 114 , at the top of the front face portion 120 , defines a shoulder 122 , and beyond the shoulder 122 an inner margin portion 124 extends further away from the “A” end wall 44 into the inflow end 112 of the upper plenum 52 , extending away from the shoulder 122 at a gentle downward slope, such as an angle 125 in the range of 3-6 degrees and preferably of about four degrees to the plenum bottom panel 90 . The shoulder 122 and the inner margin portion 124 may be considered to be a flow transition portion of the diverter 114 .
[0043] A flow of air from the outlet port 84 of the refrigeration unit 64 is forced to follow the sloping front face 120 of the diverter 114 upward to and through a most restricted area, or throat, near the inflow end 112 of the upper plenum 52 , at the location of the shoulder 122 . The available area for flow of air into the upper plenum 52 then expands gradually along the gently sloping inner margin portion 124 toward the interior of the upper plenum 52 and the “B” end of the car 20 . A blocking panel 123 aligned with each side panel 92 seals the space above the diverter 114 to the upper plenum 52 at each side.
[0044] Preferably, in addition to the diverter 114 an upper deflector panel 126 is also provided and extends generally horizontally from the interior face of the “A” end wall toward the “B” end wall from the top of the refrigeration unit opening 68 defined through the “A” end wall 44 , thus at a small distance beneath the ceiling 50 , to a location approximately above the interior face of the refrigeration unit 64 and the lower, front margin 128 of the diverter 114 . From that location, the upper deflector 126 extends arcuately upward and away from the “A” end wall 44 toward a location on the ceiling 50 at the inflow end 112 of the upper plenum 52 , in a downwardly facing, concave shape, appearing in side view in FIGS. 2 and 7 as a partial cylinder. The upper deflector 126 thus aids in smoothly directing the flow of air from the outlet port 84 of the refrigeration unit 64 into the inflow end 112 of the upper plenum, and in gradually reducing the space available for the flow of air to a minimum located approximately at the location of the shoulder 122 .
[0045] Both the diverter 114 and the upper deflector 126 may be of fiber reinforced plastic resin sheet material, in order to minimize the weight of the car 20 .
[0046] As a result of the arrangement of the diverter 114 and upper deflector 126 , the air from the refrigeration unit 64 , which initially flows generally horizontally from the outlet port 84 , is diverted upward by the sloping front face 120 of the diverter 114 . The flow of air is shaped further by the concave lower face of the upper deflector 126 , and is then redirected to a horizontal flow into the inflow end 112 of the upper plenum. The flow is slightly constricted by the shoulder 122 at the top of the forward face of the diverter 114 and is thereafter allowed to expand gradually as it accelerates and proceeds along the gently sloping inner margin portion 124 of the diverter 114 as shown by the arrow 127 . The air thus moves smoothly in a suppressed turbulent state in a generally horizontal direction through the upper plenum 52 toward the “B” end of the car body as it leaves the diverter 114 . This construction permits an interior length of the cargo space 53 of as much as 72 feet, 3 inches (22.02 m) between the conduit 98 at the “B” end and the return plenum 80 at the “A” end.
[0047] Since the upper plenum 52 is essentially airtight near the input end 112 and for a distance toward the “B” end of the car, until the pattern of perforation is encountered, a distance 94 of about 8 feet from the end wall 44 at the “A” end of the car 20 , the flow of air continues within the upper plenum 52 toward a region of gradually decreasing pressure extending toward the “B” end, created as air is exhausted from the upper plenum 52 through the perforations along the sides 92 and bottom panel 90 of the upper plenum 52 to flow over and around cargo toward the floor 40 . Because the interior surfaces of the plenum 52 are generally planar and smooth, rather than being obstructed by raised joints or ribs extending transversely across the upper plenum 52 to provide stiffness as in previously utilized ceiling panels and plenum panels, the smooth flow of air continues from the “A” end to the “B” end of the car body relatively free from turbulence.
[0048] Referring to FIGS. 8 and 9 , each side wall 42 rests atop and extends upwardly from a respective one of the side sills 26 , with a sheet steel outer skin sheet 131 supported by a plurality of upright side posts 132 spaced apart at intervals between corner posts 134 . A doorway frame 136 is incorporated, and all of the side posts 132 , corner posts 134 and doorway frame members 136 are securely fastened to the outer skin sheet 131 as by welding. The end walls 44 and 46 also include steel skin sheets 131 and extend upward to join the roof 48 at each end of the car 20 . As an interior face of each side wall 42 , corrugated fiber-reinforced plastic panels 138 are fastened, as by suitable adhesives or nails, to nailing strips 140 of non-metallic material fastened, as by bolts or other suitable fasteners, to each of the side wall posts 132 . Flat interior panels 137 are mounted in the end walls 44 and 46 . Spaces within the side walls 42 , between the skin 131 and panels 138 are preferably filled with foamed-in-place insulating foam resin 139 , such as closed cell urethane foam, and the spaces between the skin 131 and interior panels 137 of the end walls 44 and 46 are filled preferably with foam blocks.
[0049] At the top of each side wall 42 and extending longitudinally along the entire length 141 of the car body 20 is a top chord assembly 142 having an exterior structural layer 144 of sheet steel incorporating a horizontal leg, a downwardly angled diagonal leg, a small inwardly protruding L-shaped portion, and a downwardly extending leg that mates with and is parallel with outer sheet 131 of the side wall. The roof assembly 48 fits between the top chords 142 with the margins of the steel skin 57 of the roof extending above and along the horizontal portions of the top chord assemblies 142 . An arcuate wall closure panel 146 extends from the top of the wall 42 , 44 , 46 on the interior of the car, to the ceiling panel 62 defining the bottom side of the roof structure 48 , and the space between the wall closure panel 146 and the top chord outer structural member 144 is filled with insulating closed cell foam, preferably foamed in place.
[0050] The upper plenum 52 extends to the “B” end wall 46 of the car body with a uniform interior height 102 and is there interconnected to the vertical conduit 98 , which carries the remainder of the air flow downward from the plenum 52 and along the interior face of the end wall 46 at the “B” end of the car body and connects the adjacent end of the upper plenum 52 to the end of the floor 40 .
[0051] The floor 40 , as shown also in FIGS. 10 and 11 is supported by the composite subfloor 38 , and includes a weight bearing tubular support structure 150 resting on and fastened to the subfloor 38 and defining the longitudinally extending parallel air pathways 100 . The tubular support structure 150 is unified and covered by a set of floor plates 152 connected to and extending over the entire length and width of the assembled tubular support structure 150 .
[0052] As mentioned briefly above, the underframe of the car is preferably of welded steel construction. The stringers 36 , which may be steel I-beams, rest atop the transversely extending cross-bearers 32 and crossties 34 , and extend longitudinally, spaced apart from each other and parallel with the side sills 26 and center sill 24 , between the body bolsters 28 and between each body bolster 28 and the nearby end sill 41 . Preferably the stringers 36 , body bolsters 28 , and center sill 24 all include generally horizontal top surfaces that are all substantially coplanar, and the subfloor 38 , preferably of composite construction, rests atop those coplanar surfaces.
[0053] In a preferred construction of the car body, the composite subfloor 38 includes a bottom panel 156 of fiber reinforced plastic resin, 0.1 inch (2.5 mm) thick, for example, and extends horizontally and rests atop the stringers 36 and center sill 24 , attached to their coplanar horizontal top surfaces by a suitable adhesive, such as Normount V2800 bonding tape.
[0054] The bottom panel 156 of the subfloor 38 rests on an upwardly offset outwardly extending steel sheet margin mount 157 which rests atop upper flanges of the side sills 26 , as shown in FIG. 11 . Rectangular support tubes 158 of fiber reinforced plastic, preferably about 5 inches (12.7 cm) high and 4 inches (10.2 cm) wide, with tube sidewall thickness 160 of ⅜ inch (9.5 mm) and top and bottom wall thicknesses 162 of ¼ inch (6.4 mm) extend transversely, across the width 148 of the car body, establishing a vertical spacing distance between the bottom panel 156 and top panels 166 of similar fiber-reinforced plastic resin material. The tubes 158 are spaced evenly apart from one another along the length of the interior of the car body, with a regular spacing 164 of, for example, eighteen inches (45.7 cm) center-to-center. The tubes 158 are filled preferably with closed cell polymeric resin foam, for example, a urethane foam having a density of 1.16×10 −3 lb/in. 3 (0.032 g./cm 3 ). The spaces between the tubes 158 are occupied by closed cell resin foam insulating material preferably having a similar density and preferably installed in the form of urethane foam blocks 167 .
[0055] The fiber-reinforced plastic top panels 166 rest atop the rectangular tubes 158 and foam blocks 167 and are fastened to the rectangular tubes by adhesive bonding tape, such as Ashland Chemical 8000/6660. Each top panel 166 preferably extends the full width 148 of the interior of the car body and extends longitudinally a distance equal to a multiple of the spacing 164 of the transversely extending support tubes 158 , except for a smaller panel at each end of the car body, where the floor 40 and subfloor 38 would never be subjected to as great a weight loading as where a lift truck can be located inside the car 20 . At the base of each side wall 92 , flexible elastic filler and seal members 168 , seen best in FIG. 11 b , are provided between a plastic resin spacer 169 at the base of the side wall 42 and the adjacent margins of the subfloor 38 .
[0056] As may be seen in FIGS. 11 a and 12 , the floor 40 , resting atop the subfloor 38 , includes a top plate 152 resting on the tubular support structure 150 of weight bearing support elements defining parallel tubes 172 extending longitudinally along the subfloor 38 and functioning as the passageways 100 for flow of air from the “B” end of the car 20 toward the “A” end.
[0057] A narrow channel 174 extends longitudinally along each side of the floor 40 at the base of the adjacent side wall 42 , and the floor 40 includes sets of holes 176 aligned with each other and extending laterally inward about one-third the width of the floor 40 , toward the central longitudinal axis of the car and communicating between adjacent passageways 100 . The sets of holes 176 are spaced apart along the length 141 of the car at regular intervals 178 , of, for example, one foot (30.5 cm), allowing air which has flowed downward within the cargo space 53 from the upper plenum 52 into the channel 174 to pass laterally inward into the parallel tubes 172 to be carried away longitudinally of the car body from the “B” end toward the “A” end of the car.
[0058] The refrigeration unit return air intake plenum 80 is connected to the floor 40 at the “A” end of the car body to carry the air upward from the floor 40 and thus back into the intake opening 82 in refrigeration unit 64 . The floor 40 thus plays an integral part in forming the path for circulation of the air to maintain the desired temperature within the cargo space 53 and thus to protect the cargo carried within the car.
[0059] The tubular support structure 150 of the floor 40 is preferably constructed as a group of extruded aluminum alloy segments 180 , each preferably including a pair of complete tubes 182 , 184 and a pair of horizontal arms 186 , 188 extending laterally from the tube 184 , one at the top and one at the bottom of the extruded segment 180 . The segments 180 could also be designed to have the arms extending in opposite directions away from the tubes 182 , 184 , or to have only a single complete tube, or more than the two complete tubes 182 , 184 of the segment 180 as shown herein.
[0060] Each segment 180 thus includes three upstanding parallel load bearing side wall members 190 , 192 , 194 extending between and interconnecting a generally planar bottom member 196 with a generally planar top member 198 that is parallel with the bottom member. Each segment 180 may have a height of about 3 inches (76 cm), with each wall member 190 , 192 , 194 having a thickness of 3/16 (0.48 cm), and the top and bottom members each having a thickness of about ⅛ inch (0.32 cm), for a floor 40 designed to carry a loading of 60,000 lb per lift truck axle. The tube side wall members 190 , 192 , 194 are interconnected with the top and bottom members 196 , 198 in smoothly radiused connection zones, making each parallel tube segment a rigid, strong structure, in which each of the upright side wall members 190 , 192 , 194 is a weight bearing member capable of transmitting forces between the top and bottom members 196 , 198 and capable of withstanding lateral components of forces acting on the floor structure 40 .
[0061] The segments 180 are designed to interlock with each other when properly placed alongside each other, so that the segments 180 lying parallel with each other can be securely integrated into a single unified floor 40 . This is preferably accomplished by providing a groove 200 along an upper shoulder of each segment 180 , adjacent an outer tube side wall 190 , and by providing a flange 202 having a sloping outer surface, extending out from the bottom of the same tube side wall 190 . At the opposite side, shown at the left of each segment in FIG. 12 , the upper horizontal arm 186 , extending parallel with and as an extension of the top member 198 , includes a downwardly projecting rib 204 that fits interlockingly into the groove 200 .
[0062] The lower horizontal arm 188 extends a slightly smaller distance away from the adjacent tube side wall 194 than does the upper arm 186 , and an upwardly sloping lip 206 is provided as the outer margin of the lower horizontal arm 188 . The lip 206 fits snugly against the sloping outer surface of the flange 202 of an adjacent segment 180 when the rib is engaged with the groove of that adjacent segment 180 and the two adjacent segments are both supported on a planar surface such as the top panel 166 of the subfloor 38 . As shown in FIG. 11 , a number, for example four, of the parallel floor segments 180 having holes 176 through their tube side walls 190 , 192 , 194 are preferably aligned with one another, with the holes 176 aligned with one another along each lateral side of the floor. Air flowing through the tubes 172 of those segments 180 toward the “A” end can draw more air into the tubes 172 , by Venturi action, from the channels 174 along the sides of the floor 40 .
[0063] Other segments 180 , for example six segments in the middle of the width of the floor 40 , are closed; that is, they have no holes 176 through the tube side wall members 190 , 192 , 194 , and each tube 172 of those parallel segments 180 forms a closed path extending from the conduit 98 at the “B” end of the car 20 to the “A” end and thence into the return air plenum 80 leading to the supply air intake 82 of the refrigeration unit 64 .
[0064] Extending along the outermost elongate segment 180 along each longitudinally extending side margin of the floor 40 is a respective flanged hold-down member 208 or 210 , which may also be of extruded aluminum. A first, or right side hold-down member 208 corresponds to and mates with the tube side wall 190 on the closed side of a tubular segment 180 , while the other hold-down member 210 is of a different form, in order to mate appropriately with the two horizontal arms 186 , 188 extending laterally from the side of a segment 180 at the opposite, or left side of the floor 40 , as shown in FIGS. 11 and 12 . A first, or right side hold-down member 208 thus includes a short laterally extending arm 212 with a downwardly extending rib 214 , as well as a downwardly facing sloped surface 216 , near the bottom end of its upright portion, that fits matingly against the sloping outer surface of the flange 202 at the bottom of the tube side wall 190 . An adjoining horizontally outwardly extending fastening flange 218 that can be fastened to the subfloor 38 on which the floor is supported, using suitable mechanical fasteners, such as blind Huck™ fasteners 220 spaced appropriately apart along the length of the floor 40 and extending through the flange 218 , the top panel 166 , and the top flange of the adjacent support channel 221 , shown in FIGS. 11 a and 11 b . The channel 221 may be of fiber reinforced plastic filled with insulating foam and closes off the outboard ends of the transverse tubes 158 .
[0065] At the opposite, or left, side of the floor 40 as shown in FIG. 12 , a second, or left side, extruded hold-down member 210 serves both as a hold-down and as a weight bearing closure member for the segment 180 along which it is located. The hold-down member 210 in a preferred embodiment includes a pair of parallel upright members each similar in thickness to one of the tube side walls 190 , 192 , 194 . At a top end the left side hold-down member 210 includes a groove 220 to receive the downwardly facing rib 204 of the top horizontal arm 186 of an adjacent tubular floor segment 180 . An inner side of a base portion of the hold-down member 210 has a laterally extending rib 222 above an inner flange 224 with a sloping outer face similar to the face of the flange 202 on each segment 180 . The rib 222 and the sloping face of the inner flange 224 together define a groove for receiving the upwardly sloping lip 206 of the bottom horizontal arm 188 of the adjacent tubular floor segment 180 . A wider, outwardly extending fastening flange 226 extends laterally away from the base and serves to receive fasteners 220 to attach the left hold-down unit 210 to the subfloor preferably in the same fashion as the fastening flange 218 . Holes 176 ′ in the hold-down members 208 , 210 are aligned with the holes 176 in the tube side walls 190 , 192 , 194 of the adjacent floor segments 180 .
[0066] Atop the assembled group of tubular segments 180 and preferably seated in notches 228 in upper margins of the hold-down members 208 , 210 are an array of top plate members 152 , preferably of metal such as aluminum plate embossed or rolled with a suitable non-skid surface. Alternatively, a stainless steel top plate 152 with a suitable non-skid surface, although heavier, might be used if preferred because of its better durability. The top plates 152 are also fastened to each of the several segments 180 of the tubular support structure 150 by suitable fasteners such as blind Huck™ fasteners 220 extending through corresponding openings in the floor top plates 152 and the top members 198 of the segments 180 , thus fastening together the adjacent tubular segments 180 of the floor 40 as a unified structure.
[0067] In most portions of the floor 40 adjacent ones of the top plates 152 meet along joint lines spaced apart from the interconnects between adjacent tubular segments 180 . Smaller top plate sections 152 ′ are located adjacent the doorways 54 of the car 20 , as shown in FIG. 13 . Each top plate section 152 ′ is removable, as by grinding away the head of its fasteners 220 , and the underlying tubular segments 180 are arranged with respective ends along transversely extending lines 234 and 236 to permit removal and replacement of tubular segments 180 ′ aligned with the doorways 54 , where floor damage is most likely to result, and to facilitate cleaning of the tubes 172 . Additionally, at each end of the car 20 smaller floor top plates 230 are supported on more widely spaced underlying channels 238 and are held by removable fasteners such as threaded bolts 232 , to facilitate cleanout of the tubes 172 of the tubular segments 180 after removal of the segments 180 ′.
[0068] The terms and expressions that have been employed in the foregoing specification are used therein 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 scope of the invention is defined and limited only by the claims that follow. | An air flow conduit ( 98 ) and a related plenum ( 80 ) for distributing conditioned air from a refrigeration and heating unit ( 64 ) on an end ( 44 ) of a railroad freight car ( 20 ) into a cargo space ( 53 ) within the car ( 20 ). A deflector directs a flow of air upward into an inlet end of the plenum ( 80 ) and allows the flow to expand gradually within the plenum, smoothing the flow of air within the plenum so that it continues effectively at sufficient rates over the length of the car ( 20 ). | 1 |
FIELD OF THE INVENTION
[0001] This invention relates generally to water wells and more particularly to a method and apparatus for enhancing development of wells and rehabilitating existing wells that have lost capacity.
BACKGROUND OF THE INVENTION
[0002] Water wells and other wells that have been in production for a considerable length of time often lose capacity for a variety of reasons. One of the main reasons is that the well screen and/or the filter pack and surrounding formation fractures tend to become clogged with sand, clay, bacteria and other growths and materials that build up and impede entry of liquid into the well.
[0003] Various techniques have been used to restore lost capacity, including chemical injection, mechanical agitation, sonic energy application and electrical stimulation. None of these approaches has been entirely satisfactory. Chemical cleaning methods have typically involved pumping or gravity feeding chemicals into the well. The chemicals follow the path of least resistance which is usually not where the clogging takes place. Thus, conventional chemical injection has not been wholly effective.
[0004] Mechanical agitation of the well and screen from the inside dislodges scale and other built up material from the inside of the well. However, it does not affect the filter pack surrounding the well or the fractures in the surrounding formation, so deposit laden areas located outside of the well remain as a source of plugging. The use of sonic energy and electrical energy has been attempted but has not achieved widespread acceptance due largely to cost problems and lack of effectiveness.
SUMMARY OF THE INVENTION
[0005] Accordingly, a need remains for an effective way to remove material that clogs wells, well screens, and the surrounding filter pack and fractures, both in newly developed wells and in existing wells that have lost production capacity. It is the primary goal of the present invention to met that need.
[0006] In accordance with the invention, gas is applied under pressure in a sidewardly direction in the production zone of a well in controlled bursts. The pressurized gas creates shock waves that cause water and gas to flow outwardly and break down materials that have built up on the screen and also in the surrounding filter pack and formation fractures. At the end of each burst, a flushing effect ensues to draw the loosen particulate material into the well from the surrounding formation. These particles are then removed by a submersible pump or air lift assembly that forces water from the well to the surface. The gas bursts are generated throughout the entirety of the production zone of the well in order to thoroughly clean it and thereby significantly enhance its capacity.
[0007] Preferably, the gas bursts are controlled by a relief valve which is positioned down in the well and set to open when subjected to a selected pressure. When the relief valve opens, the gas is discharged sidewardly through side ports or through an open annulus so that the gas is applied directly to the well screen or louvers in a manner to maximize the dislodging of materials that plug the well. Mechanical agitation with agitating discs may be used along with the gas bursts. Chemicals may also be used and are particularly effective because they are carried by the gas outwardly into the formation where they can attack the deposits located there.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] In the accompanying drawings which form a part of the specification and are to be read in conjunction therewith and in which like reference numerals are used to indicate like parts in the various views:
[0009] [0009]FIG. 1 is a diagrammatic elevational view of a system that may be used to stimulate water well production in accordance with a preferred embodiment of the present invention;
[0010] [0010]FIG. 2 is a fragmentary sectional view similar to FIG. 1, but showing only part of the system and depicting a submersible pump in the well in place of an air lift assembly;
[0011] [0011]FIG. 3 is a fragmentary sectional view on an enlarged scale showing the detail identified by numeral 3 in FIG. 1; and
[0012] [0012]FIG. 4 is a fragmentary sectional view on an enlarged scale showing an alternative way of applying gas bursts in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Referring now to the drawings in more detail and initially to FIG. 1, numeral 10 generally designates a well which may be used for the production of water or other fluids. The well 10 is bored into the surface 12 of the earth, and a casing 14 is installed in the well bore in a conventional manner. In the production zone or zones of the well 10 , a screen 16 is provided on the casing 14 in order to allow liquid from the surrounding formation to enter the well inside of the casing.
[0014] The well 10 is equipped with a production string which includes vertical piping 18 through which liquid from the well is delivered to the surface. A pipe 20 is connected with the lower end of the production piping 18 by a coupling 22 . At its upper end, the production piping 18 connects above the surface 12 with an elbow 24 . The elbow 24 connects through a valve 26 with a discharge hose 28 used to direct the water or other liquid from the well to a point of further use.
[0015] The water that is produced in the well 10 may be raised to the surface through the production string by an air lift assembly that includes an air lift line 30 connected with an air compressor 32 . Line 30 connects through a valve 34 with an elbow fitting 36 . The fitting 36 connects with a vertical line 38 that extends down through the production piping 18 in order to direct compressed air into the lower portion of the piping 18 to provide an air lift force for raising the water through the piping 18 and the discharge line 28 .
[0016] The elbow 24 may be provided with a lifting bracket 40 which allows the production piping 18 and the components carried on it to be raised and lowered in the well. A crane or boom (not shown) may be used for lifting of the bracket 40 .
[0017] [0017]FIG. 2 depicts an alternative arrangement in which the air lift assembly is replaced by a submersible pump 42 . The pump 42 may be an open or closed impeller pump having a housing 44 carried on the production piping 18 at a location immediately above pipe 20 . Within the housing 44 , the pump 42 is provided with a screen intake 46 . A pump cap 48 is provided at the upper end of the housing 44 where the pump connects with the production piping 18 .
[0018] In accordance with the present invention, compressed gas is supplied by a suitable source such as a bank of cylinders 50 (FIG. 1) containing a gas under pressure such as air, nitrogen or carbon dioxide. The cylinders 50 connect at their outlets with a supply line 52 leading to a fitting 54 . One outlet of the fitting 54 connects with an automatic flow loop 56 equipped with pressure gauges 58 and an automated flow control panel 60 . The loop connects with a cross-fitting 62 through a valve 64 which is controlled by the flow control panel 60 .
[0019] A manually operated flow path is connected with the other outlet of the fitting 54 in order to provide an alternative to the automatic flow control loop 56 . A flow line 65 connects with fitting 54 and extends to a cross 66 through a T-fitting 68 and a ball valve 70 . The T-fitting 68 is provided with a pressure gauge 72 . The cross 66 is similarly provided with a pressure gauge 74 . One of the connections for the cross 66 is provided with a ball valve 76 . A line 78 leading from the cross 66 to cross 62 provides a flow path along the manually controlled flow line. The cross 62 is provided with a relief valve 80 which opens in the event of application of excessive pressure.
[0020] In accordance with a preferred embodiment of the present invention, a flexible hose 82 extends from the outlet side of cross 62 down into the well 10 where it connects with a fitting 84 on the side of pipe 20 . The fitting 84 in turn connects with a vertical tube 86 extending downwardly inside of pipe 20 . As best shown in FIG. 3, tube 86 connects at its lower end with a bushing 88 on which a valve shroud 90 is carried. The shroud 90 contains a valve 92 which is capped at 94 on its lower end. The shroud 90 is provided with four (4) side ports 96 which are spaced equidistantly around the valve shroud. Gas nozzles 98 are threaded or otherwise secured in the ports 96 .
[0021] The valve 92 is a relief valve which may be of a type that is available commercially. The relief valve 92 can be set to open when a preset pressure is applied to it. For example, the valve may be set to open at any pressure setting between 50 and 1000 psi above hydrostatic pressure. When closed, the valve 92 is bubble tight to within 5 psi of the set pressure. When the valve 92 is closed, it blocks flow from the gas supply line 86 to the ports 96 and nozzles 98 . When line 86 is subjected to a pressure level equal to the setting of valve 92 , the valve opens and thereby applies air through ports 96 and 98 in bursts that are applied at the pressure level at which valve 92 is set to open. The flow rate of the bursts may be between 0.3 and 120 cubic feet per second.
[0022] The equipment in the well may include a double disk agitator assembly that includes a pair of agitating disks 100 located immediately above the nozzles 98 and another pair of agitators disks 102 located below the nozzles 98 . The disks 100 and 102 may be suitably carried on the lower end of the pipe 20 . The peripheries of the disks 100 and 102 are adjacent to the inside surface of the casing 14 and screen 16 so that the disks are able to provide mechanical agitation for removing scale and other deposits from the casing and screen.
[0023] Normally, liquid flows into the well through screen 16 and is delivered to the surface through the production string 18 by the air lift assembly or the submersible pump 42 . When the well becomes clogged to the extent that cleaning is desired, gas is applied from the cylinders 50 and flows to cross 62 along either the automatic flow control loop 56 or the manually controlled flow path provided by lines 65 and 78 . The gas is applied under pressure through the hose 82 to tube 86 and then to the relief valve 92 which remains closed until subjected to a pressure that exceeds its preselected pressure setting. When the gas pressure is sufficient to open the relief valve 92 , the valve pops open to provide a burst of gas through the nozzles 98 at a pressure equal to the setting of valve 92 and at a volume rate of flow between 0.3 and 20 cfm.
[0024] The gas bursts are applied directly to the side through the nozzles 98 to the screen 16 . The speed with which the gas is released by valve 92 generates a shockwave and a volume that forces the water outwardly to the side, thereby breaking down any materials that are built up on the screen or in the well, including sand, clay, bacteria, and other growths and materials. The energy of the gas bursts is sufficient to apply a shock wave to the surrounding filter pack and the fractures in the surrounding formation to loosen deposits in these areas as well.
[0025] When the valve 92 reseats due to the pressure dropping below the valve setting, the water displaced by the air bursts recovers and creates a flushing effect that draws the loosen particles from the filter pack and the fractures back into the well through the screen 16 . These particles are then carried to the surface by the rising gas bubbles or by the operation of the submersible pump 42 or the air lift assembly installed in the well. The sudden change in the water column that is generated by the burst of gas pulls additional particles into the well.
[0026] The cleaning assembly including the nozzles 98 is adjusted vertically up and down within the entirety of the production area of the well, and the procedure for cleaning involving the application of gas bursts is repeated so that the entire height of the production zone is subjected to gas bursts, thereby cleaning the entire screen 16 and applying the cleaning technique to the entirety of the producing area or zone of the well 10 . The lifting bracket 40 allows a crane or boom to move the cleaning equipment up and down. The entire production zone may be subjected to this cleaning procedure enough times to result in a situation where the discharge water is free of bacteria and/or fine materials built up in the well. The pumping by pump 42 and the air lift created by the air lift assembly, along with the agitation provided by the agitating disks 100 and 102 , enhances the ability of the cleaning equipment to dislodge the build up that may be encountered during development of a new well or rehabilitation of an existing well that is plugged. The velocities and pressure changes that result from the cleaning procedure facilitate removal of the materials that are dislodged from the well screen and adjacent areas.
[0027] Chemicals may also be injected into the well to enhance the cleaning effect. The chemicals may be applied by know techniques, and the chemicals are forced out through the screen 16 into the surrounding filter pack and formation fractures in order to dislodge materials from these deposit laden areas. The spent chemicals are eventually pumped or air lifted from the well for neutralization and disposal. After the chemicals have been removed, the well may be subjected to additional bursts of air and/or mechanical agitation followed by additional pumping and air lifting until the discharge water is substantially free of all traces of bacteria and particle matter.
[0028] [0028]FIG. 4 depicts an alternative arrangement that is used primarily for smaller diameter wells and/or wells that are provided with louvers 116 in place of screen 16 . Louver openings 116 a are provided between adjacent louvers 116 which are typically inclined upwardly at an angle from the inside of the casing 14 to the outside of the casing.
[0029] In the arrangement shown in FIG. 4, the assembly of the nozzles 98 is replaced with a shroud 104 which includes on its upper portion a horizontal disc 106 and on its lower portion a conical plate 108 . The disc 106 and plate 108 are spaced apart to provide an interior chamber 110 between them. The outside edges of disc 106 and plate 108 are adjacent to the casing and louvers 116 and are spaced slightly apart to provide an annular discharge slot 112 through which the gas is applied. The chamber 110 is supplied with gas through ports 114 when the valve 92 is open. The plate 108 inclines upwardly as it extends toward the casing 14 and is preferably oriented at an incline that matches the upward incline of the louvers 116 . This allows gas flowing along the upper surface of the plate 108 and through the discharge slot 112 to flow in a direction to readily pass directly through the louver openings 116 a to enhance removal of materials that may plug one or more of the louver openings.
[0030] The arrangement shown in FIG. 4 operates in substantially the same manner described previously. The principal difference is that rather than being discharged at discrete locations defined by the nozzles 98 , the gas is applied substantially continuously around the diameter of the well through the discharge slot 112 . Additionally, due to the incline of the bottom plate 108 , the air discharges from slot 112 at any desired angle matching the incline of the perforated openings 116 a.
[0031] From the foregoing it will be seen that this invention is one well adapted to attain all ends and objects hereinabove set forth together with the other advantages which are obvious and which are inherent to the structure.
[0032] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
[0033] Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative, and not in a limiting sense. | A method and apparatus for enhancing the production of newly developed water wells and existing wells that have suffered a reduction in capacity due to plugging. A gas line directs gas under pressure to a relief valve carried in the production string at a location in the production zone of the well. When the applied pressure reaches the pressure setting of the relief valve, the valve opens to apply air sidewardly in bursts which create shock waves to dislodge built up material from the well screen and the surrounding filter pack and formation fractures. Following each burst, the pressure conditions create a flushing effect which draws water back into the well along with the bacteria and particles that were dislodged. A submersible pump or airlift assembly in the production string then delivers the dislodged materials to the surface. | 4 |
BACKGROUND OF THE INVENTION
This invention is concerned with a novel lubricating composition useful in the manufacture of tufted textile articles. More particularly, this invention relates to a lubricating composition comprising a polyalkoxylate lubricating oil and a minor amount of a long chain fatty acid, which may be used to coat the primary backing fabric during the manufacture of tufted textile articles such as carpeting.
It is known to manufacture tufted textile articles by inserting yarn into a primary backing fabric by means of needles. Very simply, the yarn in threaded through holes in the ends of needles which are then pushed through the moving primary backing fabric. As the needles reach their lowest positions, the yarn is hooked on to loopers to form loops under the primary backing fabric. The needles are then withdrawn and the action repeated during which the loopers are removed from the previously formed loops and form further loops. This process is known as tufting. Further information on the manufacture of tufted textile articles may be found in "Tufting: an introduction" by D. T. Ward, Textile Business Press Limited, 1969.
Various types of primary backing fabrics are used in the manufacture of tufted textile articles. These fabrics may be of the woven or non-woven type and may be made of natural, e.g. jute, or synthetic fibers such as polyolefinic material e.g. polypropylene. Particularly useful fabrics are woven polypropylene tapes. In order for the manufacture of the articles to be technically and economically sound, it is desirable that the primary backing fabric provide little resistance against the insertion and withdrawal of the needles and that damage to the backing fabric by action of the tufting needles be minimized so that the tufted textile articles themselves are strong. The use of lubricants on the primary backing fabric to improve the manufacture in one or more of the above respects is known, e.g. see Carpet and Rug Industry, August 1976, page 28; British Pat. No. 1,347,915 and U.S. Pat. No. 3,919,097.
Polyalkoxylate lubricating oils are disclosed as fiber processing aids for textile manufacturing in British Pat. No. 1,482,963. Similarly, polyoxyalkylene polymers are disclosed as textile auxiliaries in U.S. Pat. No. 3,370,056 and as fiber lubricants in U.S. Pat. No. 4,134,841.
SUMMARY OF THE INVENTION
A lubricating composition has now been found which is exceptional in reducing needle resistance and deflection in the tufting process and in minimizing needle damage to the primary backing fabric during tufted textile manufacture. Accordingly, the present invention provides a lubricating composition comprising a major amount of polyalkoxylate lubricating oil and a minor amount of a saturated or unsaturated aliphatic carboxylic acid of from 10 to 20 carbon atoms. In a further aspect of the present invention, said lubricating composition additionally contains a minor amount of one or more of an anti-oxidant, a corrosion inhibitor, water and a wetting agent. In yet another aspect of the present invention, the process for the manufacture of tufted textile articles, e.g. carpeting; by the insertion of yarn into a primary backing fabric by means of needles is improved by coating the primary backing fabric with said lubricating composition prior to needle insertion of yarn into the primary backing fabric.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polyalkoxylate lubricating oils used in the present invention are well known and include polyoxyethylene glycols, polyoxypropylene glycols and random or block alkoxylated glycol and alkoxylated fatty acid copolymers, e.g. the reaction products of C 10 to C 20 saturated or unsaturated acids with ethylene oxide or polyoxyethylene glycol. The preferred polyalkoxylate lubricating oils are the polyalkoxylated, e.g. polyethoxy- and/or polypropoxylated, C 3 to C 20 alcohols. Such alcohols may be primary, secondary or tertiary alcohols and may be monols or polyols e.g. diols or triols. The number of alkoxy units present in such polyalkoxylate lubricating oils is suitably from 5 to 20 units per molecule. The most preferred polyalkoxylate lubricating oils are those described in British Pat. No. 1,482,963, namely one or more compounds of formula: ##STR1## wherein a, b and c are zero or integers and the average total of a+b+c is from 5 to 18, preferably from 12 to 17. Suitably a mixture of compounds is used which is prepared by reacting trimethylolpropane with ethylene oxide in amounts such that each mole of product contains on average from 5 to 18 moles of ethylene oxide per mole of trimethylolpropane.
The fatty acid component of the lubricating composition is an unsaturated or saturated aliphatic carboxylic acid of from 10 to 20 carbon atoms, preferably from 14 to 18 carbon atoms. Preferred aliphatic carboxylic acids include lauric acid, myristic acid, palmitic acid, oleic acid, linoleic acid and linolenic acid, with oleic acid being more preferred. The polyalkoxylate lubricating oil is the major component of the lubricating composition, although the amount of fatty acid present in the lubricating composition may vary between wide limits. The amount of fatty acid present is preferably between 0.001% and 10%, based on the weight of the polyalkoxylate lubricating oil, with amounts from 0.01% to 5% being more preferred.
In addition to the polyalkoxylate lubricating oil and the fatty acid, the lubricating composition may optionally and preferably also contain one or more of an anti-oxidant, a corrosion inhibitor, water and a wetting agent. In this regard, preferred anti-oxidants include phenolic anti-oxidants such as di-tert-butyl-cresol, diphenylolpropane and alkylated diphenylolpropanes. Preferred corrosion inhibitors include mono- or polyalkyl phosphates, phosphites or phosphonates, sodium benzoate or lauroylsarcosine. The presence of water is especially preferred if clear solutions are desired. Preferred wetting agents include conventional non-ionic surfactants, for example, ethoxylated alkylphenols, glycerol esters or fatty diethanolamides. Suitable amounts of anti-oxidants are from 0.05% to 1%, suitable amounts of corrosion inhibitors are from 0.1% to 5%, suitable amounts of water are from 1.0% to 25%,, and suitable amounts of wetting agents are from 1% to 5%, again all based on the weight of the polyalkoxylate lubricating oil.
The present invention is particularly useful for coating polyolefinic primary backing fabrics. The fabric may be of the non-woven type, e.g. spun-bonded polypropylene, but is preferably a woven fabric such as those prepared from polypropylene tape. Depending on the particular fabric used, it may be possible to apply the lubricating composition to the fibers thereof before or after they have been made-up into the primary backing fabric. However, the lubricating composition is preferably applied to the primary backing fabric itself. The lubricating composition may be applied to one or both sides of the fabric and the amount is preferably such to provide the fabric with from 0.5% to 10% by weight of lubricating composition, based on the weight of the fabric. Suitably, the lubricating composition is applied as a dilute aqueous solution, e.g. from 5% to 30% aqueous solution, and the water allowed to evaporate. The yarn is then inserted into the primary backing fabric by means of needles. The yarn which is used to manufacture the tufted textile articles by tufting the primary fabric backing may be of any type e.g. wool, cotton, rayon, nylon, acrylic or polyester yarns or mixtures thereof. The tufts maybe cut to produce cut pile tufting or may not be cut (loop pile tufting). The tufted textile articles may also be provided with a secondary backing material e.g latex, nonwoven polypropylene or jute. The present invention is particularly useful for manufacturing tufted textile floor coverings e.g. carpets.
The invention will be further illustrated in the following examples, which are not to be construed as limiting its scope. Additional information on the test methods may be found in Carpet and Rug Industry, Nov. 1975 at page 12 and May 1976 at page 16.
EXAMPLES
The compositions used in the Examples are given in Table 1. The polyalkoxylate oil used was prepared by reacting liquid trimethylol propane (TMP) with 14.4 moles of ethylene oxide (EO) in the presence of a basic catalyst.
TABLE 1______________________________________Lubri-cating Di-Com- Oleic phenylol Sodiumposi- Polyalkoxylate Acid Propane Benzoate Watertion Oil % w.sup.1 % w.sub.1 % w.sup.1 % w.sup.1______________________________________A TMP/EO adduct 1.0 0.075 1.5 5.0B TMP/EO adduct 0.1 0.075 1.5 5.0 C.sup.2 TMP/EO adduct -- 0.075 1.5 5.0______________________________________ .sup.1 = base on weight of polyalkoxylate oil .sup.2 = comparative (not according to the invention).
The compositions were applied as 20% by weight aqueous solutions (1% by weight on fabric) to woven polypropylene tape primary backing fabrics which when dry were tufted with nylon 6 BCF yarn, a textured nylon-filament yarn, to produce tufted textile articles.
The force required for the needles (Singer Type 0631-TDE) to penetrate and to be withdrawn from the fabric during the tufting operation was measured and the deflection of the needles also determined. These results are present in Table 2 and are expressed as the percentage of the results obtained with the same backing fabric but which had not been treated with a lubricating composition.
TABLE 2______________________________________ Lubricating Composition A B C______________________________________Force of Penetration 36 ± 1 43 ± 1 43 ± 1Force of Withdrawal 55 ± 1 58 ± 1 74 ± 1Deflection 62 ± 3 82 ± 3 95 ± 5______________________________________
In addition, the percentage decrease in strength of the backing fabrics (measured in the weft direction) caused by the damaging effect of the tufting needles was determined. The results are given in Table 3.
TABLE 3______________________________________Composition Strength loss (%)______________________________________--.sup.3 45 ± 5A 6 ± 10B 15 ± 10C 35 ± 4______________________________________ .sup.3 = no lubricant. | A novel lubricating composition useful in the manufacture of tufted textile articles comprises a polyalkoxylate lubricating oil and a minor amount of a long chain fatty acid. | 3 |
FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT
This invention (Navy Case No. 97355) was developed with finds from the United States Department of the Navy. Licensing inquiries may be directed to Office of Research and Technical Applications, Space and Naval Warfare Systems Center, San Diego, Code 2112, San Diego, Calif. 92152; telephone (619) 553-2778; email: T2@spawar.navy.mil.
BACKGROUND
This invention relates generally to cable cutters. More specifically, but without limitation thereto, this invention relates to an underwater cable cutter that uses water pressure to cut a cable underwater.
The design and use of cable cutters for ocean environments has become of increasing importance to marine engineering. Presently, the use of such cutters is desired for all depths of the world's oceans. Cable cutters are of great interest to the U.S. Navy. One major Navy application is in minesweeping operations.
The design and construction of cable cutters fall within a wide area of engineering disciplines. The general method for cable cutting is a mechanical technique usually involving severing a cable or wire placed between an anvil and a cutter. In some cases scissor-like devices are used. Operation of the cable cutter has included direct, hands-on, manipulation by a diver as well as remote operation of a cutter. Mechanical and explosive techniques are common. Generally, such cable cutters have been designed to be expendable in that they are to be used only once and/or are allowed to be lost or destroyed when operated.
Originally, cable cutters were designed mostly for cutting simple wire ropes and electrical cables. Modern state-of-the-art electrical cable construction however has resulted in the use of KEVLAR as a strength member. KEVLAR is a tough synthetic fiber that is usually difficult to cut by ordinary scissor mechanisms. Consequently, many new designs for various types of cable cutters have been presented. These generally incorporate powerful anvil/cutter blade mechanisms.
Cable cutters designed for use at great ocean depths have been required to be heavy and bulky in order to protect certain pressure sensitive components from high hydrostatic pressures.
This is particularly true where hydraulic systems are used to provide a powerful cutting force. Therefore, there remains a need to overcome one or more of the limitations in the above-described art.
SUMMARY
An underwater cable cutter apparatus (“cable cutter”) comprises an apparatus for cutting a cable, wire or other line located underwater. The apparatus includes a body with a lid and a base. A piston is located within the body, and a piston rod is coupled to the piston. A cutting element is pivotally coupled to a distal end of the piston rod and also pivotally coupled to the base. Upon actuation, water is introduced through the lid and into the body, moving the piston and piston rod and thereby operating the cutting element. The cable, wire or line to be cut is positioned in a cable holder, and the cutting element cuts the cable, wire or line when operated by the piston rod.
A feature of the cable cutter is that it is actuated by water pressure. That is, the cable cutter severs cables, wires or other types of lines that are underwater by using only the surrounding water pressure to generate the force required to cut the cable.
These and other features and advantages will be appreciated from review of the following Description, along with the accompanying figures in which like reference numerals are used to describe the same, similar or corresponding parts in the several views of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of a representative embodiment of the underwater cable cutter described herein;
FIG. 2 is a cut away view of the underwater cable cutter of FIG. 1 ;
FIG. 3 is an exploded view of the underwater cable cutter of FIGS. 1 and 2 ; and
FIG. 4 is a perspective view of the underwater cable cutter of FIGS. 1 , 2 and 3 .
It will be recognized that some or all of the Figures are schematic representations for purposes of illustration and do not necessarily depict the actual relative sizes or locations of the elements shown. The Figures are provided for the purpose of illustrating one or more embodiments with the explicit understanding that they are offered by way of example only and are not intended to limit the scope of the invention.
DESCRIPTION
Referring now to FIGS. 1-4 , an underwater cable cutter 10 is illustrated. Underwater cable cutter 10 uses a piston 12 , shown in FIGS. 2 and 3 , that is connected to a piston rod 14 with a seal 13 located therebetween. These are contained in a body 16 that in one embodiment comprises a hollow cylindrical housing. As shown in FIGS. 1 and 2 , a portion of piston rod 14 extends out of a base 18 , shown attached to body 16 . Body 16 is originally filled with air such as at sea level pressure. The extending end of piston rod 14 is pivotally attached to a cutting element 20 , which in one embodiment comprises an elongate lever member having a cutting surface at one end. When positioned underwater and actuated, water enters a water chamber 22 (see FIG. 2 ) and impinges upon piston 12 , thereby translationally moving piston rod 14 and in turn causing elongate lever cutting element 20 to cut a cable 36 ( FIG. 4 ). Cable 36 is held by a cable holder 24 and cable lock 26 .
Because the density of water is over 800 times greater than the density of air (at standard temperature and pressure), it will be appreciated that a substantial cutting force can be generated by immersing the cable cutter 10 in only a relatively small depth of water. Besides originally providing body 16 with sea level air pressure, the air located within the interior of the body 16 may be initially eliminated, or substantially eliminated, creating a vacuum, or partial vacuum. Such a low pressure environment can be selected for just that part of cutter 10 identified in the figure as air chamber 28 . Thus an even greater pressure differential can be selected to exist between the interior of the body 16 and the exterior of the body 16 .
The cutting process is initiated by removing either an exterior actuator 30 or an interior actuator 32 from lid aperture 34 . An O-ring, D-ring or other suitable sealing element is positioned between the actuators 30 / 32 and lid aperture 34 to seal against water from entering the water chamber 22 when the actuators 30 / 32 are in position. Once actuator 30 or 32 is removed, water flows into water chamber 22 and pushes upon piston 12 . Because the volume on the other side of the piston 12 , shown in FIG. 2 as air chamber 28 , contains typically air at sea level pressure or less, the force generated by the incoming water moves the piston 12 and its attached piston rod 14 to thereby actuate cutting element 20 and cut cable 36 , shown in FIG. 4 . It will be appreciated the cable 36 may be a wire rope, electrical cable, or other type of line, wire, or cable.
As shown in FIGS. 2 and 3 , underwater cable cutter 10 is partially constructed of housing or body 16 that includes attached base 18 though which piston rod 14 extends. Body 16 also includes a deployment flange 38 that defines one or more apertures for receiving a coupling element such as a clamp, bracket or other device that may be used to facilitate the lowering and raising of underwater cable cutter 10 into and out of the water. The shape of the flange 38 may, of course, vary as well as the devices and securing means used to raise and lower underwater cable cutter 10 into and out of water.
Referring to FIGS. 1 and 3 , base 18 of underwater cable cutter 10 also includes a sacrificial anode 40 . Anode 40 may be constructed of zinc, as well as of other suitable sacrificial material such as magnesium, for example. The utilization of anode 40 permits the corrosion of other components of underwater cable cutter 10 to be substantially reduced, thereby extending the service life of cutter 10 .
Referring now to FIGS. 2 and 3 , a lid 42 is positioned opposite base 18 . Lid 42 , base 18 and body 16 form a cavity, within which are located piston 12 and piston rod 14 . Lid 42 defines lid aperture 34 , designed to receive exterior actuator 30 or interior actuator 32 . A lid seal 44 is used to impede water from entering the interior of body 16 at this interface. Lid seal 44 may be an O-ring, D-ring or other type of suitable sealing element. A piston seal 46 , which may be an O-ring, D-ring or other type of suitable sealing element, is located within base 18 around piston rod 14 . The piston seal 46 impedes water from entering into the hollow interior of the body 16 when the piston rod 14 is stationary and when piston rod 14 is actuated. Piston 12 is bolted to piston rod 14 by a suitable fastener, such as a threaded bolt, for example.
In one embodiment piston 12 is fitted with two sealing rings 48 that may be O-rings, D-rings or other types of sealing elements that impede the passage of water. It will be appreciated that other numbers of sealing rings 48 may be employed. The sealing rings 48 may be the same diameter and thickness, or they may differ in diameter and thickness.
A lid retainer 50 secures lid 42 to body 16 . As shown in FIGS. 1-3 , lid retainer 50 may in one embodiment comprise three curved elements that are bolted or otherwise fastened around body 16 and lid 42 . Of course, lid retainer 50 may comprise less than or more than three elements. In the representative embodiment shown, fasteners 52 are used to secure the lid retainer 50 to the body 16 . Fasteners 52 are also used to secure anode 40 to base 18 , cutting element 20 to piston rod 14 , piston 12 to piston rod 14 , and cutting element 20 to a pivot pin 54 . These fasteners may be bolts or any other types of suitable fastening elements.
As shown in FIGS. 1 and 2 , piston rod 14 is attached to piston 12 ( FIG. 2 ) and to one end of cutting element 20 at cutting element slot 56 ( FIG. 1 ). Cutting element 20 is also attached to base 18 such as by pivot pin 54 . As shown in FIGS. 1 and 3 , two pin supports 58 extend from base 18 and each include an aperture for pivotally receiving pivot pin 54 . Pin supports 58 may be integral to base 18 , or they may be welded or otherwise affixed to the base. Pivot pin 54 is moveably secured to pin supports 58 by a pin fastener 60 , which may comprise a C-ring, lock washer, or other type suitable device.
Pivot pin 54 allows elongate lever cutting element 20 to pivot about pivot pin 54 while remaining attached to base 18 . Cutting element 20 includes a cutting edge or surface 62 , as shown in FIG. 4 , that is located at the end of cutting element 20 that lies adjacent to pivot pin 54 . Cable holder 24 is also mounted to base 18 and, as shown in FIGS. 1 and 2 , includes a cable opening-recess 64 for receiving cable 36 . As shown in FIG. 4 , cable 36 , which may also be a wire or line, is positioned in cable opening 64 . Cable locks 26 are then secured to cable holder 24 by fasteners 52 to thereby capture cable 36 within cable opening 64 .
Referring now to FIGS. 1-3 , water is introduced into water chamber 22 , this chamber being formed by lid 42 , body 16 and piston 12 . This introduction is permitted upon the activation of either exterior actuator 30 or interior actuator 32 , both of which are located in lid aperture 34 .
In one embodiment, wherein an exterior actuator 30 is employed, the exterior actuator may be removed via a buoy attached to the actuator by a cable or directly by a cable (neither shown) so that when the actuator 30 is pulled free from lid 42 , water is allowed to pass through lid aperture 34 . Alternatively, in another embodiment, an interior actuator 32 may be employed, this interior actuator also being positioned in lid aperture 34 . An acoustic release, designed to function upon receiving an acoustic signal, may be made integral with interior actuator 32 . Upon receiving a designed acoustic signal, interior actuator 32 separates from lid aperture 34 so that water pressure forces the interior actuator into the interior of body 16 . Consequently, water is allowed to push against piston 12 thereby moving the piston and attached piston rod 14 toward base 18 . It will be appreciated that other methods may be employed to seal, and subsequently un-seal lid aperture 34 .
When water is introduced into water chamber 22 , the water pressure forces piston 12 away from lid 42 and towards base 18 , thereby decreasing the size of air chamber 28 . For example, in one embodiment of cable cutter 10 , body 16 may have an internal volume of approximately 43 cubic inches, and the surface area of piston 12 is approximately 10 square inches. It will be appreciated that the internal volume of body 16 , the surface area of piston 12 , and other dimensions of the cable cutter 10 may vary from these example dimensions.
When piston 12 is driven by water pressure, cutting element 20 pivots about pivot pin 54 and piston rod 14 pushes the other end of cutting element 20 from base 18 (these actions shown by arrows in FIG. 1 ). Cutting element slot 56 allows relative movement between piston rod 14 and the elongate lever cutting element 20 . As cutting element 20 pivots about pivot pin 54 , cutting edge 62 moves toward base 18 . This leveraged cutting action thereby cuts cable 36 located in cable opening 64 . Put differently, as water pressure pushes on the piston 12 , the piston rod 14 is also pushed. Rod 14 is attached to cutting element 20 at cutting element slot 56 . As piston rod 14 moves in this fashion, cutting element 20 pivots about pivot pin 54 and thereby moves cutting edge 62 towards base 18 . As cable 36 is located in cable opening 64 , and as elongate lever cutting element 20 rotates, cutting edge 62 cuts the cable.
Because water pressure is used as an operating force to cut the cable, the underwater cable cutter disclosed herein is reliable, and circumvents a more complex hydraulic system as well as avoids the inherent complexities of dangerous explosives. Body 16 , base 18 , lid 42 , cutting element 20 , piston 12 , piston rod 14 , lid retainer 50 , cable holder 24 , cable lock 26 , and other components of the underwater cable cutter 10 may be constructed of metal, metal alloys (such as steel and stainless steel), plastics, silicone rubber, and other suitable elements.
Thus, it is seen that an apparatus and method for cutting a cable located underwater is provided. While specific embodiments have been described, it is evident that many alternatives, modifications, permutations and variations will become apparent to those of ordinary skill in the art in light of the foregoing description. Obviously, many modifications and variations are possible in light of the above description. It is therefore to be understood that within the scope of the claims the inventions may be practiced otherwise than as has been specifically described. | An apparatus for cutting an underwater cable, wire or line is provided. The apparatus includes a body with a lid and a base. A piston is located, within the body, and a piston rod is coupled to the piston. An elongate lever cutting element is pivotally coupled to a distal end of the piston rod and also pivotally coupled to the base. Upon actuation, water is introduced through the lid and into the body, moving the piston and piston rod, which actuates the elongate lever cutting element. This Abstract is provided for the sole purpose of complying with the Abstract requirement rules that allow a reader to quickly ascertain the subject matter of the disclosure contained herein. This Abstract is submitted with the explicit understanding that it will not be used to interpret or to limit the scope or the meaning of the claims. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of Federal Republic of Germany application No. P38 14 412.3 filed Apr. 28th, 1988, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a travelling flat (flat bar) for a card, wherein the flat chains are releasably secured to the outer ends of the flat heads by means of a coupling element and further, in each head terminus an opening is provided for receiving the coupling element.
In a flat of known construction the attachment of the flat chain to the flat head is effected by a flat screw which passes through a bushing at the articulation of the chain and extends into a bore which is provided in the flat head and which has an inner thread. It is a disadvantage of this arrangement that providing the inner thread is technologically complex and further, in practice, the inner thread may tend to lead to breakages of the material in the thread zone. It is also a disadvantage of the prior art flat that the flat screw must be tightened with a predetermined torque which renders, for example, a reassembling operation after replacement of clothing, very time consuming since the torque limits have to be strictly observed. In case the screw is tightened excessively, the inner thread may break out which renders the flat useless and has to be replaced
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved flat of the above-outlined type from which the discussed disadvantages are eliminated and which permits in particular a simple manufacture, a rapid assembly (installation) and a reliable locking of the coupling element in the flat head.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the travelling flat bar includes a head, an opening in the head, a coupling element received in the opening and arranged for attaching the flat bar to a flat-moving chain and a securing (locking) arrangement for readily releasably retaining the coupling element in the opening. The locking arrangement cooperates with the coupling element for form-lockingly retaining the coupling element in the opening.
The form fitting (form locking) immobilization of the coupling element ensures a reliable locking thereof without the need of an inner thread in the flat head for the coupling element; a smooth bore, or aperture provided by milling suffices. The invention thus dispenses with a flat screw, and therefore time-consuming setting of the required torque is no longer necessary. Also, breakouts of the inner thread are no longer a problem. The immobilization of the coupling element for the flat chain has the particular advantage that assembly work on the flat chain can have a significantly shorter duration. Thus, the invention permits a simple preparation of the flat head and the coupling element as well as a rapid assembly of the flats, the coupling element and the chains. The coupling element is so constructed that an unintended outward movement thereof from the opening in the flat head is prevented while the flat chain pulls the flats along the carding cylinder during operation.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic side elevational view of a carding machine incorporating the invention.
FIG. 2a is a fragmentary sectional elevational view of a flat head forming a component of a first preferred embodiment of the invention.
FIG. 2b is an elevational view of a coupling element forming another component of the first preferred embodiment of the invention.
FIG. 2c is a plan view of still another component of the first preferred embodiment of the invention.
FIG. 3a is a perspective exploded view of the components of the first preferred embodiment of the invention.
FIG. 3b is a perspective view of the components of the first preferred embodiment in an assembled state.
FIG. 4 is a front elevational view, partially in section, of a second preferred embodiment of the invention.
FIG. 5 is a sectional end view of a third preferred embodiment of the invention.
FIG. 6a is a front elevational view of a fourth preferred embodiment of the invention.
FIG. 6b is a perspective view of a component shown in FIG. 6a.
FIG. 7a is an elevational view of a component of a fifth preferred embodiment.
FIG. 7b is a sectional view of an enlarged detail of FIG. 7a.
FIG. 7c is a schematic side elevational view of a component of the fifth preferred embodiment cooperating with the component shown in FIGS. 7a and 7b.
FIG. 7d is a fragmentary front elevational view of the component of FIG. 7c.
FIG. 7e is a fragmentary top plan view of the component shown in FIGS. 7c and 7d.
FIG. 8 is a top plan view of a sixth preferred embodiment of the invention.
FIG. 9 is a front elevational view of a seventh preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1, there is illustrated a carding machine which may be, for example, an EXACTACARD DK 740 model, manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Federal Republic of Germany. The carding machine has a feed roller 1, a feed table 2 cooperating therewith, a licker-in 3, a main carding cylinder 4, a doffer 5, stripping rollers 6, crushing rollers 7, 8, a web guiding element 9, a sliver trunpet 10, calender rollers 11, 12 as well as travelling flats 13 supported by end rollers 13a, 13b which are rotated in a direction opposite to that of the main carding cylinder 4. The flats (flat bars) 14', 14", 14'" are pulled by the flat chain 15 in the direction of the arrow A. As shown in FIG. 3b, the flat chain 15 is releasably secured by a coupling pin 16 to an end of the flat head 14a. According to the invention and as described in greater detail below, the coupling pin is retained in the flat head 14a in a form-locking manner and is thus prevented from unintentional removal from the flat head.
Turning to FIG. 2a, in the flat head 14a there is provided a blind bore 14c which extends parallel to the length dimension of the elongate flat (which, in turn, is oriented transversely to the direction of its travel). A slot 14d is provided in the flat head 14a in a direction transversely to the bore 14c and intersecting the same. FIG. 2b shows a coupling pin 16 adapted to be fitted into the bore 14c. The coupling pin 16 has a shank 16a and a head 16b. The shank 16a has a circumferential groove 16c. FIG. 2c illustrates a locking element formed of an elastic circlip 17 having a discontinuity at 17a and adapted to surround the groove 16c as will be discussed below.
FIG. 3a shows, in an exploded view, the relative position of the flat head 14a, the flat chain 15, the coupling pin 16 and the circlip 17, while FIG. 3b shows these components in an actual assembled state. The elastic circlip 17 is received in the slot 14d and, within the groove 14c, projects into the groove 16c of the pin shank 16a and closely surrounds the groove bottom after it has been snapped-in.
FIG. 4 illustrates a spring-biased locking arrangement, including a leaf spring 18 mounted at one of its ends on the flat head 14a by a screw 19. At its other end the leaf spring 18 carries a pin 20 which projects through a bore 14b in the flat head 14a and extends, with its free end, into the groove 16c of the coupling pin 16.
FIG. 5 illustrates an embodiment in which a bent spring 21 is secured at one end 21a to the flat head 14a. Adjacent its other end 21d, the spring 21 has an arcuate portion 21c which lies in the pin groove 16c, thus immobilizing (locking) the pin 16.
In the embodiment according to FIGS. 6a and 6b, the pin locking arrangement comprises a yoke 22 which has a leg portion 22a provided with a bore hole 22b, an oppositely located leg portion 22c having a throughgoing bore hole 22d provided with a lateral opening 22e. The yoke 22 is inserted into slots 14d and 14d' of the flat head 14 and a pin 23 is pushed into the bore 22b. The coupling pin 16 is pushed through the opening 22d and the leg portion 22c resiliently snaps into the groove 16c of the pin 16 to thus immobilize the latter in the bore 14c of the flat head 14a.
Turning to FIG. 7a, in the embodiment illustrated therein, the shank 16a of a coupling pin 16' is provided with a radial bore 16d having an inner thread into which there is threaded a screw 23. As shown in FIG. 7b, the screw 23 is provided with a blind bore 23a in which there is held an arresting pin 231, which, with its rounded end, projects beyond the radial end face of the screw 23. The other, flat opposite end of the arresting pin 23b is, with the intermediary of a spring 23c, supported on a bottom face of the bore 23a. As illustrated in FIGS. 7c, 7d and 7e, the flat head 14a has a radial bore 14e which communicates with and is transverse to, the flat head bore 14c. When the coupling pin 16' is to be removed from the flat head 14a, first the arresting pin 23 is pushed in by a simple tool, for example, by a small bar or nail introduced through the bore 14e, to be in a withdrawn position relative to the bore 14e, so that the securing bolt 16 may be pulled out of the bore 14c.
Turning to FIG. 8, in the embodiment illustrated therein, a coupling pin 16" which has at its free end a slot 16e defining an enlarged forked construction formed of tines 16f and 16g, having an outwardly projecting enlargement 16h and 16i, respectively. The tines 16f and 16g are elastic so that they can expand (latch) into the slot 14d provided in the flat head 14a.
FIG. 9 illustrates a modification of the embodiment of FIG. 8, wherein the tines 16f' and 16g' of a coupling pin 16'" are pressable outwardly by means of a screw 24 which is positioned along an axial inner bore 16k having an inner thread 16m. The tines 16f' and 16g' are thus pressed against the inner wall of the bore 14c, so that the coupling pin 16'" is firmly anchored. The inner bore 14c is cylindrical and an anchoring of the coupling pin 16'" is effected by friction. To ensure a form-fitting relationship between tines and bore wall, the bore 14c may conically slightly widen from the end face of the flat head 14a inwardly.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A travelling flat bar includes a head, an opening in the head, a coupling element received in the opening and arranged for attaching the flat bar to a flat-moving chain and a securing (locking) arrangement for readily releasably retaining the coupling element in the opening. The locking arrangement cooperates with the coupling element for form-lockingly retaining the coupling element in the opening. | 3 |
BACKGROUND OF THE INVENTION
[0001] The accumulation of snow and other wintery precipitation, such as sleet, hail, and freezing rain, on an automobile commonly results in the windshield wipers of the automobile becoming covered and encased in one or more layers of snow and/or ice. This can be problematic, because even after a majority of the snow and ice have been removed from atop the windshield wipers an amount of frozen precipitation will typically remain adhered to various surfaces of the wipers, including surfaces of the wipers' blades that are designed to engage and clean the windshield of the automobile. Moreover, conventional methods for removing snow and ice from the windshields of automobiles, such as by employing snow brushes or ice scrapers, are generally ineffective for removing snow and ice from tight areas underneath and around most windshield wipers, and in some cases can even cause damage to the wipers.
[0002] Frozen precipitation that is not cleared from the windshield wipers, or from the areas of the windshield surrounding the wipers, can interfere with the operation of the wipers, such as by creating a barrier between the working edges of the wiper blades and the surface of the windshield. In extreme cases, heavily accumulated snow and ice surrounding the wipers can prevent movement of the wipers entirely.
[0003] In view of the foregoing, it would be advantageous to provide a means for preventing the accumulation of frozen precipitation on and around an automobile's windshield wipers. It would further be advantageous to provide such a means that is highly portable and relatively inexpensive.
BRIEF SUMMARY OF THE INVENTION
[0004] In accordance with the present invention, there is provided a protective sleeve for covering the windshield wiper of an automobile to shield the wiper from external elements such as frozen precipitation. The sleeve is generally conical in shape and is preferably formed of polyester laminate industrial fabric. The sleeve is preferably made substantially flat, such as by forming laterally-opposing, longitudinally-extending creases in the fabric of the sleeve.
[0005] The protective sleeve is preferably used by sliding it longitudinally onto the windshield wiper of an automobile that is to be parked outdoors for a period of time, with the sleeve flatly abutting the automobile's windshield. This is typically done in advance of the predicted onset of frozen precipitation. A pair of sleeves will usually be employed simultaneously for covering both of the automobile's front windshield wipers (unless the automobile only has one front wiper).
[0006] When the automobile is to be driven or otherwise needs to be cleared of accumulated frozen precipitation, the driver of the automobile or another individual removes any accumulated frozen precipitation from the windshield and from atop the protective sleeves, such as by using a conventional snow brush and/or ice scraper. The driver then removes the sleeves from the windshield wipers and allows the blades of the wipers to come to rest on the surface of the windshield. Because the wipers and the areas of the windshield surrounding the wipers were covered by the protective sleeves, they will be substantially free of any frozen precipitation that could have otherwise impaired the operation of the wipers. The protective sleeves are then stored (preferably somewhere in the automobile) for future use.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] FIG. 1 is a perspective view illustrating the preferred embodiment of the present invention.
[0008] FIG. 2 is a front view illustrating a pair of the protective sleeves of the present invention mounted on the windshield wipers of a truck.
[0009] In describing the preferred embodiment of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific term so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
DETAILED DESCRIPTION OF THE INVENTION
[0010] This application claims the benefit of U.S. Provisional Application No. 61/295,725, which is incorporated herein by reference.
[0011] Referring to FIG. 1 , a protective sleeve 10 for preventing the accumulation of frozen precipitation on a windshield wiper of an automobile, as well as on the areas of the automobile's windshield that surround the windshield wiper, is shown. The term “windshield wiper” is used herein to describe a conventional windshield wiper that is defined by an elongated wiper blade and a pivotably mounted wiper arm to which the wiper blade is attached.
[0012] For the sake of convenience and clarity, terms such as “top,” “bottom,” “up,” “down,” “inwardly,” “outwardly,” “lateral,” and “longitudinal” will be used herein to describe the shape and configuration of the invention, all with respect to the geometry and orientation of the exemplary embodiment of the device as it appears in FIG. 1 , with the term “longitudinal” defined as the direction in which the sleeve extends from the upper left to the lower right, and the term “lateral” defined as a direction perpendicular thereto. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.
[0013] The protective sleeve 10 is generally conical in shape with a first, relatively wide end 12 that is open and a second, relatively narrow end 14 that is closed. The sleeve 10 is formed of a sheet of, for example, 10 mil polyester laminate industrial fabric that is cut and sewn (in a manner that will be described in greater detail below) to produce the desired, generally conical shape. Polyester laminate is preferred for its durability, flexibility, impermeability to water, ability to shed frozen precipitation and longevity in a wide range of temperatures. In particular, a product sold under the trademark SHELTER-RITE manufactured by Seaman Corporation can be used. However, those of ordinary skill in the art will recognize that any sufficiently durable and moisture-resistant material, including, but not limited to nylon laminate, rubber, plastic, metal, various composites, and certain other fabrics can be substituted for the polyester-laminate without departing from the present invention.
[0014] The sleeve 10 is preferably partially flattened, such as by forming laterally-opposing, longitudinally-extending creases 16 and 18 in the material of the sleeve 10 . This can be accomplished, for example, by compressing the sleeve 10 between two heated plates. When substantially flattened, the sleeve 10 has a generally trapezoidal shape with an overall length of about 26 inches and open and closed ends that measure about 5 inches wide and about 1.75 inches wide, respectively. These dimensions are suitable for accommodating the windshield wipers of most passenger cars. However, it is contemplated that the length and width of the sleeve 10 can be varied for accommodating a variety of other applications. For example, the sleeve 10 can be made longer and wider for accommodating the larger windshield wipers of vehicles such as vans, trucks, buses, airplanes, and trains, as well as the windshield wipers of some passenger cars that employ a single, large windshield wiper instead of two, smaller wipers as is common with most passenger cars. Alternatively, the sleeve 10 can be made shorter and narrower for accommodating smaller windshield wipers, such as those commonly found on the rear windshields of sport utility vehicles. The sleeve 10 can be made smaller still for accommodating headlight wipers that are found on some automobiles.
[0015] In order to use the protective sleeve 10 , a person first grasps a windshield wiper that they wish to cover and then gently pulls and pivots the wiper away from its adjacent windshield. Wiper arms conventionally pivot to this position, for example, in order to clean the windshield. The sleeve 10 is then slid longitudinally onto the wiper, in the manner of a sock, with the wiper tip first passing through the open end of the sleeve 10 and extending into the interior of the sleeve 10 . The wiper and the mounted sleeve 10 are pivoted back toward the windshield once the wiper tip has reached or come close to the closed end 14 , and are brought to rest with the sleeve 10 flatly abutting the windshield, as shown in FIG. 2 . This process is repeated with additional protective sleeves 10 for each of the automobile's windshield wipers that are to be covered. Mounted thusly, the lowest edge of the open end 12 of the protective sleeve 10 is positioned below the closed end 14 of the sleeve 10 . Water tends thereby to flow out of the sleeve 10 by the force of gravity, as gravity draws the water down the sleeve's lower crease and out of the lowest, open end 12 . Water is thereby prevented from entering the sleeve 10 except by blowing through the open end 12 . Any such water that enters the open end 12 will tend to flow back out of the sleeve due to the force of gravity.
[0016] If, upon returning to the automobile, the person finds that the protective sleeves and the windshield of the automobile have been covered with frozen precipitation, the person preferably first clears away the frozen precipitation using conventional methods, such as by employing a snow brush or an ice scraper. During this clearing process the protective sleeves 10 shield the wipers against direct strikes from a brush or a scraper that could otherwise result in damage to the wipers. After the windshield has been substantially cleared of precipitation and the sleeves have been substantially uncovered, the person grasps and pivots each of the sleeved windshield wipers away from the windshield. The person then slides the sleeves 10 longitudinally off of the wipers. The wipers, having been covered by the sleeves during the accumulation of precipitation on the automobile, will be substantially free of any frozen precipitation. Moreover, the areas of the windshield that were underneath the flattened sleeves 10 during the accumulation of precipitation will also be substantially free of precipitation. The clean, precipitation-free wipers are then pivoted back against the windshield, with the working edges of the wiper blades being brought into engagement with the clean surface of the windshield. The windshield wipers can then be operated in a conventional manner with the wiper blades cleanly engaging the windshield without residual frozen precipitation interfering with effective contact therebetween.
[0017] The protective sleeve 10 is typically employed when near-term weather forecasts predict the onset of frozen precipitation. For example, a person may cover the windshield wipers of his or her automobile with a pair of the protective sleeves before going to bed in anticipation of predicted overnight snowfall. Alternatively, the protective sleeves can be employed to cover the windshield wipers of an automobile that is to be parked out-of-doors for an extended period of time without being driven or cleared of precipitation, regardless of near-term or long-term weather forecasts. Moreover, in addition to shielding windshield wipers from frozen precipitation, it is contemplated that the protective sleeves can be employed to cover the windshield wipers of an automobile that is parked under direct sunlight which can cause rubber windshield wiper blades to become dry and brittle after lengthy exposure.
[0018] A preferred method for fabricating the above-described protective sleeve 10 will now be described. It will be understood by those having ordinary skill in the art that various others methods for fabricating the sleeve 10 , including a variety of manual and automated processes, can be employed in addition or in the alternative to those described below.
[0019] A first step in fabricating the above-described protective sleeve 10 is to cut a template from a sheet of Plexiglas or other sufficiently rigid material. To form a standard size protective sleeve 10 , the template will be trapezoidal in shape, measuring 28 inches long at center with a first end measuring 11 inches wide and a second, opposite end measuring 3 and ⅜ inches wide. A sheet of 10 mil polyester industrial fabric measuring at least about 12 inches by 30 inches is then placed on a table or other flat surface that is suitable for razor type cutting. The template is then placed firmly on top of the fabric and is used as a pattern guide for cutting the fabric with a razor to produce a work piece having the shape of the template.
[0020] Next, using a sewing machine with a Teflon foot, a 100% polyester thread and bobbin, and a heavy duty (size 16) sewing needle, the wide end of the work piece is hemmed at ⅜ inch with the rough side of the fabric facing up. The stitch is reversed at both ends of the hem in a conventional manner for ½ inch to secure the hem. The work piece is then folded in half lengthwise with the rough side of the fabric facing outwardly (thus putting the partially fabricated sleeve in an inside-out configuration). The two long sides of the work piece are then sewn together with a ⅜ inch seam, with the stitch being reversed at both ends of the seam for ½ inch.
[0021] Next, the configuration of the work piece must be reversed so that the work piece is right-side-out. This is accomplished by first inserting a string, which can be a tape, ribbon or band, through the wide end of the work piece and extending the string a short distance though the opposing, narrow end of the work piece. Using the sewing machine as described above, a seam is sewn laterally across the work piece at a distance of about 26 inches from the wide end of the work piece, and the stitch is reversed to secure the enclosed string in place.
[0022] Next, the inside-out work piece is longitudinally slid onto a broom handle or other elongated instrument, with the broom handle extending into the work piece until the broom handle engages the closed end of the work piece. Starting at the wide, hemmed end of the work piece, the work piece is manually turned right-side-out for about 6 inches to form a cuff at the wide end. Next, the string protruding from the wide end of the work piece is held securely against the broom handle with one hand while another hand is used to pull the partially folded cuff away from the first hand until the work piece is right-side-out. The string is then trimmed and the completed sleeve is ready for further processing or use. It will be appreciated that the string can be a fabric label that remains in place during use to hold indicia, such as a trademark or instructions.
[0023] An alternative method for turning the work piece from inside-out to right-side-out without using the above-described string involves longitudinally sliding the work piece onto a first elongated instrument, such as an elongated shaft extending downwardly from a ceiling. A second elongated instrument, such as an elongated shaft mounted to a base, is placed end-to-end with the first elongated instrument in a substantially collinear relationship therewith. The wide, open end of the work piece is then gripped with two hands and is longitudinally pulled over the second elongated instrument until the work piece is right-side-out. The completed sleeve can be pulled off of the second elongated instrument, once the instruments' ends are spaced apart, and passed along for further processing or use.
[0024] This detailed description in connection with the drawings is intended principally as a description of the presently preferred embodiments of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the designs, functions, means, and methods of implementing the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and features may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention and that various modifications may be adopted without departing from the invention or scope of the following claims. | A device for preventing the accumulation of frozen precipitation on and around an automobile's windshield wipers. The device is defined by an elongated, substantially conical sleeve that is formed of polyester laminate industrial fabric. The sleeve is slid onto the windshield wiper of an automobile in advance of oncoming frozen precipitation. After frozen precipitation has accumulated on the automobile, the precipitation can be cleared from atop the protective sleeve and the sleeve can be removed to expose a clean, precipitation-free windshield wiper. Then windshield wiper can then be employed immediately in a conventional manner for cleaning the windshield of the automobile without being impeded by residual frozen precipitation that could otherwise accumulate on the wiper. | 1 |
RELATED APPLICATIONS
[0001] This application is a National Stage application of PCT application serial number PCT/EP2005/053212 filed on Jul. 5, 2005, which in turn claims priority to German application serial number 10 2004 033 195 filed on Jul. 9, 2004.
FIELD OF THE INVENTION
[0002] The invention relates to a device for inspecting a microscopic component. In particular, the invention relates to a device for inspecting a microscopic component with a stage for the microscopic component, at least one objective that is implemented as an immersion objective, and which defines an imaging beam path.
BACKGROUND OF THE INVENTION
[0003] The term inspection is understood here as meaning all activities that can occur in the context of the control of microscopic components. These include, for example, in addition to pure inspection, measurement of defined structures, simulation of structures and structural errors, repair of and to structures, and post-inspection of defined object positions. A person skilled in the art refers to this process as review.
[0004] European patent application 1 420 302 A1 discloses a lithography device and a method for producing a component using the lithography device. An immersion objective is used to increase resolution, and the immersion fluid is applied to the surface of the substrate to be structured. The entire table with the substrate to be structured is covered with a fluid. To avoid turbulence in the fluid, a transparent pan is dipped in the fluid. The pan is provided with the same fluid in which the imaging objective is dipped. This device is not suitable for inspecting masks, wafers, or components of a similar type.
[0005] The publication of US patent application 2004075895 discloses a device and a method for immersion lithography. The wafer to be structured is covered completely with a fluid. There is a small space between the imaging optic and the wafer such that only a small quantity of fluid is present therein. The fluid is constantly pumped, filtered, and also replenished.
[0006] None of the devices according to the state of the art suggest using an immersion objective or applying the immersion fluid directly to the microscopic component to be inspected (mask, wafer, micromechanical component).
SUMMARY OF THE INVENTION
[0007] The object of the present invention is therefore to increase the resolution of the inspection device, while simultaneously avoiding contamination of the components to be inspected.
[0008] According to the invention, this object is solved by a device for inspecting with the characteristics in claim 1 .
[0009] It is of advantage if the device for inspecting a microscopic component has at least one objective that is implemented as an immersion objective. Furthermore, the device is provided with a device for applying a small dosed quantity of fluid to the surface of the microscopic component. Likewise, a device for suctioning the small quantity of fluid is positioned above the surface of the microscopic component, whereby the device at least partially surrounds the immersion objective, or whereby it is arranged in the vicinity of the objective. The small quantity of fluid is a drop of fluid that represents the immersion fluid. It is particularly advantageous to use water as the immersion fluid. Highly purified water is recommended as the immersion fluid for a number of applications. Consequently, the immersion objective is a water immersion objective. The device may also be operated with other immersion fluids that are described in the literature.
[0010] In order to achieve high resolution, a portion of the light for inspecting with an immersion objective should have a wavelength of 248 nm or shorter (e.g., 193 nm). The several objectives may be mounted to a turret. Likewise, a fixed arrangement of two or several objects to each other is also conceivable, whereby one objective is the immersion objective, and the other(s) is/are used for alignment and other inspectional tasks using visible light.
[0011] The arrangement of the device for suctioning a small quantity of fluid is provided with a multiplicity of suction nozzles on the surface of the opposite side of the microscopic component. The suctioning nozzles comprise an edge and a suction channel, whereby the edge is at a controlled distance of less than 300 μm from the surface of the microscopic component. Furthermore, the device has for the purpose of suctioning a prominence on the side that is opposite the surface of the microscopic component, on which the suction nozzles are arranged such that the individual suction nozzles jut out over the prominence. The prominence is implemented in the present embodiment. For the suction device to function, it is simply required that the nozzles themselves be elevated.
[0012] Further advantages and advantageous embodiments of the invention are the subject of the following figures and their descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The object of the invention is schematically represented in the diagram and is described on the basis of the figures below. They show:
[0014] FIG. 1 —a schematic design of the device for inspecting and/or measuring, simulating, and repairing a microscopic component;
[0015] FIG. 2 —a schematic view of several objectives are arranged on a turret and their allocation to the microscopic component to be inspected;
[0016] FIG. 3 —a schematic view of an immersion objective in the working position;
[0017] FIG. 4 —a schematic view of the method of the device for suctioning to enable shifting of the immersion objective from the working position;
[0018] FIG. 5 —a further schematic representation of an embodiment of the suction device;
[0019] FIG. 6 —a schematic representation of an embodiment of the invention from FIG. 6 along the A-A line of intersection;
[0020] FIG. 7 —a bottom view of the device for inspecting a microscopic component, whereby the area around the suction device is represented;
[0021] FIG. 8 —a bottom view of the device for inspecting a microscopic component, whereby the area around the suction device is represented and other elements from the area around the objective are extended;
[0022] FIG. 9 —a detailed perspective view of the area around the objective and the microscopic component;
[0023] FIG. 10 —a schematic representation of a further embodiment of the device for inspecting and/or measuring a microscopic component, whereby two objectives that are fixedly arranged in relation to each other are provided;
[0024] FIG. 11 —a perspective top view of an embodiment of the device for suctioning the small quantities of fluid;
[0025] FIG. 12 —a perspective bottom view of an embodiment of the device for suctioning the small quantities of fluid;
[0026] FIG. 13 —a bottom view of the embodiment in FIG. 11 ;
[0027] FIG. 14 —a lateral view of the embodiment in FIG. 11 ;
[0028] FIG. 15 —a sectional view along the line B-B in FIG. 13 ;
[0029] FIG. 16 —a schematic view of the arrangement of the suction nozzles;
[0030] FIG. 17 —a further schematic view of the arrangement of the suction nozzles;
[0031] FIG. 18 —a schematic view of the switching the various segments of the U-shaped suction device;
[0032] FIG. 19 —an embodiment of the segmentation of a square device for suctioning; and
[0033] FIG. 20 —a further embodiment of the segmentation of a ring shaped device for suctioning.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] FIG. 1 shows a schematic design of a device 1 for inspecting a microscopic component 2 . A stage 4 that is implemented as a scanning table is provided for the microscopic component 2 on the basic frame 3 . The stage 4 is movable in an x-coordinate direction and in a y-coordinate direction. The microscopic component 2 to be inspected is placed on the stage 4 . The microscopic component 2 may be held in an additional holder 6 on the stage 4 . The microscopic component 2 is a wafer, a mask, several micromechanical components on a substrate, or a component of related type. At least one objective 8 , which defines an imaging beam path 10 , is provided for imaging the microscopic component 2 . The stage 4 and the additional holder 6 are implemented such that they are suitable both for incident light illumination and also for transmitted light illumination. For this purpose, the stage 4 and the additional holder 6 are implemented with a recess (not depicted) for passage of an illumination light path 12 . The illumination light path 12 exits from a light source 20 . A beam splitter 13 that couples or outcouples an auxiliary beam for focusing 14 is provided in the imaging beam path 10 . The focal position of the microscopic component is determined or measured, as the case may be, by a detection unit 15 with which the distance between the surface of the microscopic component to the objective and the devices for applying and removing the immersion fluid may be controlled. A CCD camera 16 is provided behind the beam splitter 13 in the imaging beam path 10 , with which the image of the site on the microscopic component 2 that is to be inspected can be recorded or imaged. The CCD camera 16 is connected to a monitor 17 and a computer 18 . The computer 18 serves to control the device 1 for inspecting, for processing the image data that has been captured, and for storing the pertinent data, as well as for controlling the application and suctioning of immersion fluid. In the embodiment of the invention represented here, several objectives 8 on a turret (not depicted) are provided such that a user may select various enlargements. System automation is achieved using the computer 18 . In particular, the computer serves to control the stage 4 , to read out the CCD camera 16 , to apply a small quantity of fluid to the microscopic component 2 , and to drive the monitor 17 . The stage 4 is movable in an x-coordinate direction and a y-coordinate direction; the X-coordinate direction and a y-coordinate direction are perpendicular to each other. In this manner, each site on the microscopic component 2 that is to be inspected may be introduced into the imaging beam path 10 . The device 1 for inspecting a microscopic component 2 further comprises a device 21 for applying a small quantity of fluid to the microscopic component 2 . A nozzle 22 is provided to apply the small quantity of fluid, and which may be moved in an appropriate manner to precisely the site where the small quantity of fluid is to be applied.
[0035] FIG. 2 shows a schematic view of several objectives 8 that are mounted to a turret 25 . The objectives 8 may be moved into the imaging beam path 10 , depending on the desired method of inspection. One of the several objectives 8 on the turret is an immersion objective 8 a ; in addition, there is a dry objective 8 b (not an immersion objective) and an alignment objective 8 c . A turret 25 , which holds the various objectives 8 , is mounted above the microscopic component 2 to be inspected. In the diagram represented here, the immersion objective 8 a is in the working position and is provided opposite the surface 2 a of the microscopic component 2 . In addition, a device 21 for applying a small dosed quantity of fluid to the surface 2 a of the microscopic component 2 is allocated to the immersion objective 8 a . In addition, a device 23 is mounted for suctioning the small quantity of fluid above the surface 2 a of the microscopic component 2 . The device 21 for applying the fluid is arranged closer to the immersion objective 8 a than is the suctioning device 23 . In the embodiment of the invention represented here, the suctioning device 23 is implemented such that it at least partially surrounds the immersion objective 8 a.
[0036] FIG. 3 shows a schematic view of the immersion objective 8 a in the working position. A small quantity of fluid 26 is applied between the immersion objective 8 a and the surface 2 a of the microscopic component 2 . In the process, the small quantity of fluid 26 completely wets the front-most lens 27 of the immersion objective 8 a.
[0037] FIG. 4 shows a schematic view of the method of the suction device 23 in order to enable shifting of the immersion objective 8 a from the working position. A device 23 for suctioning the small quantities of fluid are provided opposite the surface 2 a of the microscopic component 2 . As previously detailed, the suction device 23 partially surrounds the objective 8 a . Embodiments are also feasible in which only one suction device is arranged next to the objective. In order to enable shifting of the objective, the suction device 23 must be moved out of the area of linear or pivoting movement of the objective. The suction device 23 is moved as indicated by an arrow 30 in FIG. 4 . The suction device 23 is no longer in the area of the objective, as is evident from the bottom diagram in FIG. 4 .
[0038] FIG. 5 shows a further schematic representation of an embodiment of the suction device 23 . Here, the immersion objective 8 a is completely surrounded by the suction device 23 . The suction device 23 is implemented in the shape of a ring. It will be obvious to a person skilled in the art that the suction device 23 may assume any closed or open shape in order to at least partially surrounds the immersion object 8 a . Within the suction device 23 , a device 24 for applying a small quantity of fluid to the microscopic component 2 is also provided.
[0039] FIG. 6 is a schematic representation of the embodiment in FIG. 5 along the A-A line of intersection. The immersion objective 8 a is arranged opposite the surface 2 a of the microscopic component 2 . A small quantity of fluid 26 is applied between the front-most lens 27 of the immersion objective 8 a and the surface 2 a of the microscopic component 2 . The immersion objective 8 a is surrounded by the suction device 23 . The suction device 23 is implemented with several openings 34 on a side 32 that is opposite the surface 2 a of the microscopic component 2 . The fluid from the surface 2 a of the microscopic component 2 may be suctioned off as needed through these openings 34 . The suction device 23 is connected to a negative pressure reservoir (not depicted) via a tubing 35 . The fluid is suctioned from the surface 2 a by applying negative pressure.
[0040] FIG. 7 shows a bottom view of the device for inspecting a microscopic component 2 , whereby the area around the suction device 23 is represented. The suction device 23 is allocated to the immersion objective 8 a . In the embodiment represented here, the suction device 23 is implemented in a U-shape. Although the following description is limited to a U-shaped suction device 23 , this should not be interpreted as a limitation of the invention. The suction device 23 is mounted to a carrier 28 . The carrier 28 is movably implemented such that the suction device 23 may be moved out of the area of linear or pivoting movement of the objective 8 a , and the distance to the surface of the microscopic component can be controllably adjusted. Furthermore, a device 21 for applying a small quantity of fluid and a cleaning device 36 are provided on the carrier 8 a . The cleaning device 36 serves to remove reliably from the objective 8 a any fluid that still adheres to it. The application device 21 and the cleaning device 36 are positioned in the area around the immersion objective 8 a by corresponding recesses 37 and 38 in the suction device 23 . The cleaning device 36 comprises a nozzle tip 39 with which residual fluid that adheres to the immersion objective 8 a may be suctioned off.
[0041] FIG. 8 is a bottom view of the device for inspecting a microscopic component 2 , whereby the area around the suction device 23 is represented, and further elements are extended beyond the area around the objective 8 a . As previously mentioned, the further elements are the suction device 23 and the cleaning device 36 . As previously described in FIG. 4 , the objective can only be shifted when the cleaning device 36 is completely extended beyond the suction device 23 . The cleaning device 36 is movably implemented and is mounted for the purpose to a corresponding movable mimic 40 .
[0042] FIG. 9 shows a detailed perspective view of the area around the objective 8 , 8 a , and the microscopic component 2 . The device 21 for applying a small quantity of fluid to the microscopic component 2 and the cleaning device 36 are attached to the mimic 40 , which is movably implemented. The device 23 for suctioning small quantities of fluid is provided in the working position directly opposite the surface 2 a of the microscopic component 2 . In the embodiment represented in FIG. 9 , the microscopic component 2 is a mask for producing semiconductors. Here, the mask is positioned in a separate mask holder 42 . The carrier 28 is mounted via a rigid arm 43 to a lifting device 44 , which lifts the carrier 28 together with the suction device 23 from the surface 2 a of the microscopic component 2 . The arm 43 on the lifting device 44 is movable for the purpose in the direction of two elongated holes 45 .
[0043] FIG. 10 is a schematic representation of a further embodiment of the device for inspecting and/or measuring a microscopic component 2 . Here, the turret 25 is replaced by two objectives 8 , 8 a that are fixedly arranged in relation to each other. One of the objectives is an immersion objective 8 a that is implemented and intended for DUV illumination (248 nm or 193 nm). The second objective 8 is an objective for visible light that can be used for alignment or other inspectional tasks. Each of the objectives is allocated at least one CCD 48 , which is used for capturing images. The microscopic component 2 in this case is a mask, the substrate of which is transparent. An illumination optic 46 is provided below the mask for illumination.
[0044] FIG. 11 is a perspective top view of an embodiment of the device 23 for suctioning small quantities of fluid. The suction device 23 in this embodiment is implemented in a U-shape and comprises a first leg 51 , a second leg 52 , and a third leg 53 the suction device 23 exhibits a prominence 54 on the side opposite the microscopic component 2 , in which the suction nozzles 55 are implemented (see FIG. 12 ).
[0045] FIG. 12 is a perspective bottom view of an embodiment of the device 23 for suctioning small quantities of fluid. The prominence 54 is implemented as a continuous band along the first, second, and third legs 51 , 52 , and 54 . The prominence bears a multiplicity of suction nozzles 55 which, in the working position of the suction device 23 , lie opposite to the surface 2 a of the microscopic component 2 .
[0046] FIG. 13 shows a bottom view of the embodiment of the suction device 23 from FIG. 11 . As mentioned previously, the multiplicity of suction nozzles 55 is formed on the prominence 54 . The suction nozzles 55 run as a continuous band along the first, second, and third legs. The individual suction nozzles 55 are themselves elevated above the prominence 54 . Furthermore, the suction nozzles are staggered. The line B-B in FIG. 13 illustrates the staggering of the suction nozzles 55 .
[0047] FIG. 14 shows a lateral view of the embodiment of the suction device 23 from FIG. 13 . The individual suction nozzles 55 jut above the prominence 54 . The arrangement of the individual suction nozzles 55 is staggered such that they form in projection a closed barrier to the immersion fluid to be suctioned. This ensures that no immersion fluid can pass by the suction nozzles 55 .
[0048] FIG. 15 shows a sectional view of the suction device 23 along the B-B line from FIG. 13 . The individual suction nozzles 55 of the third leg 53 are connected with a suction channel 56 . Likewise, the suction nozzles 55 of the second leg 52 are connected with a further, separate suction channel 57 . As a result of this separation of the suction channels, it is possible to pressurize the individual legs 51 , 52 , and 53 with negative pressure.
[0049] FIG. 16 is a schematic view of the embodiment of the suction nozzles 55 . The suction nozzles 55 are formed with an edge 60 that is additionally elevated above the prominence 54 . The suction channels 56 , 57 of the suction nozzles 55 have a diameter 61 of approximately 1 mm. The edge 60 is arranged parallel to the surface 2 a of the microscopic component 2 (mask). The edge 60 is positioned at a controlled distance of less then 300 μm from the surface 2 a.
[0050] FIG. 17 shows a further schematic view of the design of the suction nozzles 55 . The suction channel 57 of the suction nozzle 55 comprises a slanted edge 63 , so that the distance of the edge 63 increases from the center of the suction channel 57 outwardly in a continuous manner from the surface 2 a of the microscopic component 2 . This design serves, in particular, to draw immersion fluid by means of capillary action in the direction of the suction channel 57 in order to achieve reliable suctioning of the immersion fluid.
[0051] FIG. 18 is a schematic view of the switching of the various segments of the U-shaped suction device 23 . The first leg 51 , the second leg 52 , and the third leg 53 of the U-shaped suction device 23 are separated into discrete segments 65 . Each of the segments is provided with its own tubing 67 for applying negative pressure. Negative pressure may be applied to the corresponding segments 65 independent of the relative movement between the stage 4 (see FIG. 1 ) and the suction device 23 . The relative movement between the stage 4 and the suction device 23 is indicated by an arrow 68 in FIG. 18 . As a result, the first leg 51 moves toward a drop of fluid 70 such that the segment 65 of the first leg 51 must be pressurized with negative pressure. A control 71 is provided that applies negative pressure to the corresponding leg independent of the direction of movement of the suction device 23 . Optimal suctioning is achieved at each segment as a result of this circuitry.
[0052] FIG. 19 shows an embodiment of the segmentation of a square suction device 23 . The individual segments 65 comprise sides 81 , 82 , 83 , and 84 of the square.
[0053] FIG. 20 shows a further embodiment of the segmentation of a round suction device 23 . Here, the individual segments 65 are here the orthogonal sectors 91 , 92 , 93 and 94 of the round suction device 23 . It will be clear to a person skilled in the art that another division of the segments 65 is feasible. | A device 1 is disclosed for inspecting, measuring defined structures, simulating structures and structural defects, repair of and to structures, and post-inspecting defined object sites on a microscopic component 2 with an immersion objective 8 a . The device 1 comprises a stage that is movable in the x-coordinate direction and in the y-coordinate direction and a holder 42 for the microscopic component 2 , whereby the holder 42 is placed on the stage 4 with the microscopic component 2 in it. The holder 42 has a reservoir 51 a with immersion or cleaning fluid, respectively. The stage 4 is movable such that the immersion objective 8 a is located directly above the reservoir 51 a and may dip into the fluid with its front-most lens. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from Japanese Patent Application No. 2002-264638 filed on Sep. 10, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for a pivot assembly used as the bearing of a swing arm type actuator in a hard disk drive, and more particularly to the improvement of the fixing means of a sleeve that maintains the spacing of two ball bearings.
2. Description of the Related Art
The kind of pivot assembly that fixes ball bearings at both ends of a shaft and, in addition, mates a sleeve to the outer circumference of the ball bearings, and maintains by the bottom wall part of the sleeve a space between both ball bearings is known. This pivot assembly is mated to the base part of a swing arm having a magnetic head on the tip, and is attached by means of a screw passed through the swing arm to a screw hole formed in the sleeve.
Now, in the above-mentioned conventional pivot assembly the outer ring of the ball bearing and the sleeve were fixed by an adhesive. Because of this, the problem arose that gas would be generated from the adhesive that would result in a harmful effect on the surface of the hard disk and magnetic head. In order to solve this outgassing problem, even pressing of the outer ring into a sleeve and fixing was carried out. However, with fixing by pressing in, management of the allowance for pressing in was difficult and there was the problem that the reliability of the fixing of the sleeve was deficient.
Consequently, the present invention aims to offer a pivot assembly that can reliably and securely fix a sleeve and, in addition, can also solve the problem of outgassing.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a pivot assembly for hard disk drive use in which ball bearings are mated to both ends of a shaft, an inner wall part extending to the outer circumference of these ball bearings is mated to a sleeve disposed between both of the ball bearings, and in which the sleeve is fixed by laser welding to the outer ring of the ball bearing.
In this pivot assembly for hard disk drive use (hereinafter, called simply, “pivot assembly”) of the above-mentioned configuration, because the sleeve is fixed by laser welding to the outer ring, the sleeve can be reliably and securely fixed, and, moreover, the problem of outgassing can be solved.
There is no limit on the laser source of the laser welding; for example, a YAG laser can be used. Furthermore, laser welding can be carried out along the entire circumference of the point of contact of the outer ring with the sleeve (seam weld), or can be carried out at multiple places mutually separated along the contact part (spot weld).
When welding a sleeve to the outer ring of a ball bearing, spot welding cannot be used, because with spot welding by means of electric resistance welding and gas welding, the welding part greatly lowers the bearing precision due to the thermal effect. In the present invention, because the sleeve is welded to the outer ring by means of laser welding, the weld part can be made smaller by narrowing the spot diameter of the laser beam to, for example, about 0.4 mm. In this manner, the thermal effect that the weld part imparts to the outer ring is reduced, and a reduction in bearing precision can be prevented.
Furthermore, the sleeve and the outer ring can be welded at the boundary of the end face of the outer ring and the inner circumference of the sleeve. However, because it is normal for the outer ring to have a cross-section abbreviated circular arc-shaped chamfer at the intersection of the outer circumference face and end face thereof, a concave part is formed between the edge part of the end face of the outer ring and the sleeve. In this case, the gap becomes smaller toward the inner part of the concave part, and a laser beam must correctly hit the contact part of the sleeve and outer ring positioned in the innermost part thereof. Moreover, the laser beam must irradiate so as to follow the common tangent of the chamfer and the inner circumference of the sleeve, in short, the inner circumference of the sleeve. If the laser beam is of a small diameter as mentioned above, when the position of the sleeve fluctuates even slightly, the laser beam cannot irradiate the necessary place, and so laser welding is not easy.
The present invention, including its features and advantages, will become more apparent from the following detailed description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side cross-section view that shows the pivot assembly of the first embodiment of the present invention.
FIG. 2 is a cross-section view of 11 —II of FIG. 1 .
FIG. 3 is an enlarged side cross-section view of the part indicated by arrow III of FIG. 1 .
FIG. 4 is a side cross-section view that shows the pivot assembly of the second embodiment of the present invention.
FIG. 5 is a cross-section view of the V—V line of FIG. 4 .
FIG. 6 is an enlarged side cross-section view of the part indicated by arrow VI of FIG. 4 .
DETAILED DESCRIPTION
In one mode of the present invention, a concave part that reaches up to the vicinity of the outer circumference of the outer ring is formed, and the bottom wall of this concave part is laser welded to the outer circumference of the outer ring. With this kind of mode, if the laser beam is irradiated to any place on the bottom wall of the concave part, laser welding is carried out. Consequently, since the irradiation angle and the irradiation position of the laser beam do not need to be strictly controlled, laser welding can be easily carried out. However, in order to cause the bottom wall to be welded by a laser beam narrowed as mentioned above, it is desirable that its thickness be 0.3 mm or less. Here, the concave part can be made as a groove that extends along the entire circumference of the sleeve. In this case, welding that extends along the entire circumference of the groove can be done, or spot welding at multiple places mutually separated along the circumferential direction can be done. Furthermore, in the case of forming a sleeve, in order to ensure the strength of the sleeve, it is desirable that the thickness of the bottom wall be 0.1 mm or more. It is even acceptable if in the concave part holes are provided mutually separated in the circumferential direction of the sleeve, and spot welding at one or two or more places of the bottom walls of those holes can also be done.
In another mode to make laser welding easy, holes are formed on the outer circumference of a sleeve, linked to the outer circumference of the outer ring, and the edge part of these holes are laser welded to the outer circumference of the outer ring. In this case also, since laser welding can be carried out it a laser beam is irradiated to any place of the edge part of the hole, and since strict control of the irradiation angle and irradiation position of the laser beam is not necessary, laser welding can be easily carried out. Furthermore, with this kind of mode, there is also the advantage that, different from the case of forming the groove, the strength of the sleeve, practically, does not decrease.
Carrying out the above-mentioned kind of laser welding at places separated in the axial direction from the rolling groove of the outer ring is desirable. By this means, the thermal effect on the rolling groove and balls due to the laser welding can be reduced, and the bearing precision can be improved.
The first embodiment of the present invention will be explained with reference to FIG. 1 ˜FIG. 3 . Reference numeral 1 in these figures is a shaft. A hole 11 is formed in the center of the shaft 1 and, by means of a shaft passed through this hole 11 ; a pivot assembly is attached to a hard disk drive. A flange 12 is formed at the lower end part of the shaft 1 . On the outer circumference of the shaft 1 , the ball bearing 2 caused to contact the end face is caused to mate with the flange 12 .
A ball bearing 2 is provided with an inner ring 21 and an outer ring 22 and multiple balls 23 which can move by rolling in a circumferential direction between them. The balls 23 are maintained at regular intervals in a circumferential direction by means of a retainer that is not illustrated. The opening part between the inner ring 21 and the outer ring 22 is blocked by a seal 25 . Furthermore, reference numeral 26 in the figures is a snap ring to fix the seal 25 .
A ball bearing 2 the same as mentioned above is caused to mate with the upper end part of the shaft 1 . Also, a sleeve 3 is caused to mate with the outer circumference of these two ball bearings 2 . The sleeve 3 forms a cylindrical shape, and in the center part in the axial direction thereof, a spacer part (inner wall part) 31 with an inner diameter smaller than both end parts is formed. At both end faces of the spacer part 31 , the outer rings 22 of ball bearings 2 make contact, and by means of this, the outer rings 22 are separated from each other by a fixed interval. Furthermore, on the outer circumference of both end parts of the sleeve 3 , a groove (concave part) 32 that reaches to the vicinity of the outer circumference of the outer rings 22 is formed along the entire circumference. The center of the bottom wall 33 of the groove 32 is caused to correspond to the end face of the outer ring 22 . And, the center of the bottom wall 33 is laser welded to the edge part of the outer ring 22 at multiple places separated at regular intervals in the circumferential direction, and, by means of this, the sleeve 3 is fixed to the outer ring 22 . Reference numeral P in FIG. 2 indicates the nugget due to welding. Furthermore, seam welding along the entire circumference of the center of the bottom wall 33 is also possible.
To the outer circumference of a pivot assembly of the abovementioned configuration the base of a swing arm provided with a magnetic head on the tip is attached. In the base of the swing arm, a hole that mates the pivot assembly is formed, and a screw passed through the above-mentioned base is screwed in a screw hole (omitted from the figure) formed in the sleeve 3 .
In a pivot assembly of the above-mentioned constitution, because the sleeve 3 is fixed by laser welding to the outer ring 22 , the sleeve can be reliably and securely fixed, moreover, the problem of outgassing can be solved.
In particular, in the above-mentioned first embodiment, in the outer circumference of the sleeve 3 , a groove 32 that reaches up to the vicinity of the outer circumference of the outer ring 22 is formed, and because the bottom wall 33 of this groove 32 is laser welded to the outer circumference of the outer ring 22 , strictly controlling the irradiation angle and irradiation position of the laser beam is not necessary; thus, laser welding can be easily carried out. Furthermore, since the laser welding is carried out at a place furthest separated from the rolling groove of the ball bearing 2 , there is no thermal effect with respect the rolling groove and balls 23 , and bearing precision can be improved.
Next, the second embodiment of the present invention will be explained with reference to FIG. 4 ˜FIG. 6 . The second embodiment differs from the first embodiment on the point that a hole 35 was formed, instead of the groove 32 of the first embodiment. Accordingly, in the following explanation, the same reference numerals were given to the constituent elements that are the same as those of the above-mentioned first embodiment and the explanation thereof is omitted.
As shown in the figure, on the outer circumference of both end parts of the sleeve 3 , multiple holes (concave part) 35 are formed at regular intervals in a circumferential direction. The tip of the hole 35 forms a tapered shape, and at this tip, an opening 36 that links to the outer circumference of the outer ring 22 is formed. The opening 36 is positioned in a place that approaches the ball 23 side from the end face of the outer ring 22 . And, the edge part of the opening 36 is laser welded to the outer circumference of the outer ring 22 at one place or the entire circumference thereof, and by means of this, the sleeve 3 is fixed to the outer ring 22 .
In the second embodiment, the action and effect equal to that of the above-mentioned first embodiment can also be obtained. Particularly, in the second embodiment, there is the advantage that there is essentially no decrease in the strength of the sleeve 3 , compared to the case of forming a groove 32 , as in the first embodiment, because a hole 35 that links to the outer circumference of the outer ring 22 is formed.
According to the present invention as explained above, because a sleeve is fixed by laser welding to the outer ring of a ball bearing, the sleeve can be reliably and securely fixed; moreover, the problem of outgassing can be solved and like effects can be obtained.
In the foregoing description, the apparatus and method of the present invention have been described with reference to specific examples. It is to be understood and expected that variations in the principles of the apparatus and method herein diaclosed may be made by one skilled in the art and it is intended that such modifications, changes, and substitutions are to be included within the scope of the present invention as set forth in the appended claims. The specification and drawings are accordingly to be regarded in an illustrative rather than in a restrictive sense. | An apparatus for a pivot assembly that can strongly and reliably fix a sleeve to an outer ring, and in addition, that can also solve the problem of out gas. Ball bearing 2 are mated to both ends of a shaft 1 , and to the outer circumference of these ball bearings 2 , an inner wall part 31 mates a sleeve disposed between both ball bearings 2 , and the sleeve 3 was fixed by laser welding to the outer ring 22 of the bell bearings 2. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an assembly which will lock one drill string to another and form a pressure seal.
2. Prior Art
The present invention is a device which can be installed in the annulus between two coaxial drill strings and will; lock one string, in tension, with regard to the other, form a pressure tight seal, and center one string with the other. The device may be used in most drilling operations, however, it is particularly suitable for use in offshore drilling installations.
In any drilling operation it is possible to have some impairment occur which limits the ability to continue drilling operations, this is commonly referred to as losing the hole. However, in offshore drilling this problem is compounded due to the large distance between the drilling platform and the ground surface, or mudline. If some disaster or problem arises which causes the hole to be lost, the capability of recovering the hole must exist. Thus, in most offshore drilling operations a large first casing is drilled to a given depth below the mudline, then a second smaller casing is drilled through the first larger casing to a greater depth, a third and smaller casing may then be used to drill to any given depth through the first and second casings. The present invention is used to secure and seal the first two casings one to the other. The present invention is placed immediately after the second casing is drilled into its final position and remains in position until it is no longer needed.
In the drilling industry there exists many prior art methods for packing off (sealing) one portion of a casing, or for sealing one casing off with respect to the other. However, these devices serve only to provide a seal and do not secure one casing to the other. A separate problem is that prior art devices are not recoverable and when positioned, become a permenant part of the casing. There also exists devices for centering one string of casing with respect to the other, however, the device does not secure one string to the other, nor pack off the annulus.
The present invention attempts to solve these problems by providing a device which will pack off, center and secure one coaxial string of casing to the other. An additional feature is that the device is retrievable and may be reused.
SUMMARY OF THE INVENTION
The present invention is a device which may be employed in drilling operations to secure an inner coaxial casing string to an outer coaxial casing, and to provide a pressure seal for the annulus between the coaxial casing strings. The securing portion of the device is comprised of an upper supporting ring which has a plurality of inner and outer circumferentially disposed slip arms having corrugated feet which engage the inner and outer casing walls. The corrugated feet are adjustably mounted such that the outer feet can be secure against the outer casing while the inner feet are secured against the inner casing. Then by adjusting the verticle placement of the inner slip arm the inner casing is placed in tension in relation to the outer casing. A resilient sealing ring is mounted over the upper supporting ring and held in place by an upper packing ring. The upper packing ring is able to be secured to the upper support ring by a plurality of bolts. Tightening of these bolts compresses the packing ring and provides a pressure tight seal.
It is an object of this invention to provide a device which will secure one coaxial string to another and seal the annulus there between.
It is another object to provide a device for sealing and securing which is retrievable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut away side view of the upper end of the coaxial casings showing the present invention installed in place;
FIG. 2 is a section view taken along line 2--2 of FIG. 1;
FIG. 3 is a section view taken along line 3--3 of FIG. 2 showing the slip portion of the assembly and the temporary spacing and support plate;
FIG. 4 is a section view taken along line 4--4 of FIG. 2 showing the invention in position;
FIG. 5 is a sectional view of an offshore drilling platform and coaxial casing utilizing the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The presently preferred embodiment of the invention is shown diagrammatically in FIG. 5 to illustrate the environment and the application of the present invention. The packer and tension slip assembly 20 shown in place, in FIG. 5, is located between two coaxial casing strings 15 and 16. The outer casing 15 is larger in diameter than the inner casing 16. In offshore drilling operations, the larger outer casing 15 is normally drilled to a specified depth below the mudline 17. An inner casing 16 having a smaller diameter is then drilled through the outer casing to a greater depth than the outer casing 15. This step diameter reducing method of drilling a hole is especially essential in offshore drilling operations because of the increased possibility of an emergency or problem arising in which the casings may break or become damaged somewhere between the deck 19 and the mudline 17. If this step diameter reduction procedure is used it is possible to cap or recover the drill hole at the mudline 17.
The present invention is employed near the deck level 19 of the casings, as shown generally in FIG. 5 and in detail in FIG. 1. The device serves to pack off (pack off is a term which refers to the ability to seal some portion of a casing or to seal one casing to another in order that pressurized drilling or other operations may continue), center one casing the relation to the other casing, allow a third casing to be drilled through the inner casing and hold the inner casing in tension with respect to the outer casing. An additional feature of the device is that it is retrievable and may be reused.
The device 20 (FIG. 4) is basically comprised of: an upper supporting ring 37 having a plurality of inner and outer slip arms 28 and 27, an inner and outer slip setting ring 31 and 32, a packing ring assembly 60 having an upper and lower packing ring 47 and 49 with a resilient packing ring 48 disposed therebetween, and a spacer and support plate 40 (FIG. 3) which is used to position and retrieve the assembly 20.
The upper supporting ring 37 forms the basic body of the assembly 20. It is generally annular in shape having an inner diameter slightly larger than the outer diameter of the inner casing 16 and an outer diameter slightly smaller than the inner diameter of the outer casing 15. The depth of the annular support ring 37 is not critical except it must provide sufficient rigidity. This annular supporting ring has a top surface 56 and a bottom surface 57. Around the outer periphery of the annular supporting ring 37 are disposed a plurality of generally rectangular shaped slots 54 which extend through the thickness of the annular supporting ring. Thus, when the upper support ring 37 is viewed from the top as in FIG. 2, the annular support ring 37 has a plurality of recesses or slots 54 around its outer periphery. On one of the sides of slot 54, which extend perpendicular to the outer periphery, is disposed a threaded pin 23 which is capable of receiving an aperture in the end of the outer slip arm 27. The slot 54 is of sufficient dimension so as to allow the end of the outer slip arm 27 to be disposed in the slot and on pin 23. Also disposed cirumferentially around the inner periphery of the annular upper support ring is a plurality of recessed slots 55 disposed in alignment with the slot recess 54. This rectangular recessed slot 55 also contains a threaded pin 24 which is capable of being disposed through a slot in the inner slip arm 28. This inner recessed slot 55 is also capable of containing the inner slip arm 28 and providing sufficient area for the inner slip arm 28 to rotate freely about pin 24. This recessed slot 55 is disposed into the upper support ring 37 from the bottom 57, but does not extend through the upper support ring 37. A circular recess 38 extends from the base of the recessed slot 55 still further upward into the upper support ring 37, but does not extend through the upper support ring. The circular recess 38 is capable of receiving a circular spring 39.
The upper support ring 37 has a plurality of pairs of apertures 61 and 62 disposed circumferentially around and through the upper support ring 37. These apertures 61 and 62 allow the inner and outer cap bolts 21 and 22 to be disposed through the upper support ring 37, as best shown in FIG. 2. These apertures 61 and 62 are counter bored to allow the heads of the inner and outer cap bolts 21 and 22 to be disposed so as to be flush with the top 56 of the upper support ring. Also, disposed circumferentially around the upper support ring are a plurality of apertures 45 which are threaded but do not extend through the upper support ring, also shown in FIG. 2. These apertures 45 are to receive bolt 53 (FIG. 4) which secures the packing ring assembly 60 in position. A third set of apertures is disposed circumferentially around the upper support ring to receive bolt 44 which secures the spacing and support plate to the upper support ring 37. These apertures 63 do not extend through the upper support ring and are threaded to receive bolt 44.
A plurality of outer slip arms 27 (FIG. 3) are circumferentially disposed in each of the circumferentially disposed slots 54 on pins 23. The outer slip arms 27 each have a body which is generally rectangular in cross section and elongated in shape (FIG. 3 and FIG. 4). The outer slip arms 27 extend downward from the bottom 57 of the upper support plate. One end of the outer slip arm 27 contains an aperture 26 which is disposed on pin 23 and may be contained in place by a nut or other locking means. It is especially important, however, that the fastening means allow the outer slip arm to freely rotate on pin 23 within the slot 54. The opposite end of the outer slip arm contains a foot 29. The foot 29 is generally arcular in shape, triangular in cross section. The outer arcular periphery of the foot 29 is formed to the same diameter as the inner diameter of the outer casing. The foot 29 however, only extends radially around a portion of the arc. Side 74 of the foot 29 which faces the wall of the outer casing has a plurality of surfaces in a generally corrugated pattern so as to be able to grip into the wall of the outer casing. The opposite side 70 of the foot 29 is beveled and intersects the bottom of side 74 such that the foot 29 appears to be generally triangular in shape, best shown in FIG. 3. This inclined face 70 engages the inclined face 72 of the outer slip setting ring 32. In addition, to side 72 of the foot being inclined a portion of the body of the outer slip arm is tapered to allow the outer slip setting ring to be disposed upwardly without contacting the body of the slip arm.
The inner slip arm 28 is formed in much the same manner as the outer slip arm 27, a body, a foot 30 with a corrugated side 75 for engaging the wall of the inner casing, and an inclined side 71 which is engagable with the inclined side 73 of the inner slip setting ring 31. The only distinction between the inner and outer slip arm is that the inner slip arm has a slotted aperture 25, as shown in FIG. 3, which is disposed over pin 24. This slot extends longitudinally along the body of the inner slip arm and allows the inner slip arm to be displaced vertically in addition to radially in relation to pin 24.
The inner slip setting ring 31 is annular in shape and has a rectangular cross-section with side 73 being inclined. The outer diameter of the inner slip setting ring 31 bisects the annulus between the casings. The inner diameter of side 73 varies from top to bottom thereby forming the inclined surface which is engagable with the inclined surface 71 of the foot 30. When the inner slip ring 31 is disposed in position as shown in FIG. 4, the inner diameter of the bottom of side 73 is smaller than the upper diameter of side 73. Thus, as the inner slip setting ring is disposed vertically upward, the engagement of the inclined surfaces forces the foot 30 to dispose radially upward toward the inner casing. The inner slip setting ring 31 also has a plurality of apertures 64 disposed circumferentially through it which are in alignment with apertures 61 in the upper supporting ring 37. These apertures 64 allow the inner cap bolts 21 to be disposed therethrough, and allow a nut 36 to be engaged with the threaded end of the inner cap bolt.
The outer slip setting ring 32 is the mirror image of the inner slip setting ring 31 and is disposed such that the inclined end can be disposed so as to engage the inclined surface of foot 29 while the inner perphery engages the outer perphery of the inner slip setting ring 31. Apertures 65 are threaded through the outer slip setting ring 32. These apertures 65 are to receive the outer cap bolt 22 which extends through the outer slip setting ring 32.
The spacer and support plate 40 is generally annular in shape and best illustrated in FIG. 3. The cross section of the spacing and support plate 40 is generally Z-shaped, having an upper flange 42, a bottom flange 43 and a web 41. The upper flange 42 serves to engage the end of the inner casing 16 while the bottom flange is fastened to the top of the upper support ring 37. Flange 43 has a plurality of circumferentially disposed apertures which are aligned with apertures 45 in the upper support ring 37. The spacer and support plate 40 is disposed such that web 41 is parallel the wall of the inner casing 16, and the aperture 63 in flange 43 is aligned with apertures 45 in the upper support ring 37. Bolts 44 are disposed through the bottom flange 43 into the upper support ring 37 and and thereby secure the spacing and support plate 40 to the slip assembly 20. The spacing and support plate 40 is for temporary use and is used to position the slip assembly 20 until the feet 29 and 30 are engaged with the walls of the casing, and thereby secure the assembly 20 in position. Once the slip assembly 20 is secured in position by feet 29 and 30, the spacing and support plate 40 is removed since the slip assembly 20 will secure itself in position. It is an additional feature of this invention to provide a retrievable slip and packing assembly 20, consequently the upper spacing and support plate may be used to retrieve the slip assembly 20.
The packing portion 60 of the assembly 20, best shown in FIG. 4, is comprised of: a top and bottom spacing ring 49 and 47, a bolt 53 and a resilient packing ring 48. The bottom packing ring 47 is annular in shape and has a generally rectangular cross section. The bottom packing ring 47 is sized such that it fits over the top of the slip assembly 20 in the annular area between the inner and outer casings. The bottom packing ring 47 is formed from a metal and is solid except for a plurality of apertures 68 which are in alignment with apertures 45 in the upper supporting ring 37. The apertures 68 are threaded to allow bolt 53 to be disposed therethrough.
The upper packing ring 49 is also annular in shape, but has a generally triangular shaped cross section, as best illustrated in FIG. 4. The outer diameter of the upper packing ring 49 is slightly smaller than the inner diameter of the outer casing 15. The inner diameter of the upper packing ring 49 is approximately equal to the inner diameter of the inner diameter of the inner casing 16. The thickness of the upper packing ring 49 varies and consequently the upper surface is generally inclined. The thickness of the upper packing ring 49 is smallest near the inner casing 16 and largest near the outer casing 15. A small recess 51 is formed on the bottom surface of the upper packing ring 49 near the inner casing 16 such that the upper packing ring will engage the end and wall of the casing 16. The upper packing ring 49 has a plurality of apertures 69 disposed therethrough, in alignment with apertures 45 and the upper support ring 37 to allow bolts 53 to be disposed therethrough. Each aperture 69 is counter bored 50 such that the head of bolt 53 will not extend into or beyond the top of the upper packing ring 49.
The resilient packing ring 48 is annular in shape and has a generally rectangular cross section. The packing ring is normally formed from a heavy rubber or neoprene material or any other suitable sealing expanding type of material. The outer diameter of the packing ring is slightly smaller than the inner diameter of the outer casing 15 and the inner diameter of the packing ring 48 is slightly larger than the outer diameter of the inner casing 16. Thus, when the packing ring 48 is disposed in position it will fit into the annular area between the inner and outer casing. The packing ring 48 has a plurality of apertures 52 disposed therethrough, in alignment with aperture 45 in the upper support ring 37 for receiving bolt 53. The packing ring 48 must be compressable such that when bolt 53 is engaged with the upper support ring 37 and tightened that is expands and thereby seals the annular area between the two casings.
Having now described the physical characteristics of the packing and tension slip assembly 20, a typical use of the present invention will be described. Initially the outer and inner slip arms 27 and 28 must be mounted on respective pins 23 and 24, in addition, the springs 39 must be disposed in recesses 38 such that when it is in its initial position it urges the inner slip arm downward such that pin 24 engages the top of slot 25 as best illustrated in FIG. 3. The inner and outer cap bolts 21 and 22 are then disposed through the upper support ring 37 and are threaded through the inner and outer slip setting rings 31 and 32. Nuts 36 and 35 are then disposed on the threaded ends 31 and 34 of the inner and outer cap bolts 21 and 22. However, the lock nuts 35 and 36 should not be positioned such that the inner and outer slip setting rings force the feet 29 and 30 of the outer and inner slip arms into their extended positions. The bolt should allow the inner and outer slip setting rings to be disposed such that the feet 29 and 30 are in their collapsed position as illustrated in FIG. 3. The spacing and support plate 40 is then fastened to the upper support ring by bolts 44.
The slip portion of the assembly 20 is then lowered into the annulus between the two casings with the spacing with the support plate temporarily attached thereto, as best illustrated in FIG. 3. The plurality of outer slip arms 27 are then engaged with the outer casing 15, by tightening the outer cap bolt 22 which causes the outer slip setting ring 32 to move upward. This results in the foot 29 and outer slip arm 27 rotating about pin 23 until foot 29 engages the outer casing 15. The inner slip arm arms 28 are then positioned by tightening the inner cap bolts 21. This tightening of inner cap bolts 21, causes the inner casing to be stretched as the inner slip arm is forced to dispose vertically upward, as pin 24 moves along slot 25. Spring 39 initially held the inner slip arm 28 down but after the feet are set, the inner slip arm may be disposed vertically upward. It should be noted that tensioning of the casings is possible because of the frictional force which the earth exerts against the embedded end of the casing. Without this force, the casings would displace and not become tensioned.
After the inner and outer slip arms are set and the inner string tensioned, as illustrated in FIG. 4, the spacing and support plate 40 may be removed by disengaging bolts 44. The bottom packing ring 47 is then disposed over the top 56 of the upper support ring 37. Next, the resilient packing ring 48 is disposed in position on top of the bottom ring 47. Last, the upper packing ring 49 is disposed on top of the resilient packing ring 48. The packing unit 60 is then secured in place by disposing bolt 53 through the upper packing ring 49, resilient packing ring 48, bottom packing ring 47 and into the aperture 45 in the upper support ring 37. As bolt 53 is tightened, the resilient packing ring 48 is compressed and forms a seal between the inner and outer casing. This seal prevents any moisture from entering or leaving the annulus between the casings, whether the moisture is under pressure or not.
Another feature of the present invention is that the packing unit and slip assembly are retrievable. It is retrievable by first removing the packing unit by; unfastening bolt 53 and removing the upper packing ring 49, the resilient packing ring 48 and lower packing ring 47. Next, the spacing and support plate 40 is disposed in position in the annulus and bolted to the top of the upper support ring 37 by bolts 44. The inner and outer slip arms 27 and 28 can be disengaged by loosening cap bolts 21 and 22. The cap bolts cannot completely disengage due to stop nuts which are disposed at the end 33 and 34 of the inner and outer cap bolts. When the inner and outer cap bolts are loosened to the point where these stop nuts prevent further rotation, the inner and outer slip setting rings 31 and 32 can be disengaged from both casings by striking the head of the inner and outer cap bolts 21 and 22 with a hammer. This forces the slip setting rings 31 and 32 downward allowing the slip arms 27 and 28 to rotate and become disengaged with the walls of the casings. The complete assembly 20 can then be removed from the annular hole between the casings, and later reused. | A packer and tension slip assembly is disposed in the annular area between two coaxial drilling casings having different diameters. The coaxial casings are secured one to the other by placing the inner casing in tension with the outer casing. A packoff unit is attached to and completes the assembly forming an pressure tight seal in the defined annulus. The packer and tension slip assembly also serves to center one string in respect to the other and can be retrieved when no longer required, and subsequently reused. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to shoe drying apparatus, and more particularly pertains to a new and improved shoe dryer bracket wherein the same is arranged for the positioning and mounting of shoes within a rotary tumbling dryer apparatus.
2. Description of the Prior Art
A shoe drying rack is indicated in U.S. Pat. No. 4,109,397 for positioning within a drying machine, as well as U.S. Pat. No. 5,080,312.
The instant invention attempts to overcome deficiencies of the prior art by providing for a bracket structure arranged for accommodating various thicknesses of shoe soles and dryer drums and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of shoe drying apparatus now present in the prior art, the present invention provides a shoe dryer bracket wherein the same is arranged for ease of mounting and positioning of a shoe pair within a rotary dryer drum. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved shoe dryer bracket which has all the advantages of the prior art shoe drying apparatus and none of the disadvantages.
To attain this, the present invention provides first and second telescoping support tubes arranged for securement relative to one another in an extended orientation and provided with respective first and second rigid foot members, wherein the foot members are arranged to be received within respective shoes to be imposed to the interior surface of a conventional rotary drying machine.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 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.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved shoe dryer bracket which has all the advantages of the prior art shoe dryer apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved shoe dryer bracket which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved shoe dryer bracket which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved shoe dryer bracket which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such shoe dryer brackets economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved shoe dryer bracket which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of the invention.
FIG. 2 is an isometric illustration of the dryer bracket structure.
FIG. 3 is an orthographic view, taken along the lines 3--3 of FIG. 1 in the direction indicated by the arrows.
FIG. 4 is an orthographic view, taken along the lines 4--4 of FIG. 1 in the direction indicated by the arrows.
FIG. 5 is a cross-sectional illustration of a modified bracket foot structure.
FIG. 6 is an isometric illustration of a modified bracket structure.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 6 thereof, a new and improved shoe dryer bracket embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, the shoe dryer bracket 10 of the instant invention essentially comprises (see FIG. 2) first and second support tubes 11 and 12 respectively arranged for coaxial telescoping engagement relative to one another, such that a first rigid polymeric foot 13 is fixedly mounted to a free distal end of the first support tube 11 and a second rigid polymeric foot 14 is mounted to a free end of the second support tube 12. The first foot 13 having a first foot floor 15 orthogonally oriented relative to the first tube 11, with the second foot 14 having a second foot floor 16 orthogonally mounted to the second tube 12. The first foot includes a first foot top wall 17 that is arranged in a canted relationship relative to the first support tube, and the second foot having a second foot top wall 18 canted relative to the second tube 12 arranged for inter-fitting within respective shoes, in a manner as indicated in FIG. 1 for example, within a conventional rotary drying machine 20 having a rotary drum 21, such that the bracket structure is positioned through the drum entrance opening 22 and extended relative to one another. When the opposed shoes are in contiguous diametrically opposed engagement within the rotary drum 21, a fastener 19 threadedly directed through the first support tube 11 is arranged to engage the second support tube 12 to maintain the first and second tubes in the extended orientation, such as indicated in FIG. 1 and FIG. 3.
The FIG. 6 includes modified first and second rigid polymeric feet 13 and 14 respectively, such that each of the modified feet include a foot cavity 24 (see FIG. 5), as well as a plurality of foot top wall apertures 25, with each foot having a foot front wall 26 having a plurality of front wall apertures 27. The foot cavity 24 is accessed through a door plate 23 (see FIG. 6) permitting the filling of the cavity 24 with a scented fluid 28 or with various characteristics such as bactericides, germicides, and the like. In this manner, during the rotary action of the drum 21, the fluid is expelled through the various apertures 25 and 27 within an individual shoe member. Further, the structure as indicated includes a first clamp jaw pair 29 mounted upon the first support tube 11, with a second clamp jaw pair 30 mounted upon the second support tube 12, such that the shoe laces 31 may be secured between the first and second clamp jaw pairs 29 and 30 for enhanced drying of the shoe laces during a drying procedure.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | First and second telescoping support tubes are arranged for securement relative to one another in an extended orientation and provided with respective first and second rigid foot members, wherein the foot members are arranged to be received within respective shoes to be imposed to the interior surface of a conventional rotary drying machine. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to a novel water-borne ink, its composition and its use as a surface printing ink for printing plastic substrates such as polyolefin, polyester, polyamide and paper substrates coated with plastic polymers of this type. In addition, the invention is directed to the preparation of novel polyamide resin compositions and their use as binder resin in surface printing inks.
Surface printing inks are liquid inks which dry by solvent evaporation sometimes with heat or air blower assistance.
Solvent systems may be either water systems which use water as a partial or total solvent, or systems using volatile organic solvents. Primary solvents are usually alcohols, though some contain other oxygenated and/or aliphatic solvents.
Commonly used film formers for printing unto plastic substrates are usually solvent based. Water based inks have found limited use and are typically made by raising the alkalinity (pH) of an ink system to solubilize carboxylic resins such as rosin resins, modified acrylics and other acidic film formers. Inks of this type have found limited applicability for printing onto plastic substrates.
SUMMARY OF THE INVENTION
The present invention is therefore directed to novel water-based surface and lamination printing ink compositions and to their use as surface printing inks for printing onto substrates and in particular for printing onto plastic substrates. The surface printing inks of the present invention are superior in printing aptitude and color strength.
The binder resin useful in the water-borne surface inks of the present invention is typically based on an acrylic polymer.
Typical acrylic monomers for use as binder resin in the present invention include, for instance, styrenic monomers, acrylic acid or methacrylic acid ester-acrylic acid copolymers. As the acrylic acid ester constituting one component of the foregoing copolymer, ethyl, butyl, isobutyl, n-hexyl, n-octyl, lauryl 2-ethylhexyl and stearyl acrylates are desirable, and particularly 2-ethylhexyl acrylic is effective. Among these copolymers, those having a molecular weight in the range of 30,000-300,000 and a second glass transition in the range of 20°-105° C. are useful. In addition, water-borne resins other than acrylics can also be used according to this invention.
In addition, a carboxylated rosin modified polyamide resin is used at from 5-20% preferably 7-10% by weight as part of the binder resin composition. Carboxylated rosin modified polyamide can be prepared by a fusion process utilizing condensation chemistry. Suitable polymer compositions and the process used is detailed in copending U.S.S.N. 241,533, filed Sept. 7, 1988 of Stone and Wasyliw and entitled Carboxylated Polyamides For Ink Formulations. If desirable an amine crosslinker can be used to increase the molecular weight. Polyamides useful according to this invention include any typically used in printing inks or as hot melt adhesives. Typical polyamides used include products offered by the Henkel Co. under the trade name Macromelts 6238, 6239, 6240; Versamid 750,900,930,940 and 950 as well as Polyamides sold by Union Camp under the trade names Unirez 2220 and 2211. It has been found that this carboxylated rosin modified polyamide, when incorporated into a waterborne printing ink, results in a printing ink exhibiting superior printing aptitude and color strength when used to print onto plastic substrates.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to produce an ink composition according to the present invention, a vehicle is first prepared by dissolving an acrylic resin in ammoniated water. Subsequently, this vehicle is mixed with an aqueous solution of a carboxylated rosin polyamide, and then a pigment or dyestuff is dispersed in the resulting mixture, followed by the addition of wax, an antifoaming agent, surfactant(s) and a plasticizer and further adding water as the occasion demands to thereby adjust such properties as viscosity, color appearance, etc.
The carboxylated rosin polyamide is an essential ingredient in the foundation and is responsible for its good adhesion, clean printing, excellent film wetting, and superior resolubility.
The following examples illustrate the preparation of maleated rosinated polyamide resin and its use in a varnish and water-borne ink formulations. All parts are parts by weight.
EXAMPLE 1
Preparation of Rosinated Polyamide
45.23 parts of maleated rosin is mixed with 45.23 parts polyamide resin and heated at 240° C. for 5 minutes and then 9.54 parts diethanol amine is added. The mixture is heated at 180° C. for 10 minutes. A rosinated polyamide was formed.
EXAMPLE 2
Prepartion of Varnish Blend
The following were blended together:
______________________________________Parts______________________________________56.0 Fortified Latex Lucidene 60420.0 Polyamide Resin (of Example 1)4.0 Wax Compound20.0 n-Propanol100.00______________________________________
The varnish blend of Example 2 was then used to prepare ink compositions according to the present invention. The ratio used to prepare the inks was 50 parts varnish of Example 2 blended with 50 parts of the of the following acrylic water-based inks.
EXAMPLE 3
Rubine Base (Red)
______________________________________Parts______________________________________47.0 Water36.0 Styrene Maelic Anhydride Rubine Chip5.0 Reagent NH.sub.4 OH1.0 Defoamer1.0 Amine10.0 Water100.0______________________________________
EXAMPLE 4
Red Shade Cyan Blue Base
______________________________________Parts______________________________________47.0 Water36.0 Styrene Maelic Anhydride Blue Chip5.0 Reagent NH.sub.4 OH1.0 Defoamer100.00______________________________________
EXAMPLE 5
Green Shade Cyan Blue
______________________________________Parts______________________________________50.0 Water36.0 Styrene Maelic Anhydride Blue Chip1.0 Amine6.0 Reagent NH.sub.4 OH1.0 Defoamer6.00 Water100.00______________________________________
EXAMPLE 6
H.R. Yellow Base
______________________________________Parts______________________________________52.0 Water36.0 Styrene Maelic Anhydride Yellow Chip1.0 Amine6.0 Reagent NH.sub.4 OH1.0 Defoamer4.0 Water100.0______________________________________
EXAMPLE 7
AAOT Diarylide Yellow
______________________________________Parts______________________________________52.0 H.sub.2 O36.0 Styrene Maelic Anhydride Yellow Chip1.0 Defoamer6.0 Reagent NH.sub.4 OH1.0 Amine4.0 Water100.0______________________________________
Example 8
The rubine red base of example 3 and the red shade cyan blue of example 4 were printed onto treated polyethylene using an anilox roll. Press speeds of 700 to 1,000 fpm were used to apply the ink. Both water-borne inks exhibited excellent gloss and had no pinholes. Scotch tape™ adhesion performance was found to be excellent for both inks. | Water-borne printing ink compositions based on acrylic resins and maleated rosin modified polyamides are disclosed. The ink compositions are especially useful for printing onto plastic substrates. | 2 |
FIELD OF INVENTION
This invention relates to devices for protecting vehicle parts during cleaning. More specifically, the invention relates to devices or shields for protecting vehicle wheel rims when cleaning vehicle tires.
DESCRIPTION OF THE PRIOR ART
Protective devices or shields for protecting parts of vehicles while other operations are being performed have been in existence for several years. The most common use for protective devices has been during the painting of vehicles. Essentially, the protective device is applied to a portion of the vehicle that is not to receive paint. Thus, the portions which are to be painted can be painted and the protective device receives any spatter or careless paint spray.
A typical example of a paint protective device is U.S. Pat. No. 2,728,323, issued to Walton, which discloses a protective cover for automobile headlights during painting. Walton teaches a circular cover with a side wall which is placed over a headlight assembly and which frictionally engages the headlight assembly. The cover encloses the entire headlight assembly. Walton also teaches a split side wall which provides the flexibility and spring-like tension to engage the headlight assembly.
Protective devices are also used to protect vehicle wheels during the painting of the vehicle. U.S. Pat. No. 4,844,005, issued to Filomeno, discloses such a protective cover for automobile wheels. Filomeno teaches a free-standing oval shaped cover which is installed within the wheel-well of the automobile and in front of the wheel and tire. The protective cover totally covers the wheel and tire protecting them from paint being applied to the automobile in the vicinity of the wheel-well.
Also, protective covers have been used to protect vehicle wheels and tires from hazards other than paint. An example of such a protective device is U.S. Pat. No. 4,190,939, issued to Keller, which discloses a protective shield or sunscreen for a vehicle wheel and tire for use during extending parking periods. The shield has a circular cover with a side wall or skirt. Keller teaches that the side wall frictionally engages the tire, thus covering both the wheel and the tire.
Although the above-cited prior art references address protecting vehicle headlights and vehicle wheels in various situations, they do not address the problems that arise when cleaning the tires of the vehicle with toxic chemicals.
Very often, chemicals are used to clean the tires of the vehicle. These chemicals may be toxic to wheel rims and wheel covers such as hub-caps. The chemicals may stain or corrode the rims and covers which are made from metals such as aluminum.
The tire cleaning operations are usually short-term and do not take as long to accomplish as painting the vehicle. Also, tire cleaning is usually done by one person moving from tire to tire in a short period of time. Thus, a protective device must be easy to handle, portable and capable of being held in place for the period of use without tiring the user.
An inexpensive protective device which is portable, can be handled by one person and easily held in place over the wheel by the user while cleaning a tire would substantially reduce any damage to the wheels and wheel covers from chemicals used to clean the tires. It is to all of these goals that the present invention is directed.
SUMMARY OF THE PRESENT INVENTION
The present invention provides for a protective device for protecting vehicle wheel rims and wheel covers or hubcaps while cleaning tires with chemicals that are toxic to the rims and the wheel covers. The protective device generally comprises:
(a) a cylindrical shield which may be removably disposed between the tire and the wheel rim, the shield having means for engaging the wheel rim; and
(b) means for manually setting and retaining the shield over the wheel rim.
The means for engaging cooperates with the means for setting and retaining to assist the user in holding the protective device in place over the wheel rim.
The shield preferably includes a cylindrical wall having a closed end formed therewith and an open end. The shield accesses the wheel rim through the open end of the wall.
The means for engaging the wheel rim preferably comprises a flexible lip integrally formed with the cylindrical wall proximate the open end. The lip frictionally engages the wheel rim when the shield is positioned over the wheel.
The means for manually setting and retaining the shield over the wheel preferably includes a handle disposed on the closed end of the shield. A user of the protective device grips the handle to set and retain the device over the wheel rim and wheel cover.
The present invention will be better understood with reference to the following detailed discussion and to the accompanying drawings, wherein like reference numbers refer to like elements and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a first embodiment of the present invention in use with a vehicle;
FIG. 2 is a top plan view of an embodiment of the present invention;
FIG. 3 is a bottom plan view of an embodiment of the present invention;
FIG. 4 is a side elevational view of an embodiment of the present invention;
FIG. 5a is a partial sectional view of an embodiment of the present invention taken along line 5--5 of FIG. 2;
FIG. 5b is a partial sectional view of an alternative embodiment of the present invention taken along line 5--5 of FIG. 2.
FIG. 6 is a partial sectional view of another embodiment of the present invention taken along line 6--6 of FIG. 2; and
FIG. 7 is a side elevational view of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now with reference to the drawings, FIGS. 1-5, there is depicted therein an embodiment of a protective device in accordance with the present invention, generally denoted at 10, for protecting or shielding vehicle wheel rims 12 while cleaning tires 13 with cleaning chemicals The protective device 10 generally comprises:
(a) a cylindrical shield 16 adapted to be removably disposed over the wheel rim and between the tire and wheel rim, the shield having means for engaging the wheel rim; and
(b) means 20 for manually setting and retaining the shield over the wheel rim.
As shown and as noted, the protective device 10 is used to cover a wheel rim 12 of a vehicle 14. The device 10 may be used to cover wheel rims without wheel covers or hub-caps or may be used to cover wheel rims 12 having wheel covers (not shown) or hub-caps (not shown), as will be described in greater detail below.
The cylindrical shield 16 may be made from a lightweight material, including lightweight metal, such as aluminum, plastic or reinforced cardboard.
The cylindrical shield 16 includes a cylindrical side wall 24 having a closed end 26 integrally formed with the side wall 24 and an open end 28 formed therein opposite the closed end 26. The open end 28 is adapted to access or receive the wheel rim 12. The closed end 26 of the shield 16 is preferably a flat cover surface 29 attached to the side wall 24. The cover surface 29 may be formed with the side wall 24 or may be attached to the side wall 24 by welding or the like. Alternatively, the cylindrical side wall 24 of the shield 16 is a hollow cylinder (not shown). The means 20 for manually setting and retaining the shield is disposed proximate one end of the cylinder. The other end of the cylinder is adapted to receive the wheel rim 12.
As shown in FIG. 5a, the cylindrical wall 24 also has means 18 for engaging the wheel rim 12. The means 18 for engaging preferably comprises a flexible lip 30 extending inward from the side wall 22 proximate the open end 28 which frictionally engages the wheel rim 12. The lip 30 is preferably made from a flexible material such as plastic, rubber or the like. Preferably, the lip 30 is integrally molded and unitary with the side wall 22. The lip 30 upon contact with an edge of the wheel rim 12 flexes inward toward the side wall 22 until it passes the edge of the wheel rim 12. After the lip 30 passes the edge of the wheel rim 12, it returns to its unflexed condition and urges against the wheel rim 12.
Alternatively as shown in FIG. 5b, the flexible lip 30 may be formed separately and then attached to the side wall 22 proximate the open end 28. The lip 30 may be attached to the side wall 22 by any suitable commercially available adhesive.
As shown in FIGS. 2, 3, 4 and 7, the means 20 for manually setting and retaining the shield 16 over the wheel rim 12 preferably comprises a handle 32 attached to the closed end 26 of the shield 16 by welding or the like. If the shield 16 is plastic, the handle 32 may be integrally formed with the shield 16. The handle 32 is adapted to be gripped by a hand of a user. The user may carry the shield 16 by the handle 32. Also, the user holds the shield 16 in place over the wheel rim 12 via the handle 32.
The means 18 for engaging and the means 20 for setting and retaining the shield 16 cooperate to assist the user in retaining the shield 16 in position over the wheel rim 12 while the user cleans the exposed tire 13.
As shown in FIG. 6, the means 18 for engaging the wheel rim 12 may alternatively be a plurality of spring-like flexible strips 34 attached to the side wall 24 of the shield 16. Each flexible strip 34 has a crimp 36 disposed at one end which frictionally engages the edge of the wheel rim 12. The flexible strip 34 is preferably made from spring steel and is attached to the side wall 24 by a fastening device such as a screw, rivet, etc.
In FIG. 7, there is depicted another embodiment of the protective device 100 in accordance herewith. The device 100 includes a cylindrical shield 110 having means 112 for operatively engaging a wheel rim. The shield 110 comprises a cylindrical side wall 114, the side wall 114 having a convex shaped closed end 116 integrally formed with the side wall 114. The shield 110 also includes an open end 118 formed therein opposite the closed end 116. The open end 118 is adapted to provide access for a wheel rim. Further, the shield has means 120 for setting and retaining the shield over the wheel rim 12 and a hub-cap. The means 120 for setting and retaining cooperates with the means 112 for operatively engaging to assist the user in holding the shield 110 in place over a wheel rim and/or hub-cap.
In use, the user grips the device 10 by the handle 32 and, before cleaning a tire with the toxic cleaning solution, the user positions the device over the wheel rim. This enables the means for engaging 18 or 112 to grasp the wheel rim. After the protective device is in the position over the wheel rim, the user is then free to clean the surrounding tire with the toxic cleaner. The protective device prevents the toxic cleaner from reaching the wheel rim 12, thus, preventing any corrosion or staining of the wheel rim by the toxic cleaner.
The protective device of the present invention provides for an effective shield for a wheel rim from toxic cleaners used to clean the surrounding tire. The protective device provides for ease of handling and being held in place for temporary use. The device also provides for ease of removal from the wheel rim when it is no longer needed as a shield for the rim. | A protective covering device suitable for protecting the surface of the wheel rim of an automobile against damage by toxic cleaning solutions used to clean the surrounding tire. The shield is temporarily attached to the rim with a grasping device which provides assistance to the user who is holding the protective device over the rim while applying cleaning solution to the surrounding tire. | 1 |
FIELD OF THE INVENTION
The present invention relates to vibration isolators, and more particularly, the present invention relates to non-fluid mounts capable of damping motion in at least two directions.
BACKGROUND OF THE INVENTION
Over the past several years, so-called fluid mounts have found application in a variety of uses where motion damping is required. For instance, in some modern vehicles, engines are mounted to frames utilizing fluid mounts which can be designed to provide desired amplitude and/or frequency responsive vibration isolation. An example of such a mount is disclosed in U.S. Pat. No. 4,709,907 owned by the assignee of the present invention.
While fluid mounts may function satisfactorily for their intended purposes, fluid mounts, in general, have certain drawbacks. For instance, they are somewhat difficult to manufacture on a mass-production basis because of the need both to fill the mount and to insure against leakage in use. Hence, fluid mounts are not as inexpensive as desired for applications in which cost and reliability are important considerations.
An isolator that does not require fluid to damp vibrations has been proposed. Such an isolator is disclosed in U.S. Pat. No. 3,232,597 to Gaydecki. In the Gaydecki isolator, uniaxial vibration damping is provided by means of a rigid rib and groove member which is slidably moved in pressure engagement along an elastomeric element. The Gaydecki isolator utilizes the hysteresis of the elastomer to effect damping.
While the Gaydecki isolator may function satisfactorily to damp motion along a single axis, there are many applications, such as the aforedescribed automotive engine to frame mounting application, which require damping along a plurality of axes, such as the X, Y and Z axes. Moreover, there is a need for such a fluidless mount which can be manufactured readily utilizing conventional mass-production manufacturing techniques and equipment. There is also a need for a mount which of this type which can provide amplitude-sensitive damping.
OBJECTS OF THE INVENTION
With the foregoing in mind, a primary object of the present invention is to provide a novel fluidless mount which can damp vibrations in more than one direction.
Another object of the present invention is to provide an improved non-fluid vibration isolator which can damp vibrations imparted either independently or simultaneously along the X, Y and Z axes.
A further object of the present invention is to provide a unique fluidless mount which can provide different levels of damping in different directions in response to different amplitudes of input motion.
Yet another object of the present invention is to provide a rugged, reliable, readily manufacturable fluidless mount which can damp vibrations imparted on one or more of three orthogonal intersecting axes.
SUMMARY OF THE INVENTION
More specifically, the present invention provides a mount for damping motion in at least two directions. The mount comprises a first member, such as a tube, which is adapted to be connected to a first object; a second member, such as a shell, surrounding the first member and adapted to be connected to a second object; and a resilient element interposed between the members and mounting the first member for translation in a first direction alongside and relative to the second member and for motion in a second direction lateral to the first direction. A first resiliently deformable layer extends along the first direction, and at least one second resiliently deformable layer extends along the second direction. The first layer is preferably provided by the resilient element which has an interior surface forming a cavity in the resilient element. The second resiliently deformable layer is preferably provided on a flange mounted on the first member for movement therewith in the second direction in the cavity. A rigid rib means is provided for engaging both the first and second resilient layers and slidably deforming the layers in response to motion of the first member relative to the second member in either, or both directions. In one embodiment, a lost motion connection is provided between the rigid rib means and either or both of the members to accommodate small amplitude displacements with little or no damping. Another embodiment provides certain additional advantages including accommodating greater cocking motions.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the present invention should become apparent from the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is an end elevational view of one embodiment of a mount constructed in accordance with the present invention, portions being broken away to expose interior details of construction;
FIG. 2 is an enlarged longitudinal cross-sectional view taken on line 2--2 of FIG. 1;
FIG. 3 is a longitudinal fragmentary view, similar to FIG. 2, but illustrating a portion of the mount in a downwardly and laterally displaced position;
FIG. 4 is a longitudinal sectional view, similar to FIG. 2, but of a modified embodiment of the present invention which is amplitude-sensitive;
FIG. 5 is a longitudinal fragmentary cross-sectional view, similar to FIG. 3, but illustrating a portion of the mount in a downwardly and laterally displaced position; and
FIG. 6 is a longitudinal cross-sectional view of a third embodiment of a mount constructed in accordance with the present invention and particularly suited for automotive powerplant mounting applications.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 illustrates one preferred embodiment of a mount 10 which embodies the present invention. The mount 10 is of the so-called tube form variety which comprises a first member, such as a bushing 11 which is adapted to be connected to a first object, such as the spaced parallel mounting plates 12 and 13, by means of a bolt 14, shown in phantom. A second member, such as a cylindrical tube, or shell, 15 surrounds the first member 11 and is coaxial therewith about a central longitudinal axis Z. The second member 15 is adapted to be connected to a second object, as by being inserted in a bore of a base, or connecting rod (not shown).
The first and second members 11 and 15 are mounted for movement relative to one another on the Z axis, and laterally, or transversely of the Z axis on the X and Y axes by means of a resilient block 16 interposed between the first and second members 11 and 15. Preferably, the resilient block 16 is of an elastomeric material, such as rubber and is bonded to the members 11 and 15. Thus, the elastomeric block 16 permits the inner, or first member 11 to move vertically on the Z axis, horizontally on the X axis, and horizontally on the Y axis (perpendicular to the plane of the drawing).
As best seen in FIG. 2, the elastomeric block 16 has an internal annular cavity, or chamber 17 which contains a damping assembly indicated generally at 18. In the embodiment illustrated in FIGS. 1-3, the damping assembly 18 includes a first resiliently deformable layer 19 which extends along the inner periphery of the shell 15 along the Z axis. Preferably, the first layer 19 has a constant relatively uniform thickness in the direction of the Z axis and has a predetermined axial extent in that direction. The first layer 19 has a certain minimum thickness in the radial direction, i.e. transverse, or lateral to the path of movement of the bushing 11 on its longitudinal, or Z axis. Preferably, as illustrated in FIG. 2, the first resiliently deformable layer 19 is molded integral with the resilient block 16, and the cylindrical inner peripheral surface 19' of the first deformable layer 19 is smooth.
In addition to the first resiliently deformable layer 19, the damping assembly 18 also includes at least one, and preferably a pair, of second resiliently deformable layers 20 and 21 contained in the cavity 17. In the embodiment illustrated, the layers 20 and 21 are bonded to circular washer-like flanges 22 and 23, respectively. The washer-like flanges are mounted in the cavity 17 with their deformable surfaces 20 and 21 in axially spaced confronting relation with a gap G disposed therebetween. The flanges 22 and 23 are located on the bushing 11 between shoulders 11a and 11b provided at axially spaced locations and move in unison with the bushing 11. Preferably, the layers 20 and 21 extend continuously about the bushing 11, and are of a substantially constant and uniform thickness for a predetermined extent in the Z direction.
For the purpose of slidably resiliently deforming both the first layer 19 and the second layers 20 and 21 in response to motion of the bushing 11 along its central Z axis and laterally on either or both of the X and Y axes, a ring-like, or annular, slide element 25 is mounted in the gap G. The ring-like slide element 25 surrounds the bushing 11 and has an inner circumferential portion 25a engaged between the opposed resilient layers 20 and 21 and has an outer peripheral portion 25b which engages the peripheral resilient layer 19. In the embodiment illustrated in FIG. 2, the circumferential portion 25a has opposite sides, each of which, such as the upper side, has a pair of parallel continuous ridges 27a and 28a separated by a groove 29a. Like ridges and grooves 27b, 28b and 29b, respectively are provided on the opposite, or lower side of the slide ring 25. A similar pair of ridges 30 and 31 are provided on the outer peripheral portion 25b of the slide ring 25, and they are separated by a groove 32.
The ridges and grooves on the slide ring element 25 are configured relative to the elastomeric layers 19, 20 and 21 to cause the elastomeric layers to deform adjacent their zones of engagement with the ridges. As a result, any movement of the slide ring element 25 under pressure relative to its engaged elastomeric layer causes the elastomeric layer in the zone adjacent the point of contact to move in a wave-like manner, either ahead of or behind the ridge. Such wave-like movement of the elastomeric layer develops hysteresis within the elastomeric layer, and such hysteresis acts in a well-known manner to absorb energy and thereby to damp relative movement. Thus, for example, when the inner bushing 11 is displaced downwardly relative to the sleeve 15, such as from the neutral or home position illustrated in FIG. 2 into the downwardly and laterally displaced position illustrated in FIG. 3, the slide-ring 25 moves downward a corresponding amount, and its ridges 30 and 31 slide along the peripheral elastomeric wall 19 to damp motion of the bushing 11 relative to the sleeve 15 in the direction of the Z axis. In like manner, motion of the bushing 11 laterally along the X axis relative to the sleeve 15 causes the flanges 22 and 23, and their respective elastomeric layers 20 and 21 to move laterally relative to the inner portion 25a of the slide-ring 25, thereby damping motion along that axis. Motion along the other horizontal, or Y, axis is damped in a similar manner. In addition, in this embodiment certain limited cocking motions of the bushing 11 relative to the sleeve 15 can also be damped.
In order to enable the mount 10 to be assembled, and to enable manufacturing economies to be realized by minimizing the use of different parts, the mount 10 is fabricated in two identical sections 10a and 10b which are divided horizontally in the plane of the X and Y axes. Prior to assembly of the sections 10a and 10b into the configuration illustrated in FIGS. 1 and 2, the washer-like flanges 22 and 23 are each first slid axially on their respective reduced-diameter portions of the bushing 11 into engagement with their respective shoulders 11a and 11b. Afterward, the slide-ring 25 is placed in the gap G, and the sections 10a and 10b are forced axially toward one another into the assembled position illustrated in FIG. 2. Preferably, adjacent surfaces, particularly the elastomeric surfaces of the resilient block 19, may be provided with an appropriate adhesive to bond the elastomeric portions together along the horizontal line of juncture of the mount sections 10a and 10b. In many applications the connecting bolt 14 will provide clamping pressure in the Z axial direction; however, in applications where a connecting bolt 14 is not utilized, the sections 10a and 10b may be connected together as by spot welding at peripheral locations externally of the sleeve 15 and internally of the bushing 11, although this mode of providing clamping pressure may increase manufacturing costs somewhat.
Usually axial and radial damping values are different and can be made equal by proper design of the damping ring an rubber configuration.
In the embodiment of FIGS. 1-3, any movement of the bushing 11 relative to the sleeve 15 causes some relative movement to occur between the slide-ring 25 and either the elastomeric layer 19 or the elastomeric layers 20 and 21. Thus, in this embodiment, virtually all relative motion is subject to damping. There may be, however, applications where such damping is undesirable, and it may be desired either to provide for a limited range of relative movement to occur before damping is induced or to provide different degrees of damping in different directions. To this end, the embodiment of FIG. 4 is provided.
The embodiment of FIG. 4 is similar in most respects to the embodiment of FIGS. 1-3, except for a novel slide-ring assembly 125. In the embodiment of FIGS. 1-3, the slide-ring 25 is of one-piece construction. In the embodiment of FIG. 4, however, the slide-ring assembly 125 is of multi-piece construction which provides a lost motion connection between the sleeve 111 and bushing 115 in at least one direction, and preferably in directions along all three orthogonal intersecting X, Y and Z axes.
To provide a lost motion connection in the Z direction, the slide-ring assembly 125 includes a rigid annular carrier ring element 126 which has an outer peripheral groove 126a that slidably receives a radially-inwardly extending flange portion 140a of a rib providing means 140. The rib providing means 140 has a profile which is like in configuration to the ridges and grooves provided in the embodiment of FIGS. 1-3 and cooperates in a similar fashion to deform the elastomeric layer 119 in response to relative movement between the bushing 111 and sleeve 115 along the Z axis. In this embodiment, however, the peripheral groove 126a is dimensioned larger relative to the width of the flange 140a to provide a clearance in the Z direction. The magnitude of the clearance is preselected to enable the bushing 111, and hence the carrier ring 126, to move a predetermined limited amount before the slide-element 140 is engaged and displaced along the elastomeric layer 119. Thus, it should be apparent that limited degrees of oscillation of the bushing 111 on the Z axis relative to the sleeve 115 can be accommodated without causing significant damping to occur. The slide-element 140 may be assembled on its carrier ring 126 either by being split, much like a piston ring, or by splitting the carrier ring 126 into upper and lower sections along a horizontal plane which intersects the peripheral groove 126a.
In order to provide a lost motion connection in the X and Y directions, the carrier ring 126 is provided with a circumferential region 126b of reduced thickness in the region of the gap G between the elastomeric layers 120 and 121. Slide-elements 141 and 142 of identical construction are mounted on opposite sides of the carrier ring 126 in the region of the reduced thickness portion 126b. Upper and lower annular shoulders 126' and 126" are provided on the carrier ring 126 outwardly of the reduced thickness portion 126b.
With this construction, motion of the bushing 111 on either the X or Y axis relative to the sleeve 115 causes the resilient layers 120 and 121 to displace the slide-elements 141 and 142 relative to the carrier ring 126 until such time as the slide elements 141 and 142 engage the shoulders 126' and 126", whereupon further motion of the bushing 111 relative to the sleeve 115 causes the elastomeric layers 120 and 121 to move relative to the slide-elements 141 and 142 for causing damping to occur in the manner described heretofore.
The present invention also provides an embodiment which is particularly suited for use in mounting the engine of a vehicle to its frame in a manner providing multi-dimensional damping and accommodating cocking motions. To this end, the mount 210 of FIG. 6 is provided.
The mount 210 includes a stem 211 extending vertically on the Z axis and adapted at its upper end to threadedly receive a mounting bolt (not shown). A drawn metal shell 215 surrounds the lower portion of the stem 211 and is relatively movably connected thereto by a resilient elastomeric block 219 having an upper frustoconical portion 219a extending between and bonded to a bulbous portion 211a of the stem 211 and an outturned peripheral flange 215a of the shell 215. The lower portion 215b of the shell 215 is cylindrical and has an outturned mounting flange, and the inside of the lower portion 215b of the shell 215 has a layer of elastomeric material 219b bonded thereto. The layer 219b has an inner peripheral surface 219' which defines a cavity 217 that receives a damping assembly 218.
The damping assembly 218 is similar in construction to the assembly 18 in the embodiment of FIGS. 1-3, but with certain differences. It should be understood, of course, that the damping assembly which incorporates lost motion connections, such as illustrated in the embodiment of FIG. 4, may also be utilized in the embodiment of FIG. 6 in those applications which warrant amplitude-sensitive damping.
The damping assembly 218 includes a slide-ring 225, like in construction to the slide-ring 25 in FIG. 2, and upper and lower washer-like flange elements 222 and 223 to which are bonded resilient layers 220 and 221, respectively. Preferably, the elastomeric layers 220 and 221 wrap around the outer peripheral edges of the flanges 222 and 223 to provide snubbing in the X and Y directions. The upper portion 219a of the resilient bock 219 has a portion 219c which overlies the outer peripheral portion of the upper flange 222 to provide snubbing in the Z direction. The upper washer-like flange 222 abutts against a shoulder 211a on the stem 211, and the lower washer-like flange 223 is mounted to the stem 211 by means of a washer 245 and a threaded fastener 246 received axially in the bottom of the stem 211. Thus, the slide-ring 225 is clamped firmly between the washer-like flanges 222 and 223 by a form of clamping means which is structurally different from that utilized in the aforementioned embodiments but which is functionally similar. In addition to meeting the particular requirements of an engine mount, this embodiment has the advantage of being straightforward to assemble. It also permits a greater degree of cocking motion to be accommodated and damped because the bulk of the elastomeric block is disposed primarily to one side of the damping assembly 218, rather than being located on both sides as in the aforementioned embodiments.
The present invention enables different levels of damping to be provided in different directions by a proper selection of the coefficients of friction between relatively slidable parts. For instance, the elastomeric layers 20 and 21 bonded to the washers 22 and 23 in the embodiment of FIG. 2 can be different in composition from the elastomeric material forming the wall 19. Alternatively, different pressures may be applied in the Z direction than in the X and Y directions, as by varying the axial spacing between the shoulders 11a and 11b, or the thickness of the layers 19, 20 and 21 relative to a slide-ring 25 of a particular dimensional configuration. Also, the profile of the ridges and grooves in the circumferential portion of the slide-ring 25 may be different from the profile of the ridges and grooves on the peripheral portion.
In the embodiment of FIGS. 1-3 and 6, the elastomeric material utilized to provide all the layers is preferably of a composition which is abrasion resistant, highly damped and resistant to crack propagation. Such an elastomeric material may be a blend of natural and synthethic rubber components, such as an SBR type material. The elastomeric layers are preferably precompressed to a predetermined extent, preferably in a range of about 5% to about 30% of their thickness in the direction of compression in order to provide acceptable damping and service life. The slide element 25 may be fabricated of a metal, such as steel, aluminum or the like, which is coated with a tetrafluoroethylene-filled silicone grease or other antifriction coating, or it may be molded of polymeric material which is internally lubricated and reinforced, such as glass reinforced nylon having up to about 5 to 30%, by weight, of tetrafluoroethylene filler and up to about 2%, by weight, of silicone oil additive. The surface finish is most important for improved life and should be in the 1 to 25 microinch range for best results.
In the embodiment of FIG. 4, it is important for the coefficient of sliding friction between the carrier element 126 and the ribbed and grooved elements 140-142 carried thereon to be different from the coefficient of sliding friction between the same elements and their engaged elastomeric layers in order to ensure that the elastomeric layers 120 and 121 are coupled with the slide elements 141 and 142 for causing them to slide relative to the carrier ring 126 before the limits of motion are reached in the X and Y directions, and to permit limited motion in the Z direction before the limits of motion are reached between the carrier ring 126 and the peripheral slide element 140. For this purpose, the coefficient of sliding friction between the elements 140-142 and their associated elastomeric layers and carrier ring 126 are preferably in a predetermined ratio with respect to one another. For instance, the coefficient of sliding friction between the carrier ring 126 and the slide elements 141 and 142 is lower than the coefficient of sliding friction between the elements 140 and 142 and their engaged elastomeric layers 120 and 121, respectively, by a ratio in a range of about 1:3 to about 1:15. In the embodiment of FIG. 4, the range of lost motion provided by the construction illustrated is typically in a range of about 0.005 inches to about 0.060 inches.
In view of the foregoing, it should be apparent that the present invention now provides an improved mounts which provide damping in a plurality of directions without requiring fluid as a working medium. Their design is such as to enable different levels of damping to be incorporated in different directions without major revisions in overall construction. The mounts of the present invention can, therefore, be designed in a straightforward manner and manufactured readily utilizing known manufacturing techniques. Thus, the mounts overcome many of the drawbacks of known fluid-filled vibration isolators.
As described above, the damping results primarily hysteresis in the elastomer. By proper selection of the materials at the rubbing interface, the hysteresis damping can be supplemented by significant amounts of either friction damping or viscous shear damping. The exact proportions depend upon the application and specific design geometries.
While preferred embodiments of the present invention have been described in detail, various modifications, alterations and changes may be made without departing from the spirit and scope of the present invention as defined in the appended claims. | Fluidless mounts capable of damping motion in several directions are disclosed. The mounts utilize hysterisis losses in an elastomeric material to absorb energy. The losses are induced by rigid rib and grooved elements which are displaced along the surface of an elastomeric layer in pressure engagement therewith. Amplitude-sensitive damping embodiments are disclosed. | 5 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application is related to U.S. Provisional Patent Application Ser. No. 60/117,873, filed Jan. 29, 1999, entitled “IN-LINE PROGRAMMING DEVICE WITH SELF-TEACHING CAPABILITY,” and U.S. Provisional Patent Application Ser. No. 60/122,023, filed Feb. 26, 1999, entitled “PICK AND PLACE TEACHING METHOD AND APPARATUS FOR IMPLEMENTING THE SAME,” the disclosures of which are each hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The present invention generally relates to automatic configuration of semiconductor device handling equipment to accommodate multiple applications and random variations among machines and devices.
In the semiconductor industry, a considerable number of electronic devices are provided by vendors in programmable form with blank memories or unspecified connections between arrays of logic. Users can then custom configure or program the electronic devices to perform their intended function by programming them, transferring or “burning in” a sequence of operating codes into the memory, or by specifying a particular arrangement of gating logic connections.
Numerous manufacturers have developed automated machinery for handling and programming such devices. Such machinery moves blank devices from a source medium (e.g., trays, tubes, etc.) to one or more programming sites, carries out the programming operation on each device, and moves programmed devices from the programming sites to an output medium (e.g., trays, tubes, etc.).
Both to allow flexible handling of a wide variety of automated programming operations (different types of input or output media, different device package types, etc.) and to account for inevitable manufacturing variations from machine to machine, it is necessary for the equipment operator to configure (or “teach”) the automated programming machinery the precise locations from which to pick up devices and to which to place devices. This includes all input and output media locations, the locations of all programming site sockets, and any other such locations within the system.
Accurate teaching is critical to the robust operation of automated programming systems. While older, larger programmable devices are relatively insensitive to placement accuracy, modem fine pitch devices have very delicate leads and suffer damage unless placement operations are highly accurate (for instance, correct to within 0.001″).
Not all automated equipment can achieve such accurate placement. In order to do so, high-end equipment uses a technique known as vision centering. The system picks up each device with a pick and place nozzle and holds the device in the path of a series of parallel laser beams. The device is then rotated in the path of the laser beams. A bank of sensors monitors which of the beams is interrupted during the rotation of the device. This information can be processed numerically to identify the precise angle and position of the device on the pick and place nozzle. Linear encoder technology allows the system to place the nozzle at any desired location. The results of the vision centering operation allow a correction move in the lateral horizontal (i.e., X, Y) and angle coordinates to be performed so that the part can be precisely placed at the desired location.
Traditional vision centering does not assist the user in determining the correct pick and place locations. Rather, it merely enables the system to place with extreme accuracy once those locations are specified.
While the ease with which the operator can carry out the teaching operation does not directly affect the physical treatment of devices, it does affect the efficiency of system operation. Typical users of automated programming equipment are highly sensitive to system throughput (measured in correctly programmed devices per hour) and yield (defined as the percentage of devices which are correctly programmed). Furthermore, more difficult teaching techniques require more highly trained personnel that draw higher wages. As a result of all of these considerations, automated programming equipment users prefer fast, easy teaching techniques.
A variety of teaching techniques has been implemented to date. These include none, file-controlled, trial-and-error, single point downward vision teaching, and double point downward vision teaching. Each of these techniques is characterized by advantages and disadvantages when considered in terms of accuracy and ease of use.
Some equipment requires no teaching whatsoever. This equipment is simple to set up and use, but is limited to devices that are rugged and can tolerate the relatively imprecise component placement that results from inevitable manufacturing variations from machine to machine. Such equipment is normally also limited to a specific device type or a small range of types and offers little flexibility to handle new devices.
Some equipment requires no active teaching on the part of the user, but offers improved flexibility by utilizing CAD data files to determine the location of device pick and place points. Systems of this type offer more flexible handling of a variety of jobs, but are still limited to rugged components that can tolerate relatively poor placement accuracy, because this teaching technique doesn't account for random manufacturing variations.
A wide variety of equipment is available that provides operator control over the various pick and place locations but offers no systematic technique to help the operator determine the proper settings. The operator of such equipment must pursue a trial-and-error approach until correct settings are determined. Once accurately configured, such equipment can operate very reliably, but the trial-and-error process can be very time consuming and can result in many damaged (and hence unusable) parts. Equipment of this type still normally handles only rugged devices.
Some automated device programming systems are equipped with downward vision cameras. Such a camera is mounted to the movable portion of the system and can be positioned over any point in the system workspace. The camera can “look down” on the components or component locations. The operator can observe the camera field of view on a monitor which is normally equipped with crosshairs for precise positioning. Downward vision cameras can be used in “single point” or “double point” teaching mode.
In a system that employs single point downward vision teaching, the operator positions the camera crosshairs over the estimated center of the component location to be taught and indicates via a keystroke, mouse click, or some other event that the proper position has been identified. The system then stores this position and returns to it when necessary. This approach provides better accuracy than all previously described techniques, and requires only a single camera positioning operation by the user. However, the approach requires that the operator visually estimate the proper crosshair location. This can be inaccurate unless the location being taught exhibits some kind of distinct “landmark” at the center point, which is not always the case. When such a landmark is available, systems of this type can properly handle delicate fine pitch parts, while some device damage can result in the absence of such landmarks.
Double point downward vision teaching improves upon the single point technique by allowing the user to teach two points and taking as the teach point the arithmetic average of those two points. In most systems it's much easier to find two symmetrically located “landmarks” than to find a single landmark at the precise target location. A disadvantage of this approach, however, is that the operator must position the crosshairs twice, doubling the labor involved in the teaching process. Historically, double point downward vision teaching has provided the most reliable results and has proven most successful in handling fine pitch devices.
None of the approaches described above fully exploit the fine positioning capability of modem motion control equipment. Even the most accurate of the above methods, double point downward vision teaching, requires that the operator visually align two references (the camera crosshair and the image landmark) with one another. Human vision is not capable of performing this feat to the full accuracy of motion control hardware. The approaches that do work well require extensive operator involvement and thus admit the possibility of human error.
A much more serious limitation of all existing approaches is that none of them deal effectively with angular and vertical axis coordinates. All of the approaches described above address only the lateral horizontal components of the device location. In the above approaches, angular error is normally neglected, and the vertical coordinate must be set by the operator using visual inspection of the proximity of the pick and place nozzle to the top of the device.
SUMMARY OF THE INVENTION
Briefly, the present invention provides a new and improved technique for teaching automated programming equipment that exploits the full accuracy of the system's pick and place capabilities while requiring minimal effort on the operator's part. The approach requires that the operator place a device in the location to be taught. The system then picks the device up, performs vision centering measurements on the device, and uses the results of these measurements to determine the precise place coordinates for the device. This information is stored in the system in a manner that prevents the need to perform teaching for any given combination of hardware items more than once.
The teaching process begins automatically when the system, e.g., via software, recognizes that the target coordinates associated with an imminent placement have not been initialized. The system guides the operator through the steps required to determine the proper values for all four coordinates (X, Y, Z, and angle).
First, the system displays an alert box on the computer monitor identifying the location in question and instructing the user to place a device in the location. Some locations (e.g., programming site sockets) hold the device in a very well defined position. Others (e.g., device pockets in input and output media) may allow a degree of play in the device's location. After the user has placed a device in the location, he or she must ensure that the system nozzle is roughly over the device. This subjective specification of a position by the operator does not affect the final coordinates determined by the teach process. The operator must merely be close enough to allow the system to pick the part up. When the operator is satisfied with the rough location, he or she notifies the system software to indicate permission to move to the next step.
Once the operator indicates that the vacuum nozzle is over the device, the system software takes over and begins to step the nozzle downward toward the device's upper surface. After each step the system uses a proximity sensor to determine whether the nozzle is in contact with the device. As long as the nozzle has not made contact with the device, the downward stepping process continues. Once contact is established, this part of the teaching process is complete and the vertical position of the nozzle is stored as the Z coordinate associated with the teach process for this particular location and device.
Once the Z coordinate is established, the system is capable of picking the device from its location. In one embodiment, a vacuum nozzle is used. The device is picked up by activating the vacuum nozzle while the nozzle is in contact with the device.
The system software continues the teaching process by positioning the device in the laser align beam(s) and using the vision centering process to determine the precise X, Y, and angle offsets with respect to the nozzle. The software is also able to determine the nozzle X and Y coordinates (relative to initialized X and Y axes) using linear encoder feedback. By suitably combining the encoder readings with the laser align measurement results, the system software determines the precise X and Y location of the device center as well as the device angle with respect to the system's global reference frame. When the measurement process is complete, the system places the device back in its original position.
According to an aspect of the invention, a method is provided for teaching a location in a device programming apparatus. The method typically comprises the steps of providing a device in the location to be taught, providing a nozzle capable of picking up the device, wherein the nozzle has an initial set of horizontal coordinates and an initial vertical coordinate, and positioning the nozzle to a first set of horizontal coordinates different from the initial set of horizontal coordinates such that the nozzle is above the device. The method also typically comprises the steps of automatically determining, with the nozzle, the vertical position of the device relative to the initial vertical coordinate, automatically determining, for each of the horizontal coordinates, offset coordinates of the center of the device relative to the nozzle, and combining the horizontal offset coordinates with the first set of horizontal coordinates so as to determine the location of the device relative to the initial set of coordinates.
According to another aspect of the invention, a method is provided for teaching a location in a device programming apparatus. The method typically comprises the steps of providing a device in the location to be taught, wherein the device has an associated identifier, determining whether teaching data associated with the identifier is stored in a memory; and if not, providing a nozzle capable of picking up the device, wherein the nozzle has an initial set of horizontal coordinates and an initial vertical coordinate, and positioning the nozzle to a first set of horizontal coordinates different from the initial set of horizontal coordinates such that the nozzle is above the device. The method also typically comprises the steps of automatically determining, with the nozzle, the vertical position of the device relative to the initial vertical coordinate, automatically determining, for each of the horizontal coordinates, offset coordinates of the center of the device relative to the nozzle, combining the horizontal offset coordinates with the first set of horizontal coordinates to produce teaching data that identifies the location of the device relative to the initial set of coordinates, and storing the teaching data to the memory in association with the device identifier.
According to yet another aspect of the invention, a device programming apparatus with self-teaching capability is provided. The apparatus typically comprises a nozzle assembly having a nozzle capable of picking up a device in a location to be taught, wherein the center of the nozzle has an initial set of horizontal coordinates and an initial vertical coordinate, and a means for positioning the nozzle to a first set of horizontal coordinates different from the initial set of horizontal coordinates such that the nozzle is above the device. The apparatus also typically comprises a means for automatically determining, with the nozzle, the vertical position of the device relative to the initial vertical coordinate, a means for automatically determining, for each of the horizontal coordinates, offset coordinates of the center of the device relative to the center of the nozzle, and a means for modifying the first set of horizontal coordinates with the horizontal offset coordinates so as to produce teaching data that identifies the location of the device relative to the initial set of coordinates.
According to a further aspect of the invention, a method is provided for teaching a location in a device programming apparatus. The method typically comprises the steps of providing a device in the location to be taught, providing a nozzle capable of picking up the device, wherein the nozzle has an initial set of coordinates defined by three orthogonal axes and an initial angle coordinate defined by a first and a second one of the three axes, and positioning the nozzle to a first set of coordinates such that the nozzle is proximal the device, wherein the first set of coordinates is different from the initial coordinates along the first and second axes. The method also typically comprises the steps of automatically determining, with the nozzle, the position of the device along the third axis relative to the initial third axis coordinate, automatically determining offset coordinates of the center of the device relative to the nozzle for each of the first and second axes coordinates and the angle coordinate, and combining the offset coordinates with the first set of coordinates and the initial angle coordinate so as to determine the location and orientation of the device relative to the initial set of coordinates and initial angle coordinate.
Reference to the remaining portions of the specification, including the drawings and claims, will realize other features and advantages of the present invention.
Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with respect to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a and 1 b illustrate a side view and a top view, respectively, of the general hardware layout of an exemplary system for implementing the teaching techniques of the present invention;
FIG. 2 is a flowchart that illustrates a process of establishing the position of Z=0 using a laser align unit according to an embodiment of the present invention;
FIG. 3 is a flowchart that illustrates a process of detecting the Z-location of the surface of a device according to an embodiment of the present invention;
FIG. 4 is a flowchart that illustrates a process for establishing an initial estimate of a device's X, Y, and angle coordinates, and for rendering the estimate exact using an alignment process according to an embodiment of the present invention; and
FIGS. 5 a and 5 b are flowcharts that illustrate an alignment process according to an embodiment of the present invention.
DETAILED DESCRIPTION
FIGS. 1 a and 1 b illustrate a side view and a top view, respectively, of the general hardware layout of an exemplary system for implementing the teaching techniques of the present invention. As depicted in FIGS. 1 a and 1 b, the preferred embodiment of the system includes a nozzle assembly 10 , a base plate 45 , a laser alignment system, a Z-rail tower 60 and an arrangement of bearings, motors, and supporting hardware (not shown) to allow the nozzle tip to move in all three Cartesian directions as well as rotate. Nozzle assembly 10 includes a pick and place nozzle 15 attached to a spindle 20 which is driven by an angle motor 25 . Motor 25 , via spindle 20 , causes nozzle 15 to rotate in the horizontal X, Y plane. Motor 25 preferably rotates nozzle 15 in either direction. The laser align system includes a laser source 50 and a sensor 55 mounted to base plate 45 so that nozzle 15 is able to move a device into the laser alignment system's field of view and spin the device through any angle. Linear encoders (not shown) are provided to accurately determine position along the X and Y axes corresponding to the horizontal coordinates of the device on the system tabletop.
In one embodiment, the system also includes a laser pointer 30 coupled to nozzle assembly 10 which can shine through nozzle 15 from above to illuminate a point on the tabletop immediately below nozzle 15 . In addition, pneumatic components, including accumulator 35 and vacuum port 40 allow the application of vacuum pressure to the nozzle tip to enable nozzle 15 to lift devices as is well known.
In a preferred embodiment, stepper motors (not shown) drive all four motions. In one embodiment, belts are used to convey power from the X and Y motors to the appropriate points of application, a lead screw is provided to convey power from the Z motor to move the nozzle assembly 10 in the vertical (Z) direction along Z-rail tower 60 , and angle motor 25 operates in a direct drive arrangement. These stepper motors are preferably controlled by a commercial 4-axis motion control card installed in a computer system such as an ordinary desktop personal computer.
The system must initialize all four axes of motion. In preferred aspects, the X and Y axes are initialized by a built-in operation of the motion control card. Issuance of the appropriate command causes the pick and place nozzle head 15 to automatically seek the X and Y coordinates at which the home sensors are triggered. The motion control system then automatically sets the X and Y coordinates to zero at that point. Angle motor 25 can spin endlessly in either direction, and there is no preferred origin angle. Therefore, the angle coordinate is initialized by simply setting the angle coordinate stored within the motion control system to zero.
The Z-axis initialization is described in FIG. 2 . In preferred aspects, the laser align system is used to determine the Z=0 point. Z=0 is defined as that point at which the laser align unit transitions between being able to “see” nozzle 15 and being unable to see nozzle 15 . That is, the position is defined such that nozzle 15 blocks the laser align beam for all positive Z and does not block the beam for all negative Z.
Briefly, the system looks for the nozzle with the laser align unit. If it can see the nozzle, it begins moving the nozzle up, for example, 50 steps at a time, until it can no longer see it. If it can't see it, it begins moving it down 50 steps at a time until it can see the nozzle. Once this process is completed, the same algorithm is repeated in steps of one in order to obtain the most accurate Z=0 coordinate.
At step 100 , the step count N is set to 50. To speed the process, the initial seek operation preferably moves in vertical increments of 50 motors steps, however any number greater than 1 can be used as desired. At step 105 , it is determined whether the laser alignment system can “see” nozzle 15 , i.e., whether nozzle 15 is in the path of a laser beam from laser source 50 directed at sensor 55 . If nozzle 15 is not seen, the system proceeds to step 110 , where it is determined whether nozzle 15 is at a lower limit (i.e., cannot be lowered further by the current step count N). If it is, an error is reported in step 120 as the nozzle can not be lowered further. If it is not at the lower limit, nozzle 15 is lowered by a number of steps defined by the step count N (initially N=50) in step 115 . At step 125 , it is again determined whether the laser alignment system is able to see nozzle 15 . If not, step 110 is repeated. If the nozzle is seen, the system proceeds to step 130 . In step 130 , it is determined whether the step count N is the same as the initialized step count from step 100 . If so, the step count is reset to 1 in step 135 and step 105 is repeated. This allows the system to obtain the most accurate Z=0 coordinate by lowering or raising nozzle 15 by the smallest possible increment.
If it is determined at step 105 that nozzle 15 is seen, the system proceeds to step 140 , where it is determined whether nozzle 15 is at an upper limit (i.e., cannot be raised further by the current step count N). If it is, an error is reported in step 120 as the nozzle can not be raised further. If it is not at the upper limit, nozzle 15 is raised by a number of steps defined by the step count N in step 145 . At step 150 , it is again determined whether the laser alignment system is able to see nozzle 15 . If it is seen, step 140 is repeated. If the nozzle is not seen, the system proceeds to step 130 where it is determined whether the step count N is the same as the initialized step count from step 100 . If so, the step count is reset to 1 in step 135 and step 105 is repeated. Again, this allows the system to obtain the most accurate Z=0 coordinate by lowering or raising nozzle 15 by the smallest possible increment. If the step count N=1, the nozzles Z position is reported as the Z=0 position at step 160 .
Once all coordinates, i.e., X, Y, Z and angle have been initialized, the system proceeds to learn the location of a device. In one embodiment, the device is provided (e.g., physically placed) in the desired location to be taught by an operator of the system.
According to an embodiment of the present invention, the system is capable of identifying a particular hardware configuration (by serial numbers or any other uniquely identifying feature) and determining whether or not to invoke teaching for that combination based on the prior existence of stored teaching data. For example, in one embodiment, the system is equipped with a bar code reader for reading a bar code associated with a device. In another embodiment, the operator inputs an identifier, such as a device serial number or product number or the like. The system checks a memory to see if stored teaching data exists for the particular identified device. If not, the system proceeds to learn the location of the provided device.
FIG. 3 is a flowchart that illustrates a process of detecting the Z-location of the surface of a device according to an embodiment of the present invention. The algorithm for learning the Z coordinate of a device assumes that the pick and place nozzle is above the top surface of the device. In one embodiment, laser pointer 30 is used to allow a system operator to position nozzle 15 above the device in the location to be taught. The position set by the operator does not affect the final coordinates determined by the teach process. The position must merely be close enough to allow the system to pick the part up. When the operator is satisfied with the rough location, he or she notifies the system software to indicate permission to move to the next step.
In one embodiment, the system's vacuum equipment includes a vacuum sensor which is capable of detecting whether or not the nozzle is in contact with the device while the vacuum is turned on. Briefly, starting at any Z coordinate, the algorithm proceeds by gradually lowering the nozzle. At each step the vacuum is activated and the sensor is sampled to determine whether or not the nozzle is in contact with the surface of the device.
Referring to FIG. 3, in step 200 , the vacuum is turned on. At step 210 , it is determined whether the vacuum is sensed, i.e., whether nozzle is in contact with the device. If a vacuum is sensed, the Z-position of the surface of the device is reported in step 220 . If the vacuum is not sensed, the vacuum is turned off. In step 240 , it is next determined whether the Z position is greater than a predetermined maximum descent level. In order to prevent damage to the system, a maximum descent is imposed; if nozzle 15 reaches this level without detection of a vacuum, an error is reported in step 250 . If not, in step 260 the nozzle is lowered a number of steps. Nozzle 10 is preferably lowered 10 steps in step 260 , however fewer or greater number of steps may be used as desired.
FIG. 4 illustrates the process of learning the X and Y coordinates of the center of the device in the location to be taught and the angle coordinate (i.e., orientation in the X-Y plane) of the device in the location to be taught. In the first step, step 300 , it is determined whether or not default coordinates for the location being learned exist in the system's database. There are many ways in which this could be accomplished. In a preferred embodiment, for example, a serial number is read from the piece of equipment (device) that presents the location. If this serial number appears in the database, then the default coordinates are read from the corresponding disk file. If this serial number doesn't appear in the database, there are no default coordinates associated with the location. If default coordinates do exist, in step 305 the pick and place nozzle head is moved to those coordinates before the algorithm proceeds.
The next step of the process is to offer the user an opportunity to set or correct the location coordinates. In many cases where default coordinates exist, no correction is required as the default coordinates are typically close enough to allow the self-teaching process to determine necessary corrections. In a preferred embodiment, in step 310 laser pointing device 30 is activated and a laser beam is directed through the shaft of the spindle 20 and along the angle axis defined thereby. The laser beam illuminates a point on the tabletop immediately below nozzle 15 . This approach makes it extremely easy for the user to position the pick and place head appropriately. The user may either move the pick and place nozzle head by hand or use user interface controls to move the head to the precise location required in step 315 .
When the head is in the proper position, the user indicates this fact in step 320 by triggering a user interface control (e.g., pointing the cursor at a particular control and clicking the mouse). Laser pointer 30 is deactivated in step 325 . In step 330 , to determine the initial value of angle, the user activates a control which specifies the location of pin one of the programmable device. For example, in one embodiment, if pin one is in the front left corner or in the center of the left side of the device (viewed from the front of the machine), the estimated angle is defined as zero. If pin one is in the front right corner or in the center of the front side of the device, the angle is initialized to 90 degrees, and so on. Four initial angles (0, 90, 180, and 270 degrees) are possible. The system then reads the current value of the X and Y encoder devices in step 335 , which sets the initial (uncorrected) X and Y coordinates of the device location being taught. In step 340 , the system learns the Z-coordinate of the surface of the device in the location being taught, for example using the process as shown in FIG. 3 .
Once initial estimates are made and nozzle 15 is over the target device, a counter is set in step 345 , and nozzle 15 is then lowered to the device surface and the vacuum is used to lift the device in front of the laser align unit. Specifically, in step 350 , nozzle 15 is moved to the Z-coordinate of the surface of the device, and the vacuum is activated in step 355 . In step 360 , the nozzle is moved so that the device is within the field of view of the laser align system. For example, in one embodiment, nozzle 15 is moved to a z position roughly equal to half of the thickness of the device. In step 365 , an align routine is used to determine the distance from the center of the device to the center of its rotation (i.e., the center of nozzle 15 ) in X and Y, and to determine the angle between the device and the system's X axis. An embodiment of an align process is illustrated in FIGS. 5 a and 5 b and will be described in more detail below. Briefly, the laser align unit takes measurements as the device is rotated. For example, one or more sensors monitor which of one or more laser beams is interrupted during a rotation of the device. At any given time the image can be characterized by a width and a center position. The laser align unit identifies the four positions (corresponding to the four sides of the device) at which the image exhibits local width minima, and returns the center position associated with each of the four positions. Using these four center coordinates, the software is able to compute a correcting move for the X, Y and angle coordinates.
Once the laser align unit has taken measurements and determined necessary X, Y and angle corrections, the device is placed back in the location to be taught. Specifically, in step 370 , the nozzle is lowered to the stored Z-coordinate of the surface of the device when in the location being taught. In step 375 , the vacuum is turned off, and in step 380 , the nozzle is raised to the initial Z=0 position. According to a preferred embodiment, the alignment process is repeated three times, and the results are averaged to get a better estimate of the error associated with the initial coordinate estimates. According to this embodiment, the counter is increased by one in step 385 , and in step 390 it is determined whether the counter is greater than three. If not, indicating that the alignment process has not been repeated three times, steps 350 through 385 are repeated.
If the align process has been repeated three times, the system proceeds to step 395 , where the corrected X, Y and angle coordinates are determined. The nature of the align routine is such that the results (e.g., averages) of the routine can be subtracted from the initial coordinates in order to generate the corrected coordinates. After this process is complete, the corrected coordinates are returned to the calling routine for storage in the default coordinate database in step 398 .
FIGS. 5 a and 5 b are flowcharts that illustrate an alignment process according to an embodiment of the present invention. In step 400 it is determined whether X, Y, Z and angle information needs to be taught, or whether only Z information needs to be taught. Referring to FIG. 5 a , !Package is a flag, which in a preferred embodiment, if non-null indicates that X, Y, Z and angle information needs to be taught, and provides information about the device under test that is necessary for this process. If the package pointer is null, only Z-coordinate information need be taught, and in step 405 , the known coordinate information is provided. In step 410 , the system determines which pair of opposite faces is shortest. In step 415 , after determining which pair of faces is shortest, the system determines how far it is necessary to rotate the part from its starting position to guarantee that, if measurement is started at that point, the shadow cast by the part on the laser align sensor will decrease to a minimum corresponding to the short face. This process guarantees that the sensor doesn't inadvertently detect the shadow minimum corresponding to the long dimension of the device under test.
In step 420 , the system rotates the device by at least 270 degrees to get a full alignment measurement. In one embodiment, in step 420 a spin angle is computed that accounts for any error in the assumed initial angle of the part. Preferably, the spin angle computation is accomplished as follows:
1. Rotate through the holdoff angle calculated in step 415 ;
2. Rotate further until a shadow minimum width (short dimension) is detected;
3. Rotate 270 degrees more to detect three more shadows (e.g., long, short long); and
4. Rotate an additional small amount for “buffer”. In preferred aspects, the system rotates the device by at least 310 degrees.
In step 425 , the part is moved to the coordinates X, Y and the device is rotated. In preferred aspects, the device is rotated through an angle equal to spin as determined in the previous step. In step 430 , four measurements are obtained, one for each side of the device.
In step 435 , it is determined whether the measurements taken are square, e.g., if face 0 =face 2 , and if face 1 =face 3 . If not, an error is returned. If the measurements are square, it is determined in step 440 whether the length (longest face) and width (shortest face) are within proper specifications. An error is returned if the measurements are not within the defined range of values. In step 445 , the final angle is determined. In one embodiment, the computed angle includes three components:
1. The laser align result (e.g., the actual initial angle modulo 90 degrees).
2. “d * face” is “90 * face”. This corrects for the modulo operation.
3. The total spin (e.g., a measure from the initial angle to the final angle).
In step 450 , the difference in both X and Y coordinates of the center of the device relative to the nozzle are determined. In general, the laser align process makes four measurements of the center location of the component shadow, each taken 90 degrees apart (e.g., corresponding to the four sides labeled in step 410 ). Measurements 0 and 2 are the same if the nozzle is perfectly centered along the long dimension. Measurements 1 and 3 are the same if the nozzle is perfectly centered along the short dimension. If the nozzle is not centered along one or the other dimension, one of the center measurements increases by the error amount, while the opposing measurement decreases. Thus, in one embodiment, the difference in the two measurements for both the short and long dimensions are taken and divided by 2 to obtain the nozzle offset relative to the center of the device.
In step 455 , the parameter t is determined. The angles to_w and from_w are multiples of 90 degrees, which makes the sines and cosines of those angles 1, 0, or −1. These values alter the signs of X_diff and Y_diff appropriately to make the calculations generic for all cases. According to an alternative, a switch statement is used and almost identical equations are used in all four sections. In step 460 the correction values for the X, Y and angle coordinates are determined using the parameter t from step 455 .
It will be apparent to one skilled in the art that the techniques of the present invention are particularly useful in an apparatus for programming a variety of types of programmable devices and programmable integrated circuit devices (PICs), including for example, flash memories, EEPROMs, microcontrollers, PLDs, PALs, FPGAs and the like.
While the invention has been described by way of example and in terms of the specific embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. For example, although the location of only one device is taught in the above description, linear interpolation of multiple measured device coordinates can be used to compute the coordinates of a large number of identical devices located along with the measured devices in a matrix arrangement. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. | Systems and methods for teaching a location in a device programming apparatus. The X, Y, Z and angle coordinates of a pick and place nozzle are initialized, and the nozzle is moved in the X and Y coordinates to a position above the device in the location to be taught. The new X and Y coordinates of the nozzle are stored to a memory along with the initial angle coordinate. The system automatically determines the Z location of the surface of the device. The nozzle then automatically picks up the device and performs vision centering to determine the X, Y and angle offsets with respect to the initialized coordinates. The X, Y and angle offsets are used to modify the stored X, Y and angle coordinates so as to precisely determine the X and Y location of the device center as well as the device angle with respect to the system's global reference frame. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to electrically variable transmissions with selective operation both in power-split variable speed ratio ranges and in fixed speed ratios, and having three or four planetary gear sets, two motor/generators and five, six or seven torque transmitting devices.
BACKGROUND OF THE INVENTION
[0002] Internal combustion engines, particularly those of the reciprocating piston type, currently propel most vehicles. Such engines are relatively efficient, compact, lightweight, and inexpensive mechanisms by which to convert highly concentrated energy in the form of fuel into useful mechanical power. A novel transmission system, which can be used with internal combustion engines and which can reduce fuel consumption and the emissions of pollutants, may be of great benefit to the public.
[0003] The wide variation in the demands that vehicles typically place on internal combustion engines increases fuel consumption and emissions beyond the ideal case for such engines. Typically, a vehicle is propelled by such an engine, which is started from a cold state by a small electric motor and relatively small electric storage batteries, then quickly placed under the loads from propulsion and accessory equipment. Such an engine is also operated through a wide range of speeds and a wide range of loads and typically at an average of approximately a fifth of its maximum power output.
[0004] A vehicle transmission typically delivers mechanical power from an engine to the remainder of a drive system, such as fixed final drive gearing, axles and wheels. A typical mechanical transmission allows some freedom in engine operation, usually through alternate selection of five or six different drive ratios, a neutral selection that allows the engine to operate accessories with the vehicle stationary, and clutches or a torque converter for smooth transitions between driving ratios and to start the vehicle from rest with the engine turning. Transmission gear selection typically allows power from the engine to be delivered to the rest of the drive system with a ratio of torque multiplication and speed reduction, with a ratio of torque reduction and speed multiplication known as overdrive, or with a reverse ratio.
[0005] An electric generator can transform mechanical power from the engine into electrical power, and an electric motor can transform that electric power back into mechanical power at different torques and speeds for the remainder of the vehicle drive system. This arrangement allows a continuous variation in the ratio of torque and speed between engine and the remainder of the drive system, within the limits of the electric machinery. An electric storage battery used as a source of power for propulsion may be added to this arrangement, forming a series hybrid electric drive system.
[0006] The series hybrid system allows the engine to operate with some independence from the torque, speed and power required to propel a vehicle, so the engine may be controlled for improved emissions and efficiency. This system allows the electric machine attached to the engine to act as a motor to start the engine. This system also allows the electric machine attached to the remainder of the drive train to act as a generator, recovering energy from showing the vehicle into the battery by regenerative braking. A series electric drive suffers from the weight and cost of sufficient electric machinery to transform all of the engine power from mechanical to electrical in the generator and from electrical to mechanical in the drive motor, and from the useful energy lost in these conversions.
[0007] A power-split transmission can use what is commonly understood to be “differential gearing” to achieve a continuously variable torque and speed ratio between input and output. An electrically variable transmission can use differential gearing to send a fraction of its transmitted power through a pair of electric motor/generators. The remainder of its power flows through another, parallel path that is all mechanical and direct, of fixed ratio, or alternatively selectable.
[0008] One form of differential gearing, as is well known to those skilled in this art, may constitute a planetary gear set. Planetary gearing is usually the preferred embodiment employed in differentially geared inventions, with the advantages of compactness and different torque and speed ratios among all members of the planetary gear set. However, it is possible to construct this invention without planetary gears, as by using bevel gears or other gears in an arrangement where the rotational speed of at least one element of a gear set is always a weighted average of speeds of two other elements.
[0009] A hybrid electric vehicle transmission system also includes one or more electric energy storage devices. The typical device is a chemical electric storage battery, but capacitive or mechanical devices, such as an electrically driven flywheel, may also be included. Electric energy storage allows the mechanical output power from the transmission system to the vehicle to vary from the mechanical input power from the engine to the transmission system. The battery or other device also allows for engine starting with the transmission system and for regenerative vehicle braking.
[0010] An electrically variable transmission in a vehicle can simply transmit mechanical power from an engine input to a final drive output. To do so, the electric power produced by one motor/generator balances the electrical losses and the electric power consumed by the other motor/generator. By using the above-referenced electrical storage battery, the electric power generated by one motor/generator can be greater than or less than the electric power consumed by the other. Electric power from the battery can sometimes allow both motor/generators to act as motors, especially to assist the engine with vehicle acceleration. Both motors can sometimes act as generators to recharge the battery, especially in regenerative vehicle braking.
[0011] A successful substitute for the series hybrid transmission is the two-range, input-split and compound-split electrically variable transmission now produced for transit buses, as disclosed in U.S. Pat. No. 5,931,757, issued Aug. 3, 1999, to Michael Roland Schmidt, commonly assigned with the present application. Such a transmission utilizes an input means to receive power from the vehicle engine and a power output means to deliver power to drive the vehicle. First and second motor/generators are connected to an energy storage device, such as a battery, so that the energy storage device can accept power from, and supply power to, the first and second motor/generators. A control unit regulates power flow among the energy storage device and the motor/generators as well as between the first and second motor/generators.
[0012] Operation in first or second variable-speed-ratio modes of operation may be selectively achieved by using clutches in the nature of first and second torque transfer devices. In the first mode, an input-power-split speed ratio range is formed by the application of the first clutch, and the output speed of the transmission is proportional to the speed of one motor/generator. In the second mode, a compound-power-split speed ratio range is formed by the application of the second clutch, and the output speed of the transmission is not proportional to the speeds of either of the motor/generators, but is an algebraic linear combination of the speeds of the two motor/generators. Operation at a fixed transmission speed ratio may be selectively achieved by the application of both of the clutches. Operation of the transmission in a neutral mode may be selectively achieved by releasing both clutches, decoupling the engine and both electric motor/generators from the transmission output. The transmission incorporates at least one mechanical point in its first mode of operation and at least two mechanical points in its second mode of operation.
[0013] “Compound split” means that neither the transmission input nor output is directly connected to a motor/generator. A compound split architecture includes a mode with two mechanical points, each of which is attained when one of the motor/generators reaches zero speed. This allows a reduction in the size and cost of the electric motor/generator required to achieve desired vehicle performance. “Output split” means a motor/generator is directly connected to the input. This mode is useful for launching the vehicle. “Input split” means a motor/generator is directly connected to the output member. This is useful in capturing regenerative energy during braking and for providing torque assist to the engine as needed.
[0014] U.S. Pat. No. 6,527,658, issued Mar. 4, 2003 to Holmes et al, commonly assigned with the present application, discloses an electrically variable transmission utilizing two planetary gear sets, two motor/generators and two clutches to provide input split, compound split, neutral and reverse modes of operation. Both planetary gear sets may be simple, or one may be individually compounded. An electrical control member regulates power flow among an energy storage device and the two motor/generators. This transmission provides two ranges or modes of electrically variable transmission (EVT) operation, selectively providing an input-power-split speed ratio range and a compound-power-split speed ratio range. One fixed speed ratio can also be selectively achieved.
SUMMARY OF THE INVENTION
[0015] The present invention provides a family of electrically variable transmissions offering several advantages over conventional automatic transmissions for use in hybrid vehicles, including improved vehicle acceleration performance, improved fuel economy via regenerative braking and electric-only idling and launch, and an attractive marketing feature. The purpose of the invention is to provide the best possible energy efficiency and emissions for a given engine. In addition, optimal performance, capacity, package size, and ratio coverage for the transmission are sought.
[0016] The electrically variable transmission family of the present invention provides low-content, low-cost electrically variable transmission mechanisms including first, second and third (and optional fourth) differential gear sets, a battery, two electric machines serving interchangeably as motors or generators, and five, six or seven selectable torque-transmitting devices. Additionally, a dog clutch may be provided. Preferably, the differential gear sets are planetary gear sets, such as simple or compound (including Ravigneaux) gear sets, but other gear arrangements may be implemented, such as bevel gears or differential gearing to an offset axis.
[0017] In this description, the first, second, or third (or fourth) planetary gear sets may be counted first to third (or fourth) in any order (i.e., left to right, right to left, etc.).
[0018] Each of the three (or four) planetary gear sets has three members. The first, second or third member of each planetary gear set can be any one of a sun gear, ring gear or carrier member, or alternatively a pinion.
[0019] Each carrier member can be either a single-pinion carrier member (simple) or a double-pinion carrier member (compound).
[0020] The input shaft is selectively or continuously connected with at least one member of the planetary gear sets. The output shaft is continuously connected with at least one member of the planetary gear sets.
[0021] An interconnecting member continuously connects a first member of the first planetary gear set with the first member of the second planetary gear set or with a stationary member (transmission housing/casing).
[0022] A first torque transmitting device selectively connects a member of the first, second or third planetary gear set with another member of the second or third planetary gear set.
[0023] A second torque transmitting device selectively connects a member of the third planetary gear set with a member of the first or second planetary gear set.
[0024] A third torque transmitting device selectively connects a member of the first or second planetary gear set with another member of the first, second or third planetary gear set.
[0025] A fourth torque transmitting device selectively connects a member of the first, second or third planetary gear set with another member of the first or second planetary gear set.
[0026] A fifth torque transmitting device selectively connects a member of the first, second or third planetary gear set with a stationary member (transmission housing/casing).
[0027] An optional sixth torque transmitting device selectively connects a member of the first or second planetary gear set with another member of the first or second planetary gear set or with a stationary member (transmission housing/casing).
[0028] An optional seventh torque transmitting device selectively connects a member of the second planetary gear set with the input member.
[0029] An optional second interconnecting member continuously connects the carrier member of the second planetary gear set with the carrier member of the optional fourth planetary gear set.
[0030] An optional third interconnecting member continuously connects the second and fourth planetary gear sets via long pinion gears.
[0031] The first motor/generator is mounted to the transmission case and is connected either continuously to a member of the first, second or third planetary gear set or selectively via a dog clutch to one of a pair of members of the first, second or third planetary gear sets. The first motor/generator may also incorporate offset gearing. The dog clutch, if present, allows the first motor/generator to be switched between a pair of members on the first, second or third planetary gear sets. The dog clutch may reduce clutch spin losses, and allows motor/generator operation at low speeds throughout the operating range of the transmission. The dog clutch may be replaced by a pair of conventional torque transfer devices.
[0032] The second motor/generator is mounted to the transmission case and is connected continuously to a member of the first, second or third planetary gear set. The second motor/generator connection may incorporate offset gearing.
[0033] The selectable torque transmitting devices are engaged in combinations to yield an EVT with a continuously variable range of speeds (including reverse) and up to six mechanically fixed forward speed ratios and up to three mechanically fixed reverse speed ratios. A “fixed speed ratio” is an operating condition in which the mechanical power input to the transmission is transmitted mechanically to the output, and no power flow (i.e. almost zero) is present in the motor/generators. An electrically variable transmission that may selectively achieve several fixed speed ratios for operation near full engine power can be smaller and lighter for a given maximum capacity. Fixed ratio operation may also result in lower fuel consumption when operating under conditions where engine speed can approach its optimum without using the motor/generators. A variety of fixed speed ratios and variable ratio spreads can be realized by suitably selecting the tooth ratios of the planetary gear sets.
[0034] Each embodiment of the electrically variable transmission family disclosed has an architecture in which neither the transmission input nor output is directly connected to a motor/generator. This allows for a reduction in the size and cost of the electric motor/generators required to achieve the desired vehicle performance.
[0035] The torque transmitting devices, and the first and second motor/generators are operable to provide five or six operating modes in the electrically variable transmission, including battery reverse mode, EVT reverse mode, reverse and forward launch modes, continuously variable transmission range mode and fixed forward ratio mode. The transmission of the present invention may also include a mechanical or fixed reverse ratio. This is useful for meeting reverse gradeability requirements and also for cold-weather operation when the electrical torque assist may not be available due to poor battery operation.
[0036] The above features and advantages, and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 a is a schematic representation of a powertrain including an electrically variable transmission incorporating a family member of the present invention;
[0038] FIG. 1 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 1 a ;
[0039] FIG. 2 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0040] FIG. 2 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 2 a;
[0041] FIG. 3 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0042] FIG. 3 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 3 a;
[0043] FIG. 4 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0044] FIG. 4 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 4 a;
[0045] FIG. 5 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0046] FIG. 5 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 5 a;
[0047] FIG. 6 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0048] FIG. 6 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 6 a;
[0049] FIG. 7 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0050] FIG. 7 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 7 a;
[0051] FIG. 8 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0052] FIG. 8 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 8 a;
[0053] FIG. 9 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0054] FIG. 9 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 9 a;
[0055] FIG. 10 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0056] FIG. 10 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 10 a;
[0057] FIG. 11 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0058] FIG. 11 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 11 a;
[0059] FIG. 12 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention;
[0060] FIG. 12 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 12 a;
[0061] FIG. 13 a is a schematic representation of a powertrain having an electrically variable transmission incorporating another family member of the present invention; and
[0062] FIG. 13 b is an operating mode table and fixed ratio mode table depicting some of the operating characteristics of the powertrain shown in FIG. 13 a.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0063] With reference to FIG. 1 a , a powertrain 10 is shown, including an engine 12 connected to one preferred embodiment of the improved electrically variable transmission (EVT), designated generally by the numeral 14 . Transmission 14 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 14 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0064] In the embodiment depicted the engine 12 may be a fossil fuel engine, such as a diesel engine which is readily adapted to provide its available power output typically delivered at a constant number of revolutions per minute (RPM).
[0065] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 14 . An output member 19 of the transmission 14 is connected to a final drive 16 .
[0066] The transmission 14 utilizes three differential gear sets, preferably in the nature of planetary gear sets 20 , 30 and 40 . The planetary gear set 20 employs an outer gear member 24 , typically designated as the ring gear. The ring gear member 24 circumscribes an inner gear member 22 , typically designated as the sun gear. A carrier member 26 rotatably supports a plurality of planet gears 27 such that each planet gear 27 meshingly engages both the outer, ring gear member 24 and the inner, sun gear member 22 of the first planetary gear set 20 .
[0067] The planetary gear set 30 also has an outer gear member 34 , often also designated as the ring gear, that circumscribes an inner gear member 32 , also often designated as the sun gear member. A plurality of planet gears 37 are also rotatably mounted in a carrier member 36 such that each planet gear member 37 simultaneously, and meshingly, engages both the outer, ring gear member 34 and the inner, sun gear member 32 of the planetary gear set 30 .
[0068] The planetary gear set 40 also has an outer gear member 44 , often also designated as the ring gear, that circumscribes an inner gear member 42 , also often designated as the sun gear. A plurality of planet gears 47 are also rotatably mounted in a carrier member 46 such that each planet gear member 47 simultaneously, and meshingly, engages both the outer, ring gear member 44 and the inner, sun gear member 42 of the planetary gear set 40 .
[0069] The first preferred embodiment 10 also incorporates first and second motor/generators 80 and 82 , respectively. The stator of the first motor/generator 80 is secured to the transmission housing 60 . The rotor of the first motor/generator 80 is secured to the sun gear member 22 of the planetary gear set 20 .
[0070] The stator of the second motor/generator 82 is also secured to the transmission housing 60 . The rotor of the second motor/generator 82 is secured to the sun gear member 32 of the planetary gear set 30 .
[0071] The input member 17 is secured to the sun gear member 42 of the planetary gear set 40 . The output drive member 19 of the transmission 14 is secured to carrier member 36 of the planetary gear set 30 . An interconnecting member 70 continuously connects the ring gear member 24 of the planetary gear set 20 with the sun gear member 32 of the planetary gear set 30 .
[0072] A first torque transmitting device, such as clutch 50 , selectively connects the sun gear member 22 of the planetary gear set 20 with the ring gear member 34 of the planetary gear set 30 . A second torque transmitting device, such as clutch 52 , selectively connects the sun gear member 22 of the planetary gear set 20 with the sun gear member 32 of the planetary gear set 30 . A third torque transmitting device, such as clutch 54 , selectively connects the ring gear member 42 of the planetary gear set 40 with the carrier member 26 of the planetary gear set 20 . A fourth torque transmitting device, such as clutch 55 , selectively connects the ring gear member 44 of the planetary gear set 40 with the carrier member 26 of the planetary gear set 20 . A fifth torque transmitting device, such as brake 57 , selectively connects the ring gear member 34 of the planetary gear set 30 with the transmission housing 60 . A sixth torque transmitting device, such as brake 58 , selectively connects the carrier member 46 of the planetary gear set 40 with the transmission housing 60 . The first, second, third, fourth, fifth and sixth torque transmitting devices 50 , 52 , 54 , 55 , 57 and 58 are employed to assist in the selection of the operational modes of the hybrid transmission 14 , as will be hereinafter more fully explained.
[0073] Returning now to the description of the power sources, it should be apparent from the foregoing description, and with particular reference to FIG. 1 a , that the transmission 14 selectively receives power from the engine 12 . The hybrid transmission also receives power from an electric power source 86 , which is operably connected to a controller 88 . The electric power source 86 may be one or more batteries. Other electric power sources, such as fuel cells, that have the ability to provide, or store, and dispense electric power may be used in place of batteries without altering the concepts of the present invention.
General Operating Considerations
[0074] One of the primary control devices is a well known drive range selector (not shown) that directs an electronic control unit (the controller or ECU 88) to configure the transmission for either the park, reverse, neutral, or forward drive range. The second and third primary control devices constitute an accelerator pedal (not shown) and a brake pedal (also not shown). The information obtained by the ECU from these three primary control sources is designated as the “operator demand.” The ECU also obtains information from a plurality of sensors (input as well as output) as to the status of: the torque transfer devices (either applied or released); the engine output torque; the unified battery, or batteries, capacity level; and, the temperatures of selected vehicular components. The ECU determines what is required and then manipulates the selectively operated components of, or associated with, the transmission appropriately to respond to the operator demand.
[0075] The invention may use simple or compound planetary gear sets. In a simple planetary gear set a single set of planet gears are normally supported for rotation on a carrier member that is itself rotatable.
[0076] In a simple planetary gear set, when the sun gear is held stationary and power is applied to the ring gear of a simple planetary gear set, the planet gears rotate in response to the power applied to the ring gear and thus “walk” circumferentially about the fixed sun gear to effect rotation of the carrier member in the same direction as the direction in which the ring gear is being rotated.
[0077] When any two members of a simple planetary gear set rotate in the same direction and at the same speed, the third member is forced to turn at the same speed, and in the same direction. For example, when the sun gear and the ring gear rotate in the same direction, and at the same speed, the planet gears do not rotate about their own axes but rather act as wedges to lock the entire unit together to effect what is known as direct drive. That is, the carrier member rotates with the sun and ring gears.
[0078] However, when the two gear members rotate in the same direction, but at different speeds, the direction in which the third gear member rotates may often be determined simply by visual analysis, but in many situations the direction will not be obvious and can only be accurately determined by knowing the number of teeth present on all the gear members of the planetary gear set.
[0079] Whenever the carrier member is restrained from spinning freely, and power is applied to either the sun gear or the ring gear, the planet gear members act as idlers. In that way the driven member is rotated in the opposite direction as the drive member. Thus, in many transmission arrangements when the reverse drive range is selected, a torque transfer device serving as a brake is actuated frictionally to engage the carrier member and thereby restrain it against rotation so that power applied to the sun gear will turn the ring gear in the opposite direction. Thus, if the ring gear is operatively connected to the drive wheels of a vehicle, such an arrangement is capable of reversing the rotational direction of the drive wheels, and thereby reversing the direction of the vehicle itself.
[0080] In a simple set of planetary gears, if any two rotational speeds of the sun gear, the planet carrier member, and the ring gear are known, then the speed of the third member can be determined using a simple rule. The rotational speed of the carrier member is always proportional to the speeds of the sun and the ring, weighted by their respective numbers of teeth. For example, a ring gear may have twice as many teeth as the sun gear in the same set. The speed of the carrier member is then the sum of two-thirds the speed of the ring gear and one-third the speed of the sun gear. If one of these three members rotates in an opposite direction, the arithmetic sign is negative for the speed of that member in mathematical calculations.
[0081] The torque on the sun gear, the carrier member, and the ring gear can also be simply related to one another if this is done without consideration of the masses of the gears, the acceleration of the gears, or friction within the gear set, all of which have a relatively minor influence in a well designed transmission. The torque applied to the sun gear of a simple planetary gear set must balance the torque applied to the ring gear, in proportion to the number of teeth on each of these gears. For example, the torque applied to a ring gear with twice as many teeth as the sun gear in that set must be twice that applied to the sun gear, and must be applied in the same direction. The torque applied to the carrier member must be equal in magnitude and opposite in direction to the sum of the torque on the sun gear and the torque on the ring gear.
[0082] In a compound planetary gear set, the utilization of inner and outer sets of planet gears effects an exchange in the roles of the ring gear and the planet carrier member in comparison to a simple planetary gear set. For instance, if the sun gear is held stationary, the planet carrier member will rotate in the same direction as the ring gear, but the planet carrier member with inner and outer sets of planet gears will travel faster than the ring gear, rather than slower.
[0083] In a compound planetary gear set having meshing inner and outer sets of planet gears the speed of the ring gear is proportional to the speeds of the sun gear and the planet carrier member, weighted by the number of teeth on the sun gear and the number of teeth filled by the planet gears, respectively. For example, the difference between the ring and the sun filled by the planet gears might be as many teeth as are on the sun gear in the same set. In that situation the speed of the ring gear would be the sum of two-thirds the speed of the carrier member and one third the speed of the sun. If the sun gear or the planet carrier member rotates in an opposite direction, the arithmetic sign is negative for that speed in mathematical calculations.
[0084] If the sun gear were to be held stationary, then a carrier member with inner and outer sets of planet gears will turn in the same direction as the rotating ring gear of that set. On the other hand, if the sun gear were to be held stationary and the carrier member were to be driven, then planet gears in the inner set that engage the sun gear roll, or “walk,” along the sun gear, turning in the same direction that the carrier member is rotating. Pinion gears in the outer set that mesh with pinion gears in the inner set will turn in the opposite direction, thus forcing a meshing ring gear in the opposite direction, but only with respect to the planet gears with which the ring gear is meshingly engaged. The planet gears in the outer set are being carried along in the direction of the carrier member. The effect of the rotation of the pinion gears in the outer set on their own axis and the greater effect of the orbital motion of the planet gears in the outer set due to the motion of the carrier member are combined, so the ring rotates in the same direction as the carrier member, but not as fast as the carrier member.
[0085] If the carrier member in such a compound planetary gear set were to be held stationary and the sun gear were to be rotated, then the ring gear will rotate with less speed and in the same direction as the sun gear. If the ring gear of a simple planetary gear set is held stationary and the sun gear is rotated, then the carrier member supporting a single set of planet gears will rotate with less speed and in the same direction as the sun gear. Thus, one can readily observe the exchange in roles between the carrier member and the ring gear that is caused by the use of inner and outer sets of planet gears which mesh with one another, in comparison with the usage of a single set of planet gears in a simple planetary gear set.
[0086] The normal action of an electrically variable transmission is to transmit mechanical power from the input to the output. As part of this transmission action, one of its two motor/generators acts as a generator of electrical power. The other motor/generator acts as a motor and uses that electrical power. As the speed of the output increases from zero to a high speed, the two motor/generators 80 , 82 gradually exchange roles as generator and motor, and may do so more than once. These exchanges take place around mechanical points, wiere essentially all of the power from input to output is transmitted mechanically and no substantial power is transmitted electrically.
[0087] In a hybrid electrically variable transmission system, the battery 86 may also supply power to the transmission or the transmission may supply power to the battery. If the battery is supplying substantial electric power to the transmission, such as for vehicle acceleration, then both motor/generators may act as motors. If the transmission is supplying electric power to the battery, such as for regenerative braking, both motor/generators may act as generators. Very near the mechanical points of operation, both motor/generators may also act as generators with small electrical power outputs, because of the electrical losses in the system.
[0088] Contrary to the normal action of the transmission, the transmission may actually be used to transmit mechanical power from the output to the input. This may be done in a vehicle to supplement the vehicle brakes and to enhance or to supplement regenerative braking of the vehicle, especially on long downward grades. If the power flow through the transmission is reversed in this way, the roles of the motor/generators will then be reversed from those in normal action.
Specific Operating Considerations
[0089] Each of the embodiments described herein has fourteen to eighteen functional requirements (corresponding with the 14 to 18 rows of each operating mode table shown in the Figures) which may be grouped into five or six operating modes. These five or six operating modes are described below and may be best understood by referring to the respective operating mode table accompanying each transmission stick diagram, such as the operating mode tables of FIGS. 1 b , 2 b , 3 b , etc.
[0090] The first operating mode is the “battery reverse mode” which corresponds with the first row (Batt Rev) of each operating mode table, such as that of FIG. 1 b . In this mode, the engine is off and the transmission element connected to the engine is not controlled by engine torque, though there may be some residual torque due to the rotational inertia of the engine. The EVT is driven by one of the motor/generators using energy from the battery, causing the vehicle to move in reverse. Depending on the kinematic configuration, the other motor/generator may or may not rotate in this mode, and may or may not transmit torque. If it does rotate, it is used to generate energy which is stored in the battery. In the embodiment of FIG. 1 b , in the battery reverse mode, the brake 57 is engaged, the generator 80 has zero torque, the motor 82 has a torque of −1.00, and a torque ratio of −2.88 is achieved, by way of example. In each operating mode table an (M) next to a torque value in the motor/generator columns 80 and 82 indicates that the motor/generator is acting as a motor, and the absence of an (M) indicates that the motor/generator is acting as generator.
[0091] The second operating mode is the “EVT reverse mode” (or mechanical reverse mode) which corresponds with the second row (EVT Rev) of each operating mode table, such as that of FIG. 1 b . In this mode, the EVT is driven by the engine and by one of the motor/generators. The other motor/generator operates in generator mode and transfers 100% of the generated energy back to the driving motor. The net effect is to drive the vehicle in reverse. Referring to FIG. 1 b , for example, in the EVT reverse mode, the clutch 54 and brake 57 are engaged, the generator 80 has a torque of −0.35 units, the motor 82 has a torque of −3.55 units, and an output torque of −8.33 is achieved, corresponding to an engine torque of 1 unit.
[0092] The third operating mode includes the “reverse and forward launch modes” (also referred to as “torque converter reverse and forward modes”) corresponding with the third and fourth rows (TC Rev and TC For) of each operating mode table, such as that of FIG. 1 b . In this mode, the EVT is driven by the engine and one of the motor/generators. A selectable fraction of the energy generated in the generator unit is stored in the battery, with the remaining energy being transferred to the motor. In FIG. 1 , this fraction is approximately 99%. The ratio of transmission output speed to engine speed (transmission speed ratio) is approximately ±0.001 (the positive sign indicates that the vehicle is creeping forward and negative sign indicates that the vehicle is creeping backwards). Referring to FIG. 1 b , in the TC Reverse mode, the clutch 54 and brake 57 are engaged, the motor/generator 80 acts as a generator with −0.35units of torque, the motor/generator 82 acts as a motor with −3.09 units of torque, and a torque ratio of −7.00 is achieved. In the TC Forward mode, the clutch 54 and brake 57 are engaged, the motor/generator 80 acts as a generator with −0.35 units of torque, the motor/generator 82 acts as a motor with 0.98 units of torque, and a torque ratio of 4.69 is achieved.
[0093] The fourth operating mode is a “continuously variable transmission range mode” which includes the Range 1 . 1 , Range 1 . 2 , Range 1 . 3 , Range 1 . 4 , Range 2 . 1 , Range 2 . 2 , Range 2 . 3 and Range 2 . 4 operating points corresponding with rows 5 - 12 of each operating point table, such as that of FIG. 1 b . In this mode, the EVT is driven by the engine as well as one of the motor/generators operating as a motor. The other motor/generator operates as a generator and transfers 100% of the generated energy back to the motor. The operating points represented by Range 1 . 1 , 1 . 2 . . . , etc. are discrete points in the continuum of forward speed ratios provided by the EVT. For example in FIG. 1 b , a range of torque ratios from 4.69 to 1.86 is achieved with the clutch 54 and brake 57 engaged. A range of torque ratios from 1.36 to 0.54 is achieved with the clutches 50 and 54 engaged.
[0094] The fifth operating mode includes the “fixed forward ratio” modes (F 1 , F 2 , F 3 ) corresponding with rows 16 - 18 of the operating mode table (i.e. operating mode table), such as that of FIG. 1 b . In this mode the transmission operates like a conventional automatic transmission, with three torque transmitting devices engaged to create a discrete transmission ratio. The clutching table accompanying each figure shows only three fixed-ratio forward speeds but additional fixed forward ratios may be available. Referring to FIG. 1 b , in fixed ratio F 1 the clutches 52 , 54 and brake 57 are engaged to achieve a fixed torque ratio of 2.82. In fixed ratio F 2 , the clutches 50 , 54 and brake 57 are engaged to achieve a fixed ratio of 1.74. In fixed ratio F 3 , the clutches 50 , 52 and 54 are engaged to achieve a fixed ratio of 1.00.
[0095] The sixth operating mode includes the “mechanical or fixed reverse ratio” modes (R 1 , R 2 , R 3 ) corresponding with rows 13 - 15 of the operating mode table (i.e., operating mode table), such as that of FIG. 1 b . In this mode the transmission operates like a conventional automatic transmission, with four torque transmitting devices engaged to create a discrete transmission ratio. The clutching table accompanying each figure shows only three fixed reverse ratios, but additional fixed reverse ratios may be available. Referring to FIG. 1 b , in fixed reverse ratio R 1 the clutches 52 , 55 and brakes 57 , 58 are engaged to achieve a fixed reverse ratio of −5.30. In fixed reverse ratio R 2 , the clutches 50 , 55 and brakes 57 , 58 are engaged to achieve a fixed reverse ratio of −3.27. In fixed reverse ratio R 3 , the clutches 50 , 52 , 55 and brake 58 are engaged to achieve a fixed reverse ratio of −1.88.
[0096] The powertrain 10 may also operate in a “charge-depleting mode”. For purposes of the present invention, a “charge-depleting mode” is a mode wherein the vehicle is powered primarily by an electric motor/generator such that the battery 86 is depleted or nearly depleted when the vehicle reaches its destination. In other words, during the charge-depleting mode, the engine 12 is only operated to the extent necessary to ensure that the battery 86 is not depleted before the destination is reached. A conventional hybrid vehicle operates in a “charge-sustaining mode”, wherein if the battery charge level drops below a predetermined level (e.g., 25%) the engine is automatically run to recharge the battery. Therefore, by operating in a charge-depleting mode, the hybrid vehicle can conserve some or all of the fuel that would otherwise be expended to maintain the 25% battery charge level in a conventional hybrid vehicle. It should be appreciated that the vehicle powertrain is preferably only operated in the charge-depleting mode if the battery 86 can be recharged after the destination is reached by plugging it into an energy source (not shown).
[0097] Also, the engine 12 may be powered using various types of fuel to improve the efficiency and fuel economy of a particular application. Such fuels may include, for example, gasoline; diesel; ethanol; dimethyl ether; etc.
[0098] The transmission 14 is capable of operating in so-called single or multiple modes. In single mode, the engaged torque transmitting device remains the same for the entire continuum of forward speed ratios (represented by the discrete points: Ranges 1 . 1 , 1 . 2 , 1 . 3 and 1 . 4 ). In dual-, three-, four- etc. mode, the engaged torque transmitting device is switched at some intermediate speed ratio (e.g., Range 2 . 1 in FIG. 1 ). Depending on the mechanical configuration, this change in torque transmitting device engagement has advantages in reducing element speeds in the transmission.
[0099] As set forth above, the emgagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 1 b . FIG. 1 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 1 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 20 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 30 ; and the N R3 /N S3 value is the tooth ratio of the planetary gear set 40 . Also, the chart of FIG. 1 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.63, the step ratio between the second and third fixed forward torque ratios is 1.74, and the ratio spread is 2.82.
Description of a Second Exemplary Embodiment
[0100] With reference to FIG. 2 a , a powertrain 110 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 114 . Transmission 114 is designed to receive at least a portion of its driving power from the engine 12 .
[0101] In the embodiment depicted the engine 12 may also be a fossil fuel engine, such as a diesel engine which is readily adapted to provide its available power output typically delivered at a constant number of revolutions per minute (RPM). As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 14 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0102] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 114 . An output member 19 of the transmission 114 is connected to a final drive 16 .
[0103] The transmission 114 utilizes three differential gear sets, preferably in the nature of planetary gear sets 120 , 130 and 140 . The planetary gear set 120 employs an outer gear member 124 , typically designated as the ring gear. The ring gear member 124 circumscribes an inner gear member 122 , typically designated as the sun gear. A carrier member 126 rotatably supports a plurality of planet gears 127 such that each planet gear 127 meshingly engages both the outer, ring gear member 124 and the inner, sun gear member 122 of the first planetary gear set 120 .
[0104] The planetary gear set 130 also has an outer gear member 134 , often also designated as the ring gear, that circumscribes an inner gear member 132 , also often designated as the sun gear. A plurality of planet gears 137 are also rotatably mounted in a carrier member 136 such that each planet gear member 137 simultaneously, and meshingly, engages both the outer, ring gear member 134 and the inner, sun gear member 132 of the planetary gear set 130 .
[0105] The planetary gear set 140 also has an outer gear member 144 , often also designated as the ring gear, that circumscribes an inner gear member 142 , also often designated as the sun gear. A plurality of planet gears 147 are also rotatably mounted in a carrier member 146 such that each planet gear member 147 simultaneously, and meshingly, engages both the outer, ring gear member 144 and the inner, sun gear member 142 of the planetary gear set 140 .
[0106] The input member 17 is connected with the sun gear member 142 of the planetary gear set 140 . The transmission output member 19 is connected with the carrier member 136 of the planetary gear set 130 . An interconnecting member 170 continuously connects the carrier member 146 of the planetary gear set 140 with the transmission housing 160 .
[0107] The transmission 114 also incorporates first and second motor/generators 180 and 182 , respectively. The stator of the first motor/generator 180 is secured to the transmission housing 160 . The rotor of the first motor/generator 180 is secured to the sun gear member 122 of the planetary gear set 120 .
[0108] The stator of the second motor/generator 182 is also secured to the transmission housing 160 . The rotor of the second motor/generator 182 is secured to the sun gear member 132 of the planetary gear set 130 .
[0109] A first torque transmitting device, such as clutch 150 , selectively connects the sun gear member 122 of the planetary gear set 120 with the ring gear member 134 of the planetary gear set 130 . A second torque transmitting device, such as clutch 152 , selectively connects the ring gear member 124 of the planetary gear set 120 with the sun gear member 132 of the planetary gear set 130 . A third torque transmitting device, such as clutch 154 , selectively connects the sun gear member 122 of the planetary gear set 120 with the sun gear member 132 of the planetary gear set 130 . A fourth torque transmitting device, such as clutch 155 , selectively connects the sun gear member 142 of the planetary gear set 140 with the carrier member 126 of the planetary gear set 120 . A fifth torque transmitting device, such as clutch 156 , selectively connects the ring gear member 144 of the planetary gear set 140 with the carrier member 126 of the planetary gear set 120 . A sixth torque transmitting device, such as brake 157 , selectively connects the ring gear member 134 of the planetary gear set 130 with the transmission housing 160 . The first, second, third, fourth, fifth and sixth torque transmitting devices 150 , 152 , 154 , 155 , 156 and 157 are employed to assist in the selection of the operational modes of the hybrid transmission 114 .
[0110] Returning now to the description of the power sources, it should be apparent from the foregoing description, and with particular reference to FIG. 2 a , that the transmission 114 selectively receives power from the engine 12 . The hybrid transmission also exchanges power with an electric power source 186 , which is operably connected to a controller 188 . The electric power source 186 may be one or more batteries. Other electric power sources, such as fuel cells, that have the ability to provide, or store, and dispense electric power may be used in place of batteries without altering the concepts of the present invention.
[0111] As described previously, each embodiment has fourteen to eighteen functional requirements (corresponding with the 14 to 18 rows of each operating mode table shown in the Figures) which may be grouped into six operating modes. The first operating mode is the “battery reverse mode” which corresponds with the first row (Batt Rev) of the operating mode table of FIG. 2 b . In this mode, the engine is off and the transmission element connected to the engine is effectively allowed to freewheel, subject to engine inertia torque. The EVT is driven by one of the motor/generators using energy from the battery, causing the vehicle to move in reverse. The other motor/generator may or may not rotate in this mode. As shown in FIG. 2 b , in this mode brake 157 is engaged, the generator 180 has zero torque, the motor 182 has a torque of −1.00 units and an output torque of −2.88 is achieved, by way of example.
[0112] The second operating mode is the “EVT reverse mode” (or mechanical reverse mode) which corresponds with the second row (EVT Rev) of the operating mode table of FIG. 2 b . In this mode, the EVT is driven by the engine and by one of the motor/generators. The other motor/generator operates in generator mode and transfers 100% of the generated energy back to the driving motor. The net effect is to drive the vehicle in reverse. In this mode, the clutches 152 , 155 and brake 157 are engaged, the generator 180 has a torque of −0.35 units, the motor 182 has a torque of −3.55 units, and an output torque of −8.33 is achieved, corresponding to an input torque of 1 unit.
[0113] The third operating mode includes the “reverse and forward launch modes” corresponding with the third and fourth rows (TC Rev and TC For) of each operating mode table, such as that of FIG. 2 b . In this mode, the EVT is driven by the engine and one of the motor/generators. A selectable fraction of the energy generated in the generator unit is stored in the battery, with the remaining energy being transferred to the motor. In TC Rev, the clutches 152 , 155 and brake 157 are engaged, the motor/generator 180 acts as a generator with −0.35 units of torque, the motor/generator 182 acts as a motor with −3.09 units of torque, and a torque ratio of −7.00 is achieved. In TC For, the clutches 152 , 155 and brake 157 are engaged, the motor/generator 180 acts as a generator with −0.35 units of torque, the motor/generator 182 acts as a motor with 0.98 units of torque, and a torque ratio of 4.69 is achieved. For these torque ratios, approximately 99% of the generator energy is stored in the battery.
[0114] The fourth operating mode includes the “Range 1 . 1 , Range 1 . 2 , Range 1 . 3 , Range 1 . 4 , Range 2 . 1 , Range 2 . 2 , Range 2 . 3 and Range 2 . 4 ” modes corresponding with rows 5 - 12 of the operating mode table of FIG. 2 b . In this mode, the EVT is driven by the engine as well as one of the motor/generators operating as a motor. The other motor/generator operates as a generator and transfers 100% of the generated energy back to the motor. The operating points represented by Range 1 . 1 , 1 . 2 . . . , etc. are discrete points in the continuum of forward speed ratios provided by the EVT. For example in FIG. 2 b , a range of ratios from 4.69 to 1.86 is achieved with the clutches 152 , 155 and brake 157 engaged, a range of ratios from 1.36 to 0.54 is achieved with the clutches 150 , 152 and 155 engaged.
[0115] The fifth operating mode includes the “fixed forward ratio” modes (F 1 , F 2 , F 3 ) corresponding with rows 16 - 18 of the operating mode table of FIG. 2 b . In this mode the transmission operates like a conventional automatic transmission, with four torque transmitting devices engaged to create a discrete transmission ratio. In fixed ratio F 1 the clutches 152 , 154 , 155 and brake 157 are engaged to achieve a fixed ratio of 2.82. In fixed ratio F 2 , the clutches 150 , 152 , 155 and brake 157 are engaged to achieve a fixed ratio of 1.74. In fixed ratio F 3 , the clutches 150 , 152 , 154 and 155 are engaged to achieve a fixed ratio of 1.00.
[0116] The sixth operating mode includes the “mechanical or fixed reverse ratio” modes (R 1 , R 2 , R 3 ) corresponding with rows 13 - 15 of the operating mode table of FIG. 2 b . In this mode the transmission operates lie a convention automatic transmission, with four torque transmitting devices engaged to create a discrete reverse transmission ratio. In fixed reverse ratio R 1 , the clutches 152 , 154 , 156 and brake 157 are engaged to achieve a fixed reverse ratio of −5.30. In fixed reverse ratio R 2 , the clutches 150 , 152 , 156 and brake 157 are engaged to achieve a fixed reverse ratio of −3.27. In fixed reverse ratio R 3 , the clutches 150 , 152 , 154 and 156 are engaged to achieve a fixed reverse ratio of −1.88.
[0117] As set forth above, the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 2 b . FIG. 2 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 2 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 120 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 130 ; and the N R3 /N S3 value is the tooth ratio of the planetary gear set 140 . Also, the chart of FIG. 2 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.63, and the ratio spread is 2.82.
Description of a Third Exemplary Embodiment
[0118] With reference to FIG. 3 a , a powertrain 210 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 214 . The transmission 214 is designed to receive at least a portion of its driving power from the engine 12 . As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 214 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission 214 .
[0119] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member is operatively connected to a planetary gear set in the transmission 214 . An output member 19 of the transmission 214 is connected to a final drive 16 .
[0120] The transmission 214 utilizes four differential gear sets, preferably in the nature of planetary gear sets 220 , 230 , 240 and 290 . The planetary gear set 220 employs an outer gear member 224 , typically designated as the ring gear. The ring gear member 224 circumscribes an inner gear member 222 , typically designated as the sun gear. A carrier member 226 rotatably supports a plurality of planet gears 227 such that each planet gear 227 meshingly engages both the outer, ring gear member 224 and the inner, sun gear member 222 of the first planetary gear set 220 .
[0121] The planetary gear set 230 also has an outer ring gear member 234 that circumscribes an inner sun gear member 232 . A plurality of planet gears 237 are also rotatably mounted in a carrier member 236 such that each planet gear 237 simultaneously, and meshingly, engages both the outer ring gear member 234 and the inner sun gear member 232 of the planetary gear set 230 .
[0122] The planetary gear set 240 also has an outer ring gear member 244 that circumscribes an inner sun gear member 242 . A plurality of planet gears 247 are rotatably mounted in a carrier member 246 such that each planet gear member 247 simultaneously and meshingly engages both the outer, ring gear member 244 and the inner, sun gear member 242 of the planetary gear set 240 .
[0123] The planetay gear set 290 has an inner sun gear member 292 . A plurality of planet gears 297 , 298 are rotatably mounted in a carrier member 296 such that each planet gear member 297 engages the sun gear member 292 and the respective planet gear member 298 . The planet gear members 298 are integral with the planet gear members 237 (i.e., they are formed by long pinions).
[0124] The transmission input member 17 is connected to the sun gear member 242 . The transmission output member 19 is connected to the ring gear member 234 . A first interconnecting member 270 continuously connects the ring gear member 224 with the sun gear member 232 . The carrier member 296 is continuously connected with (integral with) the carrier member 236 . This integral connection is referred to herein as the second interconnecting member 272 . The integral connection of the long pinion gears 237 and 298 is referred to herein as the third interconnecting member 274 .
[0125] The transmission 214 also incorporates first and second motor/generators 280 and 282 , respectively. The stator of the first motor/generator 280 is secured to the transmission housing 260 . The rotor of the first motor/generator 280 is secured to the sun gear member 222 . The stator of the second motor/generator 282 is also secured to the transmission housing 260 . The rotor of the second motor/generator 282 is secured to the ring gear member 224 .
[0126] A first torque transmitting device, such as clutch 250 , selectively connects the ring gear member 234 with the carrier member 236 . A second torque transmitting device, such as clutch 252 , selectively connects the carrier member 236 with the carrier member 226 . A third torque transmitting device, such as clutch 254 , selectively connects the sun gear member 242 with the carrier member 226 . A fourth torque transmitting device, such as clutch 255 , selectively connects the ring gear member 244 with the carrier member 226 . A fifth torque transmitting device, such as brake 257 , selectively connects the sun gear member 292 with the transmission housing 260 . A sixth torque transmitting device, such as brake 258 , selectively connects the carrier member 246 with the transmission housing 260 . The first, second, third, fourth, fifth and sixth torque transmitting devices 250 , 252 , 254 , 255 , 257 and 258 are employed to assist in the selection of the operational modes of the hybrid transmission 214 .
[0127] The hybird transmission 214 receives power from the engine 12 , and also from electric power source 286 , which is operably connected to a controller 288 .
[0128] The operating mode table of FIG. 3 b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the six operating modes of the transmission 214 . These modes include the “battery reverse mode” (Batt Rev), “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “range 1 . 1 , 1 . 2 , 1 . 3 . . . modes”, “fixed forward ratio modes” (F 1 , F 2 ), and mechanical “reverse fixed ratio modes” (R 1 , R 2 ), as described previously.
[0129] As set forth above the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 3 b . FIG. 3 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 3 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 220 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 230 ; the N R3 /N S3 value is the tooth ratio of the planetary gear set 240 ; and the N R4 /N S4 value is the tooth ratio of the planetary gear set 290 . Also, the chart of FIG. 3 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between the first and second fixed forward torque ratios is 1.69.
Description of a Fourth Exemplary Embodiment
[0130] With reference to FIG. 4 a , a powertrain 310 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 314 . The transmission 314 is designed to receive at least a portion of its driving power from the engine 12 .
[0131] As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 314 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0132] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 314 . An output member 19 of the transmission 314 is connected to a final drive 16 .
[0133] The transmission 314 utilizes four planetary gear sets 320 , 330 , 340 and 390 . The planetary gear set 320 employs an outer ring gear member 324 which circumscribes an inner sun gear member 322 . A carrier member 326 rotatably supports a plurality of planet gears 327 such that each planet gear 327 meshingly engages both the outer ring gear member 324 and the inner sun gear member 322 of the first planetary gear set 320 .
[0134] The planetary gear set 330 also has an outer ring gear member 334 that circumscribes an inner sun gear member 332 . A plurality of planet gears 337 are also rotatably mounted in a carrier member 336 such that each planet gear member 337 simultaneously, and meshingly engages both the outer, ring gear member 334 and the inner, sun gear member 332 of the planetary gear set 330 .
[0135] The planetary gear set 340 also has an outer ring gear member 344 that circumscribes an inner sun gear member 342 . A plurality of planet gears 347 , 348 are also rotatably mounted in a carrier member 346 such that each planet gear member 347 engages the inner sun gear member 342 and each planet gear 348 simultaneously, and meshingly engages both the outer ring gear member 344 and the respective planet gear 347 of the planetary gear set 340 .
[0136] The planetary gear set 390 has an inner sun gear member 392 . A plurality of planet gears 397 , 398 are rotatably mounted in a carrier member 396 such that each planet gear member 397 engages the sun gear member 392 and the respective planet gear member 398 . The planet gear members 398 are integral with the planet gear members 337 (i.e., they are formed by long pinions).
[0137] The transmission input member 17 is connected with the sun gear member 342 . The transmission output member 19 is connected with the ring gear member 334 . A first interconnecting member 370 continuously connects the carrier member 346 with the transmission housing 360 . The carrier member 396 is continuously connected with (integral with) the carrier member 336 . This integral connection is referred to herein as the second interconnecting member 372 . The integral connection of the long pinion gears 337 and 398 is referred to herein as the third interconnecting member 374 .
[0138] The transmission 314 incorporates first and second motor/generators 380 and 382 , respectively. The stator of the first motor/generator 380 is secured to the transmission housing 360 . The rotor of the first motor/generator 380 is secured to the sun gear member 322 . The stator of the second motor/generator 382 is also secured to the transmission housing 360 . The rotor of the second motor/generator 382 is secured to the sun gear member 332 .
[0139] A first torque transmitting device, such as clutch 350 , selectively connects the ring gear member 334 with the carrier member 336 . A second torque transmitting device, such as clutch 352 , selectively connects the carrier member 336 with the carrier member 326 . A third torque transmitting device, such as clutch 354 , selectively connects the sun gear member 342 with the carrier member 326 . A fourth torque transmitting device, such as clutch 355 , selectively connects the ring gear member 344 with the carrier member 326 . A fifth torque transmitting device, such as clutch 356 , selectively connects the ring gear member 324 with the sun gear member 332 . A sixth torque transmitting device, such as brake 357 , selectively connects the sun gear member 392 with the transmission housing 360 . The first, second, third, fourth, fifth and sixth torque transmitting devices 350 , 352 , 354 , 355 , 356 and 357 are employed to assist in the selection of the operational modes of the transmission 314 .
[0140] The hybrid transmission 314 receives power from the engine 12 , and also exchanges power with an electric power source 386 , which is operably connected to a controller 388 .
[0141] The operating mode table of FIG. 4 b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the six operating modes of the transmission 314 . These modes include the “battery reverse mode” (Batt Rev), the “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “continuously variable transmission range modes” (Range 1 . 1 , 1 . 2 , 1 . 3 . . . ) mechanical “fixed forward ratio modes” (F 1 , F 2 ) and mechanical “fixed reverse ratio modes” (R 1 , R 2 ) as described previously.
[0142] As set forth above, the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 4 b . FIG. 4 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 4 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 320 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 330 ; the N R3 /N S3 value is the tooth ratio of the planetary gear set 340 ; and the N R4 /N S4 value is the tooth ratio of the planetary gear set 390 . Also, the chart of FIG. 4 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.69.
Description of a Fifth Exemplary Embodiment
[0143] With reference to FIG. 5 a , a powertrain 410 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 414 . The transmission 414 is designed to receive at least a portion of its driving power from the engine 12 .
[0144] As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 414 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0145] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 414 . An output member 19 of the transmission 414 is connected to a final drive 16 .
[0146] The transmission 414 utilizes three planetary gear sets 420 , 430 and 440 . The planetary gear set 420 employs an outer ring gear member 424 which circumscribes an inner sun gear member 422 . A carrier member 426 rotatably supports a plurality of planet gears 427 such that each planet gear 427 meshingly engages both the outer ring gear member 424 and the inner sun gear member 422 of the first planetary gear set 420 .
[0147] The planetary gear set 430 also has an outer ring gear member 434 that circumscribes an inner sun gear member 432 . A plurality of planet gears 437 are also rotatably mounted in a carrier member 436 such that each planet gear member 437 simultaneously, and meshingly engages both the outer, ring gear member 434 and the inner, sun gear member 432 of the planetary gear set 430 .
[0148] The planetary gear set 440 also has an outer ring gear member 444 that circumscribes an inner sun gear member 442 . A plurality of planet gears 447 are also rotatably mounted in a carrier member 446 such that each planet gear member 447 simultaneously, and meshingly engages both the outer, ring gear member 444 and the inner, sun gear member 442 of the planetary gear set 440 .
[0149] The transmission input member 17 is continuously connected with the carrier member 426 . The transmission output member 19 is continuously connected with the carrier member 436 . An interconnecting member 470 continuously connects the carrier member 446 with the sun gear member 422 .
[0150] The transmission 414 also incorporates first and second motor/generators 480 and 482 , respectively. The stator of the first motor/generator 480 is secured to the transmission housing 460 . The rotor of the first motor/generator 480 is secured to the sun gear member 442 . The stator of the second motor/generator 482 is also secured to the transmission housing 460 . The rotor of the second motor/generator 482 is secured to the sun gear member 432 .
[0151] A first torque transmitting device, such as clutch 450 , selectively connects the sun gear member 422 with the ring gear member 434 . A second torque transmitting device, such as clutch 452 , selectively connects the ring gear member 424 with the sun gear member 432 . A third torque transmitting device, such as clutch 454 , selectively connects the sun gear member 422 with the sun gear member 432 . A fourth torque transmitting device, such as clutch 455 , selectively connects the carrier member 446 with the sun gear member 442 . A fifth torque transmitting device, such as brake 457 , selectively connects the ring gear member 434 with the transmission housing 460 . A sixth torque transmitting device, such as brake 458 , selectively connects the ring gear member 444 with the transmission housing 460 . The first, second, third, fourth, fifth and sixth torque transmitting devices 450 , 452 , 454 , 455 , 457 and 458 are employed to assist in the selection of the operational modes of the transmission 414 . The hybrid transmission 414 receives power from the engine 12 and also from an electric power source 486 , which is operably connected to a controller 488 .
[0152] The operating mode table of FIG. 5 b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the five operating modes of the transmission 414 . These modes include the “battery reverse mode” (Batt Rev), the “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “continuously variable transmission range modes” (Range 1 . 1 , 1 . 2 , 2 . 1 . . . ) and “fixed forward ratio modes” (F 1 , F 2 , F 3 ) as described previously.
[0153] As set forth above, the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 5 b . FIG. 5 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 5 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 420 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 430 ; and the N R3 /N S3 value is the tooth ratio of the planetary gear set 440 . Also, the chart of FIG. 5 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.63, and the ratio spread is 2.82.
Description of a Sixth Exemplary Embodiment
[0154] With reference to FIG. 6 a , a powertrain 510 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 514 . The transmission 514 is designed to receive at least a portion of its driving power from the engine 12 .
[0155] As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 514 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0156] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 514 . An output member 19 of the transmission 514 is connected to a final drive 16 .
[0157] The transmission 514 utilizes three planetary gear sets 520 , 530 and 540 . The planetary gear set 520 employs an outer ring gear member 524 which circumscribes an inner sun gear member 522 . A carrier member 526 rotatably supports a plurality of planet gears 527 such that each planet gear 527 meshingly engages both the outer ring gear member 524 and the inner sun gear member 522 of the first planetary gear set 520 .
[0158] The planetary gear set 530 also has an outer ring gear member 534 that circumscribes an inner sun gear member 532 . A plurality of planet gears 537 are also rotatably mounted in a carrier member 536 such that each planet gear member 537 simultaneously, and meshingly engages both the outer, ring gear member 534 and the inner, sun gear member 532 of the planetary gear set 530 .
[0159] The planetary gear set 540 also has an outer ring gear member 544 that circumscribes an inner sun gear member 542 . A plurality of planet gears 547 are also rotatably mounted in a carrier member 546 such that each planet gear member 547 simultaneously, and meshingly engages both the inner, sun gear member 542 and the outer, ring gear member 544 of the planetary gear set 540 .
[0160] The transmission input member 17 is continuously connected with the carrier member 526 . The transmission output member 19 is continuously connected with the ring gear member 544 . A first interconnecting member 570 continuously connects the carrier member 536 with the sun gear member 542 .
[0161] The transmission 514 also incorporates first and second motor/generators 580 and 582 , respectively. The stator of the first motor/generator 580 is secured to the transmission housing 560 . The rotor of the first motor/generator 580 is secured to the sun gear member 522 . The stator of the second motor/generator 582 is also secured to the transmission housing 560 . The rotor of the second motor/generator 582 is secured to the sun gear member 532 .
[0162] A first torque transmitting device, such as clutch 550 , selectively connects the sun gear member 522 with the ring gear member 534 . A second torque transmitting device, such as clutch 552 , selectively connects the ring gear member 524 with the sun gear member 532 . A third torque transmitting device, such as clutch 554 , selectively connects the sun gear member 522 with the sun gear member 532 . A fourth torque transmitting device, such as clutch 555 , selectively connects the sun gear member 542 with the carrier member 546 . A fifth torque transmitting device, such as brake 557 , selectively connects the ring gear member 534 with the transmission housing 560 . A sixth torque transmitting device, such as brake 558 , selectively connects the carrier member 546 with the transmission housing 560 . The first, second, third, fourth, fifth and sixth torque transmitting devices 550 , 552 , 554 , 555 , 557 and 558 are employed to assist in the selection of the operational modes of the hybrid transmission 514 .
[0163] The hybrid transmission 514 receives power from the engine 12 , and also exchanges power with an electric power source 586 , which is operably connected to a controller 588 .
[0164] The operating mode table of FIG. 6 b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the six operating modes of the transmission 514 . These modes include the “battery reverse mode” (Batt Rev), the “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “continuously variable transmission range modes” (Range 1 . 1 , 1 . 2 , 1 . 3 . . . ), “fixed forward modes” (F 1 , F 2 , F 3 ) and mechanical “fixed reverse ratio modes” (R 1 , R 2 , R 3 ) as described previously.
[0165] As set forth above, the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 6 b . FIG. 6 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 6 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 520 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 530 ; and the N R3 /N S3 value is the tooth ratio of the planetary gear set 540 . Also, the chart of FIG. 6 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.63, and the ratio spread is 2.82.
Description of a Seventh Exemplary Embodiment
[0166] With reference to FIG. 7 a , a powertrain 610 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designate generally by the numeral 614 . The transmission 614 is designed to receive at least a portion of its driving power from the engine 12 .
[0167] As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 614 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0168] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 614 . An output member 19 of the transmission 614 is connected to a final drive 16 .
[0169] The transmission 614 utilizes three planetary gear sets 620 , 630 and 640 . The planetary gear set 620 employs an outer ring gear member 624 which circumscribes an inner sun gear member 622 . A carrier member 626 rotatably supports a plurality of planet gears 627 such that each planet gear 627 simultaneously, and meshingly engages both the inner sun gear member 622 and the outer ring gear member 624 of the planetary gear set 620 .
[0170] The planetary gear set 630 has an outer ring gear member 634 that circumscribes an inner sun gear member 632 . A plurality of planet gears 637 are rotatably mounted in a carrier member 636 such that each planet gear member 637 simultaneously, and meshingly engages both the outer, ring gear member 634 and the inner, sun gear member 632 of the planetary gear set 630 .
[0171] The planetary gear set 640 also has an outer ring gear member 644 that circumscribes an inner sun gear member 642 . A plurality of planet gears 647 are also rotatably mounted in a carrier member 646 such that each planet gear member 647 simultaneously, and meshingly engages both the outer, ring gear member 644 and the inner, sun gear member 642 of the planetary gear set 640 .
[0172] The transmission input member 17 is continuously connected with the carrier member 626 . The transmission output member 19 is continuously connected with the ring gear member 644 . An interconnecting member 670 continuously connects the carrier member 636 with the ring gear member 644 .
[0173] The transmission 614 also incorporates first and second motor/generators 680 and 682 , respectively. The stator of the first motor/generator 680 is secured to the transmission housing 660 . The rotor of the first motor/generator 680 is secured to the sun gear member 622 . The stator of the second motor/generator 682 is also secured to the transmission housing 660 . The rotor of the second motor/generator 682 is secured to the sun gear member 642 .
[0174] A first torque transmitting device, such as clutch 650 , selectively connects the ring gear member 644 with the carrier member 646 . A second torque transmitting device, such as clutch 652 , selectively connects the carrier member 646 with the carrier member 626 . A third torque transmitting device, such as clutch 654 , selectively connects the sun gear member 632 with the sun gear member 642 . A fourth torque transmitting device, such as clutch 655 , selectively connects the ring gear member 624 with the sun gear member 642 . A fifth torque transmitting device, such as brake 657 , selectively connects the ring gear member 634 with the transmission housing 660 . The first, second, third, fourth and fifth torque transmitting devices 650 , 652 , 654 , 655 and 657 are employed to assist in the selection of the operational modes of the transmission 614 . The hybrid transmission 614 receives power from the engine 12 and also from an electric power source 686 , which is operably connected to a controller 688 .
[0175] The operating mode table of FIG. 7 b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the five operating modes of the transmission 614 . These modes include the “battery reverse mode” (Batt Rev), the “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “continuously variable transmission range modes” (Range 1 . 1 , 1 . 2 , 1 . 3 . . . ) and “fixed ratio modes” (F 1 , F 2 ,) as described previously.
[0176] As set forth above, the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 7 b . FIG. 7 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 7 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 620 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 630 ; and the N R3 /N S3 value is the tooth ratio of the planetary gear set 640 . Also, the chart of FIG. 7 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.69.
Description of an Eighth Exemplary Embodiment
[0177] With reference to FIG. 8 a , a powertrain 710 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 714 . The transmission 714 is designed to receive at least a portion of its driving power from the engine 12 .
[0178] As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 714 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0179] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 714 . An output member 19 of the transmission 714 is connected to a final drive 16 .
[0180] The transmission 714 utilizes four planetary gear sets 720 , 730 , 740 and 790 . The planetary gear set 720 employs an outer ring gear member 724 which circumscribes an inner sun gear member 722 . A carrier member 726 rotatably supports a plurality of planet gears 727 such that each planet gear 727 meshingly engages both the outer ring gear member 724 and the inner sun gear member 722 of the first planetary gear set 720 .
[0181] The planetary gear set 730 also has an outer ring gear member 734 that circumscribes an inner sun gear member 732 . A plurality of planet gears 737 are also rotatably mounted in a carrier member 736 such that each planet gear member 737 simultaneously, and meshingly engages both the outer, ring gear member 734 and the inner, sun gear member 732 of the planetary gear set 730 .
[0182] The planetary gear set 740 also has an outer ring gear member 744 that circumscribes an inner sun gear member 742 . A plurality of planet gears 747 are also rotatably mounted in a carrier member 746 such that each planet gear member 747 simultaneously, and meshingly engages both the inner sun gear member 742 and the outer ring gear member 744 .
[0183] The planetary gear set 790 has an inner sun gear member 792 . A plurality of planet gears 797 , 798 are rotatably mounted in a carrier member 796 such that each planet gear member 797 engages the sun gear member 792 and the respective planet gear member 798 . The planet gear members 798 are integral with the planet gear members 737 (i.e., they are formed by long pinions).
[0184] The transmission input member 17 is connected with the carrier member 726 . The transmission output member 19 is connected with the ring gear member 744 . A first interconnecting member 770 continuously connects the ring gear member 734 with the sun gear member 742 . The carrier member 796 is continuously connected with (integral with) the carrier member 736 . This integral connection is referred to herein as the second interconnecting member 772 . The integral connection of the long pinion gears 737 and 798 is referred to herein as the third interconnecting member 774 .
[0185] The transmission 714 also incorporates first and second motor/generators 780 and 782 , respectively. The stator of the first motor/generator 780 is secured to the transmission housing 760 . The rotor of the first motor/generator 780 is secured to the sun gear member 722 . The stator of the second motor/generator 782 is also secured to the transmission housing 760 . The rotor of the second motor/generator 782 is secured to the sun gear member 732 .
[0186] A first torque transmitting device, such as clutch 750 , selectively connects the ring gear member 734 with the carrier member 736 . A second torque transmitting device, such as clutch 752 , selectively connects the carrier member 736 with the carrier member 726 . A third torque transmitting device, such as clutch 754 , selectively connects the carrier member 746 with the sun gear member 742 . A fourth torque transmitting device, such as clutch 755 , selectively connects the ring gear member 724 with the sun gear member 732 . A fifth torque transmitting device, such as brake 757 , selectively connects the sun gear member 792 with the transmission housing 760 . A sixth torque transmitting device, such as brake 758 , selectively connects the carrier member 746 with the transmission housing 760 . The first, second, third, fourth, fifth and sixth torque transmitting devices 750 , 752 , 754 , 755 , 757 and 758 are employed to assist in the selection of the operational modes of the transmission 314 .
[0187] The hybrid transmission 714 receives power from the engine 12 , and also exchanges power with an electric power source 786 , which is operably connected to a controller 788 .
[0188] The operating mode table of FIG. 8 b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the six operating modes of the transmission 714 . These modes include the “battery reverse mode” (Batt Rev), the “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “continuously variable transmission range modes” (Range 1 . 1 , 1 . 2 , 1 . 3 . . . ), “fixed forward modes” (F 1 , F 2 ) and mechanical “fixed reverse ratio modes” (R 1 , R 2 ) as described previously.
[0189] As set forth above, the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 8 b . FIG. 8 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 8 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 720 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 730 ; the N R3 /N S3 value is the tooth ratio of the planetary gear set 740 ; and the N R4 /N S4 value is the tooth ratio of the planetary gear set 790 . Also, the chart of FIG. 8 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.69.
Description of a Ninth Exemplary Embodiment
[0190] With reference to FIG. 9 a , a powertrain 810 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 814 . The transmission 814 is designed to receive at least a portion of its driving power from the engine 12 .
[0191] As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 814 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0192] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 814 . An output member 19 of the transmission 814 is connected to a final drive 16 .
[0193] The transmission 814 utilizes four planetary gear sets 820 , 830 , 840 and 890 . The planetary gear set 820 employs an outer ring gear member 824 which circumscribes an inner sun gear member 822 . A carrier member 826 rotatably supports a plurality of planet gears 827 such that each planet gear 827 meshingly engages both the outer ring gear member 824 and the inner sun gear member 822 of the first planetary gear set 820 .
[0194] The planetary gear set 830 also has an outer ring gear member 834 that circumscribes an inner sun gear member 832 . A plurality of planet gears 837 are also rotatably mounted in a carrier member 836 such that each planet gear member 837 simultaneously, and meshingly engages both the outer, ring gear member 834 and the inner, sun gear member 832 of the planetary gear set 830 .
[0195] The planetary gear set 840 also has an outer ring gear member 844 that circumscribes an inner sun gear member 842 . A plurality of planet gears 847 , 848 are also rotatably mounted in a carrier member 846 such that each planet gear member 847 engages the inner sun gear member 842 and each planet gear member 848 simultaneously, and meshingly engages both the outer ring gear member 844 and the respective planet gear member 847 of the planetary gear set 840 .
[0196] The planetary gear set 890 has an inner sun gear member 892 . A plurality of planet gears 897 , 898 are rotatably mounted in a carrier member 896 such that each planet gear member 897 engages the sun gear member 892 and the respective planet gear member 898 . The planet gear members 898 are integral with the planet gear members 837 (i.e., they are formed by long pinions).
[0197] The transmission input member 17 is connected with the carrier member 826 . The transmission output member 19 is connected with the ring gear member 834 . A first interconnecting member 870 continuously connects the ring gear member 844 with the sun gear member 832 . The carrier member 896 is continuously connected with (integral with) the carrier member 836 . This integral connection is referred to herein as the second interconnecting member 872 . The integral connection of the long pinion gears 837 and 898 is referred to herein as the third interconnecting member 874 .
[0198] The transmission 814 also incorporates first and second motor/generators 880 and 882 , respectively. The stator of the first motor/generator 880 is secured to the transmission housing 860 . The rotor of the first motor/generator 880 is secured to the sun gear member 822 . The stator of the second motor/generator 882 is also secured to the transmission housing 860 . The rotor of the second motor/generator 882 is secured to the sun gear member 842 .
[0199] A first torque transmitting device, such as clutch 850 , selectively connects the ring gear member 834 with the carrier member 836 . A second torque transmitting device, such as clutch 852 , selectively connects the carrier member 836 with the carrier member 826 . A third torque transmitting device, such as clutch 854 , selectively connects the carrier member 846 with the sun gear member 842 . A fourth torque transmitting device, such as clutch 855 , selectively connects the ring gear member 824 with the sun gear member 832 . A fifth torque transmitting device, such as brake 857 , selectively connects the sun gear member 892 with the transmission housing 860 . A sixth torque transmitting device, such as brake 858 , selectively connects the carrier member 846 with the transmission housing 860 . The first, second, third, fourth, fifth and sixth torque transmitting devices 850 , 852 , 854 , 855 , 857 and 858 are employed to assist in the selection of the operational modes of the transmission 814 .
[0200] The hybrid transmission 814 receives power from the engine 12 , and also exchanges power with an electric power source 886 , which is operably connected to a controller 888 .
[0201] The operating mode table of FIG. 9 b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the five operating modes of the transmission 814 . These modes include the “battery reverse mode” (Batt Rev), the “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “continuously variable transmission range modes” (Range 1 . 1 , 1 . 2 , 1 . 3 . . . ) and “fixed forward ratio modes” (F 1 , F 2 ) as described previously.
[0202] As set forth above, the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 9 b . FIG. 9 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 9 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 820 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 830 ; the N R3 /N S3 value is the tooth ratio of the planetary gear set 840 ; and the N R4 /N S4 value is the tooth ratio of the planetary gear set 890 . Also, the chart of FIG. 9 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.69.
Description of a Tenth Exemplary Embodiment
[0203] With reference to FIG. 10 a , a powertrain 910 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 914 . The transmission 914 is designed to receive at least a portion of its driving power from the engine 12 .
[0204] As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 914 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0205] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 914 . An output member 19 of the transmission 914 is connected to a final drive 16 .
[0206] The transmission 914 utilizes three planetary gear sets 920 , 930 and 940 . The planetary gear set 920 employs an outer ring gear member 924 which circumscribes an inner sun gear member 922 . A carrier member 926 rotatably supports a plurality of planet gears 927 such that each planet gear 927 simultaneously, and meshingly engages both the inner sun gear member 922 and the outer ring gear member 924 of the planetary gear set 920 .
[0207] The planetary gear set 930 has an outer ring gear member 934 that circumscribes an inner sun gear member 932 . A plurality of planet gears 937 are rotatably mounted in a carrier member 936 such that each planet gear member 937 simultaneously, and meshingly engages both the outer, ring gear member 934 and the inner, sun gear member 932 of the planetary gear set 930 .
[0208] The planetary gear set 940 also has an outer ring gear member 944 that circumscribes an inner sun gear member 942 . A plurality of planet gears 947 are also rotatably mounted in a carrier member 946 such that each planet gear member 947 simultaneously, and meshingly engages both the outer, ring gear member 944 and the inner, sun gear member 942 of the planetary gear set 940 .
[0209] The transmission input member 17 is continuously connected with the sun gear member 942 . The transmission output member 19 is continuously connected with the carrier member 936 . An interconnecting member 970 continuously connects the ring gear member 944 with the transmission housing 960 .
[0210] The transmission 914 also incorporates first and second motor/generators 980 and 982 , respectively. The stator of the first motor/generator 980 is secured to the transmission housing 960 . The rotor of the first motor/generator 980 is secured to the sun gear member 922 . The stator of the second motor/generator 982 is also secured to the transmission housing 960 . The rotor of the second motor/generator 982 is secured to the sun gear member 932 .
[0211] A first torque transmitting device, such as clutch 950 , selectively connects the sun gear member 922 with the ring gear member 934 . A second torque transmitting device, such as clutch 952 , selectively connects the ring gear member 924 with the sun gear member 932 . A third torque transmitting device, such as clutch 954 , selectively connects the sun gear member 922 with the sun gear member 932 . A fourth torque transmitting device, such as clutch 955 , selectively connects the sun gear member 942 with the carrier member 926 . A fifth torque transmitting device, such as clutch 956 , selectively connects the carrier member 946 with the carrier member 926 . A sixth torque transmitting device, such as brake 957 , selectively connects the ring gear member 934 with the transmission housing 960 . The first, second, third, fourth, fifth and sixth torque transmitting devices 950 , 952 , 954 , 955 , 956 and 957 are employed to assist in the selection of the operational modes of the transmission 914 .
[0212] The hybrid transmission 914 receives power from the engine 12 and also from an electric power source 986 , which is operably connected to a controller 988 .
[0213] The operating mode table of FIG. 10 b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the five operating modes of the transmission 914 . These modes include the “battery reverse mode” (Batt Rev), the “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “continuously variable transmission range modes” (Range 1 . 1 , 1 . 2 , 2 . 1 . . . ) and “fixed forward ratio modes” (F 1 , F 2 , F 3 , F 4 , F 5 , F 6 ) as described previously.
[0214] As set forth above, the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 10 b . FIG. 10 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 10 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 920 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 930 ; and the N R3 /N S3 value is the tooth ratio of the planetary gear set 940 . Also, the chart of FIG. 10 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.62, and a ratio spread of 8.29.
Description of an Eleventh Exemplary Embodiment
[0215] With reference to FIG. 11 a , a powertrain 1010 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 1014 . The transmission 1014 is designed to receive at least a portion of its driving power from the engine 12 .
[0216] As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 1014 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0217] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 1014 . An output member 19 of the transmission 1014 is connected to a final drive 16 .
[0218] The transmission 1014 utilizes four planetary gear sets 1020 , 1030 , 1040 and 1090 . The planetary gear set 1020 employs an outer ring gear member 1024 which circumscribes an inner sun gear member 1022 . A carrier member 1026 rotatably supports a plurality of planet gears 1027 such that each planet gear 1027 meshingly engages both the outer ring gear member 1024 and the inner sun gear member 1022 of the first planetary gear set 1020 .
[0219] The planetary gear set 1030 also has an outer ring gear member 1034 that circumscribes an inner sun gear member 1032 . A plurality of planet gears 1037 are also rotatably mounted in a carrier member 1036 such that each planet gear member 1037 simultaneously, and meshingly engages both the outer, ring gear member 1034 and the inner, sun gear member 1032 of the planetary gear set 1030 .
[0220] The planetary gear set 1040 also has an outer ring gear member 1044 that circumscribes an inner sun gear member 1042 . A plurality of planet gears 1047 are also rotatably mounted in a carrier member 1046 such that each planet gear member 1047 simultaneously, and meshingly engages both the inner sun gear member 1042 and the outer ring gear member 1044 .
[0221] The planetary gear set 1090 has an inner sun gear member 1092 . A plurality of planet gears 1097 , 1098 are rotatably mounted in a carrier member 1096 such that each planet gear member 1097 engages the sun gear member 1092 and the respective planet gear member 1098 . The planet gear members 1098 are integral with the planet gear members 1037 (i.e., they are formed by long pinions).
[0222] The transmission input member 17 is connected with the sun gear member 1042 . The transmission output member 19 is connected with the ring gear member 1034 . A first interconnecting member 1070 continuously connects the ring gear member 1044 with the transmission housing 1060 . The carrier member 1096 is continuously connected with (integral with) the carrier member 1036 . This integral connection is referred to herein as the second interconnecting member 1072 . The integral connection of the long pinion gears 1037 and 1098 is referred to herein as the third interconnecting member 1074 .
[0223] The transmission 1014 also incorporates first and second motor/generators 1080 and 1082 , respectively. The stator of the first motor/generator 1080 is secured to the transmission housing 1060 . The rotor of the first motor/generator 1080 is secured to the sun gear member 1022 . The stator of the second motor/generator 1082 is also secured to the transmission housing 1060 . The rotor of the second motor/generator 1082 is secured to the sun gear member 1032 .
[0224] A first torque transmitting device, such as clutch 1050 , selectively connects the ring gear member 1034 with the carrier member 1036 . A second torque transmitting device, such as clutch 1052 , selectively connects the carrier member 1036 with the carrier member 1026 . A third torque transmitting device, such as clutch 1054 , selectively connects the sun gear member 1042 with the carrier member 1026 . A fourth torque transmitting device, such as clutch 1055 , selectively connects the ring gear member 1024 with the sun gear member 1032 . A fifth torque transmitting device, such as clutch 1056 , selectively connects the carrier member 1046 with the carrier member 1026 . A sixth torque device, such as brake 1057 , selectively connects the sun gear member 1092 with the transmission housing 1060 . The first, second, third, fourth, fifth and sixth torque transmitting devices 1050 , 1052 , 1054 , 1055 , 1056 and 1057 are employed to assist in the selection of the operational modes of the transmission 1114 .
[0225] The hybrid transmission 1014 receives power from the engine 12 , and also exchanges power with an electric power source 1086 , which is operably connected to a controller 1088 .
[0226] The operating mode table of FIG. 11 b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the five operating modes of the transmission 1014 . These modes include the “battery reverse mode” (Batt Rev), the “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “continuously variable transmission range modes” (Range 1 . 1 , 1 . 2 , 1 . 3 . . . ) and “fixed forward ratio modes” (F 1 , F 2 , F 3 , F 4 ) as described previously.
[0227] As set forth above, the emgagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 11 b . FIG. 11 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 11 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 1020 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 1030 ; the N R3 /N S3 value is the tooth ratio of the planetary gear set 1040 ; and the N R4 /N S4 value is the tooth ratio of the planetary gear set 1090 . Also, the chart of FIG. 11 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.69, and the ratio spread is 4.97.
Description of a Twelfth Exemplary Embodiment
[0228] With reference to FIG. 12 a , a powertrain 1110 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 1114 . The transmission 1114 is designed to receive at least a portion of its driving power from the engine 12 .
[0229] As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 1114 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0230] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 1114 . An output member 19 of the transmission 1114 is connected to a final drive 16 .
[0231] The transmission 1114 utilizes three planetary gear sets 1120 , 1130 and 1140 . The planetary gear set 1120 employs an outer ring gear member 1124 which circumscribes an inner sun gear member 1122 . A carrier member 1126 rotatably supports a plurality of planet gears 1127 such that each planet gear 1127 simultaneously, and meshingly engages both the inner sun gear member 1122 and the outer ring gear member 1124 of the planetary gear set 1120 .
[0232] The planetary gear set 1130 has an outer ring gear member 1134 that circumscribes an inner sun gear member 1132 . A plurality of planet gears 1137 are rotatably mounted in a carrier member 1136 such that each planet gear member 1137 simultaneously, and meshingly engages both the outer, ring gear member 1134 and the inner, sun gear member 1132 of the planetary gear set 1130 .
[0233] The planetary gear set 1140 also has an outer ring gear member 1144 that circumscribes an inner sun gear member 1142 . A plurality of planet gears 1147 are also rotatably mounted in a carrier member 1146 such that each planet gear member 1147 simultaneously, and meshingly engages both the outer, ring gear member 1144 and the inner, sun gear member 1142 of the planetary gear set 1140 .
[0234] The transmission output member 19 is continuously connected with the carrier member 1136 . An interconnecting member 1170 continuously connects the carrier member 1146 with the sun gear member 1122 .
[0235] The transmission 1114 also incorporates first and second motor/generators 1180 and 1182 , respectively. The stator of the first motor/generator 1180 is secured to the transmission housing 1160 . The rotor of the first motor/generator 1180 is secured to the sun gear member 1142 . The stator of the second motor/generator 1182 is also secured to the transmission housing 1160 . The rotor of the second motor/generator 1182 is secured to the sun gear member 1132 .
[0236] A first torque transmitting device, such as clutch 1150 , selectively connects the sun gear member 1122 with the ring gear member 1134 . A second torque transmitting device, such as clutch 1152 , selectively connects the ring gear member 1124 with the sun gear member 1132 . A third torque transmitting device, such as clutch 1154 , selectively connects the sun gear member 1122 with the sun gear member 1132 . A fourth torque transmitting device, such as clutch 1155 , selectively connects the carrier member 1146 with the sun gear member 1142 . A fifth torque transmitting device, such as clutch 1156 , selectively connects the carrier member 1126 with the input member 17 . A sixth torque transmitting device, such as brake 1157 , selectively connects the ring gear member 1134 with the transmission housing 1160 . A seventh torque transmitting device, such as brake 1158 , selectively connects the ring gear member 1144 with the transmission housing 1160 . The first, second, third, fourth, fifth, sixth and seventh torque transmitting devices 1150 , 1152 , 1154 , 1155 1156 , 1157 and 1158 are employed to assist in the selection of the operational modes of the transmission 1114 . The hybrid transmission 1114 receives power from the engine 12 and also from an electric power source 1186 , which is operably connected to a controller 1188 .
[0237] The operating mode table of FIG. 12b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the five operating modes of the transmission 1114 . These modes include the “battery reverse mode” (Batt Rev), the “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “continuously variable transmission range modes” (Range 1 . 1 , 1 . 2 , 1 . 3 . . . ) and “fixed forward ratio modes” (F 1 , F 2 , F 3 ) as described previously.
[0238] As set forth above, the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 12b . FIG. 12b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 12b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 1120 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 1130 ; and the N R3 /N S3 value is the tooth ratio of the planetary gear set 1140 . Also, the chart of FIG. 12 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.63.
Description of a Thirteenth Exemplary Embodiment
[0239] With reference to FIG. 13 a , a powertrain 1210 is shown, including an engine 12 connected to another embodiment of the improved electrically variable transmission, designated generally by the numeral 1214 . The transmission 1214 is designed to receive at least a portion of its driving power from the engine 12 .
[0240] As shown, the engine 12 has an output shaft that serves as the input member 17 of the transmission 1214 . A transient torque damper (not shown) may also be implemented between the engine 12 and the input member 17 of the transmission.
[0241] Irrespective of the means by which the engine 12 is connected to the transmission input member 17 , the transmission input member 17 is operatively connected to a planetary gear set in the transmission 1214 . An output member 19 of the transmission 1214 is connected to a final drive 16 .
[0242] The transmission 1214 utilizes three planetary gear sets 1220 , 1230 and 1240 . The planetary gear set 1220 employs an outer ring gear member 1224 which circumscribes an inner sun gear member 1222 . A carrier member 1226 rotatably supports a plurality of planet gears 1227 such that each planet gear 1227 meshingly engages both the outer ring gear member 1224 and the inner sun gear member 1222 of the first planetary gear set 1220 .
[0243] The planetary gear set 1230 also has an outer ring gear member 1234 that circumscribes an inner sun gear member 1232 . A plurality of planet gears 1237 are also rotatably mounted in a carrier member 1236 such that each planet gear member 1237 simultaneously, and meshingly engages both the outer, ring gear member 1234 and the inner, sun gear member 1232 of the planetary gear set 1230 .
[0244] The planetary gear set 1240 also has an outer ring gear member 1244 that circumscribes an inner sun gear member 1242 . A plurality of planet gears 1247 are also rotatably mounted in a carrier member 1246 such that each planet gear member 1247 simultaneously, and meshingly engages both the inner, sun gear member 1242 and the outer, ring gear member 1244 of the planetary gear set 1240 .
[0245] The transmission input member 17 is continuously connected with the carrier member 1226 . The transmission output member 19 is continuously connected with the carrier member 1236 .
[0246] The transmission 1214 also incorporates first and second motor/generators 1280 and 1282 , respectively. The stator of the first motor/generator 1280 is secured to the transmission housing 1260 . The rotor of the first motor/generator 1280 is selectively alternatively connectable with the sun gear member 1242 or the carrier member 1226 via engagement of the clutches A and B, respectively, of the dog clutch 1292 . The dog clutch 1292 may be replaced by two conventional clutches, as is understood by those skilled in the art.
[0247] The stator of the second motor/generator 1282 is also secured to the transmission housing 1260 . The rotor of the second motor/generator 1282 is continuously connected with the sun gear member 1232 .
[0248] A first torque transmitting device, such as clutch 1250 , selectively connects the sun gear member 1222 with the ring gear member 1234 . A second torque transmitting device, such as clutch 1252 , selectively connects the ring gear member 1224 with the sun gear member 1232 . A third torque transmitting device, such as clutch 1254 , selectively connects the sun gear member 1222 with the sun gear member 1232 . A fourth torque transmitting device, such as clutch 1255 , selectively connects the carrier member 1246 with the sun gear member 1242 . A fifth torque transmitting device, such as brake 1257 , selectively connects the ring gear member 1234 with the transmission housing 1260 . A sixth torque transmitting device, such as brake 1258 , selectively connects the ring gear member 1244 with the transmission housing 1260 . The first, second, third, fourth, fifth, sixth torque transmitting devices 1250 , 1252 , 1254 , 1255 , 1257 , 1258 and the dog clutch 1292 are employed to assist in the selection of the operational modes of the hybrid transmission 1214 .
[0249] The hybrid transmission 1214 receives power from the engine 12 , and also exchanges power with an electric power source 1286 , which is operably connected to a controller 1288 .
[0250] The operating mode table of FIG. 13 b illustrates the clutching engagements, motor/generator conditions and output/input ratios for the five operating modes of the transmission 1214 . These modes include the “battery reverse mode” (Batt Rev), the “EVT reverse mode” (EVT Rev), “reverse and forward launch modes” (TC Rev and TC For), “continuously variable transmission range modes” (Range 1 . 1 , 1 . 2 , 1 . 3 . . . ) and “fixed forward ratio modes” (F 1 , F 2 , F 3 ) as described previously.
[0251] As set forth above, the engagement schedule for the torque transmitting devices is shown in the operating mode table and fixed ratio mode table of FIG. 13 b . FIG. 13 b also provides an example of torque ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 13 b . The N R1 /N S1 value is the tooth ratio of the planetary gear set 1220 ; the N R2 /N S2 value is the tooth ratio of the planetary gear set 1230 ; and the N R3 /N S3 value is the tooth ratio of the planetary gear set 1240 . Also, the chart of FIG. 13 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second fixed forward torque ratios is 1.63, and the ratio spread is 2.82.
[0252] In the claims, the language “continuously connected” or “continuously connecting” refers to a direct connection or a proportionally geared connection, such as gearing to an offset axis. Also, the “stationary member” or “ground” may include the transmission housing (case) or any other non-rotating component or components. Also, when a torque transmitting mechanism is said to connect something to a member of a gear set, it may also be connected to an interconnecting member which connects it with that member. It is further understood that different features from different embodiments of the invention may be combined within the scope of the appended claims.
[0253] While various preferred embodiments of the present invention are disclosed, it is to be understood that the concepts of the present invention are susceptible to numerous changes apparent to one skilled in the art. Therefore, the scope of the present invention is not to be limited to the details shown and described but is intended to include all variations and modifications which come within the scope of the appended claims. | The electrically variable transmission family of the present invention provides low-content, low-cost electrically variable transmission mechanisms including first, second and third (and possibly fourth) differential gear sets, a battery, two electric machines serving interchangeably as motors or generators, five, six or seven selectable torque-transfer devices and possibly a dog clutch. The selectable torque transmitting devices are engaged to yield an EVT with a continuously variable range of speeds (including reverse) and up to six mechanically fixed forward speed ratios. The torque transmitting devices and the first and second motor/generators are operable to provide five operating modes in the electrically variable transmission, including battery reverse mode, EVT reverse mode, reverse and forward launch modes, continuously variable transmission range mode, and fixed ratio mode. | 8 |
RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of United States Provisional Patent Application No. 60/726,863 filed Oct. 14, 2005, and of German Patent Application No. 10 2005 049 243.6 filed Oct. 14, 2005, the disclosures of which are hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates to level measuring. In particular, the present invention relates to a parabolic antenna for a level radar, a level radar comprising such a parabolic antenna, the utilization of such a parabolic antenna for level measuring, and a method for measuring a level with a parabolic antenna.
BACKGROUND TO THE INVENTION
[0003] Known level measuring instruments have a parabolic antenna, which emits or receives radar or microwaves for determining the filling level of a medium in a filling material container. In this case, the parabolic antenna of such a level measuring instrument is arranged e.g. inside a container.
[0004] The quality of the measuring signals received at level measuring with a level radar having a parabolic antenna largely depends on the quality of the transmitting-receiving unit. In particular, contamination of the antenna feed or the exciter, which may be caused e.g. by filling material dust or liquid, may significantly deteriorate the quality of measuring results. In the extreme case, serious contamination of the exciter (which by the way may also be used as a radiation receiver) may even lead to no signals being transmitted at all.
SUMMARY OF THE INVENTION
[0005] According to an exemplary embodiment of the present invention a parabolic antenna for a level radar is provided, the parabolic antenna comprising a parabolic reflector, an exciter for emitting electromagnetic waves to the parabolic reflector, an outlet member and a rinsing device with a rinsing outlet for rinsing the exciter with a rinsing agent, wherein the rinsing outlet is mounted in the outlet member, and wherein the outlet member is mounted at the parabolic reflector.
[0006] Thus, apart from the parabolic reflector and exciter, the parabolic antenna according to the invention has a rinsing device, which may be configured so as to rinse and clean the exciter with rinsing agent or protect it from contaminants. Herein, the rinsing agent is injected, dropped, or else blown from a rinsing outlet in an outlet member at the parabolic reflector onto the exciter. By mounting the rinsing outlet, which may be configured e.g. in the shape of outlet nozzles, directly at the parabolic reflector the exciter may be cleaned from the parabolic reflector. In this case, the outlet member may be mounted at the parabolic reflector after production of the parabolic reflector, or else it may be produced as one piece with the parabolic reflector. Also, the outlet member may be mounted on a wave guide, which is joined to the exciter/receiver.
[0007] The outlet member may be produced independently from shape and size of the parabolic reflector. The rinsing ports and the number of rinsing channels may be designed according to the implemented exciter so that the most efficient cleaning effect is obtained. The central position of the outlet member may be the shortest possible distance from the exciter.
[0008] Thereby, simple and inexpensive individual manufacturing of the level radar or antenna may be possible, in that during final assembly, various antenna systems are equipped with corresponding individual outlet members. This may allow for high flexibility at low production cost.
[0009] Also, the diffusing panel according to the invention may allow for high stability of the junction between wave guide and parabolic reflector. E.g. the diffusing panel may be screwed to the wave guide and welded to the parabolic reflector.
[0010] Thus, exact fill level measuring even under unclean environmental conditions may be provided.
[0011] According to another sample embodiment of the present invention the rinsing device has a rinsing channel, wherein the rinsing channel is configured for conducting the rinsing agent to the rinsing outlet, and wherein the rinsing outlet is configured for letting the rinsing agent out towards the exciter.
[0012] E.g. the rinsing channel may be mounted inside an antenna coupling (which is configured as a wave guide). The rinsing channel is thus integrated into the antenna coupling, and is consequently configured during the production process of the antenna coupling.
[0013] According to another exemplary embodiment of the present invention the rinsing device also has a rinsing connection, wherein the rinsing connection is configured for connecting the rinsing device to a rinsing agent reservoir.
[0014] Herein, the rinsing connection is joined to the rinsing channel so that rinsing agent is conducted from the reservoir via the rinsing connection and the rinsing channel (i.e. directly through the antenna coupling) to the rinsing outlet.
[0015] According to another exemplary embodiment of the present invention the outlet member is embodied as a ring, wherein the ring is mounted centrically to the parabolic reflector.
[0016] Due to the rotationally symmetrical configuration of the outlet member and the centrical mounting of the outlet member to the parabolic reflector, a globally rotationally symmetric and simple construction of the parabolic antenna may be ensured. The recess in the middle of the ring may allow a wave guide to be guided through the ring. In this case, the ring may be mounted directly to the wave guide.
[0017] It should be noted that the outlet member may also have other shapes. E.g. a rectangular, pyramidal, or oval configuration may be possible.
[0018] According to another exemplary embodiment of the present invention the rinsing outlet is configured as a plurality of bores in the ring, which communicate with the rinsing channel.
[0019] Thereby several nozzles may be provided, through which the rinsing agent may be vaporized or blown onto the exciter.
[0020] According to another exemplary embodiment of the present invention the parabolic antenna has an antenna coupling, wherein the rinsing connection is threaded for screwing into the antenna coupling.
[0021] According to this exemplary embodiment of the present invention the thread may exemplary ensure easy mounting of the rinsing connection to the antenna coupling.
[0022] According to another exemplary embodiment of the present invention the rinsing device has a check valve, wherein the check valve is configured for preventing return mass transport.
[0023] Thereby it may be prevented that when e.g. the pressure of the rinsing agent drops under a predetermined value, the junction between the outside (rinsing agent reservoir) and the container inside (rinsing outlet) stays open. Thereby e.g. explosion protection may be created.
[0024] According to another exemplary embodiment of the present invention the check valve has a spring member and a ball.
[0025] Spring member and ball provide a simple but efficient check system.
[0026] The rinsing device may be configured on the one hand for preventing contamination of the exciter, and on the other hand for cleaning the exciter after contamination.
[0027] E.g. the exciter may comprise a Teflon cone.
[0028] According to another exemplary embodiment of the present invention, the rinsing agent may be air, nitrogen, or water. As required, it may also be possible to add cleansing agents. Also, the rinsing agent may be heated in order to enhance the cleaning effect. Possibly the rinsing agent may be vaporized onto the exciter under high pressure. Of course, using other rinsing agents may also be possible, such as for instance natural gases, or else reactive mixtures, which may further enhance the cleaning effect
[0029] According to another exemplary embodiment of the present invention the electromagnetic waves emitted by the exciter are first electromagnetic waves, wherein the parabolic reflector is configured for concentrating the first electromagnetic waves.
[0030] According to another exemplary embodiment of the present invention the outlet member is configured as a diffusing panel, wherein the electromagnetic waves emitted by the exciter comprise second electromagnetic waves, and wherein the diffusing panel is configured for laterally removing the second electromagnetic waves past the exciter.
[0031] It may thus be possible for undesirable radiation from the outlet member to be removed laterally or dispersed so that it does not reach the exciter, and thus cannot deteriorate or falsify the measuring result.
[0032] The quality of the measurement may thus be increased in two ways. On the one hand, it may be ensured that the exciter is always clean and free of contaminants. On the other hand, it may be ensured that interfering radiation is dispersed away from the exciter and thus no longer supplied to the measuring and analysis electronic unit.
[0033] According to another exemplary embodiment of the present invention the diffusing panel has a conical shape with a rotational axis, so that a beam of parallel rays incident on the diffusing panel towards the rotational axis is guided away from the rotational axis via a backscattering process.
[0034] The conical shape may allow e.g. for the parallel rays, which are incident on the diffusing panel, to be globally guided away under the same angle to the rotational axis of the parabolic antenna. Such a conical diffusing panel may easily be manufactured. Thus, production and manufacturing cost may be reduced.
[0035] According to another exemplary embodiment of the present invention a level radar is provided, which comprises a parabolic antenna described above.
[0036] Moreover, the utilization of a parabolic antenna according to the invention for level measuring is provided.
[0037] Moreover, a method for measuring a level with a parabolic antenna is provided, wherein electromagnetic waves are emitted to a parabolic reflector by means of an exciter, rinsing agent is let out via a rinsing device with a rinsing outlet to the exciter, and the exciter is rinsed with the rinsing agent. Herein, the rinsing outlet is mounted in an outlet member, which is mounted to the parabolic reflector.
[0038] Thereby, a method is provided, which may allow for the quality of the measuring signals to be maintained even under adverse environmental conditions, in that the exciter/receiver is rinsed with rinsing agent for cleaning.
[0039] According to another exemplary embodiment of the present invention the rinsing agent is introduced from a rinsing agent reservoir into a rinsing connection of the rinsing device, and then transmitted from the rinsing connection to the rinsing outlet through a rinsing channel.
[0040] Other sample embodiments, tasks, and advantages of the invention result from the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Hereafter, with reference to the figures, sample embodiments of the present invention will be described.
[0042] FIG. 1 shows a cross-sectional view of a parabolic antenna according to an exemplary embodiment of the present invention.
[0043] FIG. 2 shows a cross-sectional view of another parabolic antenna according to another exemplary embodiment of the present invention.
[0044] FIG. 3 shows a perspective top view of the parabolic antenna of FIG. 2 .
[0045] FIG. 4 shows a schematic cross-sectional view of a parabolic antenna according to another exemplary embodiment of the present invention.
[0046] FIG. 5 shows a schematic cross-sectional view of a parabolic antenna according to another exemplary embodiment of the present invention.
[0047] FIG. 6 shows a schematic cross-sectional view of a check valve for a rinsing device connected to the diffusing panel according to an exemplary embodiment of the present invention.
[0048] FIG. 7 shows a schematic view of a diffusing panel according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0049] In the following description of the figures, the same reference numerals will be used for like or similar elements.
[0050] FIG. 1 shows a schematic cross-sectional view of a parabolic antenna according to an exemplary embodiment of the present invention. As may be seen in FIG. 1 , the parabolic antenna 100 is substantially composed of a parabolic reflector 2 with a diffusing panel 1 and an exciter/receiver 3 . Herein, the parabolic reflector 2 comprises a rotary parabolic reflector edge 20 . The parabolic reflector edge 20 transitions into an additional collar 9 with an outside collar edge 90 . Herein, the wall of the collar 9 extends approximately axially in parallel to a central parabolic reflector axis X of the parabolic reflector 2 .
[0051] Furthermore, the parabolic antenna 100 comprises the exciter and/or receiver 3 , which is arranged on the parabolic reflector axis X, and is spaced away from the backside wall of the parabolic reflector 2 with a wave-guiding member, e.g. an antenna tube or wave guide 4 . The wave guide 4 transitions at the back to a wave guide array of at least one wave guide 5 , at the rear end section of which a connector 6 for a transmitting-receiving device is arranged. The transmitting-receiving device comprises an electronic unit and components for generating an electromagnetic wave, in particular a radar or microwave.
[0052] The thus generated electromagnetic wave is transmitted from the connector 6 through wave guide 5 and wave guide 4 to the exciter 3 . From the exciter 3 the wave is radiated towards the parabolic reflector, and reflected thereby in an axially parallel direction to the parabolic reflector axis X.
[0053] When the thus emitted electromagnetic wave has reached some filling material, the wave is reflected by the filling material, and in general, received at least partially by the parabolic reflector 2 . The wall of the parabolic reflector 2 reflects the back reflected wave portions to the receiver 3 of the exciter/receiver assembly 3 . From the receiver 3 the wave received is transmitted via wave guide 4 and wave guide 5 through the connector 6 to the receiving device of the transmitting-receiving device and picked up therein. The electronic unit of the transmitting-receiving device or another, downstream analysis device determines the time difference between emission of the electromagnetic wave and receipt of the electromagnetic wave reflected by the filling material or surface. Therefrom, the level of the filling material in a container may be determined.
[0054] For fixing the parabolic antenna 100 in a container wall, in particular in a container flange 8 , the backside components at the wave guide 5 have a fastening device 7 , e.g. with a flange. The exciter/receiver 3 lies within the assembly composed of parabolic reflector 2 and collar 9 , so that the exciter/receiver 3 is partially arranged within the parabolic reflector edge 20 and partially outside the parabolic reflector edge 20 . One portion of the exciter/receiver 3 protrudes into the area of the parabolic reflector 2 , and another portion protrudes from the area of the parabolic reflector 2 , into the area of the collar 9 . In the embodiment represented in FIG. 1 the exciter/receiver 3 is arranged completely within the inside defined by the collar edge 9 and the parabolic reflector 2 .
[0055] Thereby, the exciter/receiver 3 may mechanically be protected. Furthermore, with full illumination, side lobes and back lobes, which are undesirable secondary lobes e.g. due to spillover of the parabolic reflector 2 , may beavoided as much as possible.
[0056] According to a sample embodiment of the present invention the ratio of focal distance f to diameter D of the parabolic antenna is 0.27. However, totally different values, either greater or smaller, may be equally possible.
[0057] Moreover, an integral configuration in one piece of parabolic reflector 2 and collar 9 may be possible. Optionally, the collar 9 may be made of the same material as the parabolic reflector 2 , or of another material different therefrom. In particular, an inside coating or a complete collar material for absorbing electromagnetic waves incident on the inner wall of collar 9 may be possible.
[0058] For further reducing interfering reflections and minimizing or decreasing the ringing behavior at close range, a diffusing panel 1 is arranged in the middle of the parabolic reflector 2 , which laterally removes electromagnetic waves emitted by the exciter 3 so that the reflected waves can no longer reach the exciter 3 . As can be seen in FIG. 1 , the diffusing panel 1 herein has such a shape that rays incident from the exciter 3 on the diffusing panel 1 are reflected away from the rotational axis X. Thereby, the ringing behavior at close range may be reduced significantly. In this case, the shape of the diffusing panel 1 may not necessarily be conical, it may only be essential that it has a slope with respect to the plane perpendicular to the rotational axis X so that axially parallel rays are scattered away. Alternatively or additionally, the diffusing panel 1 may be made of a radiation absorbing material so that incident radiation is absorbed at least partially.
[0059] As the diffusing panel now scatters away electromagnetic waves, which would otherwise after emission from the exciter/receiver 3 and reflection at the parabolic reflector 2 have been immediately absorbed again by the exciter/receiver 3 , the risk of overloading the receiving electronics is reduced. As the undesirable interfering radiation is scattered away or absorbed by the diffusing panel 1 (and not detected), it is possible for instance to increase dissipation capacity without having to fear overloading of the receiving electronics.
[0060] Globally, background noise of the measurement is reduced, which may lead to improved measuring results.
[0061] Moreover, the diffusing panel 1 according to the invention has rinsing outlets (not shown in FIG. 1 ), through which a rinsing agent for cleaning the exciter/receiver 3 may be injected, dropped, blown, or otherwise carried towards the exciter/receiver 3 .
[0062] If required, the whole parabolic antenna 2 , with exciter member 3 and wave guide 4 , may be covered with a simple, plain protective covering, a so-called radome, which is pulled over the collar edge 9 of the parabolic antenna. This may be e.g. polytetrafluoroethylene (PTFE). Also a PTFE plate, or a possibly curved lid for covering the parabolic antenna may be provided.
[0063] FIG. 2 shows a schematic cross-sectional view of a parabolic antenna according to another sample embodiment of the invention. The parabolic antenna shown in FIG. 2 substantially corresponds to the parabolic antenna of FIG. 1 . Herein, the diffusing panel 1 is configured to be conical, consequently having an uncurved surface oriented to the incident electromagnetic radiation. Moreover, fastening members 22 , 23 are provided for supporting the antenna array 100 , or fastening thereof to a filling material container lid.
[0064] The rinsing device 11 has a rinsing connection 14 , which is threaded so as to be fastened in the antenna coupling 21 . The rinsing connection 14 is connected via the rinsing channel 13 to several rinsing outlets 12 , 25 , 26 , 27 (see FIGS. 5 and 7 ).
[0065] FIG. 3 shows a perspective top view of the antenna array of FIG. 2 . In particular, herein the arrangement of the fastening members 22 , 23 and other fastening members 301 - 304 is shown.
[0066] FIG. 4 shows an antenna array in a schematic cross-sectional view according to another sample embodiment of the present invention. As can be seen in FIG. 4 , the exciter/receiver 3 is provided with a (e.g. metallic) holding clip 24 .
[0067] FIG. 5 shows another schematic view of another sample embodiment of the present invention. As may be seen in FIG. 5 , the antenna coupling 21 is placed on the antenna body 29 . Inside the antenna body 29 and the antenna coupling 21 rinsing channels 13 extend, which conduct a rinsing agent from the rinsing connection 14 to the outlet 12 . The outlet 12 , which is configured as a bore, lies in the diffusing panel 1 , which is meant for scattering away unwanted radiation. The rinsing connection 12 is implemented for cleaning the exciter/receiver 3 by means of a rinsing agent jet or for keeping the exciter/receiver 3 clean.
[0068] FIG. 6 shows a schematic cross-sectional view of a check valve 15 in order to prevent return mass transport. As can be seen in FIG. 6 , the check valve 15 has a ball 17 and a spring 16 , which are mounted in a case 20 . Herein, the spring 16 pushes the ball 17 against a supply line 18 , which is connected to a rinsing agent reservoir. If the pressure of the rinsing agent, which is flowing from the reservoir to the supply line 18 and pushing against the ball 17 , is high enough (typically over 0.5 bar), then the spring 16 is compressed, and the ball 17 gives access to the case 20 so that the rinsing agent may flow through the case to the drain line 19 . The drain line 19 is herein connected to the outlet 12 . However, if the positive pressure of the rinsing agent drops below a preset threshold value, the spring 16 pushes the ball 17 against the entry of the supply line 18 so that the supply line 18 is sealed close. Further mass transport is thus prohibited. In case of ignition of an explosive gas mixture outside the container, the explosion cannot propagate into nor have an effect in the container, due to the check valve 15 . This may ensure explosion protection.
[0069] FIG. 7 shows a schematic top view of a diffusing panel 1 . Herein, the diffusing panel 1 has several rinsing outlets 12 , 25 , 26 , 27 , through which the rinsing agent may be output for rinsing the exciter/receiver 3 . Moreover, the diffusing panel 1 has a passage 28 for a wave guide for feeding the exciter/receiver 3 . Herein, the diffusing panel 1 is configured to be conical so that electromagnetic waves, which are incident perpendicularly to the drawing plane onto the diffusing panel 1 , are scattered away in a direction different from the axis of incidence. Of course, it may also be possible to provide more than four or less than four rinsing outlets.
[0070] The diffusing panel 1 is made e.g. as a separate component, and is mounted during assembly to the parabolic reflector 2 , or else e.g. to the wave guide 4 . Mounting may be done e.g. by bonding, welding, riveting, screwing, or crimping. Of course, the parabolic reflector 2 and diffusing panel 1 may also be configured as one piece. It may also be possible to embody diffusing panel 1 and wave guide 4 as one piece.
[0071] Additionally, it is to be noted that “comprising” does not exclude any other items or steps, and that “a” or “an” do not exclude a plurality. Furthermore, it is to be noted that features or steps having been described with reference to one of the above sample embodiments may also be used in combination with other features or steps of other embodiments described above. Reference numerals in the claims are not to be construed as limitations. | Contamination at the exciter of a parabolic antenna can lead to impaired signal quality, or even system downtime. A parabolic antenna is described which in addition to a parabolic reflector and an exciter has a rinsing device, which is configured so as to rinse and clean the exciter with rinsing agent or protect it from contaminants. Herein, the rinsing agent is injected, dropped, or else blown from a rinsing outlet in an outlet member at the parabolic reflector onto the exciter. Mounting the rinsing outlet directly to the parabolic reflector allows for the exciter to be cleaned from | 6 |
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