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This is a continuation of application Ser. No. 018,832 filed Feb. 24, 1987, now abandoned, which is a continuation of application Ser. No. 740,102, filed May 31, 1985, now abandoned.
This invention relates to silicon, wafer reinforcing materials, and more particularly, to a method of thinning a silicon wafer using such material.
BACKGROUND OF THE INVENTION
One form of charge-coupled device (CCD) comprises a silicon die that has been processed using conventional MOS technology to form a buried channel beneath its front surface (the surface through which the die is processed). The channel is made up of a linear array of like elementary regions, and each region has a well defined potential profile including several, e. g. three, potential levels of controlled potential depth. A clocking electrode structure overlies the front surface of the die, and by application of selected potentials to the clocking electrode structure, charge present in a given elementary region may be advanced through the linear array of elementary regions, in the manner of a shift register, and extracted from the channel at an output electrode. Charge may be introduced into the channel at an input electrode that is at the opposite end of the channel from the output electrode, or may be generated photoelectrically. Thus, if electromagnetic radiation is incident on the substrate beneath the channel layer it may cause generation of conduction electrons and these conduction electrons may enter the channel layer and become trapped in a potential well defined between two zones at higher potentials. The diffusion length of the conduction electrons is sufficiently short that a conduction electron generated in the substrate will not pass by diffusion farther than the elementary channel region that immediately overlies the substrate region in which the conduction electron was generated.
A CCD may be constructed with a plurality of parallel buried channels. One application of such a multiple channel CCD, using photoelectrically generated conduction electrons, is as a solid state imager or opto-electric transducer. The die in which the CCD is fabricated is thinned from its back surface, so as to bring the back surface as close as possible to the channel layer, and the die is placed with its back surface at the focal plane of a camera so that the camera lens forms an image of a scene on the back surface of the die. The CCD may comprise, e. g. 512 parallel channels each having 512 elementary regions and the resulting 512 ×512 array of elementary regions resolves the back, or image receiving, surface of the die into 512×512 picture elements or pixels. The intensity of the optical energy incident on a given pixel can influence the electron population of the associated elementary region of the channel layer, and so the number of electrons that are transferred out of an elementary region, and ultimately extracted from the CCD, indicate the intensity of the light incident on the pixel. By controlling the timing of the clock pulses in relation to the illumination of the CCD, the CCD can be used to generate an electrical signal representative of the distribution of light intensity over the image receiving surface of the CCD, i. e. of the image formed by the camera lens.
The interface between the channel layer and the substrate of the die is located at a physical depth beneath the first surface of the die in the range from about 5 μm to about 150 μm and therefore in order to maximize the diffusion of photoelectrically-generated conduction electrons into the channel layer it is desirable that the thickness of the silicon die be in the range from about 10 μm to about 160 μm. Since an unprocessed silicon wafer normally has a thickness of about 1 mm because it must be sufficiently thick to be self-supporting during processing, this implies that the wafer must be thinned in order to produce a die having a thickness of 160 μm or less.
It is conventional to carry out thinning of a silicon wafer by grinding or etching. .However, in order to thin a wafer to less than about 250 μm, it is necessary to provide the wafer with a mechanical support layer, and it has hitherto been conventional to use a wax support layer. The wax is applied in molten form to the front surface of the wafer, and the wafer is thinned from its back surface. However, waxes that have conventionally been used do not adhere to the wafer particularly well, and therefore when the wafer is thinned to 160 μm or less the silicon die frequently peels from the wax layer and disintegrates. Even if the die does not disintegrate, it may suffer local detachment from the wax layer, with the result that the back surface of the die ceases to be planar, and this may be unacceptable.
In order to minimize dark current generated in the CCD, it is desirable to operate the CCD at a depressed temperature. In order to achieve this, it is conventional to cool the CCD with liquid nitrogen. At standard pressure, liquid nitrogen evaporates at a temperature of about -196 degrees C. Therefore, it may be necessary for a CCD imager to be capable of withstanding temperature changes of over 200 degrees C. This implies that there must be a good matching of the coefficients of thermal expansion between the silicon die and the mechanical support layer, since otherwise differential expansion and contraction will damage the silicon die.
It is not essential that there be a perfect match between the expansion coefficients of the silicon die and the support layer, since some bowing of the back surface of the die can be tolerated. However, the degree of bowing that can be tolerated is quite small, particularly if application of the support layer involves subjecting the wafer to an elevated temperature, so that the wafer is bowed upon cooling to ambient temperature, since it is difficult to thin a bowed wafer.
In U.S. Pat. No. 4,422,091 it is proposed that a CCD imager that has been fabricated using heteroepitaxial gallium arsenide technology should be supported during thinning by means of a plate of molybdenum, aluminum or glass that is bonded to the die using epoxy adhesive or a bonding alloy, for example. U.S. Pat. No. 4,422,091 also proposes that the CCD die be supported during thinning using a GaAs or Si chip that has its own signal conditioning and amplification circuit incorporated therein.
SUMMARY OF THE INVENTION
In a preferred embodiment of the invention, a plate-like silicon body that is to be thinned is reinforced by applying to one face of the body a mechanically-supportive coating that comprises at least about 40 weight percent silica in finely divided form, and processing the coating to form a hard, mechanically-supportive mass that adheres to the body. The body is then thinned from the second face of the body.
BRIEF DESCRIPTION OF THE DRAWING
For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:
FIG. 1 is a diagrammatic partial sectional view of a buried channel CCD die,
FIG. 2 is a view similar to FIG. 1 showing a coating layer attached to the die, and
FIG. 3 is a view similar to FIG. 1 after thinning of the die.
DETAILED DESCRIPTION
The CCD die 2 shown in FIG. 1 is fabricated using conventional MOS technology from a wafer of undoped silicon by implanting a p-type impurity into the wafer by way of its front surface to form a p-type layer 6 and then implanting an n-type impurity to form an n-type channel layer 4. The concentration of n-type impurity varies in controlled fashion along the channel so as to define identical elementary regions 12 that overlie associated elementary areas 14 of the layer 6. Typically, the die comprises a rectangular or square array of from about 250,000 to 4 million elementary devices (region 12 plus associated area 14), and each elementary device has a depth perpendicular to the first surface of the die of about 5 to 150 μm and occupies a space that has a footprint, at the processed face of the device, of about 50 to 150 μm by 50 to 150 μm. The front surface of the CCD may be from about 2.75 mm on a side to about 5 cm on a side, and from one to about nine identical devices would normally occupy the processible area of a typical four inch (about 10 cm) diameter wafer.
Overlying the front surface of the wafer is a layer 8 of silicon oxide and a layer 10 of refractory metal such as molybdenum or tungsten. The layer 10 is passivated at its exposed surface. It will be appreciated by those skilled in the art that the layers 8 and 10 would not normally be continuous, but would be patterned, so that in different regions of the front surface silicon, silicon dioxide and passivated metal are exposed. However, the nature of the patterning is not relevant to the invention and therefore the patterning is not shown in detail. It will also be understood that some dimensions are shown out of proportion in the drawing for the sake of clarity.
After completing the usual steps of cleaning, masking, implantation, diffusion, oxidation and metallizing that are associated with processing of the wafer using conventional MOS technology, the wafer is scribed at its front surface to a depth of about 10 μm so as to facilitate later detachment of each CCD die from surplus wafer material and other CCD dice that are on the same wafer, and a reinforcing coating 16 is applied over the front surface of the processed wafer. The coating material preferably comprises a silica-based glass that, when fused, forms a hard mass that adheres to the front surface of the die. It has been found that a suitable glass is a borosilicate glass containing from about 40 to about 60 weight percent silica. The relatively high proportion of silicon (about 18 to about 28 weight percent) in the glass insures that there is a good match between the coefficient of thermal expansion of the die and that of the glass. The particular borosilicate glass that is used is selected to have a fusion temperature that is below the temperature at which the refractory metallization of the CCD is degraded.
The borosilicate glass is applied to the front surface of the processed wafer in the form of a paste or slurry of ground glass dispersed in a vehicle of nitrocellulose and a solvent. The paste is applied to a depth from about 30 to about 60 mils (one mil is equal to 0.001 inches, or about 0.025 mm), and the coating thickness is uniform to within about 10 mils. Coating thickness and uniformity are preferably controlled using a doctor blade. The wafer is placed with its front surface upwards on a horizontal platform between two narrow ridges that extend above the surface of the platform to a uniform, equal height of about 1.4 mm. A slurry of ground glass and liquid vehicle is placed on the front surface of the wafer, and a metal blade having a straight edge is placed with its straight edge bridging the gap between the ridges. The blade is run over the slurry and spreads the slurry over the front surface of the wafer to a uniform depth equal to the difference between the height of the ridges and the thickness of the wafer. In the case of a wafer that is 20 mil (about 0.5 mm) thick, the slurry layer has a thickness of about 36 mil (0.9 mm). The wafer is then placed in an oven and baked at about 360 degrees C. for 60 minutes in order to drive off the vehicle, leaving just the ground glass on the front surface of the wafer. The temperature in the oven is raised to about 700 to 950 degrees C. (depending on the glass that is selected) and the ground glass is fused. The fused glass adheres firmly to the front surface of the wafer.
After fusing the borosilicate glass, the wafer is allowed to cool to ambient temperature (about 20 degrees C.). At ambient temperature, the four inch (about 10 cm) diameter wafer is bowed slightly, with its front surface convex (indicating that the expansion coefficient of the coating is slightly less than that of silicon), but the center of the back surface of the wafer is only about 1 mil from the plane containing the periphery of the back surface of the wafer. This small degree of bowing is not sufficient to interfere with thinning of the wafer. The close match in coefficients of expansion is obtained because the coating contains a large proportion of silicon.
The cooled wafer is thinned from the face opposite the processed face, i. e. the back surface 18, until the scribed lines can be seen, and the wafer and the coating are then severed along the scribed lines to remove surplus material and, in the event that more than one CCD die is formed, separate the individual CCD dice. After removal of surplus material, and separation of individual CCD dice if appropriate (but leaving the coating attached), the CCD may be packaged using conventional techniques.
Upon cooling of the die and its glass coating down to the temperature of liquid nitrogen (-196 degrees C.), no unacceptable warping of the CCD die is observed, and the die remains attached to the glass coating.
It will be appreciated that the invention is not restricted to the particular methods and devices that have been described, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims, and equivalents thereof. | A plate-like body (e.g., a silicon wafer) at least about 0.5 mm thick that is to be thinned is reinforced by applying to one main surface, in adhesive relationship thereto, a coating of a finely divided material which is fused to form a hard mechanically supportive coating. The body is thinned from the second main surface to a thickness less than about 250 μm. For a silicon body, the mechanically supportive coating comprises at least about 18% silicon. | 7 |
[0001] This application is a divisional of U.S. patent application Ser. No. 12/608,978, filed Oct. 29, 2009, which is incorporated by reference as if fully set forth.
FIELD OF THE INVENTION
[0002] The present invention relates generally to Magnetic Resonance Imaging (“MRI”). More specifically, the present invention relates to systems and methods for performing MRI on more than one interacting or non-interacting people simultaneously within one MRI scanner for anatomic, functional, metabolic, and/or molecular imaging and studies.
BACKGROUND INFORMATION
[0003] One of the major functions of the human brain is to mediate interactions with other people, such as inter-personal communication and physical contact. Understanding such dynamic interactions between two minds is essential for characterizing human social behavior.
[0004] Until recently, studying brain mechanisms underlying social interactions has not been possible due to the lack of measurable methods to observe two interacting minds simultaneously. However, some progress has been made during the past ten years [1]. For example, Montague and colleagues developed a technique known as “hyperscanning” that uses the internet to connect and synchronize two MRI scanners while subjects were scanned performing a simple deception game [2]. Similarly, Babiloni and colleagues studied dyads participating in the Prisoner's Dilemma paradigm while recording EEG signals [3].
[0005] In line with this research, we have developed a novel MRI head coil that allows for the acquisition of fMRI signals from at least two subjects' brains while the subjects are in close proximity to one another, allowing for social interactions not possible with the remote hyperscanning technique. Unlike hyperscanning, which scans two people in separate scanners with only a visual or audio connection between them, the proposed device allows for fMRI studies of two people within close physical contact.
SUMMARY OF THE INVENTION
[0006] In view of the foregoing, one of the objects of the present invention is to provide systems and methods for performing MR on more than one people simultaneously within one MRI scanner.
[0007] It is another object of the present invention to provide systems and methods for design and manufacture a MRI scanner which includes at least a superconducting or non-superconducting magnet, a set of three dimensions of magnetic field gradients, RF coils, and magnetic field shimming coil set that can accommodate more than one people within one scanner.
[0008] It is another object of the present invention to provide systems and methods for performing MRI on more than one interacting or non-interacting people for anatomic, functional, metabolic, and/or molecular imaging and studies.
[0009] These and other objects of the present invention are accomplished using an exemplary embodiment which can include a twin-head coil comprising: two circular polarized volume coils side-by-side for two people; the two component coils are decoupled by both their geometrical orientation and decoupling interface circuit system [4].
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing and other objects of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
[0011] FIG. 1 is a visual illustration of an exemplary embodiment of an elliptical superconducting magnet according to the present invention;
[0012] FIG. 2 is a visual picture of an exemplary embodiment of the twin-head coil according to the present invention;
[0013] FIG. 3 is a visual diagram of exemplary layouts of the interface between the twin-head coil and MRI scanner in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] An apparatus for simultaneously acquiring magnetic resonance signals from more than one person in one magnetic resonance imaging scanner, may include: a) an arbitrary shape of inner bore superconducting or non-superconducting magnet that can generate homogeneous static magnetic field whose volume can accommodate more than one person; b) three direction magnetic field gradient coils which can produce linear magnetic gradient region that can accommodate more than one people; c) RF coils that can transmit and/or receive MR signals in the region that can accommodate more than one person; and d) a shimming coil set that can shim an elliptical volume that is large enough for accommodating more than one people.
[0015] FIG. 1 is a diagram of an elliptical superconducting magnet. The elliptical superconducting magnet includes an elliptical inner bore surrounded by a primary coil. The elliptical superconducting magnet also includes an active shield coil, vacuum port, shield temp sensor port connector, 50 k shield, vacuum chamber, quench prot diodes, junction boards, helium vessel, helium fill port, neck tube, FCL, FCL connector, FCL temp sensor, Auxiliary vent, turret connection, coolhead temp connector and sidesock.
[0016] The apparatus may include: a) an elliptical cylinder inner bore superconducting or non-superconducting magnet that can generate homogeneous static magnetic field whose volume can accommodate two people, as shown in FIG. 1 ; b) Three direction magnetic field gradient coils which can produce linear magnetic gradient region that can accommodate two people; c) RF coils that can transmit and/or receive MR signals in the region that can accommodate two people; and d) a shimming coil set that can shim an elliptical volume that is large enough for accommodating two people.
[0017] The apparatus may further include a twin-head coil comprising: a) two circular polarized volume coils side-by-side for two people, as shown in FIG. 2 ; b) The two component coils are decoupled by both their geometrical orientation and a decoupling interface circuit system; and c) the interface between MRI scanner and the twin-head coil is shown in FIG. 3 . Component b) may further include a scheme for decoupling circular-polarized RF coils.
[0018] A method for simultaneously acquiring magnetic resonance signals from more than one person in one magnetic resonance imaging scanner, comprises the steps of: a) providing an MRI scanner whose dimensions and physical features of imaging components such as magnet, gradient, and RF coil can accommodate at least two people; b) such scanner can simultaneously excite the spins and simultaneously receive their magnetic resonance signals from at least two people; c) the magnetic resonance images reconstructed from such scanner can reveal either interaction and/or non-interaction between the plurality of people inside the scanner.
[0019] A method for simultaneously acquiring magnetic resonance signals from two people in one magnetic resonance imaging scanner, may also comprise the steps of: a) providing an MRI scanner which has elliptical cylinder dimension inner bore can accommodate two people; b) such scanner can simultaneously excite the spins and simultaneously receive their magnetic resonance signals from two people;
[0020] c) the magnetic resonance images reconstructed from such scanner can reveal either interaction and/or non-interaction between two people inside the scanner.
[0021] The method of may further include the steps of: a) constructing an elliptical cylinder inner bore superconducting or nonsuperconducting magnet that can generate homogeneous static magnetic field whose volume can accommodate two people; b) constructing three direction magnetic field gradient coils which can produce linear magnetic gradient region that can accommodate two people; c) constructing RF coils that can transmit and/or receive MR signals in the region that can accommodate two people; and d) constructing shimming coil set that can shim an elliptical volume that is large enough for accommodating two people.
[0022] Step b) may further include the step of acquiring MR signal for anatomic MR imaging of two people inside scanner. Step b) may further include the step of acquiring MR signal for functional MR imaging of two people inside scanner. Step b) may further include the step of acquiring MR signal for molecular MR imaging of two people inside scanner. Step b) may further include the step of acquiring MR signal for metabolic imaging of two people inside scanner.
[0023] Step c) may further include the step of reconstructing anatomic MR images of interaction and or non-interaction between two people inside scanner. Step c) may further include the step of reconstructing functional MR images of interaction and or non-interaction between two people inside scanner. Step c) may further include the step of reconstructing molecular MR images of interaction and or non-interaction between two people inside scanner. Step c) may further include the step of reconstructing metabolic MR images of interaction and or non-interaction between two people inside scanner. Step c) may further include the step of constructing two circular polarized volume coils side-by-side for two people. The two component coils are decoupled by both their geometrical orientation and decoupling interface circuit system.
[0024] The method may further include the step of analyzing the physical sexual compatibility between man and woman. The method may further include step of analyzing the psychological compatibility between man and woman.
REFERENCES
[0025] [1] C. Frith and U. Frith, “Interacting Minds—A Biological Basis,” Science, vol. 286, pp. 1692-1695, November 1999. [0010] [2] P. R. Montague, G. Berns, J. Cohen, S. McClure, G. Pagnoni, M. Dhamala, M. Wiest, I. Karpov, R. King, N. Apple, and R. Fisher, “Hyperscanning: Simultaneous fMRI during Linked Social Interactions,” NeuroImage, vol. 16, pp. 1159-1164, 2002. [0011] [3] F. Babiloni, F. Cincotti, D. Mattia, F. de vico Fallani, A. Tocci, L. Bianchi, S. Salinari, M. Marchiani, A. Colosimo, and Astolfi, “High Resolution EEG Hyperscanning during a Card Game”, pp. 4957-4960, The 29.sup.th Annual International Conference of IEEE EMBS 2007, Lyon, France [0012] [4] R. F. Lee, R. Giaquinto, and C. Hardy, “Coupling and Decoupling Theory and its Application to the MRI Phased Array,” Magnetic Resonance in Medicine, vol. 48, pp. 203-213, 2002. | A system and method perform magnetic resonance imaging (“MRI”) on more than one people simultaneously with one MRI scanner. The system may include a superconducting or non-superconducting magnet, a set of three dimensions of magnetic field gradients, RF coils, and magnetic field shimming coil set that can accommodate more than one people within one scanner. The system and method may be used for performing MRI on more than one interacting or non-interacting people for anatomic, functional, metabolic, and/or molecular imaging and studies. | 0 |
FIELD OF THE INVENTION
The present invention relates to wafer processing and, more particularly, to wafer processing for electrical connections.
BACKGROUND
Semiconductor wafers are typically highly polished with very smooth surfaces (i.e. deviations of less than 1 nm). However, they are not necessarily uniformly flat across the extent of the wafer. The same is true for wafers of ceramic or other materials. Flatness variation, called “wafer bow,” may be a result of the wafer manufacturing process itself or processing of the wafer (e.g. through depositing of metal or dielectric onto the wafer) and can be on the order of 25 μm or more on the concave and/or convex side. If the polished side is concave, the wafer is often referred to as “dished” whereas if it is convex the wafer is called “bowed.” Note however, that an individual wafer can concurrently have both types of non-planarities (i.e. one portion is bowed whereas another portion is dished.
For simplicity herein, the terms “dished,” “bowed” and “non-planar” are interchangeably used herein to generically refer to a non-flat wafer of, for example, semiconductor or ceramic, irrespective of whether it would formally be called dished or bowed. FIG. 1 illustrates, in simplified form, a conventional non-planar wafer 100 . As shown, the wafer 100 is between 500 μm and 750 μm thick and has a maximum deviation “δ” at the edges of 25 μm from flat. As a result, in the example of FIG. 1 , the deviation from highest to lowest point across both sides is 40 μm. In most cases, with conventional processes for forming chips and interconnecting them to other chips, this amount of bow is sufficiently small relative to the size of typical connections that it can be disregarded. However, such variations can render a wafer unsuitable for use where the pitch and/or height of the individual contacts is less than or equal to 25 μm, unless further expensive polishing operations are performed to reduce the bow to an acceptable level, if it is possible to do so at all. Moreover, if the same types of connections will be used but the chip will be stacked with another chip, the bowing would be on the order of about 50 μm (i.e. taking into account the maximum deviation of 25 μm each for both chips and/or on both sides).
Thus, there is a need for a way to make use of individual wafers that have bow on a side with contacts that are less in height than the bow or on a pitch where such bow could make it impossible to connect to them.
SUMMARY OF THE INVENTION
We have devised a way to overcome the above problem, rendering wafers that are bowed by up to 20 μm each suitable for use with small pitch and/or height contacts and suitable for stacking despite their bowed nature.
One aspect of the invention involves a planarizing method performed on a non-planar wafer. The method involves forming electrically conductive posts extending through a removable material, each of the posts having a length such that a top of each post is located above a plane defining a point of maximum deviation for the wafer, concurrently smoothing the material and posts so as to form a substantially planar surface, and removing the material.
Another aspect of the invention involves an apparatus. The apparatus includes a non planar wafer having contacts thereon. The wafer has a deviation from planar by an amount that is greater than a height of at least one contact on the wafer. A set of electrically conductive posts extends away from a surface of the wafer. The distal ends of the posts collectively define a substantially flat plane.
Through use of the approaches described herein, bowed wafers can be used with various techniques that allow for via densities, pitch and placement and involve forming small, deep vias in, and electrical contacts for, the wafers—on a chip, die or wafer scale, even though the heights or densities of the contacts thereon are small relative to wafer bow.
The advantages and features described herein are a few of the many advantages and features available from representative embodiments and are presented only to assist in understanding the invention. It should be understood that they are not to be considered limitations on the invention as defined by the claims, or limitations on equivalents to the claims. For instance, some of these advantages are mutually contradictory, in that they cannot be simultaneously present in a single embodiment. Similarly, some advantages are applicable to one aspect of the invention, and inapplicable to others. Thus, this summary of features and advantages should not be considered dispositive in determining equivalence. Additional features and advantages of the invention will become apparent in the following description, from the drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates, in simplified form, a conventional non-flat wafer;
FIGS. 2 through 6 illustrate, in simplified from, use of our approach on a bowed wafer that is considered “dished;”
FIG. 7 illustrates, in simplified form, the wafer of FIG. 6 after a set of chips have been connected to it;
FIG. 8 through FIG. 15 illustrate, in simplified from, use of our approach on a bowed wafer 100 that is considered “bowed;”
FIG. 16 illustrates, in simplified form, the wafer of FIG. 15 after a set of chips have been connected to it using the planarizing posts formed using the process;
FIG. 17 illustrates, in simplified form, a pair of dished wafers that have been planarized according to the approach described herein and joined to each other; and
FIG. 18 illustrates, in simplified form, a pair of bowed wafers that have been planarized according to the approach described herein and joined to each other.
Note that all of the FIGS. are grossly distorted and out of scale for simplicity of presentation.
DETAILED DESCRIPTION
U.S. patent applications, Ser. Nos. 11/329,481, 11/329,506, 11/329,539, 11/329,540, 11/329,556, 11/329,557, 11/329,558, 11/329,574, 11/329,575, 11/329,576, 11/329,873, 11/329,874, 11/329,875, 11/329,883, 11/329,885, 11/329,886, 11/329,887, 11/329,952, 11/329,953, 11/329,955, 11/330,011 and 11/422,551, incorporated herein by reference, describe various techniques for forming small, deep vias in, and electrical contacts for, semiconductor wafers. The techniques allow for via densities, pitch and placement that was previously unachievable and can be performed on a chip, die or wafer scale. In some cases, it is desirable to perform the techniques described therein on a wafer but the contact heights or densities are small relative to wafer bow. Advantageously, we have developed a way to do so. FIGS. 2 through 6 illustrate, in simplified from, use of our approach on a bowed wafer 100 that is considered “dished.” The process is as follows:
First, as shown in FIG. 2 , a material 200 is applied to the dished side 202 of the wafer 100 to a thickness that is at least equal to, and typically more than, the maximum deflection δ on that side (as indicated by the dashed line 204 ).
Depending upon the particular implementation, the material 200 could be a flowable material or fairly solid material. In general, to reduce the number of processing steps, the material will be a photoresist or photosensitive dielectric, so that it can be patterned. Alternatively, a machine-able or moldable material could be used. In the case of a substantially solid material, example suitable materials include photoresists from the Riston® dry film line of photoresist, commercially available from E. I. du Pont de Nemours & Co. Specifically, The Riston® PlateMaster, EtchMaster and TentMaster lines of photoresist are suitable and at, respectively, about 38 μm, 33 μm and 30 μm in thickness, are all more than sufficient o handle the deviations at issue.
In the case of a device bearing wafer, using a material 200 that can be patterned makes it easier to match and create openings over the locations of the contacts or device pads on the wafer 100 . In addition, if a substantially solid material 200 is used, the wafer can also contain unfilled vias or features extending into the wafer and there is little to no risk of those vias becoming filled by the material 200 —indeed it can protect them from becoming filled by subsequent steps if desired.
FIG. 3 illustrates, in simplified form, the wafer 100 after the material has been patterned to form openings 300 - 1 , 300 - 2 , 300 - 3 , 300 - 4 , 300 - 5 , 300 - 6 , 300 - 7 , 300 - 8 , 300 - 9 , 300 - 10 in the wafer over pre-formed connection points.
Thereafter, the openings are filled with electrically conductive material, typically a metal, using any suitable process including, for example in the case of metal, deposition or plating (electro- or electroless) or some combination thereof
FIG. 4 illustrates, in simplified form, the wafer 100 of FIG. 3 after the openings 300 - 1 , 300 - 2 , 300 - 3 , 300 - 4 , 300 - 5 , 300 - 6 , 300 - 7 , 300 - 8 , 300 - 9 , 300 - 10 have each been filled with the electrically conductive material 402 .
Next, the surface 400 of the wafer 100 is polished smooth using a conventional polishing or other smooth finishing method that will result in as small a deviation as possible, with maximum deviation of less than the contact height, typically from ±0 μm to about 10 μm. However, in some implementations where a post and penetration connection will be used, that approach can allow for greater deviations due to the inherent flexibility that such connections provide.
The approach involves the use of two contacts in combination: a rigid “post” contact and a relatively malleable (with respect to the post material) pad contact, in some cases, either or both having an underlying rigid supporting structure or standoff. In simple overview, one of the two contacts is a rigid material, such as nickel (Ni), copper (Cu) or paladium (Pd) or other suitably rigid alloy such as described herein. This contact serves as the “post.” The other of the two contacts is a material that is sufficiently softer than the post that when the two contacts are brought together under pressure (whether from an externally applied force or a force caused, for example, by flexation of the wafer) the post will penetrate the malleable material (the “post and penetration” part) and heated to above a prespecified temperature (the tack phase of the tack and fuse process) the two will become “tacked” together upon cooling to below that temperature without either of them reaching a liquidus state.
Advantageously, the tack and fuse processes are both typically non-liquidus process. This means that the process is done so that the malleable material becomes softened significantly but does not become completely liquidus during either the tack or fuse processes. This is because if the malleable material were to become liquidus, there would be significant risk that the resultant liquid would run and short out adjacent contacts. By keeping the materials non-liquidus, far greater contact density can be achieved.
FIG. 5 illustrates, in simplified form, the wafer 100 after the polishing operation has been completed.
Next, as shown in FIG. 6 , after the material 200 has been removed, using a process appropriate to the selected material 200 , a series of elevated, conductive “posts” 600 , 602 , 604 606 , 608 , 610 , 612 , 614 , 616 , 618 will remain and, although the posts 600 , 602 , 604 606 , 608 , 610 , 612 , 614 , 616 , 618 may be of differing heights, their upper surfaces will be substantially flat (i.e. within the maximum deviation of the polishing or smooth finishing method). As a result, the connection points on the wafer 100 can now be connected to, or another chip, die or wafer can be stacked without encountering the problems of the prior art noted above.
FIG. 7 illustrates, in simplified form, the wafer 100 of FIG. 6 after a set of chips 702 , 704 , 706 , 708 have been connected to it using the planarizing posts 600 , 602 , 604 606 , 608 , 610 , 612 , 614 , 616 , 618 formed using the process.
FIG. 8 illustrates, in simplified form, a wafer 800 that is considered “bowed.”
FIG. 9 through FIG. 15 illustrate, in simplified from, use of our approach on the bowed wafer 800 of FIG. 8 “bowed.” The process is as follows:
First, as shown in FIG. 9 , as with FIG. 2 , a material 200 such as described in connection with FIG. 2 , is applied to the wafer 800 , although, in this case, it is applied to the bowed side 802 of the wafer 100 .
As illustrated in FIG. 10 , the material 200 is again applied to a thickness that is at least equal to, and typically more than, the maximum deflection δ on that side (as indicated by the dashed line 1002 ).
FIG. 11 illustrates, in simplified form, the wafer 800 after the material has been patterned to form openings 1100 - 1 , 1100 - 2 , 1100 - 3 , 1100 - 4 , 1100 - 5 , 1100 - 6 , 1100 - 7 , 1100 - 8 , 1100 - 9 , 1100 - 10 in the wafer over pre-formed connection points.
Thereafter, as above, the openings are filled with an electrically conductive material, typically metal, using any suitable process including, for example, deposition or plating (electro- or electroless) or some combination thereof
FIG. 12 illustrates, in simplified form, the wafer 800 of FIG. 11 after the openings have been filled.
Next, as shown in FIG. 13 , the wafer 800 will be polished smooth, in this case down to a level indicated by the dashed line 1300 , using a conventional polishing or other smooth finishing method that will result in it being substantially flat (i.e. having a deviation from a commercially creatable “perfectly flat” of between 0 μm and no more than about 10 μm).
FIG. 14 illustrates, in simplified form, the wafer 800 after the polishing operation has been completed.
Next, as shown in FIG. 15 , after the material 200 has been removed, using a process appropriate to the selected material 200 , a series of elevated, electrically conductive “posts” 1500 , 1502 , 1504 1506 , 1508 , 1510 , 1512 , 1514 , 1516 , 1518 will remain and, although the posts 1500 , 1502 , 1504 1506 , 1508 , 1510 , 1512 , 1514 , 1516 , 1518 may be of differing heights, their upper surfaces will be substantially planar (within the maximum deviation of the polishing or smooth finishing method). As a result, the connection points on the wafer 800 can now be connected to, or another chip, die or wafer can be stacked without encountering the problems of the prior art noted above.
FIG. 16 illustrates, in simplified form, the wafer 800 of FIG. 15 after a set of chips 1602 , 1604 , 1606 have been connected to it using the planarizing posts 1500 , 1502 , 1504 1506 , 1508 , 1510 , 1512 , 1514 , 1516 , 1518 formed using the process.
Thus, should now be appreciated that the approaches described above will allow one to readily connect, on a wafer basis, a pair of wafers that are at a maximum bowed deviation irrespective of whether they are dished or bowed in configuration.
FIG. 17 illustrates, in simplified form, a pair of dished wafers 1700 , 1702 that have been planarized according to the approach described herein and joined to each other.
FIG. 18 illustrates, in simplified form, a pair of bowed wafers 1700 , 1702 that have been planarized according to the approach described herein and joined to each other.
Of course, the same approach could be used to connect a dished to a bowed or a bowed to a dished wafer in the same manner.
It should thus be understood that this description (including the figures) is only representative of some illustrative embodiments. For the convenience of the reader, the above description has focused on a representative sample of all possible embodiments, a sample that teaches the principles of the invention. The description has not attempted to exhaustively enumerate all possible variations. That alternate embodiments may not have been presented for a specific portion of the invention, or that further undescribed alternate embodiments may be available for a portion, is not to be considered a disclaimer of those alternate embodiments. One of ordinary skill will appreciate that many of those undescribed embodiments incorporate the same principles of the invention and others are equivalent. | A planarizing method performed on a non-planar wafer involves forming electrically conductive posts extending through a removable material, each of the posts having a length such that a top of each post is located above a plane defining a point of maximum deviation for the wafer, concurrently smoothing the material and posts so as to form a substantially planar surface, and removing the material. An apparatus includes a non planar wafer having contacts thereon, the wafer having a deviation from planar by an amount that is greater than a height of at least one contact on the wafer, and a set of electrically conductive posts extending away from a surface of the wafer, the posts each having a distal end, the distal ends of the posts collectively defining a substantially flat plane. | 7 |
BACKGROUND OF THE INVENTION
The present invention is directed generally to circuit testing and, more particularly, to the testing of circuits constructed using solid state fabrication techniques.
After the fabrication of a chip containing one or more solid state circuits, it is common in the industry to require that the chip pass certain tests before being identified as a good part. For example, after the fabrication of a memory device, the memory device is connected to a tester which automatically performs a series of preprogrammed tests on the part. See, for example, U.S. Pat. No. 6,483,333 entitled Automated Multi-Chip Module Handler and Testing System.
Often during the fabrication of parts, particularly new parts, the signals available at the output pins of the part are insufficient to provide the designer with the information necessary to understand how the part is performing. In those situations, diagnostic systems are available such as the system disclosed in U.S. Pat. No. 6,841,991. In such diagnostic systems, probes are brought into contact with various nodes on the circuit to sample and analyze the signals available at those nodes. For that to be performed, the nodes of the circuit must be available to the probe of the diagnostic system. Thus, the part must be tested before fabrication is complete at which time the circuits of the part are accessible only through the part's output pins.
There is a need to be able to access various nodes within a circuit even after a device has been completely fabricated.
BRIEF SUMMARY
According to one embodiment of the present disclosure, a sampling circuit is comprised of a plurality of probe circuits, with each probe circuit connected to a unique node within an encapsulated and/or packaged circuit to be tested. A decode circuit selects one of the probe circuits to enable the signal available at the unique node to which the probe circuit is connected to be transmitted.
According to another embodiment of the present disclosure, a sampling circuit is comprised of a first plurality of probe circuits, with each probe circuit connected to a unique node within an encapsulated and/or packaged circuit to be tested. A first decode circuit selects one of the first plurality of probe circuits. A second plurality of probe circuits is provided with each of the probe circuits connected to a unique node within the circuit to be tested. A second decode circuit selects one of the second plurality of probe circuits. An output select circuit is provided for selecting between the first plurality of probe circuits and the second plurality of probe circuits so that a unique signal may be output for review and analysis.
Multiple pluralities of probe circuits and decode circuits may be provided. The manner of signal output may vary depending on the number of pins available. For example, if one pin is available, the multiple pluralities of probe circuits will compete with one another via the output select circuit. If two pins are available, one pin may be responsive to one plurality of probe circuits while the other pin is responsive to the other pluralities of probe circuits via a select circuit. Numerous output combinations and permutations are possible.
When the probe circuit of the present disclosure is implemented in the context of a solid state memory device, the various decode circuits and output select circuit(s) may be responsive to address signals or some portion of an address signal. A method of operating such a sampling circuit as well as systems embodying sampling circuits are also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
For the present invention to be easily understood and readily practiced, the present invention will now be described, for purposes of illustration and not limitation, in conjunction with the following figures, wherein:
FIG. 1 is a block diagram illustrating a first embodiment of a sampling circuit of the present disclosure;
FIG. 2 is a block diagram illustrating another embodiment of a sampling circuit of the present disclosure;
FIG. 3 illustrates one example of a memory device in which the sampling circuit of the present disclosure may be implemented;
FIGS. 4A and 4B illustrate various exemplary circuitry for implementing the block diagram of FIG. 2 ;
FIG. 5 illustrates another embodiment of the present disclosure;
FIG. 6 illustrates circuits, within a device to be tested, connected to the sampling circuit of the present disclosure; and
FIG. 7 illustrates a system using one or more devices incorporating the sampling circuit of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram illustrating a first embodiment of a sampling circuit 8 constructed according to the teachings of the present disclosure. A circuit 10 to be tested has discrete nodes or tap points 12 , 14 , 16 identified within the circuit 10 . The circuit 10 has been, for example, encapsulated such that the circuit 10 communicates via a plurality of pins (not shown). The nodes 12 , 14 , 16 are identified as points of interest such that the signals available at those nodes will help engineers, designers, etc. to understand how the circuit 10 is functioning. Each of the nodes 12 , 14 , 16 is connected to a probe circuit 22 , 24 , 26 , respectively. The probe circuits 22 , 24 , 26 are serially connected. Each of the probe circuits 22 , 24 , 26 is responsive to a decode circuit 28 which is responsive to control signals.
In operation, signals available at nodes 12 , 14 , 16 are received by their respective probe circuits 22 , 24 , 26 . The decode circuit 28 , in response to the control signals, selects one of the probe circuits 22 , 24 , 26 such that the signal available at the selected probe circuit's node is transmitted as shown by the arrow 30 . The transmitted signal may be transmitted to more probe circuits (not shown) or connected to an output pin (not shown). In this example, the signals available at nodes 12 , 14 , 16 are all capable of being analyzed externally of the circuit 10 , although only one at a time. In the embodiment illustrated in FIG. 1 , the probe circuits 22 , 24 , 26 together with the decode circuit 28 comprise the sampling circuit 8 .
FIG. 2 is a block diagram illustrating another embodiment of a sampling circuit of the present disclosure. The upper half of FIG. 2 is identical to FIG. 1 . However, in FIG. 2 additional nodes or tap points 12 ′, 14 ′, 16 ′ have been identified within circuit 10 to be analyzed. The nodes 12 ′, 14 ′, 16 ′ are connected to probe circuits 22 ′, 24 ′, 26 ′, respectively. In addition, an output 31 of probe circuit 26 is connected to an output select circuit 32 while an output 31 ′ of probe circuit 26 ′ is also connected to output select circuit 32 .
In operation, control signals are input to the decode circuit 28 to select one of the signals available at nodes 12 , 14 , 16 to be output at output terminal 31 . Similarly, control signals input to decode circuit 28 ′, which may be the same or different from the control signals input to decode circuit 28 , select one of the signals available at nodes 12 ′, 14 ′, 16 ′ to be output at output terminal 31 ′. A plurality of such strings of probe circuits, with each string of probe circuits responsive to various nodes or tap points, may be provided. The output of each of those strings of probe circuits is input to output select circuit 32 . Output select circuit 32 , in response to control signals input thereto, selects one of the various signals input thereto to be output, preferably to an output pin of the circuit 10 to be tested. Those of ordinary skill in the art will recognize that the number of serially connected probe circuits is limited by the capabilities of the decode circuit. That is, the decode circuit must be able to select one of the probe circuits so that the signal connected thereto is selected for transmission. Similarly, the number of serially connected strings of probe circuits is limited by the ability of the output select circuit 32 to uniquely identify each of the signals input thereto so that any one of the input signals can be selected as the output signal.
The location of the probe circuits, location of the decode circuits, and location of the output select circuit, if needed, is dependent upon available space within circuit 10 to be tested. It is anticipated that early in part life, i.e. when a part is first designed and first fabricated, the number and position of the probe circuits will depend upon various factors such as a need to know how a certain portion of the circuit 10 is operating, what manufacturing defects are being encountered in various hard to manufacture components or portions of the circuit 10 , etc. As the circuit 10 proceeds through its normal life, and various problems are solved, subsequent generations of circuit 10 may be designed with fewer probe circuits with the space used to provide other features or functions for the circuit 10 . It is anticipated that the present invention will be most useful in the context of circuits 10 which are fabricated using solid state fabrication techniques. When that is the case, it is anticipated that the various probe circuits, decode circuits, and output select circuit (if needed) will be fabricated along with the fabrication of circuit 10 .
It is anticipated that the sampling circuit 8 of the present invention may be implemented in a wide variety of devices. One type of device, a memory device 34 , is illustrated in FIG. 3 . The memory device 34 may be part of a dual in-line memory module (DIMM) or a printed circuit board (PCB) containing many such memory devices 34 . The memory device 34 may include a plurality of pins 36 located outside of memory device 34 for electrically connecting the memory device 34 to other devices. Some of those pins 36 may constitute memory address pins or an address bus 38 , data (DQ) pins or a data bus 40 , and control pins or a control bus 42 . It is evident that each of the reference numerals 38 , 40 , 42 designates more than one pin in the corresponding bus. Further, it is understood that the block diagram in FIG. 3 is for illustration purposes only. That is, the pin arrangement or configuration in other types of memory devices 34 may not be as shown in FIG. 3 . For example, in some types of memory devices 34 there is a single bus which is time multiplexed. At certain points of time, the common bus carries address information, at other points data information, and at other times control information. Thus, references to, for example, an address bus refers to both a dedicated address bus as well as a time multiplexed bus.
Continuing with the description of FIG. 3 , a processor or memory controller (not shown in FIG. 3 ) may communicate with device 34 to perform memory read/write operations. The processor and the memory device 34 may communicate using address signals on address lines or address bus 38 , data signals on data lines or data bus 40 , and control signals (e.g. row address select (RAS) signal, column address select (CAS) signal, chip select (CS) signal etc. (not shown)) on control lines or control bus 42 . The width, i.e. number of pins, of the address, data and control buses may differ from one memory configuration to another.
The device 34 may include a plurality of memory cells 44 generally arranged in an array of rows and columns. A row decode circuit 46 and a column decode circuit 48 may select the rows and columns, respectively, in the array 44 in response to decoding an address provided on the address bus 38 . Data to/from the array of memory cells 44 are then transferred to the data bus 40 via sense amplifiers and a data output path, shown generally as input/output (I/O) circuit 50 . A memory controller (not shown) may provide relevant control signals (not shown) on the control bus 42 to control data communication to/from the memory device 34 via the input output circuit 50 . The I/O circuit 50 may include the aforementioned sense amplifiers and data output path including a number of data output buffers or output drivers to receive the data bits from the memory cells comprising the array of cells 44 and provide those data bits or data signals to the corresponding data lines in the data bus 40 . The I/O circuit 50 may also include various memory input buffers and control circuits that interact with the row and column decoders 46 , 48 , respectively, to select the memory cells for data read/write operations.
The memory controller (not shown) may determine the modes of operation of memory device 34 . Some examples of the input signals or control signals not shown in FIG. 1 , but which may be available on control bus 42 include an external clock (CLK) signal, a chip select (CS) signal, a row address strobe (RAS) signal, a column address strobe (CAS) signal, a write enable (WE) signal, etc. The encapsulated/packaged memory device 34 communicates with other devices connected thereto via the pins 36 . One or more of the pins 36 , not being used for address, data, or control signals, may be used as the output pin for the sampling circuit. More than one output pin may be provided assuming unused pins are present.
In addition to the pads previously described (address, data, etc.), extra pads may be added for the express purpose of providing outputs for various embodiments. Such extra pads would likely not be made available to the customer. That is, such extra pads would not be routed to external pins on packages destined for the consumer. However, such extra pads may or may not be routed to pins on packages created for the sole purpose of engineering analysis, such as special test packages. In cases where these pads are not routed to package pins, all analysis would be performed at the wafer or pre-packaged die level. Thus, data from circuits of the present disclosure may be output in at least four ways: (1) from pads already existing for normal chip operation (address pins, data pins, etc.); (2) from package pins/balls existing for normal chip operation; (3) from pads created for the specific purpose of providing specific outputs (available or unavailable to the customer); and (4) from package pins/balls created for the specific purpose of providing outputs. These pins/balls would be connected to pads from number 3 above, and would likely be unavailable to the customer.
Those of ordinary skill in the art will recognize that the memory device 34 of FIG. 3 is simplified to illustrate one embodiment of a memory device and is not intended to be a detailed illustration of all of the features of a typical memory device. Numerous peripheral devices or circuits are typically provided for writing data to and reading data from the array of memory cells 44 . However, those peripheral devices are not shown in FIG. 3 for the sake of clarity.
FIG. 4A illustrates various exemplary circuitry for implementing the block diagram of FIG. 2 . In FIG. 4A , nodes 12 , 14 , 16 receive the signals phLock, CLK DLL, and PDR, respectively. A fourth node 58 receives the signal d 11 REF. The probe circuits 22 , 24 , 26 are illustrated along with a fourth probe circuit 60 . Each of the probe circuits is comprised in this exemplary embodiment of an inverter 62 receiving the signal from that probe circuit's node. A first logic gate 64 is responsive to the inverter 62 and a signal from the decode circuit 28 . Decode circuit 38 may be responsive to a portion of an address signal. A second logic gate 66 is responsive to the first logic gate 64 and the previous probe signal or, in the case of the first probe circuit in a series of probe circuits, a predetermined voltage source, e.g. Vdd (high). An inverter 68 , responsive to the second logic gate 66 , provides the output of the probe circuit. Each of the probe circuits 24 , 26 , 60 is similar in construction and operation to the probe circuit 22 . The series connected probe circuits 22 , 24 , 26 , 60 is referred to in FIG. 4A as the group 0 probe circuits. As shown in FIG. 4A , there are seven (7) other groups of probe circuits, each with the same logic as group 0 but with different signals connected thereto. The decode circuit 28 enables selection of any one of the probe circuits 22 , 24 , 26 , 60 within each of the groups 0 - 7 . Each of the groups of serially connected probe circuits is connected to the output select circuit 32 . The output select circuit 32 is, as shown in FIG. 4A , a group of logic gates responsive to control signals to enable one of the signals output from one of the groups 0 - 7 to be selected as the output of the sampling circuit 8 . The signal selected for output by the output select circuit 32 is input to output logic 70 which may comprise a normal output path for the device in which the sampling circuit is located. For example, in the context of a memory device 34 , output logic 70 may include latches and drivers, or other appropriate circuitry, for driving the output signal on to one of the output pads of the device, which is ultimately connected to the output pin.
Circuits that mix or compare signals before sending a signal to an output may be included. Mixing and comparing type circuits would have more than one tapped node going into the same circuit, and would provide useful relative timing information. For example, in FIG. 4B , two separate signals are input to a NAND gate 72 that may be used to provide relative timing information as shown by the simple timing diagram for the signals A, B and Y.
The figures that have been discussed so far imply that all nodes 12 , 14 , 16 , etc. are related in some way, i.e. nodes 12 and 14 are separated by the “circuit to be analyzed”. That need not necessarily be true. Nodes 12 , 14 , 16 , etc. can be from completely separate and disjoint circuits. FIG. 5 illustrates that one node to be analyzed is located in a first circuit and provides the signal A (of FIG. 4B ) while another node in another circuit to be analyzed provides the signal B (of FIG. 4B ) which are input to the probe circuit which produces the output signal Y. The probe circuit in FIG. 5 could be responsive to a decode circuit as previously discussed.
The embodiment shown in FIG. 4A assumes that only one output pin is available on the device such that the output select circuit 32 is required to enable one signal at a time to be output. However, should two output pins be available, two output select circuits 32 may be provided with each of the output select circuits handling some number of the groups 0 - 7 so that two signals may be simultaneously output. Alternatively, if one of the groups is determined to be more important than the other groups of serially connected probe circuits, one of the groups, for example group 0 , could be connected to an output pin through its own output logic 70 , and the remainder of the groups, group 1 - 7 , could be connected to their own output logic 70 through an output select circuit 32 . Thus, those of ordinary skill in the art will recognize that many output combinations are possible depending upon the number of pins available for the signals.
FIG. 6 illustrates various sections, i.e. circuits, within the circuit 10 to be tested connected to the probe circuits 22 , 24 , 26 , 60 of group 0 illustrated in FIG. 4A . FIG. 6 illustrates how the sampling circuit 8 of the present invention may be integrated within a circuit to be tested such as a memory device 34 . FIG. 6 illustrates the location of the tap points 12 , 14 , 16 , 58 within the circuit 10 to be tested. The illustrated tap points are provided for purposes of illustration and not limitation. Clearly, the number and location of tap points will depend upon the circuit to be tested and the maturity of the circuit.
FIG. 7 is a block diagram depicting a system 100 in which one or more memory chips 34 illustrated in FIG. 3 may be used. The system 100 may include a data processing unit or computing unit 102 that includes a processor 104 for performing various computing functions, such as executing specific software to perform specific calculations or data processing tasks. The computing unit 102 also includes a memory controller 108 that is in communication with the processor 104 through a bus 106 . The bus 106 may include an address bus (not shown), a data bus (not shown), and a control bus (not shown), or a single, time multiplexed bus. The memory controller 108 is also in communication with a set of memory devices 34 (i.e., multiple memory chips 34 of the type shown in FIG. 3 ) through another bus 110 . Each memory device 34 may include appropriate data storage and retrieval circuitry as shown in FIG. 3 . The processor 104 can perform a plurality of functions based on information and data stored in the memories 34 .
The memory controller 108 can be a microprocessor, digital signal processor, embedded processor, micro-controller, dedicated memory test chip, a tester platform, or the like. The memory controller 108 may control routine data transfer operations to/from the memories 34 , for example, when the memory devices 34 are part of an operational computing system 102 . The memory controller 108 may reside on the same motherboard (not shown) as that carrying the memory chips 34 . Various other configurations between the memory chips 34 and the memory controller 108 may be possible. For example, the memory controller 108 may be a remote entity communicating with the memory chips 34 via a data transfer or communications network (e.g., a LAN (local area network) of computing devices).
The system 100 may include one or more input devices 112 (e.g., a keyboard or a mouse) connected to the computing unit 102 to allow a user to manually input data, instructions, etc., to operate the computing unit 102 . One or more output devices 114 connected to the computing unit 102 may also be provided as part of the system 100 to display or otherwise output data generated by the processor 104 . Examples of output devices 114 include printers, video terminals or video display units (VDUs). In one embodiment, the system 100 also includes one or more data storage devices 116 connected to the data processing unit 102 to allow the processor 104 to store data in or retrieve data from internal or external storage media (not shown). Examples of typical data storage devices 116 include drives that accept hard and floppy disks, CD-ROMs (compact disk read-only memories), and tape cassettes.
While the present invention has been described in connection with preferred embodiments thereof, those of ordinary skill in the art will recognize that many modifications and variations are possible. The present invention is intended to be limited only by the following claims and not by the foregoing description which is intended to set forth the presently preferred embodiments. | Through addressing circuitry, a sampling circuit can choose a unique internal node/signal on an encapsulated/packaged chip to be output to one or more drivers. The chosen signals available at the target node are directed either through a select circuit to an output pin, or directly to an output pin. In a preferred mode, decode circuits used to select a unique node are serially connected, allowing for a large number of signals to be made available for analyzing without a large impact on circuit layout. | 6 |
[0001] The present invention is a continuation application of co-pending International Patent Appln. No. PCT/US00/24581, filed Sep. 8, 2000 and designating the United States of America, which application claims the benefit of Provisional U.S. application Ser. No. 60/153,375, filed Sep. 10, 1999; the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to textile treatment compositions for imparting permanent abrasion- and wrinkle-resistance to textiles.
BACKGROUND OF THE INVENTION
[0003] Cotton consists of cellulose, a polysaccharide. The cellulose molecules in a cotton fiber are arranged linearly and pass in and out of crystalline and amorphous regions and are held in place by hydrogen bonds between the molecules. Slippage between the cellulose chains or between larger structural units of the fiber occurs when a force of sufficient magnitude is placed on the fiber. The hydrogen bonds tend to resist or prevent the slippage, but once slippage occurs the bonds reform in new locations and tend to maintain the fiber in the bent or wrinkled state. In addition, cotton fiber is hydrophilic and absorbs water, which can break hydrogen bonds and allow the fiber or fabric to shrink. Thus, 100% cotton wrinkles easily and has the potential to shrink upon laundering.
[0004] Cellulose is made up of repeating anhydroglucose units. Each unit contains two secondary and one primary alcohol groups. To achieve wrinkle resistance, alcohol groups on adjacent cellulose chains are partially crosslinked to keep the chains fixed relative to each other. Over the years, a number of crosslinking agents (resins) have been explored to achieve durable-press properties. Some include isocyanates, epoxides, divinylsulfones, aldehydes, chlorohydrins, N-methylol compounds, and polycarboxylic acids. Of these, N-methylol compounds have been used the most. Examples include dimethylol urea, dimethylol ethylene urea, trimethylol trazine, dimethylol methyl carbamate, uron, triazone, and dimethylol dihydroxy ethylene urea. Dimethylol dihydroxy ethylene urea (DMDHEU) is the most common durable-press finish used today.
[0005] Resins improve wrinkle recovery, fabric smoothness, dimensional stability, washfastness of some dyes, pilling resistance, ease of ironing, durability of finishes (repellents, hand modifiers, embossing, etc.), and general appearance. However, crosslinking has its disadvantages, including loss in tear and tensile strength, loss in abrasion resistance, reduced moisture regain, possible damage due to chlorine retention, potential odors, potential discoloration, and sewing problems. Durable-press fabrics also often have stiff, harsh, uncomfortable fabric tactile (hand) properties. Therefore, fabric softeners/lubricants are commonly added to these fabrics to mitigate some of these deficiencies. Softeners improve the hand of the fabric as well as increase abrasion resistance and tear strength. The softener also functions as a sewing lubricant. There are four basic types of softeners—anionic, cationic, nonionic, and blended systems.
[0006] The anionic softeners are generally sulfated or sulfonated compounds used primarily to lubricate yarns through processing. Examples of these compounds include sulfonated tallow, glycerides, and esters. Sulfonated or sulfated castor oil, propyl oleate, butyl oleate, and tallow are used in various steps in dying fabrics. Anionics tend to provide inferior softness compared to the cationics and nonionics. Furthermore, they have limited durability to laundering or dry-cleaning. Their major limitation comes from their negative charge, which causes incompatibility in resin finishing baths and makes them most sensitive to water hardness and electrolytes.
[0007] The cationic softeners are nitrogen-containing compounds including fatty amino amides, imidazolines, amino polysiloxanes, and quaternaries. As a result of their positive charge, they are attracted to cotton or synthetic fabrics through electrostatic interactions. They tend to be compatible with most resin finishes and are somewhat durable to laundering. The most significant disadvantage of cationic softeners is their tendency to change the shade or affect the fastness of certain dyestuffs. Discoloration on white fabrics may also be a concern. The development of a fishy odor on the fabric can be a problem with certain systems.
[0008] Nonionics are the most widely used softeners. This class includes polyethylenes, glycerides such as glycerol monostearate, ethoxylates such as ethoxylated castor wax, coconut oil, corn oil, etc., and ethoxylated fatty alcohol and acids. The nonionic softeners offer excellent compatibility in resin baths due to their uncharged state. Since nonionics have no charge, they have no specific affinity for fabrics and therefore have relatively low durability to washing.
[0009] To optimize softening and lubricating properties, many manufacturers tend to formulate a softener containing both nonionic and cationic types. Typically, an aminosilicone or an imidazoline for a silky soft slick hand will be blended with a cationic or a nonionic polyethylene lubricant for sewability and tear- and abrasion-strength properties. Increased customer demand for improved durability and useful life of a garment has led to the use of high-density polyethylenes as softeners. Polyethylenes have decreased solubility in detergent solutions,which results in increased softener durability. However, the disadvantages of the softeners (such as, for example, lack of durability to repeated launderings) remain.
SUMMARY OF THE INVENTION
[0010] This invention is directed to treatment preparations useful for the permanent or substantially permanent treatment of textiles and other webs to provide tear and abrasion strength and softness to durable-press garments. The preparations comprise a softener (referred to herein as a “resin-reactive modifier”) durable to repeated laundering used in conjunction with a durable-press resin, to increase the comfort and lifetime of durable-press garments. More particularly, the preparations of the invention comprise a “rubbery” resin-reactive modifier capable of reacting with a durable-press resin during textile treatment. By “reacting” is meant that the polymer will form a covalent bond with the durable-press resin and the resin will form a covalent bond to the fiber, textile, or web to be treated. The resulting durable-press/softener preparation is substantially permanently attached to the web and provides improved softness and tear/abrasion strength retention within and/or on the textile or web fiber structure while retaining the durable-press properties of the resin through repeated launderings.
[0011] This invention is further directed to the yarns, fibers, fabrics, textiles, finished goods, or nonwovens (encompassed herein under the terms “textiles” and “webs”) treated with the textile-reactive durable-press/softener preparation. Such textiles and webs exhibit a greatly improved, durable softness and tear/abrasion strength. By “durable softness and tear/abrasion strength” and “durable wrinkle resistance, a soft hand, and tear/abrasion resistance” are meant that the textile or web will exhibit improved softness and resistance to tear and/or abrasion, even after multiple launderings, while retaining its durable press or resistance to wrinkling.
[0012] Methods are provided for treating fabrics to impart permanent wrinkle resistance as well as permanent softness and tear/abrasion resistance by combining a “rubbery” resin-reactive modifier with durable-press resins.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The textile-reactive preparations of the invention comprise a combination of i) a durable-press resin capable of imparting wrinkle resistance and ii) a resin-reactive modifier capable of imparting a soft hand and tear/abrasion resistance to textiles.
[0014] The resin-reactive modifier useful in the present invention comprises particular monomers, oligomers, or polymers having hydroxyl—or other reactive group-containing monomers, or mixtures thereof (referred to herein and in the appended claims as “reactive building blocks”), copolymerized with soft, rubbery or elastomeric monomers or polymers (referred to herein and in the appended claims as “rubbery building blocks”). The resin-reactive modifier may also comprise rubbery building blocks that are processed post-polymerization to include hydroxyl—or other reactive groups. The resin-reactive modifier is capable of reacting with a durable-press resin during textile treatment. By “reacting” is meant that the resin-reactive polymer will form a covalent bond with the durable-press resin. The resin in turn will form a covalent bond to the fiber, textile, or web to be treated. The resin-reactive modifier will impart a soft hand to the resin-treated textile and also provide tear and/or abrasion resistance to the textile. This resin-reactive modifier, because of its covalent bonding to the textile through the wrinkle-resistant resin, is durable to laundering and is permanent, and it significantly increases the comfort and lifetime of durable-press garments.
[0015] The rubbery groups of the resin-reactive modifier are selected from those groups that will provide the necessary softness and tear/abrasion resistance. Examples include polymers of isoprene, chloroprene, butadiene, ethylene, isopropylene, ethyleneoxide, isobutylene, propylene, chlorinated ethylene, and polymers such as polydimethylsiloxane, polyisobutylene, poly-alt-styrene-co-butadiene, poly-random-styrene-co-butadiene, etc., and copolymers of all of these. The rubbery group is copolymerized in such a proportion as to take about 60% to about 99.8% by weight, preferably about 80% to about 95% by weight, of the resin-reactive modifier copolymer of this invention.
[0016] The reactive groups on the resin-reactive modifier are selected from those groups that will bind chemically with a particular durable-press resin. For example, groups may consist of hydroxyls, amines, amides, or thiols. In a presently preferred embodiment, the resin modifier is selected from polymers containing at least one hydroxyl group per molecule.
[0017] The durable-press resin is chosen from those that will bind chemically with a particular fiber, yarn, fabric, or finished good. For example, cellulosic-based webs such as paper, cotton, rayon, linen, and jute contain hydroxyls. Wool, which is a proteinaceous animal fiber, contains hydroxyls, amines, carboxylates, and thiols.
[0018] Specific amine-reactive groups (for reaction with wool, for example) include isothiocyanates, isocyanates, acyl azides, N-hydroxysuccinimide esters, sulfonyl chlorides, aldehydes and glyoxals, epoxides and oxiranes, carbonates, arylating agents, imidoesters, carbodiimides, anhydrides (such as maleic anhydride), and halohydrins. Carboxylate-reactive groups (for reaction with wool, e.g.) include diazoalkanes and diazoacetyl compounds, carbonyl diimidazole, and carbodiimides. Hydroxyl-reactive chemical reactions (for, e.g., wool and cotton) include couplings with epoxides and oxiranes, carbonyl diimidazole, N,N′-disuccinimidyl carbonate or N-hydroxysuccinimidyl chloroformate, alkyl halogens, isocyanates, and halohydrins, oxidation with periodate, and enzymatic oxidization. Examples of thiol-reactive chemical reactions (for wool, for example) include couplings with haloacetyl and alkyl halide derivatives, maleimides, aziridines, acryloyl derivatives, arylating agents, and disulfide-forming reactions mediated by exchange reagents (such as pyridyl disulfides, disulfide reductants, and 5-thio-2-nitrobenzoic acid, for example).
[0019] Durable-press resins useful in the present invention include isocyanates, epoxides, divinylsulfones, aldehydes, chlorohydrins, N-methylol compounds, and polycarboxylic acids, which compounds are known to those of skill in the art. N-methylol compounds have been used the most. Examples include dimethylol urea, dimethylol ethylene urea, trimethylol trazine, dimethylol methyl carbamate, uron, triazone, and dimethylol dihydroxy ethylene urea (DMDHEU. Additionally, in the case of cotton, any compound capable of forming a crosslink between two hydroxyl groups may be used as the resin component.
[0020] In a presently preferred embodiment, the durable-press/softener preparation comprises i) a resin modifier selected from polymers consisting of butadiene or hydrogenated butadiene containing at least one hydroxyl group per molecule, and ii) the resin DMDHEU or cyanuric chloride.
[0021] In forming the durably soft, tear/abrasion-resistant textile, additional crosslinkers or complementary reactive functionalities may also be added to the solution of the durable-press/softener preparation to help create bridges between crosslinkable groups, to alter the crosslink density, and/or to add additional properties to the textile (for example water and stain resistance).
[0022] The present invention is further directed to the yarns, fibers, fabrics, textiles, or finished goods (encompassed herein under the terms “textiles” and “webs”) treated with the durable-press/softener preparation. These novel textiles or webs will display comparable durable-press performance without the harsh hand or the low tear and low abrasion resistance of traditional durable-press textiles.
[0023] These textiles, which exhibit wrinkle resistance, a soft hand, and improved tear/abrasion resistance, can be used in a variety of ways including, but not limited to: clothing, especially those for, but not limited to easily wrinkled clothing, such as formal garments, coats, hats, shirts, pants, gloves, and the like; other textiles subject to wear or tearing, such as awnings, draperies, upholstery for outdoor furniture, protective covers for barbecues and outdoor furniture, automotive upholstery, sails for boats, and the like; and industrial uses, such as those listed in Adanur, S., Wellington Sears Handbook of Industrial Textiles , p. 8-11 (Technomic Publishing Co., Lancaster, Pa., 1995).
[0024] The novel webs of the present invention are intended to include fabrics and textiles, and may be a sheet-like structure (woven, knitted, tufted, stitch-bonded, or non-woven) comprised of fibers or structural elements. The fibers may include non-fibrous elements, such as particulate fillers, binders, sizes and the like. The textiles or webs include fibers, woven and non-woven fabrics derived from natural or synthetic fibers or blends of such fibers, as well as cellulose-based papers, and the like. They can comprise fibers in the form of continuous or discontinuous monofilaments, multifilaments, staple fibers, and yarns containing such filaments and/or fibers, which fibers can be of any desired composition. The fibers can be of natural, man-made, or synthetic origin. Mixtures of natural fibers, man-made fibers, and/or synthetic fibers can also be used. Examples of natural fibers include cotton, wool, silk, jute, linen, and the like. Examples of man-made fibers include regenerated cellulose rayon, cellulose acetate and regenerated proteins. Examples of synthetic fibers include polyesters (including polyethyleneglycolterephthalate), polyamides (including nylon), acrylics, olefins, aramids, azlons, modacrylics, novoloids, nytrils, aramids, spandex, vinyl polymers and copolymers, vinal, vinyon, and the like.
[0025] To prepare the permanent durable-press, soft, and tear/abrasion-resistant webs, the fiber, the yarn, the fabric, or the finished good (the “textile” or “web”) is exposed to the resin-reactive modifier suspended in an aqueous solution in the presence of a suitable durable-press resin and suitable catalyst for activating the resin (such as, for example, MgCl 2 or any Lewis acid), by methods known in the art such as by soaking, spraying, dipping, fluid-flow, padding, and the like. The resin-reactive modifier and the durable-press resin may be added together to the solution with the web or they may be added sequentially. The textile-reactive functional groups of the durable-press resin react with the web, by covalent bonding, to permanently attach to the web. The resin-reactive functional groups on the permanent softener-tear/abrasion resistant polymer react with the durable-press resin, by covalent bonding. The durable-press resin serves to crosslink the cellulose chains, in the case of cotton for example, while at the same time reacting with the reactive group-containing resin-reactive modifier, thus serving as a covalent bridge between the cellulose and the resin-reactive modifier. The modifier may be linked by one or multiple hydroxyls to the cellulose through the resin. The treated web is then removed from the solution, dried, and cured.
[0026] The concentration of the resin-reactive modifier in solution can be from about 0.1 wt % to about 10 wt %, preferably from about 2 wt % to about 8 wt %, more preferably about 8 wt %; depending, however, on the characteristics of the particular resin-reactive modifier selected (such as molecular weight or material) and on the amount of softening and tear/abrasion resistance desired.
[0027] The concentration of the durable press resin may vary, depending on the particular resin used and the final characteristics of the product desired. For example, in the case of DMDHEU, the manufacturer of the resin recommends 8 wt % DMDHEU to obtain permanently pressed textiles, whereas a lower amount may be used when abrasion resistance without permanent press is desired.
[0028] The process temperature can vary widely, depending on the affinity of the durable press resin for the web substrate and for the resin-reactive modifier. However, the temperature should not be so high as to decompose the reactants or so low as to cause inhibition of the reaction or freezing of the solvent. Unless specified to the contrary, the processes described herein take place at atmospheric pressure over a temperature range from about 120° C. to about 180° C., more preferably from about 140° C. to about 160° C., and most preferably at about 150° C. The time required for the processes herein will depend to a large extent on the temperature being used and the relative reactivities of the starting materials. Therefore, the time of exposure of the textile to the polymer in solution can vary greatly, for example from about one minute to about two hours. Normally, the exposure time will be from about one to about five minutes. Following exposure, the treated yarn or fabric is dried at ambient temperature or at a temperature above ambient, up to about 90° C., possibly higher. The pH of the solution will be dependent on the requirements of the resin, the resin-reactive modifier, and the textile. Typically, resin-crosslinking is optimized at low pH, but cotton, for example, degrades in acid, so a balance must be reached. Furthermore, the deposition of resin-reactive modifiers with charged groups (e.g., amines, carboxylates, and the like) is expected to be dependent on solution pH. Salts (such as, for example, NaCI) may optionally be added to increase the rate of adsorption of anionic and cationic polymers onto the fibers. Unless otherwise specified, the process times and conditions are intended to be approximate.
EXAMPLES
Example 1
Preparation of Resin-Reactive Modifier Solution
[0029] Four percent (4%) by weight of hydroxy-terminated polybutadiene (PBD-OH, 1200 MW, [hydroxyl]=1.7 meq/g, CAS# 69102-90-5, Aldrich, Milwaukee, Wis.) and 4% by weight of Tween-40 (polyoxyethylene sorbitan ester, ICI Surfactants, Wilmington, Del.) were added to water with stirring to give an aqueous solution of hydroxy-terminated resin-reactive modifier.
Example 2
Application of Durable-Press/Softener Preparation to 100% Cotton, and Physical Characterization
[0030] Cotton fabric samples (400 series, Test Fabrics, West Pittston, Pa.) were treated in stirred aqueous solutions containing various percentages of hydroxy-terminated polybutadiene and Tween-40, prepared as described in Example 1 above. The samples were removed and dried at 85° C. for 10 minutes. The samples were then treated with a commercial preparation of durable press resin (Freerez 901, 38% buffered DMDHEU, BF Goodrich, Greenville, S.C.) and catalyst (Freecat LF, MgCl 2 and citric acid, BF Goodrich, Greenville, S.C.) according to the manufacturer's specifications at 8% and 2% on bath weight, respectively. Fabric samples were dipped in 200% of fabric weight resin and catalyst solution and padded to 100% pick-up. Samples were dried at 85° C. for 10 minutes, followed by curing at 160° C. for 4 min. Samples were tested for flex abrasion (measured using an ASTM 03885-92, at 4 lb tension and 1 lb pressure) and wrinkle recovery (following the AATCC test method #66-1998). Additionally, samples were washed in an accelerated laundering machine to simulate five home launderings. All sample treatments were done to mimic a dip, pad, squeeze application method with approximately 100% wet pick-up. The results are shown in Table I.
TABLE I Wrinkle recovery angle and flex abrasion cycles of various samples. # Home Wrinkle Flex Abrasion Sample % PBD-OH % DMDHEU Launderings Recovery Angle Cycles Pure Cotton 0 0 0 72° 329 ± 129 0 HL Pure Cotton 0 0 5 70° 455 ± 95 5 HL DMDHEU Treated 0 8 0 135° 168 ± 91 Cotton - 0 HL DMDHEU Treated 0 8 5 120° 138 ± 100 Cotton - 5 HL PBD-OH/DMDHEU 4 8 0 128° 585 ± 120 Treated Cotton - 0 HL PBD-OH/DMDHEU 4 8 5 127° 737 ± 291 Treated Cotton - 5 HL | This invention is directed to treatment preparations useful for the permanent or substantially permanent treatment of textiles and other webs to provide tear and abrasion strength and softness to durable-press garments. The preparations comprise a softener (a “resin-reactive modifier”) durable to repeated laundering used in conjunction with a durable-press resin, to increase the comfort and lifetime of durable-press garments. The resulting durable-press/softener preparation is substantially permanently attached to the web and provides improved softness and tear/abrasion strength retention within and/or on the textile or web fiber structure while retaining the durable-press properties of the resin. This invention is further directed to the yarns, fibers, fabrics, textiles, finished goods, or nonwovens (encompassed herein under the terms “textiles” and “webs”) treated with the textile-reactive durable-press/softener preparation. Such textiles and webs exhibit a greatly improved, durable softness and tear/abrasion strength. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 USC 119(e) of U.S. provisional No. 61/233,402 filed Aug. 12, 2009.
FIELD
[0002] Hydro-Vac Excavation
BACKGROUND
[0003] Hydro-Vac Excavation is becoming a common practice when working with underground infrastructure. Hydro-Vac excavation adds water to the excavation while vacuuming up the mud created by the added water in order to excavate. This enables excavation to be less destructive than using other digging techniques. There is demand for commercially sound and economical equipment in the industry so that the costs to hydro-vac is affordable.
SUMMARY
[0004] The unique design of the Prism Hydro-Vac allows good performance but keeps the construction costs and weight down on the Hydro-Vac trucks. The Prism Hydro-Vac is a new approach to constructing a Hydro-Excavator. There are many benefits to the Prism Hydro-Vac but this patent document focuses on the mud tank as the prime advantage, that makes the construction of the Prism Hydro-Vac much easier, lighter and more cost effective.
[0005] In an embodiment, there is provided an excavation apparatus, comprising a mud tank having an input for debris, water and air; a hose connected to the input of the mud tank; and a blower attached to the mud tank. The blower is configured to blow air out of the mud tank to establish a negative pressure within the mud tank in operation so that air, water and debris will be sucked into the mud tank through the hose. The blower is located in a recessed portion of the periphery of the mud tank, the recessed portion of the periphery of the mud tank being located in an upper part of the mud tank.
[0006] These and other aspects of the device and method are set out in the claims, which are incorporated here by reference.
BRIEF DESCRIPTION OF THE FIGURES
[0007] Embodiments will now be described with reference to the figures, in which like reference characters denote like elements, by way of example, and in which:
[0008] Fig. 1A is a cutaway view from the front of an embodiment of the mud tank.
[0009] FIG. 1B is a cutaway view from the side of an embodiment of the mud tank.
[0010] FIG. 1C is a cutaway view from above of an embodiment of the mud tank.
[0011] FIG. 2 is a cutaway side view of an embodiment of the mud tank with more detail shown.
[0012] FIG. 3A is a schematic diagram showing an embodiment of the mud tank with the blower outside the outer shell.
[0013] FIG. 3B is a schematic diagram showing an embodiment of the mud tank with the blower inside the outer shell.
DETAILED DESCRIPTION
[0014] The mud tank 20 of the Prism Hydro-Vac, an embodiment, is 10 ′ long at its longest point and is 8 ′ in diameter. It has a hinged pivoting point 22 at the back and is lifted with a cylinder at the front like a gravel box to dump. The rear door 24 is big, taking the bottom half as the door which makes dumping mud very easy. The front 26 of the tank is flat and has flat bars on the edge to make it strong enough to withstand the vacuum force that is applied to it. The sections 28 in between these flat bars are used as the air discharge silencers 30 of the blower 32 . This is a natural use for these areas and compartments to silence the blower exhaust. This means there is no piping or other silencers needed to be added to the system.
[0015] There is a portion of the top, front part of the mud tank 20 that is boxed and open to the top. The blower 32 sets down in this recessed portion 34 of the tank which is normally wasted air space anyway. By mounting the blower 32 up in this section of the tank area, it is out of the way, it uses up wasted space and it doesn't require any piping and ducting to be used which makes the construction of the Hydro-Vac much cheaper, and makes it function way better, lighter and very easy to maintain. The blower 32 is laid in a horizontal position so all liquids and particles will fall through it as it is running or when it is shut down. All the air starts high, drops into the blower, goes down through the blower, out of the bottom of the blower and down through the silencing chambers which are in between the flat bars at the front of the tank. Everything runs through and out and does not ever create a low spot liquid trap.
[0016] What makes this design so unique is the fact that it is inset into the top of the mud tank which enables Prism to reduce the needed space on deck and utilize otherwise wasted space in the tank. This eliminates the need for piping and complex separation systems.
[0017] Another feature is the clean screen curtain 36 that is in the tank 20 that contains the flying mud debris entering the tank through the inlet 38 from the boom 40 and ultimately from the hose 42 connected to the boom 40 . This eliminates the need for cyclones and other complicated ways to stop debris from getting into the blower.
[0018] Thus, in an embodiment, the new design is based on the blower being mounted right in a cut out that is in the tank in the void air space at the top of the tank which uses otherwise wasted space, eliminates all the piping going to and from the blower making it suck harder due to no piping pressure drop. Since there is no piping required they are lighter and easier to build which makes them cheaper to sell. The blower silencers may be incorporated right into the tank frame so that you can not see them, they are also using otherwise wasted space and they are much cheaper to build. This tank may be hoist to dump so it is very user friendly.
[0019] The air flow of the Prism Hydro Vac is preferably in a downwardly direction. Once the air is being vacuumed out of the tank and goes through the blower, the air goes down hill and vents out the bottom. This feature eliminates fluid buildup in the piping, blower and scrubber again making things cheaper and easier to produce. These features allow a manufacturing advantage that saves money, weight and complexity.
[0020] Depending on the embodiment, the blower 32 can reside on the outside of the outer shell 42 of the tank, as for example in a recessed portion 44 of the outer shell of the tank as shown in FIG. 3A , or it can reside inside the outer shell 42 of the tank, in a portion of the tank cut off from the main body of the tank by inner boundaries 46 , as shown in FIG. 3B . In the former case, there may be a covering 48 over the blower. In the latter case, even though the outer shell might be constructed first and the blower and inner boundaries added later, the inner boundaries are the new periphery of the tank, and thus the blower is still in a recessed portion of the periphery of the tank.
[0021] Immaterial modifications may be made to the embodiments described here without departing from what is covered by the claims. In the claims, the word “comprising” is used in its inclusive sense and does not exclude other elements being present. The indefinite article “a” before a claim feature does not exclude more than one of the feature being present. Each one of the individual features described here may be used in one or more embodiments and is not, by virtue only of being described here, to be construed as essential to all embodiments as defined by the claims. | An improved hydro-vac excavation apparatus is presented with the blower located on a recessed portion of the mud tank, saving space and eliminating piping. The blower and silencers are oriented so that airflow through the blower and out through the silencers is in a downward direction, eliminating low spots that could trap liquid. | 4 |
This application is a continuation of application Ser. No. 875,140, filed Feb. 6, 1978, now abandoned.
REFERENCE TO RELATED APPLICATIONS
This application is related to an application in the name of Lee Randolph Beck, Ser. No. 776,249 filed Mar. 10, 1977.
BACKGROUND OF THE INVENTION
A number of years ago it was commonly believed that rheumatoid arthritis had an infectious etiology. This view is not popular today, although the inflammatory features and constitutional manifestations of rheumatoid arthritis-the synovitis and granulomatous lesions, the fever, tachycardia, leukocytosis, lymphadenopathy and ocassional spelnomegaly, the accelerated erythrocyte sedimentation rate and other changes in "acute phases reactants" are all compatible with an infectious process. Competent and repeated bacteriologic studies have failed to recover consistently a single infectious agent from the blood, synovial fluid, synovial tissues or subcutaneous nodules. Attempts to transmit the disease by injecting joint fluid from patients with rheumatoid arthritis into the joints of other human subjects have been unsuccessful. Subcutaneous nodules have failed to survive following homologous transplantation (Bauer, et al, 1951) the Practitioner 166:5.
An infectious process may appear to precipitate the onset of rheumatoid arthritis in a significant number of patients, and may exert a deleterious influence on the course of the disease when it has already been established. There is statistical evidence to support this clinical impression (Lewis-Faning, 1950) Ann Rheum. Dis., Suppl. 9.
Many attempts have been madeto produce a disease in animals similar to rheumatoid arthritis. While a variety of bacteria can produce arthritis in animals, they fail to reproduce the clinical and pathologic features of rheumatoid arthritis, particularly the self-perpetuating characters of the proliferative arthritis. Arthritis bearing some semblance to the human disease has been produced in mice by pleuro-pneumonia-like organisms (Sabin, 1939) Science 89:228, and in swine by Erysipelothrix rhusiopathiae (Sikes, et al, 1955). The concept that these organisms may initiate a hypersensitivity mechanism has been postulated (Sikes, et al, 1955).
Students of rheumatoid arthritis nevertheless continue to be intrigued by certain recurring themes that suggest relationships between infections and joint disease. Gonorrhea, for instance, is capable not only of producing typical gonorrheal arthritis but also of occasionally introducing chronic arthritis which .[.evolved.]. .Iadd.evolves .Iaddend.into typical rheumatoid arthritis. No statistics are available on the incidence with which this occurs, so one cannot know how much to stress the relationship. Tonsillitis or pharyngitis may also be followed by a polyarthritis, which at first appears to be rheumatic fever but which evolves into rheumatoid arthritis. Acute viral infections, especially rubella in young women, may be followed by persistent polyarthritides involving small joints as well as large; these arhritides generally run a several-month course of persisting joint disease resembling rheumatoid arthritis before gradually subsiding.
While chronic infection by an unknown agent remains a popular assumption for the etiology of rheumatoid arthritis, no published data exist to support the presumption. Some students of the disease suspect that if infection is a factor it may not be infection by any specific type of microorganism, .Iadd.but rather infections by a wide variety of banal microorganisms .Iaddend.with an altered host response generated by the infections .Iadd.may be .Iaddend.responsible for the disease. The present invention is based on this theory for the origin of rheumatoid arthritis.
Although an infectious etiology has never been established, several recent developments appear relevant in support of this theory.
Some of these are as follows:
1. Patients with rheumatoid arthritis have lower than normal levels of IgA, the class of immunoglobulin found in secretions of the gastrointestinal tract.
2. Immunoglobulin A produced in response to immunization via the salivary glands is found in serum colostrum and milk as well as in the saliva. It is suggested that the IgA is transported to these various fluids via the gastrointestinal tract and the lymphatic system (Michelok, et al, 1975) Proc. Soc. Exptl. Biol. Med. 148:1114.
3. Following an intestinal bypass operation for morbid obesity, certain patients develop symptoms that are virtually identical with rheumatoid arthritis. The onset of arthritis is accompanied by the appearance in blood serum of circulating cryoproteins composed of IgG, IgM, IgA, complement components C 3 , C 4 , C 5 , and IgG antibody against E. coli and B. fragilis. Removal of the intestinal bypass results in complete remission of the symptoms (Woods, et al, 1976) New Engl. J. Med. 294:121.
4. A type of Diplostreptococcus agalactiae belonging to the streptococci group B has been implicated as an etiologic agent in rheumatoid arthritis (Svartz, 1972) Acta. Med. Scand. 192:231. This streptococcus is present in most commercially available pasteurized milk but not in immune milk.
5. A predisposition to rheumatic disease appears to be inherited via the histocompatibility antigens (HL-A). These antigens probably determine host response to infective agents.
On the basis of this evidence, it is concluded that rheumatoid arthritis has an infectious origin; the site of infection occurs in the gut; a number of different bacterial strains are involved in the infection; the infection probably results because of a failure in the host's immune defense mechanism; and the most effective way to treat the disease is to re-establish the immune protection against the infectious agent in the gut.
Treatment of Infection
There are basically two methods which may be used for the treatment of infection: the immune approach which involves either active or passive immunization against the infectious pathogens, and the use of antibiotics such as penicillin, tetracycline, ampicillin and the like. Antibiotics are not specific in their activity, and they kill a wide spectrum of beneficial as well as harmful bacteria. On the other hand, the immune approach is highly specific. Bactericidal antibodies produced against a specific strain of bacteria react only with that strain and have no harmful effects on other types of bacteria. Moreover, antibodies, unlike antibiotics, are natural body products and have no known side effects. Since the objective of the invention is to control infection by a specific group of bacteria, without harming beneficial bacteria in the gut, the immune approach is the method of choice.
Active and Passive Immunization
There are two different methods to achieve immune protection. Active immunization is a process whereby the host is actively immunized with a vaccine which stimulates the immune system of the host to produce protective antibodies against factors contained in the vaccine. Active immunization occurs under natural conditions when the host is exposed to infectious pathogens. Passive immunization is a process whereby antibodies obtained from one individual who has been actively immunized are given to a second individual. By this process, the protective antibodies are transferred from the immune host to the recipient. Passive immune protection is temporary and lasts only as long as the passively acquired antibodies persist in the system of the recipient. For example, antibodies collected from horses immunized against tetanus toxin can be given to humans infected with tetanus in order to obtain temporary immune protection against the toxin produced by tetanus bacteria. In a previous patent (U.S. Pat. No. 3,626,057) there is described a process for producing tetanus antitoxin in milk. This patent teaches that the cow can be actively immunized against tetanus toxin; that antibodies produced by the cow against the toxin can be obtained from the cow's milk; and that these antibodies can be used to treat animals infected with the tetanus bacteria in such a manner that the antibodies neutralize the toxin. The patent teaches that the passively administered antibodies neutralize the life-threatening toxin produced by the bacteria, thereby, providing temporary immunity against the toxin.
Passive immunization differs from active immunization in that the immune protection is temporary and lasts only as long as the protective antibodies are present. Active immunization is more permanent because the immune system of the host continues to produce protective antibodies in the presence of the stimulating antigen.
Recent studies in the field of gut immunology have shown the existence of a local immune mechanism in the gut. This immune system of the gut produces a special type of antibody which functions to control bacterial infestations in the lumen of the gut. The antibody called secretory immunoglobulin or IgA is produced in response to the local active immunization of the gut mucosa by the antigen. The secretory immune system of the gut functions to prevent the colonization and proliferation of harmful bacterial species in this environment. It is believed failure of the local immune system of the gut allows unknown harmful bacteria to become established and that .[.this.]. .Iadd.these .Iaddend.bacteria .[.causes.]. .Iadd.cause .Iaddend.rheumatoid arthritis. According to this theory, rheumatoid arthritis results from a failure of the local immune system of the gut to produce and secrete protective antibodies against harmful bacteria. Thus, the inability of the host to respond to active immunization precludes this method as an approach to the treatment of rheumatoid arthritis.
The present invention describes a method for controlling the growth and proliferation of harmful bacterial pathogens-specifically, in the environment of the gastrointestinal tract of man; the method being that of passive immunization by oral ingestion of protective antibodies produced in the cow. The method provides temporary immune protection which is highly specific for those species of bacteria used to produce the antibodies and does no harm to the normal beneficial bacteria that reside in the gut. The antibodies used in the method of this invention constitute the unique and useful product of this invention.
Cow's milk provides the preferred source of the antibody product of the invention. It is very specific in that it defines a unique population of antibodies in milk (IgG type) that react with a known spectrum of bacteria and this reaction results in the beneficial effect, which is treatment and prevention of rheumatoid arthritis.
The type of immunoglobulin is an important consideration with regard to patentability of this invention because there are five known classes .[.if.]. .Iadd.of .Iaddend.immunoglobulin which are designated IgG, IgM, IgA, IgD, and IgE (Nisonoff, et al, 1971) Molecules of Immunity In Immunobiology. Eds., Good, R. A. and Fisher, W. Sinauer Ass., Stanford, Conn. (1971). Each type of immunoglobulin differs structurally (Waldman, et al, (1970) Plasma Protein Metabolism, Academic Press, p. 269 (1970), and has a different biological function within the body Waldman et al., Immune Mechanisms on Secretory Surfaces, Postgrad. Med. 50:78 (1971); and Franklin, Prog. Allerg., 8 p. 57 (1964). Moreover, there are striking variations in the locations of immunoglobulins within the body. For example, distribution clearly distinguishes immunoglobulin classes IgA and IgG. The most striking feature of IgA is its high concentration in external secretions of the body including the gastrointestinal fluid. .[.It has been clearly shown that the immune system which contributes IgA to gastrointestinal fluid..]. It has been clearly shown that the immune system which contributes IgA to gastointestinal fluid is a separate and distinct system from that which produces IgG.
In the human, IgG occurs primarily in the vascular and intracellular spaces of the body (Waldman, et al, .[.(1970).]. Plasma Protein Metabolism, Academic Press, p. 269 (1970).Iadd.).Iaddend., and very little IgG fluids its way into the gastrointestinal fluids. Another important difference between the classes of immunoglobulin is related to their metabolic rate. The degradation of each class of immunoglobulin, regardless of its location within the body, appears to be under separate control. The functional catabolic rate varies from as low as 6.5% for IgG to as high as 90% for IgE with other classes of immunoglobulin falling in between (Waldman, et al, .[.(1970).]. Plasma Protein Metabolism, Academic Press, p. 269 (1970). Further, the different immunoglobulin classes also differ in their avidity with which .[.the.]. .Iadd.they .Iaddend.bind to antigens, and in their ability to combine with complement, which is one of the requisites for killing living bacterial cells (Heremans, .[.(1960).]. .[.Lesglobulenes.]. .Iadd.Les Globulenes .Iaddend.Seriques du Systeme Gamma Leur Nature Et Leur Pathologie, Arscia Brusseles and Masson, Paris (1960). It is important to emphasize these differences in the types of antibodies because immune effects may vary depending on the type of antibody involved.
The most commonly held theory is that the different classes of immunoglobulin have evolved to function in different environments within the body. It is .[.know.]. .Iadd.known.Iaddend., for example, that a special and distinct immune system exists for the production of antibodies which function in the environment of the gut. Moreover, there is general agreement that the immune functions of the gut are controlled specifically by IgA antibodies and not IgG. Therefore, under natural conditions, IgA is the class of immunoglobulin which regulates immune control over bacterial infections which occur in the gastrointestinal cavity of man. Since IgG, IgM, IgD, and IgE are not normally found in the intestinal secretions, it is not logical to expect that any of these types of antibodies would be effective in treating infections in the environment of the gut.
The principal immunoglobulin in the milk of cows in IgG, not IgA (Sullivan, et al. .[.1969).]. T. B. Jour of Immunol, 2, p. 103 (196.Iadd.9.Iaddend.). Therefore, bovine milk is not an obvious source of antibody for treating bacterial infections of the gut in man because of its high concentrations of IgG and low concentrations of IgA.
The method of immunization is another important parameter when considering the different classes of immunoglobulin. It is well-known to those skilled in the art that different methods of immunization result in the preferential production of different types of antibodies. For example, local immunization of secretory tissues achieved by exposing the tissue to antigens stimulates the preferential production and secretion of IgA type immunoglobulins. The technique of .[.intramammory.]. .Iadd.intramammary .Iaddend.perfusion as described in the Petersen patent (U.S. Pat. No. 3,376,198) is an example of local immunization. This method stimulates production and secretion of IgA antibodies and is not an effective method for producing IgG.
According to the present invention, intramuscular injection is used to produce the product of the invention because IgG is the principal immunoglobulin in cow's milk, not IgA, and in the cow, systemic immunization is the preferred method for generating IgG type antibodies in milk. The distinction between the IgG and IgA type immunoglobulin is important because it teaches that systemic immunization and not local immunization is the preferred method for obtaining milk antibodies of high titer. Moreover, this distinction teaches that the immune products produced by mammary perfusion of a vaccine are distinctly different from the immune product produced by intramuscular injection of the identical vaccine. Thus, the product of this invention (IgG antibodies) is distinctly different from the product obtained by the Petersen process.
The immune product of this invention is an improvement over the product of Petersen's invention because the concentration of antibodies of the IgG type is significantly higher than the concentration of antibodies of the IgA type. There is no evidence in the literature to support the claim that IgG antibodies can be produced by intramammary perfusion of antigens. .[.Mover .]. .Iadd.Moreover.Iaddend.since the levels of IgA immunoglobulins are either non-extant or extremely low in cow's milk, it is unreasonable to suggest that the teaching of Petersen's patent has any relevance to the claim of this invention. On the contrary, the teaching of the Petersen patent leads away from the discovery of this invention since it implies that IgA is a biologically active factor in cow's milk, which has potential therapeutic application.
BRIEF SUMMARY OF THE INVENTION
According to the present invention, a unique combination of bacterial species is formulated into a vaccine, which is administered to healthy dairy cows. The IgG antibodies obtained from the milk of the immunized cows constitute the products of the invention. The method of the invention involves the passive immunization of the patient by oral .[.injestion.]. .Iadd.ingestion .Iaddend.of the IgG immunoglobulin, which passively immunizes against a mixed spectrum of infectious bacteria which reside in the gastrointestinal tract. This treatment eliminates conditions in the gastrointestinal tract which cause rheumatoid arthritis.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
FIG. 1 is a specimen of a questionnaire referred to in the specification.
FIG. 1a is a continuation of the .[.questionnarire.]. .Iadd.questionnaire .Iaddend.of FIG. 1.
FIG. 2 is a graph plotting results of .[.test.]. .Iadd.tests .Iaddend.in terms of RF titer against time, over a 12 month period, 6 months on immune milk and 6 months on placebo.
DETAILED DESCRIPTION
The product of this invention is a low-fat .[.powered.]. .Iadd.powdered .Iaddend.milk which optimally contains a population of natural IgG type antibodies that react with the bacterial species listed in Table 1.
TABLE 1______________________________________Bacterial AntigensORGANISM *ATCC NO.______________________________________Staphylococcus aureus 11631Staphylococcus epidermidis 155Streptococcus pyogenes, A. Type 1 8671Streptococcus pyogenes, A. Type 3 10389Streptococcus pyogenes, A. Type 5 12347Streptococcus pyogenes, A. Type 8 12349Streptococcus pyogenes, A. Type 12 11434Streptococcus pyogenes, A. Type 14 12972Streptococcus pyogenes, A. Type 18 12357Streptococcus pyogenes, A. Type 22 10403Aerobacter aerogenes 884Escherichia coli 26Salmonella enteritidis 13076Pseudomonas aeruginosa 7700Klebsiella pneumoniae 9590Salmonella typhimurium 13311Haemophilus influenzae 9333Streptococcus viridans 6249Proteus vulgaris 13315Shigella dysenteriae 11835Streptococcus, Group BDiplococcus pneumoniaeStreptococcus mutansCorynebacterium, Acne, Types 1 & 2______________________________________ *American Type Culture Collection, 12301 Parklawn Dr., Rockville, Md. 20852
The antibacterial milk contains all of the substances normally found in low-fat powdered milk. The principal constituents comprising antibacterial milk are shown in Table 2.
TABLE 2______________________________________Quantitative and Qualitative Analysis of Antibacterial MilkProteins 35.6%Fat 1.0%Carbohydrates 52%Minerals 7.8%Moisture 3.5%Each reliquified quart of 3-4 ounces ofnon-fat dry milk contains approximately:1200 mg calcium 157%935 mg phosphorous 125%0.3 mg thiamine 32%1.78 mg riboflavin 140%1.04 mg niacin 10%324 Calories______________________________________
Antibacterial milk and normal cow's milk contain the same approximate percent by weight concentration of ingredients. Moreover, the concentration of type IgG immunoglobulin in antibacterial milk and normal milk is identical. Therefore, it is only the specificity of antibodies comprising the antibacterial milk which distinguishes it from normal milk. By specificity of the immunoglobulin is meant the spectrum of bacterial species .[.that .Iadd.with which .Iaddend.the antibodies react .[.with.]..
Antibacterial milk contains no drug additives or any other components which are not natural food products of the cow.
The immune milk of the present invention is also useful in the control of auto-immune diseases, e.g. lupus erythematosus and the like, which are caused or aggravated by bacterial infectious in the gastrointestinal tract.
The polyvalent antigen used for the induction of antibacterial milk is prepared as follows:
Preparation of the Vaccine
The bacterial strains listed in Table 1 were obtained from the American Type Culture Collection, which ensures authenticity of bacterial strains and the highest standard of purity that is available. Upon receipt, each individual bacterial strain was grown on a blood agar plate to test the viability of the culture and to determine if growth pattern is typical or atypical of the bacteria in question. A single colony from each of the test cultures was taken for histological examination to further ensure authenticity and purity of the culture. A single colony of each culture was used to inoculate 500 ml of standard culture broth. The standard broths recommended by the American Type Culture Collection were used to grow each of the specific bacteria listed in Table 1.
All organisms were incubated as static cultures with the exception of 12, 13, 14 and 16, which were incubated in the shaker to provide agitation. Identification of bacterial strains and the American Type Culture Collection catalog numbers are shown in Table 1. Each culture was cultivated for 48 hours at 37° C. Following incubation, the cultures were killed by heating at 60° C. for two hours. Samples of the killed bacteria were used to inoculate fresh broth which was then incubated for 24 hours at 37° C. to determine if the .[.filling.]. .Iadd.killing .Iaddend.process was complete. Only cultures proven sterile by this procedure were used for further processing. Sterile cultures were then washed five times in distilled water and the cells were recovered by centrifugation. The bacterial cells were frozen by immersion in liquid nitrogen and freeze-dried by the process of lyophilization. The lyophilized cells were stored in sterile vials until used for production of the polyvalent vaccine. The polyvalent vaccine was prepared by weighting out one gram quantities of each of the bacterial strains. The dry cells were mixed together and this mixture was suspended in sterile physiological saline (20 grams of bacteria per 500 ml saline).
A sample of the concentrated solution was diluted in serial fashion with saline to determine .Iadd.the .Iaddend.dilution which gives a concentration of 4×10 8 .[.ml.]. .Iadd.CL .Iaddend.per cc. The stock 55 concentrated polvalent vaccine was .[.diskpersed.]. .Iadd.dispersed .Iaddend.into multiple containers and stored frozen. A sufficient amount of concentrated antigen was included in each individual container to immunize 50 cows. The final dilution of concentrate was made just prior to immunization The preferred procedure is to remove a sufficient number of vials to immunize the number of cows to be treated. For example, the vials are removed 24 hours prior to the planned time of immunization; a sample of the concentrate is then diluted in a sterile container to a final concentration of 4×10 8 cells per ml. The maximum response in cows is obtained by injecting 20×10 8 bacterial cells or 5 cc of the sterile preparation which is 4×10 8 cells per ml according to the method of immunization described below.
Preferred Process for Immunization of Cows
The antibody product of the invention is produced by immunizing cows with the polyvalent antigen prepared as described above. The cows are injected with 5 cc of polyvalent antigen containing 20×10 8 bacterial cells. The injection is made intramuscularly in the gluteus maximus muscle of the hind leg. This procedure is repeated at one week intervals for four consecutive weeks beginning 2-3 weeks prior to the predicted day of parturition. Following the primary immunization, booster injections using the same concentration of the antigen, are given every 14 days. This method of immunization gives the maximum antibody titer.
Collection, Handling and Processing of Milk
The milk is collected from immunized cows in a modern dairy parlor. A fully automated milking system collects and stores the milk under complete sanitary conditions. The milking system consists of automated machines connected directly to refrigerated storage tanks by a closed system of pipes. The complete system is cleaned and sterilized following each milking to ensure maximum sanitary conditions. It is important to take careful steps to prevent the growth of bacteria .[.to.]. .Iadd.in .Iaddend.immune milk during processing, since such bacteria can lower the titer of antibodies in the milk.
Milk is transported daily from the refrigerated holding tanks to a dairy processing plant by milk transport trucks. At the dairy plant a high temperature short-time system is used to pasteurize the antibacterial milk. Specialized dairy machinery provides the flash heating of a continuous flow of milk to 155° F. for a period of not more than 15 seconds. Temperature and time is critical since antibody is susceptible to degradation by heat. Milk antibody is destroyed at temperatures above 165° F., if held for periods longer than one minute. Following pasteurization, the whole milk is immediately cooled and the fat is removed by centrifugation, and the skimmed whole antibacterial milk is powdered by a spray process. The spray process consists of a large drying chamber into which hot air (350° F.) is blown at high velocity. The skimmed milk is atomized into the chamber where the finely divided milk particles are instantly dried as they fall to the bottom of the tank. The dried milk is removed automatically by means of mechanical devices and the milk powder is packaged under sanitary conditions. Prior to atomizing, the skimmed milk is condensed by boiling in a chamber under vacuum (100°-110° F.). At each step it is critical to keep the bacteria from contaminating the milk since this reduces the titer of the antibody.
Testing Procedures
Immune milk was prepared in inbred Holstein cows. The cows were immunized by the intramuscular injection of a mixture of bacterial antigens identified in Table 1. The vaccine was prepared by the process described above. The immunologic response of the cows was boosted by bi-weekly injections of the vaccine. The milk from these cows was pooled, the fat removed, and the non-fat milk was pasteurized by exposure to 162° F. for 16 seconds followed by a spray-drying process in which the temperature of the milk did not exceed 85° F. The milk was packaged in one quart polyethylene containers. Control milk (placebo) was non-fat .[.powedered.]. .Iadd.powdered .Iaddend.milk purchased from a local producer.
Erythrocyte sedimentation rates were determined on freshly collected blood by the method of Westergren and corrected for hematocrit according to the method of Wintrobe & Landsberg (1935). Rheumatoid factor titers were determined by the Singer-Plotz (1966) macroscopic tube test.
Patients were accepted for the study on the basis of an elevated erythrocyte sedimentation rate and a positive rheumatoid factor titer. Nine patients were studied for 12 months and 11 patients were studied 18 months. The patient group was composed of thirteen caucasian females ranging in age from 32 to 69 years with an average of 50.4 years, and seven caucasian males ranging in age from 43 to 70 years with an average age of 58.1 years. The mean duration of arthritis was 10.8 years for the females and 11.0 for the males. Patients were randomly placed either on immune milk or on non-immune milk (a commercial product purchased in the Dayton area that served as a placebo). Both milk products were packaged in identical containers and were identified as being immune milk or placebo, respectively, by a blue or red pressure-sensitive label that was attached to each container at the time it was filled. The labels were removed just prior to dispensing the milk to the patients. Thus, at no time did the patients know whether they were receiving immune milk or placebo. Patients were randomly (as determined by the flip of a coin) selected to receive either immune milk or the placebo during the first six-month period. At the end of this time, those that were receiving immune milk were placed on the placebo and those that were receiving placebo were placed on immune milk for the second six-month period.
At the end of the second six-month period, 11 patients volunteered to remain on the study for an additional six months. The type of milk (immune or placebo) was again changed at this time and observations were continued. Thus, the study was comprised of three six-month periods, 11 of the patients participating for three periods and nine participating for two periods. Patients were seen at monthly intervals at which time a one month supply of milk was dispensed, an evaluation questionnaire were filled out and a blood sample was collected for rheumatoid factor titer, erythrocyte sedimentation rate and hematocrit determination.
Patients were instructed to take a quantity of non-fat milk solids equivalent to one quart of milk post prandially two times daily. The milk solids were freshly dissolved in one pint of cool tap water immediately before ingestion shortly after awakening in the morning and again just prior to retiring at night. They were told to see their physician as usual and to follow the treatment regimens prescribed by him. Medication was to be taken ad libitum or as prescribed by their regular doctor. We requested only that they report the quantity of medicines taken.
A questionnaire was completed by each patient at monthly intervals. It was divided into six sections that deal with:
(1) duration of morning stiffness,
(2) severity of pain experienced in each of eight joints,
(3) type and quantity of drugs with short-term actions that were taken,
(4) type and quantity of drugs with long-lasting actions that were taken,
(5) ability of patient to conduct his normal activities, and
(6) severity of symptoms of rheumatoid arthritis. The numbers shown in the spaces next to each answer indicate the score assigned to that answer in the course of evaluating the questionnaires. In scoring the sections dealing with medications, an effort was made to reflect the relative anti-inflammatory and analgesic activities of the various drugs used. A five-grain aspirin tablet .[.as.]. .Iadd.was .Iaddend.assigned a value of one. All other drugs (with the .[.except.]. .Iadd.exception .Iaddend.of gold, plaquenil and cortisone shots which were considered separately) were arbitrarily assigned values relative to aspirin. Thus, all salicylate preparations, Tylenol, Darvon, Motrin, etc. were considered equivalent to a five-grain aspirin tablet and were also assigned a value of one. The number of mg of Prednisone was multiplied times four, the number of Indocin capsules taken was multiplied times 2.5. The number of grains of codeine was multiplied times two, and the number of Butazoladin tablets taken was multiplied times seven.
The mean scores in each category were calculated for each six-month period. The differences of the means where then calculated by subtracting the mean values scored during administration of immune milk from those scored during administration of placebo. When the results were calculated in this manner, improvement in the patient's condition during the period he received immune milk was indicated by negative values for questions one and six, and by positive values for all other questions. Mean corrected erythrocyte sedimentation rates (ESR) and rheumatoid factor titers (RF) were respectively shown in a similar manner. There were calculated in such a way that positive values reflect a lower erythrocyte sedimentation rate or .[.rehumatoid.]. .Iadd.rheumatoid .Iaddend.factor titer during administration of immune milk. The data were statistically evaluated using the Statistical Analysis System of Goodnight et al. (Computer Program Used for the Statistical Analyses, Statistical Systems Institute, Raleigh, N.C.). Calculations were performed with the aid of an IBM model 370/155 computer.
Results
The immune milk was well tolerated by all patients with the exception of one who had pernicious anemia. This patient complained of diarrhea and was terminated from the study. Some patients reported a weight gain during the course of the study. This may have been due to the increased caloric intake from the milk or possibly reflects a generalized improvement in their physical condition.
TABLE 3__________________________________________________________________________ Periods of Treatment Regimen Observation Placebo Immune Mean Control Immune Mean C.V.* Mean C.V.* Difference P__________________________________________________________________________ A.M. Stiffness 27 24 0.322 95.7 0.679 35.6 -0.347 0.0001 Joint Pain a. Shoulder 27 24 0.954 67.1 0.716 60.2 +0.238 0.0420 b. Elbow 27 24 0.752 83.7 0.613 65.9 +0.139 0.0511 c. Wrist 27 24 0.824 73.6 0.539 74.8 +0.285 0.0010 d. Hand 27 24 1.073 54.7 0.828 56.5 +0.245 0.0011 e. Hip 27 24 0.533 90.3 0.227 135.0 +0.306 0.0005 f. Knee 27 24 0.904 74.1 0.683 59.0 +0.221 0.0015 g. Ankle 26 22 0.7811 66.9 0.659 65.7 +0.1221 0.0127 h. Feet 26 22 0.948 63.7 0.729 50.9 +0.219 0.0010 Pills 27 24 20.663 104.1 16.515 101.3 +4.148 0.0405 Other 27 24 0.325 140.7 0.244 175.6 +0.081 0.0276 Medication ADL 27 24 2.224 36.1 1.874 29.1 +0.350 0.0023 Monthly change a. Pain 27 24 1.903 21.8 2.247 14.1 -0.344 0.0042 b. Stiffness 27 24 1.985 18.8 2.254 12.4 -0.269 0.0024 c. Swelling 27 24 1.924 17.9 2.117 13.3 -0.193 0.00153 ESR 25 23 36.293 29.7 35.922 38.2 +0.371 0.7376 RF 27 24 6.698 45.5 6.834 41.7 -0.136 0.9635__________________________________________________________________________ *Coefficient of variation.
As shown in Table 3, patients were observed during a total of 27 control periods (six-month periods during which they received placebo) and 24 test periods (six-month periods during which they received immune milk). One patient had sustained a physical injury to one of his ankles and feet. The pain in these joints was not evaluated, which accounts for there being a smaller number of periods of evaluation for these joints. The erythrocyte sedimentation rates for one patient were so extremely abnormal (more than two standard deviations removed from the mean of the values for the other patients) that they were not included. This omission accounts for the smaller number of observations reported for that variable.
The mean values and coefficients of variation (C.V.) are listed in the table for each variable. Differences between the means were calculated by subtracting the mean value obtained during the periods the patients received immune milk from that obtained during the periods they received the placebo. A favorable response to immune milk is indicated by negative values for AM stiffness (question 1) and Monthly change (questions 6a, b, and c) and by positive values for all other variables. An effective response to immune milk was obtained for all data obtained from the questionnaires. Probabilities (P) indicate a high degree of statistical significance in every instance. The small mean differences obtained for erythrocyte sedimentation rate and rheumatoid factor titer were not significant. When erythrocyte sedimentation rates were considered on an individual basis, however, four of the twenty patients studied had statistically significant decreases while receiving immune milk.
Although immune milk had no significant effect on the mean values for rheumatoid factor titer, examination of individual patients revealed some interesting responses. Seven of the twenty patients studied had negative rheumatoid factor titers on at least one occasion during the period they were receiving immune milk. Four of them became negative during the period that they received immune milk and their titers failed to become positive during the following six-month period when they received the control (placebo) milk as shown in FIG. 2. Continuation of the study past this reporting period reveals that 13 of 25 patients lost the rheumatoid factor from their blood.
Discussion
The scientist in charge of this study personally interviewed each patient at monthly intervals.[., .]. and recorded their answers to the questions. Every effort was made not to influence the patient's answers. The patients were initially informed and were frequently reminded that, during certain periods of the study, they would receive a placebo. It was anticipated that this knowledge would serve as an inducement for the patients to answer the questions objectively and without bias. At no time were the patients informed whether they were receiving immune milk or the placebo.
The question regarding medication taken "yesterday" (question #3) and the question regarding gold shots, Plaquenil and cortisone shots (question #4) are objective and are of primary importance in considering answers given to the other questions. These questions are important for two reasons:
(1) if the immune milk is effective in relieving symptoms of the disease, the patient would be expected to take fewer medicines that were allowed ad libitum. On an average, patients reported that they took four less aspirins or their equivalent per day during the periods that they received immune milk. They also reported that they received fewer gold shots. Plaquenil and cortisone shots during these periods; and
(2) if patients took smaller quantities of analgesics and other medicines useful in the treatment of rheumatoid arthritis, one would expect them to report increased discomfort unless the immune milk was influencing the disease favorably.
As noted in Table .[.2.]. .Iadd.3.Iaddend.significantly less joint involvement was reported during periods that the patients received immune milk even though they were taking less medicines for their arthritis.
Patients started on the study at monthly intervals over a one-year period, and the type of milk product (immune milk or placebo) that they initially received was randomized. The observation that positive responses or improvement were obtained for all parameters of the questionnaire, and that these mean responses were statistically significant strongly indicate that immune milk had a beneficial effect on the patients. This conclusion is reinforced by the observation that 20% of the patients experienced a statistically significant (p<0.05) decrease in erythocryte sedimentation rate while receiving immune milk.
Results of the rheumatoid factor titers are difficult to evaluate. This is due .[.at least in part.]. .Iadd., at least in part, .Iaddend.to the fact that the origin and role of rheumatoid factors in the etiology and prognosis of rheumatoid arthritis is not understood. Rose et al.Iadd., Proc. Soc. Exp. Biol. Med. 68:1 .Iaddend.(1948) showed that sheep red blood cells that were sensitized with rabbit antibody underwent agglutination in the presence of blood serum from patients with rheumatoid arthritis. The test depends on the specific reaction between normal immunoglobulin (either rabbit or human I g G) with rheumatoid factors. The specificities exhibited by .Iadd.the .Iaddend.rheumatoid factor are like those that would be expected of antibody against I g G (Epstein, et al, .[.1956).]. Proc. Soc. Exp. Biol. Med. 91:235.Iadd.(1956)).Iaddend..
The presence of rheumatoid factors has been correlated with disease severity in rheumatoid arthritis and can be identified in proteins precipitated in the tissues of patients with rheumatoid arthritis. Although a small percentage of patients with rheumatoid arthritis do not have positive rheumatoid factor titers, it is generally agreed by most rheumatologists that positive agglutination reactions do not revert to negative even when the disease is in remission. DeForest, et al .[.(1958).]. Arth. & Rheum. 1:387, .Iadd.(1958).Iaddend., however, described a small number of patients who had positive rheumatoid factor titers that reverted to negative following a remission. When recrudescense of the disease occurred, the test again became positive. Aho, et al .[.(1959).]. Ann. Exp. Fenn. 37:377 .Iadd.(1959) .Iaddend.noted, however, the most patients whose disease had become inactive remained serologically positive. The fact that negative titers were observed in 60% of our patients and that in half of these, the titers remained negative for six months, proves that immune milk is affecting a primary etiologic factor responsible for rheumatoid arthritis.
The effect of immune milk in alleviating the symptoms of rheumatoid arthritis is particularly relevant when considered on the basis of the recently described relationship between the histocompatibility antigens (HL-A) and the susceptibility to rheumatic disease (Brewerton, .[.1976).]. Arth. & Rheum. 19:656. .Iadd.(1976)).Iaddend.. Histocompatibility antigens are genetically determined antigens that are found on all human cells. The genes controlling their inheritance are called histocompatibility genes. There are now known to be over 40 of these genetically determined antigens. They are responsible for rejection of tissue grafts made between individuals other than identical twins. Superficially the HL-A antigens resemble ABO blood groups in that they are inherited for a lifetime. Their functions .[.is.]. .Iadd.are .Iaddend.not yet known, except in the highly artificial situation produced by transplantation. It is known, however, that the histocompatibility genes are closely linked with the immune response genes on the sixth chromosome. In this relationship, they may determine the immune response of the individual to a foreign invader, such as a .[.bacteria..]. .Iadd.bacterium. .Iaddend.
Persons with HLA-B27 appear to be particularly susceptible to a variety of rheumatic diseases. It is postulated that this histocompatibility antigen dictates a type of immune response which in the presence of other predisposing factors leads to rheumatoid arthritis. After an intestinal infection with Yersinia enterocolitica, some patients develop an acute peripheral arthritis (Ahvonen, et al, .[.1969).]. Acta. Rheum. Scand. 15:232 .Iadd.(1969)).Iaddend.. Similarly, after salmonella infection, about 2% of patients develop acute peripheral arthritis (Warren, Am. Rheum. Dis. 29;484 1970). HLA-B27 was found in 43 of 49 patients with yersinia arthritis and in 15 of 16 with salmonella arthritis (Aho. .[.1974).]. Ann. Exp. Fenn. 37:377 .Iadd.(1974)).Iaddend.. It is an attractive possibility that infective agents may thrive in the intestinal tract without giving rise to local symptoms. In patients with HLA-B27, a host response is established that results in arthritis. Thus, it is not necessary for the infective agent to gain entry into the joints. Immune milk is beneficial to patients with rheumatoid arthritis because it contains antibodies that effectively inactivate or neutralize offending bacteria and/or their metabolic products. | There is disclosed a novel method and product for the treatment and prevention of rheumatoid arthritis. The method involves passive immunization against a mixed spectrum of infectious bacteria which reside in the human gastrointestinal tract. The passive immunization is accomplished by oral.[.injestion.]. .Iadd.ingestion .Iaddend.of IgG immunoglobulin obtained from the milk of cows that have been immunized against a specific spectrum of bacterial types. A unique combination of bacterial species is formulated into a vaccine which is used to immunize dairy cattle. The IgG antibody obtained from the milk of the immunized cows constitutes the product of the invention. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates to light emitting diodes (LEDs) and, in particular, to providing a network of zener diodes for protecting series-connected LEDs from high transient voltages.
BACKGROUND
[0002] It is common to protect LEDs from electrostatic discharge (ESD) or other high voltage transient signals by connecting back-to-back zener diodes in parallel with the LED. If a reverse voltage across the LED is above the zener breakdown voltage, the current is shunted through the zener diodes to the power supply and the LED is protected. Such a protection circuit is referred to as a transient voltage suppressor (TVS).
[0003] It is common to interconnect LED dice in series so that each LED drops a forward voltage and the LEDs operate at the same current. It is more efficient to generate a high voltage and low current than a high current and low voltage. Such a series connection is common in high brightness applications such as illumination and backlighting. Many LED dice may be connected in series so as to be directly connected to a 120v AC mains voltage.
[0004] Prior art FIG. 1 illustrates each LED die in a series connection being protected by an identical set of back-to back zener diodes. In FIG. 1 , the LED dice are represented by diodes D 1 -Dn, and the zener diodes are represented by Q 1 -Q 2 n . The string of LEDs is turned on by applying a voltage across the pins 1 and 2 greater than the sum of the forward voltage drops of the LEDs. A maximum forward voltage drop for turning on an InGaN LED is about 4-5 volts. Since each set of zener diodes is identical, each zener diode must have a breakdown voltage above the maximum combined forward voltages of all the LEDs so as not to break down under normal operating conditions.
[0005] It is known to form the zener diodes in a silicon substrate 12 (also known as a submount), on which is mounted a plurality of LED dice connected in series. The substrate 12 has a dielectric layer (e.g., oxide) over its top surface and a top metal pattern over the dielectric layer that interconnects the LED electrodes to form a series interconnection. The metal pattern also connects the zener diodes to the LED electrodes. The metal pattern provides leads or pads on the silicon substrate for connection to a power supply or for connection to another substrate having additional series-connected LEDs.
[0006] FIG. 2 illustrates the formation of back-to-back zener diodes (e.g., Q 1 and Q 2 in FIG. 1 ) in parallel with an LED (e.g., D 1 ). The zener diodes Q 1 and Q 2 are typically formed by ion implanted n+ regions 16 and 18 in a p+ silicon substrate 12 . The ion implantation doping level is identical for all the zener diodes in FIG. 1 , and the zener diodes have the same breakdown voltage. The distance d between the regions 16 and 18 (d is identical for all the zener diodes pairs) must be large enough so that the snapback phenomenon does not occur prior to the zener diode breakdown. The snapback phenomenon is a form of breakdown between regions 16 and 18 . In snapback, the parasitic NPN transistor formed by the n+ region 16 , the p+ substrate 12 , and the n+ region 18 turns on when enough carriers are injected into the p+ substrate base due to an ESD event or an overvoltage. When the NPN transistor turns on, a current flows between the regions 16 and 18 , resulting in more carriers being injected into the base. This creates a positive feedback, and the NPN transistor latches on, causing even more carriers to flow. This forms a shunt path in parallel with the LED, which wastes power and affects overall LED performance. By increasing the distance between the n+ regions, the gain of the NPN transistor is greatly reduced due to limited carrier lifetime, which prevents the positive feedback from occurring, thus preventing snapback.
[0007] The width W of the regions 16 and 18 directly affects the series resistance through the zener diode pair. It is desirable that the resistance be low such that the zener diodes quickly conduct a high current as soon as the voltage exceeds the breakdown voltage. A high value series resistance (W is small) limits the current through the zener diodes so the LED dice have less protection against high voltage transient signals.
[0008] The available silicon substrate area for forming two zener diodes per LED die is limited, especially for a multi-junction LED die having a small footprint (e.g., 1 mm 2 ). Each set of zener diodes is typically formed either under or next to the LED die it protects. When more and more LED junctions are connected in series, the supply voltage must increase. As the operating voltage increases, the substrate p doping must decrease to achieve the required increase in zener breakdown voltage. This requires a larger minimum spacing d between the zener diodes to avoid snapback from occurring before the zener diode pair breaks down, since it takes less charge to form a current path through the substrate between the zener diode regions. Therefore, when LED dice are connected in series on a silicon substrate within a small footprint (e.g., 1 mm 2 ), the silicon surface area underneath the dice for forming the zener diodes may be inadequate according to design rules in principle for good transient voltage protection of the LEDs.
[0009] After the silicon substrate (a wafer) is processed to create the zener diodes and the metallization pattern, LED dice are mounted on the substrate, such as by using ultrasonic bonding to bond the LED electrodes to the substrate pads. The LEDs are typically flip-chips with both electrodes formed on the bottom, and light is emitted from the top surface. The growth substrate (e.g., sapphire) is then removed from the top surface of the LEDs, such as by laser lift-off or other well known techniques. This exposes the top n-layer of the LEDs.
[0010] It is known to precision-roughen the exposed n-layer to increase light extraction (reduces internal reflection). One way to etch the LED surface to roughen it is to perform photo-electrochemical etching (PEC etching). PEC etching is well known for GaN LEDs. In one type of PEC etching process, the top surface of the LED is electrically biased, and the LED is placed in an electrolyte solution (e.g., KOH) containing a biased electrode. The LED is then exposed to ultraviolet light. The UV light creates electron-hole pairs in the GaN, and the holes migrate to the surface by diffusion and under the influence of the electric field. The holes react with the GaN and the electrolyte at the surface to break the bonds of the GaN, resulting in controlled roughening of the surface. The etching also removes damaged GaN that is created near the growth substrate/n-layer interface.
[0011] Since the p+ silicon substrate is electrically connected to the exposed n-layer of the LEDs (e.g, D 1 in FIG. 1 ) when the zener diodes (e.g., Q 2 in FIG. 1 ) connected to the n-electrodes are forward biased, the n-layer may be biased during the PEC etch by connecting a positive voltage to the p+ substrate, via a bottom metal electrode. A small current then flows from the substrate, through the zener diode, through the n-layer, through the electrolyte, and through the electrolyte electrode to perform the PEC etching.
[0012] After the PEC etching, lenses, phosphor, or other optical elements may be formed over the LEDs on a wafer scale. The silicon wafer is then diced to separate out the individual substrates, each substrate containing a plurality of LED junctions connected in series and each LED junction being protected by a set of zener diodes.
[0013] What is needed is a technique to form more robust zener diodes in the silicon substrate for improved transient voltage suppression yet still enable the top semiconductor layer of the LEDs to be etched by PEC etching.
SUMMARY
[0014] Instead of creating identical high-voltage, back-to-back zener diodes in a silicon substrate for each LED connected in series, only one zener diode is created for connection to each node between LEDs, plus zener diodes (the “end” zener diodes) are connected to the two pins (anode and cathode pads) of the substrate. Therefore, instead of 2n zener diodes, where n equals the number of LEDs, only n+1 zener diodes are used. The zener diodes are designated Q 1 to Qn+1, where Q 1 and Qn+1 are the end zener diodes connected to the pins. Therefore, the end zener diodes Q 1 and Qn+1 effectively create back-to-back zener diodes across the two pins since the zener diodes share a common p+ substrate.
[0015] The zener diodes pairs do not necessarily have identical breakdown voltages. The n+ regions of the end zener diodes Q 1 and Qn+1 have the highest breakdown voltage requirement since the full supply voltage will be applied across the two n+ regions (greater than the combined forward voltages of the series LEDs). Any breakdown of the zener diode Q 1 or Qn+1 will shunt current between the two pins. Therefore, the n+ regions for the end zener diodes Q 1 and Qn+1 must have sufficient spacing d to withstand the full power supply voltage and prevent snapback from happening. However, the n+ regions for the zener diodes Q 1 and Qn+1 will normally have a wide separation anyway since they connect to different power pins. The spacings between intermediate adjacent zener diode regions (i.e., zener diode pairs among Q 2 -Qn) only need to withstand a voltage above about 5 volts across any LED in the string, since the voltage differential between adjacent intermediate zener diodes is only the forward voltage of a single LED (e.g., less than 5 volts). Snapback is not a concern with such low voltages. So the spacings between adjacent zener diodes can be much closer than required by design rules for high breakdown voltage zener diodes.
[0016] Since fewer zener diodes are used, each zener diode can use more silicon area compared to the prior art zener diodes of FIGS. 1 and 2 . The zener diodes may be made wider to reduce the series resistance when conducting an ESD current, especially the n+ regions for the end LEDs in the string (shown in FIG. 4 and discussed later). Also, the spacings between the zener diodes may be reduced since adjacent zener diodes need not be separated by a distance to tolerate the full power supply voltage. This enables many LEDs in an array of about 1 mm 2 to be connected to underlying ion-implanted zener diode regions. For the zener diodes along the periphery of the array, more silicon area is available so a designer has more flexibility in the positioning and the sizing of those regions.
[0017] Typically, the n+dopant concentration for each zener diode region is identical for ease of fabrication, even though the shapes of the regions and the distances between the regions may vary across the substrate depending on the voltage requirements of the zener diodes.
[0018] In one embodiment, 12-20 LEDs in series are created by isolating junctions in a single 1 mm 2 chip by etching trenches through the LED semiconductor layers and connecting the LED electrodes for each junction in series. The different junctions will form an array, such as 3×4, 4×4, 3×6, 4×5, etc. The chip is then mounted on a silicon substrate containing the zener diodes for protecting each of the LED junctions and providing electrical paths for PEC etching at a same time. Due to the small size of the chip (e.g., 1 mm 2 ) and the number of junctions, the zener diodes must be very small. The series LEDs can then be directly powered from a mains voltage (e.g., 120-220v AC), depending on the string length and the operating voltage of each LED. Multiple LED dice, each containing many series-connected LED junctions, can be connected in series.
[0019] The zener diode ion implantation regions can be formed in the silicon substrate under the associated LEDs and along side the LEDs, and the ion implantation regions can have a length of several LEDs. The intermediate zener diodes can be placed close together since the silicon between them need only withstand slightly above 5 volts. Therefore, transient voltage suppression may be created for all the LED junctions using a very small area.
[0020] Since there is a zener diode connected to each of the n-layers of the LEDs, the n-layers can still be biased through the p+ silicon substrate for PEC etching.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic view of n identical LED dice connected in series on a single silicon substrate, where each LED die is associated with an identical set of zener diodes (2n total) for protection.
[0022] FIG. 2 illustrates the ion implantation regions forming the cathodes of back-to-back zener diodes, with the p+ silicon substrate separating the zener diodes as a common anode.
[0023] FIG. 3 is a schematic view of one embodiment of the invention where the intermediate zener diodes pairs connected across LEDs have a breakdown voltage much lower than the zener diode pair Q 1 , Qn+1 connected to the substrate pins. The structure enables PEC etching of the LED top semiconductor layer.
[0024] FIG. 4 is a simplified transparent top down view of a single chip having twelve isolated LED junctions, where the chip is mounted on a silicon substrate containing thirteen zener diodes. The p and n electrodes of each LED are shown within a solid outline, and the n+ zener regions are shown in dashed outline.
[0025] FIG. 5 is a cross-sectional view of the silicon substrate and chip taken along line 5 - 5 in FIG. 4 .
[0026] Elements that are the same or similar are labeled with the same numeral.
DETAILED DESCRIPTION
[0027] As a preliminary matter, an LED is formed on a growth substrate. In the example used, the LED is a GaN-based LED, such as an AlInGaN or InGaN LED, for producing UV through green light. Typically, a relatively thick n-type GaN layer is grown on a sapphire growth substrate using conventional techniques. The relatively thick GaN layer typically includes a low temperature nucleation layer and one or more additional layers so as to provide a low-defect lattice structure for the n-type cladding layer and active layer. One or more n-type cladding layers are then formed over the thick n-type layer, followed by an active layer, one or more p-type cladding layers, and a p-type contact layer (for metallization).
[0028] For a flip-chip, portions of the p-layers and active layer are etched away to expose an n-layer for metallization. In this way, the p contact and n contact are on the same side of the chip and can be directly electrically attached to the submount contact pads. Current from the n-metal contact initially flows laterally through the n-layer.
[0029] Other types of LEDs that can be used in the present invention include AlInGaP LEDs, which can produce light in the red to yellow range.
[0030] In one embodiment, each LED area in the wafer is further processed to divide up the LED into an array of separate pn junctions, such as by masking and dry etching to remove the GaN between regions. Alternatively, the isolation could be done by ion implantation between the LED sites to make the ion implanted areas of the GaN semi-insulating.
[0031] The metallization is patterned so that each junction has a set of electrodes. This effectively creates an array of separate LEDs (e.g., a 3×4 array) on a single chip, such as a 1 mm 2 chip. When the LED junctions are connected in series, using either a metal pattern on a silicon substrate or on the die itself, the chip will drop a relatively large voltage (e.g., 3 to 5 volts times the number of LEDs). This may be useful when the chip is intended to be driven by a mains voltage or driven by some other high voltage power supply.
[0032] After the LEDs are diced from the wafer (as either single-LED dice or dice having an array of LED junctions), the LEDs are then mounted on a silicon substrate wafer. The silicon substrate wafer has a specific p+ doping, and zener diode n+ regions are formed in it by masking and ion implantation steps. Masking a substrate and implanting n-type dopants to form n+ regions of any size and depth is well known. The doping levels of the substrate mainly determine the zener diode junction breakdown voltage. Forming the zener diodes in a substrate is later discussed with reference to FIGS. 4 and 5 .
[0033] A patterned dielectric (oxide) surface on the silicon substrate surface is then metalized to form an interconnection pattern for the LED electrodes to connect the LEDs in series. The metal pattern also connects the zener diode n+ regions to their associated LED electrodes.
[0034] FIG. 3 is a schematic representation of the series connection of LEDs D 1 -Dn and the zener diodes Q 1 -Qn+1. Instead of 2n identical zener diodes, as in the prior art FIG. 1 , only n+1 zener diodes need to be formed in FIG. 3 . There is only one zener diode (Q 2 -Qn) connected to each of the nodes between LEDs D 1 -Dn. These intermediate zener diode n+ regions can be formed very close to one another (small d in FIG. 2 ) since the voltage between them is limited by the forward voltage of a single LED (e.g., around 5 v). Snapback is not a problem with such low voltages.
[0035] If there is an ESD strike in the forward direction, the forward biased LEDs simply conduct the current without damage. If there is an ESD strike in the reverse direction between pins 1 and 2 , the LEDs will block the current until the reverse voltage breaks down the back-to-back zener diode pair Q 1 and Qn+1. The roles of the zener diodes Q 1 and Qn+1 are different. When zener diode Qn+1 breaks down (dropping the majority of the voltage), zener diode Q 1 simply turns on in its forward biased direction. The zener diode pair Q 1 and Qn+1 then shunts the current between the pins to the power supply.
[0036] Pins 1 and 2 may be large metal pads on the silicon substrate 22 (or submount) that are connected to a power supply after the silicon substrate wafer is diced and the LED modules are mounted on a printed circuit board.
[0037] The “end” zener diodes Q 1 and Qn+1 need to be separated from each other a distance to withstand a voltage at least equal to the expected peak operating voltage of the module before breaking down and even before any substantial leakage current occurs (on the level of microamperes), since the pair of zener diodes Q 1 and Qn+1 provide the shunting between the pins 1 and 2 . In one embodiment, there are 12-20 series-connected LEDs mounted on the same silicon substrate (after the substrate wafer is diced) for direct coupling to a mains voltage. The breakdown voltage of the zener diode pair Q 1 and Qn+1 should be greater than the peak mains voltage across the pins 1 and 2 so as not to break down or leak during normal operation.
[0038] Between any zener diode pair underlying an array of LED junctions, the breakdown voltage will depend on the number of LED junctions electrically connected between them. Since an array of LEDs will typically be formed as an M row×N column array, and the series connection may be in a serpentine configuration, adjacent zener diode regions in the horizontal direction may have a voltage differential of up to 2M times the individual LED forward voltage (Vf). Therefore, the spacing between such n+ zener regions (distance d 2 in FIG. 4 ) should be large enough to withstand 2M(Vf) before leakage or snapback to allow normal operation of the LED array to occur.
[0039] Since the number of n+ ion implanted regions is about half that of the prior art FIG. 1 , the silicon surface area used by the zener diodes can be less, or the zener diodes can be made wider to reduce series resistance between the zener diodes, or the area of the zener diodes can be made larger to reduce the resistance between the bias voltage and the n-layers during PEC etching. The layout of the LEDs and zener diodes may take any form.
[0040] Since the zener diodes use the p+ silicon substrate as a common anode, and the zener diodes are connected to the cathodes of the LED, the n-layer of the LEDs can be biased by applying a bias voltage to metallization on the backside of the silicon substrate wafer for PEC etching (described with respect to FIG. 5 ).
[0041] FIG. 4 is a simplified top down transparent view of a 3×4 array of LEDs 30 mounted on a single p+ silicon substrate 22 . The substrate 22 may still be part of a large submount wafer that is later diced to form many LED modules identical to that of FIG. 4 . The p and n contact areas for each LED 30 are shown in solid outline, and the n+ zener diode regions 34 are shown in dashed outline.
[0042] The LEDs 30 are connected in series by a patterned serpentine metal layer that generally coincides with the n+ zener regions 34 . The metal directly contacts the zener regions and is insulated from the p+ substrate by a dielectric layer outside the zener regions.
[0043] The twelve LEDs 30 may be formed in a single 1 mm 2 die, as previously described, where the junctions are isolated by etching or ion implantation. The outline of the die is shown by the solid line 35 . Alternatively, each LED may be a separate die. In another embodiment, there are eighteen or more LEDs in series so as to be directly powered by a mains AC voltage.
[0044] Since, only thirteen zener diode regions 34 can be used to protect all twelve LEDs from a transient voltage, and the eleven regions 34 forming the intermediate zener diodes can be located close together, the zener diodes can be formed larger, compared to the prior art, for a reduced series resistance without using up any more total silicon area than the 2n zener diodes of FIG. 1 .
[0045] In FIG. 4 , the distance d 1 between two n+ zener diode regions 34 arranged vertically is very small since the voltage across the regions 34 is only a single LED voltage drop. The distance d 2 between regions 34 in different columns may be larger than d 1 since the voltage between those regions 34 may be as high as six LED voltage drops. The distance d between the end regions 34 is the largest since the full operating voltage is across those two regions 34 . In one embodiment, the high-voltage end zener diode regions 34 are formed in an area not totally underneath the die to allow those regions 34 to be much wider than the other regions 34 for reduced series resistance. The lower voltage zener diode regions are substantially formed under the LED array.
[0046] The outer zener diode regions 34 may be formed along the sides of the LED array, rather than totally underneath the LED array, to provide more silicon area for the zener diodes. Forming some zener diode regions 34 along the sides of the LED array does not require a larger substrate 22 , since the substrate 22 needs to be larger than the LEDs anyway.
[0047] As shown in FIG. 4 , the two ends of the series connection terminate in robust metal bonding pads 36 and 38 formed on the metal layer for connection to a power supply or to other LED modules. The pads 36 and 38 may instead be on the backside of the substrate 22 and connect to the frontside metallization by vias through the substrate 22 .
[0048] After the LEDs 30 have been mounted on the submount wafer and the growth substrate (e.g., sapphire) has been removed from over the LEDs 30 by laser lift-off or other well-known technique, the exposed top n-layer of the LEDs 30 is then subjected to a PEC etch to remove the surface layer damaged by the lift-off process and to controllably roughen the surface to increase light extraction. This PEC etching is performed simultaneously on all LEDs mounted on the submount wafer.
[0049] FIG. 5 is a simplified cross-sectional view of the submount wafer portion of FIG. 4 along line 5 - 5 (the right side of the substrate). The LED junctions are shown being electrically insulated by etched trenches 39 .
[0050] The n+ zener diode regions 34 are shown formed between the rows of LEDs. The zener diodes share a common silicon p+ region.
[0051] A patterned metal layer 40 is formed over the substrate surface, which electrically interconnects the various LED electrodes 42 and electrically contacts the zener diode regions 34 formed in the silicon. In FIG. 5 , the three LEDs 30 are connected in series by the metal layer 40 . The metal is electrically insulated from the p+ silicon by a patterned oxide layer 44 , which is patterned to expose the zener diode regions 34 where there is to be contact by the metal layer 40 . A metal layer 50 is formed on the backside of the substrate 22 for purposes of the PEC etch process.
[0052] The PEC etching of the exposed n-layers 52 of the LEDs may be performed as follows. A positive bias voltage V+ is connected to the metal layer 50 . The submount wafer is submerged in an electrolyte 54 , such as KOH, commonly used for PEC etching. A suitable electrode 56 is then immersed in the electrolyte and biased with a negative voltage V−. A small current then flows from the backside metal layer 50 , through the p+ silicon substrate 22 , through the n+ zener diode regions 34 , through the LEDs' n-layers 52 , through the electrolyte 54 , and through the electrolyte electrode 56 . The LEDs are then exposed to ultraviolet light 58 . The UV light 58 creates electron-hole pairs in the GaN, and the holes migrate to the surface under the influence of the electric field. The holes react with the GaN and the electrolyte at the surface to break the bonds of the GaN, causing some removal of the GaN surface, resulting in controlled roughening of the surface. The surface becomes progressively more porous with time. PEC etching of GaN layer is described in US Patent Publications 2009/0045427, 2008/0237619, and 2007/0284607, all assigned to the present assignee and incorporated herein by reference.
[0053] After PEC etching, any other optical elements are added to the LEDs, such as phosphor layers and lenses. The submount wafer is then diced to form individual LED modules, such as that shown in FIG. 4 .
[0054] The n+ zener diode regions 34 may be formed to have any shape, and the LEDs 30 may instead be individual dice mounted on the common submount and connected in series by the metal layer 40 . The invention enables fewer zener diodes to be formed in a silicon submount for transient voltage suppression, allowing the zener diodes to be made wider/larger for lower series resistance and, for the intermediate zener diodes, made closer together to reduce the required silicon surface area. Increasing the area of each zener diode region also reduces the resistance during PEC etching to reduce processing time.
[0055] While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as fall within the true spirit and scope of this invention. | A transient voltage suppressor circuit is disclosed for a plurality (N) of LEDs connected in series. Only one zener diode is created for connection to each node between LEDs, and a pair of zener diodes (the “end” zener diodes) are connected to the two pins (anode and cathode pads) of the series string. Therefore, only N+1 zener diodes are used. The end zener diodes (Q 1 and Qn+1) effectively create back-to-back zener diodes across the two pins since the zener diodes share a common p+ substrate. The n+ regions of the end zener diodes Q 1 and Qn+1 have the highest breakdown voltage requirement and must be placed relatively far apart. Adjacent n+ regions of the intermediate zener diodes have a much lower breakdown voltage requirement so may be located close together. Since there are fewer zener diodes and their spacings may be small, the zener diodes may be placed within a very small footprint or can be larger for better suppressor performance. | 7 |
RELATED APPLICATIONS AND PRIORITY CLAIM
[0001] This application claims priority of U.S. Provisional Patent Application No. 60/307,976, filed Jul. 26, 2001, under 35 U.S.C. § 119.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the art of efficient and high-speed generation of fine surface patterns made of chemical resists or biological substances using micromachined or microfabricated probes.
BACKGROUND OF THE INVENTION
[0003] High-throughput lithography and surface patterning with extremely fine linewidths (e.g., on the order of 10-100 nm) are very important for the future growth of the microelectronics industry and nanotechnology. Next-generation integrated circuit technology will inevitably call for efficient and low-cost generation of features with a sub-100-nm linewidth. The emerging field of nanotechnology also requires patterning and functionalization of surfaces with a spatial resolution that is comparable with the scale of the molecules and cells that need to be manipulated and modified.
[0004] The resolution of conventional projection optical lithographic systems, still the most widely used in the microelectronics industry, is limited by optical diffraction. The resolution can be improved by using beam-based direct-writing tools with high energy and short wavelengths. High-energy beam lines, including ones that rely on electron beams and X-rays, are being used. However, such direct-write lithography systems suffer from several drawbacks. First, such systems are invariably complex and expensive. Second, these lithographic tools operate with a single beam and produce patterns in a serial manner, resulting in low throughput. Third, conventional high resolution lithography systems are not capable of depositing patterns made of biological molecules or chemical compounds. Only special chemical resists may be used.
[0005] Dip-pen Nanolithography (DPN) is a new and recently introduced method of scanning probe nanolithography. A description of DPN is contained in PCT/US00/00319, the entirety of which is incorporated herein by reference. It functions by depositing nanoscale patterns on surfaces using the diffusion of a chemical species from a scanning probe tip to the surface, sometimes via a water meniscus that naturally forms between tip and sample under ambient conditions. As a DPN tip is scanned across the surface of a substrate, molecules on the surface of the tip are transported through the water meniscus that forms between the tip and the substrate surface. Once on the surface, the molecules chemically anchor themselves to the substrate, forming robust patterns. Features in the 10 nm to many micrometer range can be fabricated with commercially available silicon nitride tips. One factor that influences the linewidth of DPN writing is the linear speed of the tip. Smaller linewidths are achieved with faster tip speeds. Other factors that influence the linewidth include the sharpness of the DPN tip and the diffusion constants of the molecules used as inks.
[0006] DPN offers a number of unique benefits, including direct writing capability, high resolution (˜10 nm linewidth resolution, ultimate˜5 nm spatial resolution), ultrahigh nanostructure registration capabilities, the flexibility to employ a variety of molecules for writing compounds (including biomolecules) and writing substrates (such as Au, SiO 2 , and GaAs), the ability to integrate multiple chemical or biochemical functionalities on a single “nano-chip”, a one-layer process for patterning, and the ability to automate patterning using customized software.
[0007] DPN technology can be implemented using a low-cost commercial scanning probe microscope (SPM) instrument. In a typical setup, the DPN probe chip is mounted on an SPM scanner tube in a manner similar to commercially available SPM tips. Precise horizontal and vertical movement of the probes is attained by using the internal laser signal feedback control system of the SPM machine.
SUMMARY OF THE INVENTION
[0008] The present invention provides nanolithography, such as Dip Pen Nanolithography, as well as nanoscale imaging, with individually addressable probes in dip pen arrays. A probe array having a plurality of active probes is provided, which allows greater functionality than in conventional, single-pen DPN by allowing independent actuation of individual probes through supplying current or voltage to an actuator coupled with the probe. A plurality of independently addressable probes produces a plurality of traces of same or different chemicals.
[0009] An apparatus is provided for applying at least one patterning compound to a substrate for nanolithography. The apparatus includes an array of parallel probes, each probe including a cantilever, a tip at a distal end of the cantilever for applying one of the at least one patterning compound to the substrate, and an actuator operatively coupled to the cantilever. The probes may be configured for Dip Pen Nanolithography. The actuator is designed to be responsive to an applied current or voltage to move the cantilever, and thus move the tip away from the substrate. The contact state between individual probe tips and the writing substrate can thus be independently controlled. In the case of DPN writing, the patterning process is suspended when the probe tip leaves the substrate. A number of preferred types of embodiments are disclosed. Methods are also provided for fabricating active probe arrays.
[0010] In one preferred type of embodiment of the invention, the actuator deflects the cantilever in response to applied electrical current to move the tip relative to the substrate. The actuator may be thermally operated.
[0011] According to a preferred embodiment, a thermal actuator includes a resistive heater connected to the cantilever and a wire connecting the resistive heater to a current source. When a current is applied through the resistive heater, heat is generated due to ohmic heating, thus raising the temperature of the resistor as well as the cantilever. Due to difference in the thermal expansion coefficient of the materials for the cantilever and for the metal resistor, the cantilever will be bent selectively in response to the applied current. A patch of thin metal film can be connected to the cantilever for enhancing the extent of thermal bending.
[0012] In a second type of preferred embodiment of the invention, the actuator deflects the cantilever in response to applied voltage. The actuator may be electrostatically operated. Preferred displacement is created by applying a voltage differential between two electrodes, at least one of them being not stationary.
[0013] A preferred embodiment of an electrostatic actuator includes a paddle electrode formed at an inner end of the cantilever opposite to the tip and a counter electrode. The paddle electrode faces the counter electrode with a gap having a predefined gap spacing. When a differential electrical voltage is applied across the top electrode and the counter electrode, the resultant electrostatic attraction force bends the cantilever beam and therefore moves the tip positions.
[0014] A preferred type of method of the current invention provides a method for applying at least one patterning compound to a substrate for high-speed probe-based nanolithography. The method includes the steps of: providing an array of individually addressable probes, each probe having a tip on a distal end; coating tips with same or different chemical substances; positioning the tips of the array of individually addressable probes over the substrate so that the tips are in contact with the substrate; raster-scanning the probes over the substrate surface; and selectively actuating at least one selected probe from the array of probes to move the tip of the selected probe away from the substrate. Accordingly, the selected probe does not apply patterning compound to the substrate when selected, while the non-selected probes apply at least one patterning compound to the substrate. Arbitrary two-dimensional patterns can be produced by raster-scanning the chip that contains the arrayed probes while controlling the position of individual probes during the scanning process. The probes may be configured for Dip Pen Nanolithography. The probes can also be generally applied to other nanolithography techniques where the interaction between a tip and a substrate alters the electrical, chemical, or molecular state of the surface, and may be used for imaging.
[0015] According to a preferred method of the present invention, the step of selectively actuating at least one selected probe includes the step of applying a current to a resistive heater connected to the cantilever, so that the cantilever beam is flexed. The deflection of the cantilever moves the tip away from the substrate to suspend writing on the substrate.
[0016] According to another preferred method of the present invention, the step of selectively actuating an individual probe includes applying a differential electrical voltage across a counter electrode and a moving electrode connected to an end of the selected probe. In this way, the moving and counter electrodes are moved towards one another, preferably to deflect the cantilever of the probe and move the tip away from the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a schematic representation of the DPN process, showing a single tip coated with chemical compounds passing over a substrate (writing surface);
[0018] [0018]FIG. 2 is a schematic diagram of a parallel nanolithography writing system having a probe array according to one type of embodiment of the present invention, interfaced with an auxiliary control unit;
[0019] [0019]FIGS. 3 a - 3 b are schematics of an array of bimetallic thermally actuated probes before and after deflection of selected probes, respectively, according to a preferred type of embodiment of the present invention;
[0020] [0020]FIGS. 4 a - 4 b are schematics of a bimetallic thermally actuated probe before and after deflection of the probe, respectively;
[0021] [0021]FIGS. 5 a - 5 e are schematic drawings showing major steps in the fabrication process of a thermally actuated probe according to a preferred aspect of the invention;
[0022] [0022]FIGS. 6 a - 6 d are schematic drawings showing a top view of the fabrication steps shown in FIGS. 5 b - 5 e, respectively;
[0023] [0023]FIG. 7 is a schematic drawing of an electrostatically actuated probe according to a preferred type of embodiment of the invention;
[0024] [0024]FIG. 8 is a schematic drawing of an array of electrostatically actuated probes according to a preferred type of embodiment of the invention;
[0025] [0025]FIG. 9 is a schematic showing a top view of an electrostatic actuator probe;
[0026] [0026]FIGS. 10 a - 10 f are schematics taken along a section of FIG. 9 and in the direction indicated, showing fabrication steps for an electrostatically actuated probe according to a preferred method of the invention; and
[0027] [0027]FIG. 11 is a schematic drawing of a two-dimensional array DPN nanoplotter according to another preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Generally speaking, the present invention provides active probes and active probe arrays, which are designed to achieve direct-write nanolithography, such as DPN. Devices according to the present invention can generate sub-100 nm patterns in a high speed, parallel, and controllable fashion. The active probe arrays offer greater functionality by allowing actuation of individual probes through supplying current or voltage to an actuator of the probe. The present invention is primarily directed to methods and devices for parallel DPN using active probe arrays, and methods for fabricating active probes and active probe arrays.
[0029] The active probe array can also be used for other existing or future surface patterning and lithography methods based on the scanning probe microscope (SPM) instrument family. An atomic force microscope (AFM) is considered a member of the SPM instrument family. Examples of such lithography systems include local thermal oxidation and displacement lithography.
[0030] Referring now to FIG. 1, an example of a conventional DPN process is shown. DPN employs a tip 20 on a distal end of a cantilever of an AFM probe 22 (or other SPM probe) to deposit, or “write”, nanoscale patterns onto a solid writing substrate 24 , such as gold. The tip 20 applies a patterning compound 26 coated on the tip 20 to the writing substrate 24 . The patterning compound 26 may be a hydrophobic patterning compound with a chemical affinity for the writing substrate 24 , such as, but not limited to, 1-octadecanethiol (ODT) or mercaptohexadecanoic acid (MHA).
[0031] Similar to traditional macroscopic “dip pens” (e.g., quill, fountain, or ball-point pens, or multi-pen plotters), DPN employs molecular (capillary) transport to transfer the patterning compound 26 from the tip 20 to the writing substrate 24 , forming a pattern 28 of the patterning compound. A water meniscus 30 forms between the tip 20 and the writing substrate 24 due to relative humidity in a work area, and carries the patterning compound 26 from the tip to the writing substrate as the tip is moved relatively to the writing substrate in the direction of the writing W, as indicated on FIG. 1.
[0032] Initial DPN processes involved a single probe 22 (pen). Parallel patterns also have been realized using an array of up to eight commercial probes 22 with an inter-probe spacing of 1.4 mm to write a plurality of patterns 28 on the writing substrate 24 . This technique also allows application of multiple patterns 28 , where each pattern contains a different patterning compound, such as a biocompound. Parallel writing is also useful, for example, to form patterns 28 during integrated circuit formation. Examples of parallel probe structures can be found in R. Piner et al., “Dip-Pen” Nanolithography, Science, 1999, v. 283, pp. 661-663; S. Hong et al., Multiple Ink Nanolithography: Toward a Multiple-Pen Nano-Plotter, 1999, v. 286, pp. 523-525; S. Hong et al., A Nanoplotter with Both Parallel and Serial Writing Capabilities, Science, v. 288, pp. 1808-1811.
[0033] Conventional parallel probe DPN processes are performed using commercially available AFM probes 22 . Individual probes 22 cannot be moved independently from one another. Hence, all probes 22 must move simultaneously. Also, the inter-probe spacing of current parallel DPN arrays is too large for certain DPN applications and cannot fully satisfy the needs for a high-throughput and high-density arrayed DPN writing system. The present invention provides a nanoplotter with an array of independently active, microfabricated, closely spaced DPN probes.
[0034] [0034]FIG. 2 shows a schematic view of an active multi-pen, parallel DPN writing system 32 according to one type of embodiment of the current invention. A DPN probe chip 34 having a probe array including a plurality of active probes 38 is mounted on an AFM scanner tube 40 in a manner similar to standard single-tip AFM probes. AFM feedback electronics 42 , typically piezo tube electronics, control horizontal and vertical movement of the probe chip 34 .
[0035] As the tips 20 of the active probes 38 are in contact with the writing substrate 24 , an integrated actuator 46 controlled by a connected auxiliary control circuit 48 directs individual movement of the tips, preferably while the probe chip 34 is raster-scanned along the substrate 24 for patterning. The location of the integrated actuator 46 indicated in FIG. 2 is illustrative, and other actuator locations are contemplated. The term “in contact” is intended to refer to a sufficient proximity between the tips 20 and the substrate 24 to allow patterning of the patterning compound 26 . When supplied with current or voltage from the control unit 48 via the probe chip 34 , the actuator 46 moves a cantilever 50 of the active probe 38 to lift the tip 20 at an end of the cantilever off the writing substrate 24 . This suspends the chemical deposition process. In this way, the active probe 38 can be individually controlled through selective application of current or voltage to create arbitrary patterns with high throughput.
[0036] [0036]FIGS. 3 a and 3 b show an array 56 of thermally actuated probes 54 according to a preferred type of embodiment of the present invention, before and after actuation of selected probes, respectively. In FIG. 3 a, the array 56 is shown having five thermally actuated probes 54 , none of which is actuated. In response to an applied current, and as shown in FIG. 3 b, the second and fourth thermally actuated probes (indicated by arrows) are flexed upwardly (in FIGS. 3 a and 3 b, into the paper), thus moving their tips 20 away from the writing substrate 24 , and suspending chemical deposition. It will be appreciated by those skilled in the art that the selective distribution of current to form the patterns 28 may be controlled by programming the control circuit 48 .
[0037] The material of the cantilever beam 50 in the thermally actuated probes 54 preferably is silicon nitride thin film formed by low pressure chemical vapor deposition methods (LPCVD). According to a preferred type of method of the present invention, the thermally actuated probes 54 are formed by creating silicon nitride probes that include a thermal actuator having at least a resistive heater 66 .
[0038] [0038]FIGS. 4 a and 4 b show one of the thermally actuated probes 54 in non-flexed and flexed (actuated) positions, respectively. The resistive heater 66 , patterned onto the silicon nitride cantilever 50 of the thermally actuated probe 54 , is coupled to a bonding wire 70 for carrying current to the resistive heater. The bonding wire 70 is in turn coupled to the control circuit 48 for selectively distributing current to the bonding wire 70 and thus actuating the thermally actuated probes 54 . Preferably, a metal film patch 68 is connected to the cantilever 50 to increase the deflection of the probe 54 .
[0039] [0039]FIGS. 5 a - 5 e and 6 a - 6 d show formation steps for the thermally actuated probe array 56 , forming a single thermally actuated probe 54 and a pair of thermally actuated probes, respectively. Referring to FIG. 5 a, a silicon dioxide thin film 60 is grown on a front side of a silicon substrate 62 , preferably a <100>-oriented silicon wafer, to form a protective mask for creating the tip 20 . The oxide layer 60 is patterned photolithographically to realize the mask for forming the tip 20 . In FIG. 5 b (also in FIG. 6 a ), a portion of the silicon substrate 62 defining the pyramidal shape of the tip 20 is formed by using anisotropic wet etching in ethylene diamine pyrocatechol (EDP). Next, as shown in FIG. 5 c ( 6 b ), a layer of LPCVD silicon nitride 64 is deposited and patterned onto the etched silicon substrate 62 to define the shape of the thermally active probe 54 , including the cantilever 50 . As shown in FIGS. 5 d ( 6 c ), the resistive (ohmic) heater 66 and the (optional) metal patch 68 are formed on the thermally active probe 54 by depositing and patterning, for example, Cr/Au onto the layer of silicon nitride 64 , creating an integrated bimetallic thermal actuator. The thermally actuated probes 54 are then released by using EDP etching to undercut the support substrate 62 . A portion of a silicon substrate 62 provides a handle for the thermally actuated probes 54 , as shown in FIGS. 4 a and 4 b.
[0040] In operation, the thermally actuated probes 54 , in response to an applied current, bend along their length to move the tip 20 as shown in FIG. 4 b, due to differential thermal expansion of the metal for resistive heater 66 and optional patch 68 and the cantilever 50 of the thermally actuated probe. In a preferred method of operation, the control circuit 48 sends a current through the bonding wire 70 to the resistive heater 66 to bend the thermally actuated probe 54 into a circular arc of radius R due to differential thermal expansion of the silicon nitride cantilever 50 and the gold patch 68 .
[0041] The expression for R under a given temperature change of ΔT is
R = - ( w 1 E 1 t 1 2 ) 2 + ( w 2 E 2 t 2 2 ) 2 + 2 w 1 w 2 E 1 E 2 t 1 t 2 ( 2 t 1 2 + 3 t 1 t 2 + 2 t 2 2 ) 6 w 1 w 2 E 1 E 2 t 1 t 2 ( t 1 + t 2 ) ( α 1 - α 2 ) Δ T .
[0042] The parameters w, t, E and α, respectively, are the width, thickness, Young's modulus of elasticity, and the coefficient of thermal expansion of two constituent materials, denoted as materials 1 and 2 . The subscripts correspond to these two materials. The temperature of a thermal actuator is dictated by the heat balance of the beam. Heat is generated by ohmic heating and lost through conduction and convection.
[0043] In the thermally actuated probe 54 , the bending of the cantilever beam 50 results in a deflection of the tip 20 of δ:
δ = R ( 1 - cos ( L R ) )
[0044] Accordingly, application of current I through selected bonding wires 70 causes the cantilever 50 of the thermally actuated probes 54 connected to the bonding wires to deflect upwardly and thus move the tip 20 , as shown in FIG. 4 b.
[0045] The throughput of probe-based nanolithography can be made very high when a large number of active probes 38 in parallel are integrated on the probe chip 34 . The thermally actuated probe array 36 , manufactured according to the preferred type of embodiment of the present invention described above, results in a compact nanoplotter with high probe densities (spaced 100 μm on center) and integrated sharp tips, and may be used for nanolithography and AFM imaging.
[0046] According to another preferred type of embodiment of the present invention, an electrostatically actuated probe 72 , shown in a preferred type embodiment in FIG. 7, is provided. Preferably, the probe 72 is formed as a unit of an electrostatic probe array 74 , shown in a preferred embodiment in FIG. 8 in combination with the probe chip 34 .
[0047] As shown in FIGS. 7 and 8, the electrostatically actuated probe 72 includes an electrostatic actuator 76 , which may include a paddle-shaped plate 78 at the inner longitudinal end of the cantilever 50 , longitudinally opposite to the tip 20 . The paddle-shaped plate 78 is preferably integrally formed with the electrostatically actuated probe 72 . The electrostatic actuator 76 further includes a counter electrode 81 , which is preferably stationary, and may be formed on the probe chip 34 , for electrostatically interacting with the paddle-shaped plate 78 . The counter electrode 81 may be formed as part of a parallel array of electrodes electrically connected to a number of bonding pads 85 longitudinally opposed to the counter electrodes, and both are patterned, adhered, or otherwise formed or attached to a glass substrate 94 which, in the completed embodiment, covers the array of counter electrodes and connecting bonding pads. The bonding pads 85 are preferably electrically connected to the control circuit 48 for selectively applying a voltage to one or more of the bonding pads. Methods for manufacturing the glass layer 94 including the counter electrodes 81 and the bonding pads 85 will be apparent to those in the art.
[0048] It is preferred that the electrostatically actuated probe 72 is also supported at or near the midpoint of the cantilever 50 by a compact, soft spring 80 , for providing torsion support to the electrostatically actuated probe, allowing deflection and thus angular motion of the probes, for moving the tips 20 of the probes. As shown in FIG. 8, the spring 80 for each of the array 74 of electrostatically actuated probes 72 is preferably a section of a unitary piece (such as a twist beam) laterally extending through each individual probe. It is further preferred that each section of the spring 80 have a relatively small cross section along the longitudinal direction of the cantilever 50 . As one in the art will appreciate, dimensions of the spring 80 such as the cross-sectional area can be varied depending on boundary conditions to control the angular flexibility of the cantilever 50 .
[0049] [0049]FIG. 9 is a top view of a preferred embodiment of the electrostatically actuated probe 72 . It is preferred, though not required, that the cantilever 50 , paddle-shaped plate 78 , and soft spring 80 be formed integrally from boron-doped silicon. This material is preferred both for its low etch rate in EDP solutions and for its relatively high electrical conductivity.
[0050] A preferred method of fabrication of the electrostatically actuated probe 72 is shown in FIGS. 10 a - 10 f. Referring first to FIG. 10 a, a silicon dioxide layer 82 is grown on a front side of a three-layered wafer containing a heavily boron-doped silicon layer 84 sandwiched between a <100>-oriented silicon wafer 86 and an epitaxial <100>-oriented silicon layer 88 . Alternatively, the silicon layer 84 may be doped by phosphorous. The silicon dioxide layer 82 defines boundaries of a mask for forming the tip 20 . Furthermore, the silicon dioxide layer 82 can define boundaries for forming a spacer 90 , which vertically separates the electrostatically actuated probe 72 from the counter electrode 81 , which is patterned on a separate glass substrate 94 . In FIG. 10 b, the silicon tip 20 and the spacer 90 are formed from the epitaxial silicon wafer 88 by EDP etching. Next, as shown in FIG. 10 c, a thermal oxide layer 92 is grown over the epitaxial silicon wafer 88 , including the tip 20 , the spacer 90 , and the boron-doped silicon layer 84 to protect the front side during the final release. As shown in FIG. 10 d, the silicon wafer 86 is then etched by EDP to remove material underneath the boron-doped silicon layer 84 , and release the boron-doped silicon cantilever 50 .
[0051] Next, as shown in FIG. 10 e, the thermal oxide layer 92 is removed, and the electrostatically actuated probes 84 are formed from the boron-doped silicon layer 84 , including, preferably integrally, the cantilever 50 , the soft spring 80 , and the paddle-shaped plate 78 , for each probe in the array. As shown in FIG. 8, the portion of the cantilever 50 longitudinally disposed between the paddle-shaped plate 78 and the soft spring 80 is preferably wider in cross-sectional area along the lateral direction, i.e. in the direction of the length of the soft spring, than the distal portion of the cantilever. In this way, the deflection of the tip 20 is greater because the bending torque is fully transferred to the support spring 80 . The electrostatically actuated probe 72 is released.
[0052] Finally, as shown in FIG. 10 f, the layer of glass 94 and the connected counter electrode 81 are formed or placed over the spacer 90 .
[0053] The preferred fabrication method results in electrostatically actuated probes 72 having a sharp tip 20 (preferably, <100 nm radius of curvature) and spaced approximately 620 μm on center. Accordingly, electrostatically actuated probes 72 according to a preferred embodiment of the present invention can be used for both DPN writing and AFM imaging.
[0054] Bonding wires 70 (not shown in FIGS. 10 a - 10 f ) preferably connect the paddle-shaped plate 78 to ground potential, while the counter electrode 81 is preferably electrically coupled to the control circuit 48 via bonding pads 85 for applying voltage to the counter electrode. It will be appreciated that the electric potentials of the paddle-shaped plate 78 and the counter electrode 81 may alternatively be reversed; i.e. the paddle-shaped plate may be coupled to a voltage source, while the counter electrode may be grounded. The modifications necessary for such an alternative embodiment will be understood by those in the art.
[0055] In a preferred method of operation, voltage is applied to the paddle-shaped plate 78 to apply potential to the paddle-shaped plate 78 , while the conductive counter electrode 81 is grounded. Again, alternatively, the voltage application and grounding functions could be reversed between the top electrode 81 and the paddle-shaped plate 78 . Either operation applies a differential electrical voltage across the top electrode 81 and the paddle-shaped plate 78 , which are preferably separated by the spacer 90 . An attractive force develops between the plates of the counter electrode 81 and the paddle-shaped plate 78 that pulls them toward each other, thus tilting the cantilever 50 , and preferably angularly deflecting the cantilever 50 about the soft spring 80 , to move the tip 20 away from the substrate 24 . As in the thermally actuated probes 54 , the tip 20 can thus be selectively lifted to suspend the writing (or imaging) process.
[0056] A number of preferred embodiments have been described for active, one-dimensional arrays. However, arrays are possible in two dimensions as well. FIG. 12 shows a two-dimensional array 100 according to another preferred embodiment of the present invention. The two-dimensional array 100 shown in FIG. 12 includes six rows and five columns of downwardly-angled probes 102 . The downwardly-angled probes 102 may be produced by, for example, modifying the formation process for the thermally actuated probe array 56 to extend cantilevers of individual, thermally actuated probes 54 from cavities (replicated cells) that are preferably evenly disposed along the two-dimensional array 100 . The thermally actuated probes 54 are preferably integrated into the two-dimensional array 100 due to a shorter required length for each cantilever 50 . The methods for modifying steps of fabrication and operation for the thermally actuated probes 54 in the two-dimensional array 100 will be understood by those in the art.
[0057] One skilled in the art can appreciate that several inventive devices and methods for DPN arrays have been shown and described, which have various attributes and advantages. By configuring each probe to be individually addressed and actuated by application of current or voltage, either thermally or electrostatically, the active probe arrays according to embodiments of the present invention allow the formation of arbitrary patterns with added resolution, at throughput comparable to conventional methods.
[0058] While various embodiments of the present invention have been shown and described, it should be understood that other modifications, substitutions and alternatives are apparent to one of ordinary skill in the art. Such modifications, substitutions and alternatives can be made without departing from the spirit and scope of the invention, which should be determined from the appended claims.
[0059] Various features of the invention are set forth in the appended claims. | A microfabricated probe array for nanolithography and process for designing and fabricating the probe array. The probe array consists of individual probes that can be moved independently using thermal bimetallic actuation or electrostatic actuation methods. The probe array can be used to produce traces of diffusively transferred chemicals on the substrate with sub-1 micrometer resolution, and can function as an arrayed scanning probe microscope for subsequent reading and variation of transferred patterns. | 8 |
This is a division of application Ser. No. 07/453,365, filed on Dec. 21, 1989, now U.S. Pat. No. 5,013,834, which is a continuation of application Ser. No. 07/412,072, filed on Sept. 25, 1989, abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the preparation of 1S,4S- and 1R,4R-2-alkyl-2,5-diazabicyclo[2.2.1]heptane intermediates having utility in the preparation of antibacterial quinolones such as those disclosed in U.S. Pat. No. 4,775,668.
A method for the synthesis of 2,5-diazabicyclo[2.2.1]heptanes has been described by Portoghese et al., J. Org. Chem., 31, 1059 (1966). According to this method, hydroxy-L-proline is transformed into tritosylhydroxy-L-prolinol which is first reacted with benzylamine and then with hydrogen iodide, phosphorus, and acetic acid to form N-benzyl-2,5-diazabicyclo[2.2.1]heptane dihydroiodide. U.S. Pat. No. 3,947,445 follows a similar procedure and then converts the dihydroiodide through a three step procedure into 2-methyl-2,5-diazabicyclo[2.2.1]heptane.
In our prior copending application, Ser. No. 350,423, filed May 11, 1989, we describe another method for the preparation of said optically active 2,5-diaza-2-alkylbicyclo[2.2.1]heptanes of the formula (IX) below from trans-4-hydroxy prolines of the formula (I) below.
SUMMARY OF THE INVENTION
The over-all processes of the present invention for the preparation of optically active 2,5-diaza-2-alkylbicyclo[2.2.1]heptanes (IX) from 4-hydroxyproline (I) are shown in Schemes I and II. In these schemes, all of the compounds depicted are chiral and optically active. Viewed as formulas which depict absolute stereochemistry, they depict, for example, trans-4-hydroxy-L-proline, also known simply as hydroxyproline, of the formula (I), and (1S,4S)-2-alkyl 2,5-diaza[2.2.1]heptanes, of the formula (IX). Viewed as formulas which depict relative stereochemistry, they also depict the corresponding enantiomers, for example, trans-4-hydroxy-D-proline (I) and (1R,4R)-2-alkyl-2,5-diaza[2.2.1]heptanes (IX). In these formulas
R, R 1 and R 3 are each independently (C 1 -C 6 )alkyl;
R 2 and R 4 are each independently (C 1 -C 6 )alkyl, trifluoromethyl or ##STR1##
X and X 1 are each independently hydrogen, (C 1 -C 6 )alkyl, bromo, chloro, trifluoromethyl, methoxy or nitro.
In particular, the present invention is directed to the process steps:
(VII)→(VIII) [carried out by the agency of at least one molar equivalent of an alkali metal carbonate salt in a reaction inert solvent]; ##STR2##
(VII)→(VIII)→(IX);
(I)→(II)→(III)→(IV)→(V)→(VII)→(VIII);
(XIII)→[(XIV)]→(VIII) [carried out by the agency of a hydride reducing agent in a reaction inert solvent, without isolation of the intermediate amine];
(XIII)→[(XIV)]→(VIII)→(IX); and
(I)→(X)→(XII)→(XIII)→[(XIV)]→(VIII).
The expression "reaction inert solvent" refers to a single or multicomponent solvent, the component(s) of which do not interact with starting materials, reagents, intermediates or products in a manner which adversely affects the yield of the desired product.
In the conversion of (VII) to (VIII), the preferred reagent is K 2 CO 3 and the preferred solvent is a lower alcohol, particularly methanol. In the conversion of (XV) to (IX), the preferred hydride reducing agent is LiAlH 4 and the preferred solvent is an ether, particularly diethylether or tetrahydrofuran.
In these processes, the preferred values of R and R 3 are each methyl; of R 1 is methyl or ethyl; and of each of R 2 and R 4 is methyl or 4-methylphenyl. Because the number of steps is reduced, it is preferred that R 2 and R 3 or R 4 have the same value.
The present invention is also directed to optically active intermediates of the relative or absolute stereochemical formulas ##STR3## wherein a first alternative,
R 5 is (C 1 -C 6 )alkyl;
R 6 is SO 2 R 2 ;
R 2 is as defined above;
R 7 is hydrogen or SO 2 R 3 ; and
R 3 is as defined above; or
in a second alternative,
R 6 is (C 1 -C 6 )alkyl;
R 5 is SO 2 R 2 ;
R 2 is as defined above;
R 7 is SO 2 R 4 ; and
R 4 is as defined above;
and ##STR4## wherein
R 2 and R 4 are defined above;
R 8 is OR 1 or NHR; and
R and R 1 are as defined above.
The preferred compounds of the formula (XV) are in the first alternative having R 5 as methyl, R 2 as methyl or 4-methylphenyl, and, when R 7 is SO 2 R 3 , R 3 as methyl;
and in the second alternative having R 6 as methyl, and R 2 and R 4 as methyl or 4-methylphenyl.
The preferred compounds of the formula (XVI) have R as methyl, R 1 as methyl or ethyl, and R 2 and R 4 the same and as methyl or 4-methylphenyl.
DETAILED DESCRIPTION OF THE INVENTION
The various process steps of the present invention are readily carried out.
The initial step according to Scheme I involves conventional reductive alkylation of a trans-hydroxyproline (I) with a (C 1 -C 6 )aliphatic aldehyde or ketone appropriate to the desired N-alkyl substituent (e.g., formaldehyde→methyl, hexanal→hexyl, acetone→isopropyl). This reductive alkylation is carried out under typical hydrogenation conditions, best over a noble metal catalyst, preferably palladium. The catalyst can be a noble metal per se, or an oxide or salt, reduced to the active metal catalyst under the conditions of hydrogenation, or a noble metal catalyst on a support such as carbon or alumina. In the present instance the most preferred catalyst is Pd/C. The reaction inert solvent includes water, an organic solvent such as ethanol or a mixed solvent such as aqueous alcohol. When R is methyl, the preferred source of formaldehyde is simply aqueous formaldehyde and in this case water alone is the preferred solvent. At least one molar equivalent of the aldehyde or ketone is usually employed, and when this reagent (like formaldehyde) is readily available, it can be employed in large excess in order to reduce reaction time and maximize the stoichiometric yield from the generally more valuable hydroxyproline. Temperature is not critical, temperatures of 0°-50° C. being generally satisfactory, and ambient temperature, avoiding the cost of heating or cooling, is most preferred. Likewise, pressure is not critical, but low to moderate pressures (e.g., 1-8 atmospheres) are preferred in order to avoid the need for expensive, high pressure reactors.
The second step in Scheme I (II→III) involves conventional conversion of a carboxylic acid group to a (C 1 -C 6 )carboxylate ester, preferably accomplished by simple strong acid catalyzed esterification with an alcohol, usually employed in gross excess and also as solvent. Suitable strong acids are such as HCl, H 2 SO 4 , and R 2 SO 3 H where R 2 is defined as above, are generally employed in anhydrous or near anhydrous form in amounts ranging from truly catalytic (e.g., 10 mol %), but generally in excess of the 100 mol % necessary to neutralize the tertiary amine group. Temperature is not critical, 0°-50° C. being generally satisfactory and room temperature particularly convenient.
In the third step of Scheme I (III→IV), the lower alkyl ester group is conventionally converted to a carboxamide group by the action of ammonia in a reaction inert solvent. When water is the solvent, undiluted, concentrated ammonia is preferred. When the solvent is a lower alcohol such as methanol, anhydrous ammonia, saturated into the solvent, is preferred. Temperature is not critical, 0°-50° C. being generally satisfactory, with ambient temperatures being especially convenient.
In the fourth step of Scheme I, the carbamoyl group in (IV) is reduced with a hydride reducing agent to the aminomethyl group in (V). Hydride reducing agents, such as diisobutyl aluminum hydride or lithium aluminum hydride which show a high level of activity in reducing amides to amines, are preferred reagents in this reduction. It is preferred to use an excess of these reagents, e.g., as many as 6 mols of diisobutyl aluminum hydride or 1.5 mols of lithium aluminum hydride per mole of amide. The reduction is carried out in a reaction inert solvent, usually an ether such as diethylether or tetrahydrofuran. Temperature is not critical, 0°-50° C. generally being satisfactory and ambient temperatures most preferred.
In Scheme I, when R 2 and R 3 are different, the conversion of (V) to (VII) will require two steps. In the first of these, the sulfonamide is best selectively formed by acylation of the amine with substantially one molar equivalent of the appropriate sulfonyl chloride in the presence of a sufficient amount of a base (such as n-butyllithium) to neutralize co-produced hydrogen chloride, in a reaction inert solvent, suitably an ether such as tetrahydrofuran. This reaction is generally carried out at a reduced temperature (e.g., -50° to +15° C.), a temperature near the middle of this range (e.g., -10° to -15° C.), being particularly satisfactory. In this case, subsequent O-sulfonylation (VI→VII) is readily accomplished using at least one molar equivalent of R 2 SO 2 Cl in the presence of at least one molar equivalent of a tertiary amine such as triethylamine, generally in an aprotic solvent such as an ether (e.g., tetrahydrofuran). Temperature in this second stage is not critical, with a temperature in the range of 0°-50° C. generally satisfactory and ambient temperature usually preferred.
As noted above in the preferred routes R 2 and R 3 are the same, in which case concurrent N- and O-sulfonylation is readily accomplished under the latter conditions, except that at least two equivalents each of the sulfonylchloride (R 3 SO 2 Cl) and the tertiary amine are employed.
At the heart of the present invention is the cyclization of the bis-sulfonylated derivative (VII) to form the 2-alkyl-5-(alkane- or benzene-)sulfonyl derivative (VIII). This cyclization is readily accomplished by the agency of at least one molar equivalent of an alkali metal carbonate (e.g., K 2 CO 3 is particularly well-suited) in a reaction inert solvent such as a lower alcohol (e.g., methanol is particularly well-suited).
In the first step of Scheme II, the hydroxyproline (I) is converted to the ester (X) best accomplished by the methods described above for the esterification of N-alkylhydroxyprolines (II→III). Bis-sulfonylation of (X) to form the compound of the formula (XII) and its ammonolysis to the amide (XIII) are also accomplished by the methods described above, except that the amine RNH 2 is substituted for NH 3 .
However, in marked contrast to Scheme I, in Scheme II, the hydride reduction of the carbamoyl group to an alkylamino group and cyclyzation are now accomplished in a single step, viz., by the action of hydride reducing agent as described above, with the expected product, (XIV), spontaneously cyclyzing to form the desired 2-alkyl-5-alkane- or benzenesulfonyl derivative (VIII).
Finally, in order to form the amine (IX), according to either Scheme, the N-sulfonyl group is removed by conventional reductive or hydrolytic methods This is best accomplished with HBr in acetic acid as reagent, conveniently with isolation of (IX) in the form of its dihydrobromide salt. Again temperature is not critical, 0°-50° C. being fully satisfactory and ambient temperature generally preferred. Those skilled in the art will understand that sodium in liquid ammonia represents an alternative reductive method for removal of the sulfonyl group, while use of strong aqueous acid (HCl, H 2 SO 4 , etc.) represents an alternative hydrolytic method for its removal.
The starting materials required in the operation of the present invention are readily available. Thus, trans-hydroxy-L-proline is a natural aminoacid which is commercially available, while its enantiomer is available according to the method of Baker, et al., J. Org. Chem., 46, pp. 2954-2960 (1981).
The amines of the formula (IX) are used as the source of side chain in the preparation of certain antibacterial quinolones such as those disclosed in U.S. Pat. No. 4,715,668, cited above.
The present invention is illustrated by the following Examples. However, it should be understood that the invention is not limited to the specific details of these examples. Nomenclature used herein is based on Rigaudy and Klesney, IUPAC Nomenclature of Organic Chemistry, 1979 Ed., Pergammon Press, New York, 1979.
EXAMPLE 1
trans-N-Methyl-4-hydroxy-L-proline (II, R=CH 3 )
To 40 g (305 mmol) of trans-4-hydroxy-L-proline in 80 ml of water was added 80 ml of 30% aqueous formaldehyde solution and 7.0 g of 5% palladium on carbon catalyst (50% wet), and the mixture was hydrogenated at 50 psig using a Parr Shaker. After 24 hours, the catalyst was recovered by filtration over diatomaceous earth and the filtrate evaporated under reduced pressure to provide 43.5 g (98.3%) of title product; mp 140°-142° C. (decomposition); 1 H-NMR (D 2 O) 4.65 (m, 1H), 4.20 (dd, 1H), 3.97 (dd, 1H), 3.2 (dm, 1H), 2.50 (m, 1H), 2.25 (m, 1H); [alpha] D =-54.8° (c=1.18, H 2 O).
By the same method, trans-4-hydroxy-D-proline is converted to enantiomec trans-N-methyl-4-hydroxy-D-proline, having identical properties except for sign of rotation.
EXAMPLE 2
trans-N-Methyl-4-hydroxy-L-proline Methyl Ester (III, R=R 1 =CH 3 )
Title product of the preceding Example (100 g, 690 mmol) was suspended in 600 ml of methanol and anhydrous HCl gas was bubbled through the reaction mixture until it became homogeneous. The reaction was then heated to reflux for 16 hours, after which it was cooled and the solvent was replaced with 150 ml of water. 200 g (1.44 mol) of potassium carbonate was then added carefully at 0° C. and the product was extracted with 4×200 ml portions of ethyl acetate. The combined organic layers were dried (Na 2 SO 4 ) and evaporated to provide 87 g (72%) of product as a white solid; mp 53°-54° C.; 1 H-NMR(D 2 O) 4.85 (s, 3H), 4.73 (m, 2H), 3.90 (s, 3H, N-methyl), 3.58 (m, 1H), 3.45 (m, 1H), 2.54 (m, 1H), 2.37 (m, 1H); [alpha] D =-80.0° (c=1.038, CH 3 OH).
By the same method, the enantiomeric product of the preceding Example is converted to the enantiomer of present title product, having identical properties except for sign of rotation.
EXAMPLE 3
(2S,4R)-1-Methyl-2-carbamoyl-4-hydroxypyrrolidine (IV, R=CH 3 )
Title product of the preceding Example (20 g, 126 mmol) was dissolved in 40 ml of ice cold, saturated NH 4 OH, and the resulting solution then warmed to room temperature. After stirring for 24 hours the solvent was removed under high vacuum to produce a quantitive yield of present title product as a white, crystalline solid; mp 138°-140° C.; Anal. C 49.99, H 8.40, N 18.27; calcd. C 49.97, H 8.40, N 19.43; 1 H-NMR (D 2 O) 4.43 (m, 1H), 3.42 (dd, 1H), 3.25 (AB pattern, 1H), 2.36 (s, H), 2.33 (M, 1H), 2.1 (m, 2H); [alpha] D =-105.48° (c=0.953, CH 3 OH).
By the same method, the enantiomeric product of the preceding Example is converted to the enantiomer of present title product, having identical properties except for sign of rotation.
EXAMPLE 4
(2S,4R)-1-Methyl-2-aminomethyl-4-hydroxypyrrolidine (V, R=CH 3 )
Title product of the preceding Example (15 g, 104 mmol) was suspended in 75 ml of tetrahydrofuran and 572.5 ml (572.5 mmol) of diisobutyl aluminum hydride (1M solution in hexanes) was added over a period of 15 minutes. The mixture was then heated to reflux for two days and judged complete by monitoring with thin layer chromatography. Diatomaceous earth (30 g) was then added to the reaction and while cooling with an ice bath, 300 ml of methanol was added dropwise. The slurry was then filtered and the solvents were evaporated to provide 8.1 g of a colorless oily product (60%); 13 C-NMR (D 2 O) 69.5 (CH), 66.8 (CH), 64.9 (CH 2 ), 44.0 (CH 2 ), 41.0 (CH 3 ), 39.5 (CH 2 ); [alpha] D =-61.94° (c=0.956, CH 3 OH).
By the same method, the enantiomeric product of the preceding Example is converted to the enantomer of present title product, having identical properties except for sign of rotation.
EXAMPLE 5
(2S,4R)-1-Methyl-2-[(4-methylbenzenesulfonylamino)methyl]-4-hydroxypyrrolidine (VI, R=CH 3 , R 2 =p-CH 3 C 6 H 4 )
To title product of the preceding Example (7.3 g, 56.2 mmol) in 200 ml of tetrahydrofuran at -10° C. was added 22.46 ml of n-butyllithium (56.2 mmol, 2.5M in hexanes) over a period of 30 minutes. p-Toluenesulfonyl chloride (10.2 g, 53.3 mmol) in 10 ml of tetrahydrofuran was then added. After stirring the mixture for two hours at -10° C., 20 ml of water were added and the reaction was extracted with 2×140 ml of methylene chloride. The combined organic layers were dried (Na 2 SO 4 ) and evaporated at reduced pressure to provide 15 g (94.3%) of present title product as a light yellow oil; 13 C-NMR (CDCl 3 ) 143.4, 136.5, 129.7, 127.0, 69.1, 64.7, 62.4, 43.0, 40.0, 38.2, 21.5; [alpha] D =-34.67° (c=0.90, CH 3 OH).
EXAMPLE 6
(2S,4R)-1-Methyl-2-[(4-methylbenzensulfonylamino)methyl]-4-(methanesulfonyloxy)pyrrolidine (VII, R=R 3 =CH 3 , R 2 =pCH 3 C 6 H 4 )
To title product of the preceding Example (1.0 g, 3.5 mmol) in 20 ml of tetrahydrofuran was added 0.49 ml (3.5 mmol) of triethylamine and 0.27 ml (3.5 mmol) of methanesulfonyl chloride. After stirring at room temperature for 30 minutes, 20 ml of water were added and the reaction was extracted with 2×40 ml of methylene chloride. The combined organic layers were then dried (Na 2 SO 4 ) and evaporated under reduced pressure to provide 1.2 g (94%) of product as an oil; 1 H-NMR (CDCl 3 ) 7.73 (d, 2H), 7.40 (d, 2H), 5.04 (m, 1H), 3.70 (m, 1H), 3.55 (dd, 1H), 3.05 (m, 1H), 3.0 (s, 3H), 2.83 (m, 1H), 2.62 (dd, 1H), 2.40 (s, 3H), 2.23 (s, 3H), 2.10 (m, 1H), 1.82 (m, 1H).
EXAMPLE 7
(2S,4R)-1-Methyl-2-[(methanesulfonylamino)methyl]-4-methanesulfonyloxypyrrolidine (VII, R=R 2 =R 3 =CH 3 )
To title product of Example 4 (100 mg, 0.76 mmol) in 2 ml of tetrahydrofuran was added 0.21 ml (1.52 mmol) of triethylamine and 0.118 ml (1.52 mmol) of methanesulfonyl chloride and the mixture was allowed to stir at 0° C. for one hour and at room temperature for an additional hour. Then 2 ml of water were added and the mixture was extracted with 2×2 ml of methylene chloride. The combined organic layers were dried (MgSO 4 ) and evaporated under reduced pressure to provide 140 mg (64%) of present title product as an oil; 1 H-NMR (CDCl 3 ) 5.05 (m, 1H), 3.50 (dd, 1H), 3.17 (m, 1H), 3.0 (s, 3H), 2.95 (s, 3H), 2.80 (m, 1H), 2.58 (dd, 1H), 2.30 (s, 3H), 2.25-2.1 (m, 3H). CMR(CDCl 3 ): 78.4, 62.3, 61.9, 42.5, 40.1, 39.8, 38.2, 35.4. MS: M+1 287(20), 191(17), 178(100).
By the same method, the enantiomeric product of Example 4 is converted to (2R,4S)-1-methyl-2-[(methanesulfonylamino)methyl]-4-methanesulfonyloxypyrrolidine.
EXAMPLE 8
(1S,4S)-2-Methyl-5-(4-methylbenzenesulfonyl)-2,5-diazabicyclo[2.2.1]heptane (VIII, R=CH 3 , R 2 =pCH 3 C 6 H 4 )
To title product of Example 6 (760 mg, 5.52 mmol) was added 760 mg (5.52 mmol) of K 2 CO 3 . After stirring the mixture for 24 hours, the solvent was removed under reduced pressure and 20 ml of water were added. The aqueous layer was then extracted with 2×40 ml of methylene chloride and the combined organic layers were dried (MgSO 4 ) and evaporated under reduced pressure to provide 470 mg (64%) of present title product as a solid; mp 87°-88° C.; 13C-NMR (CDCl 3 ) 143.5, 135.4, 129.8, 127.4, 62.9, 61.1, 61.0, 49.9, 40.2, 34.9, Anal. C 58.73, H 6.90, N 10.51, S 12.26, calcd. C 58.62, H 6.81, N 10.52, S 12.04; [alpha] D =+18.69° (c=1.18, CH 3 OH).
EXAMPLE 9
(1S,4S)-2-(Methanesulfonyl)-5-methyl-2,5-diazabicyclo[2.2.1]heptane (VIII, R=R 2 =CH 3 )
By the method of the preceding Example, title product of Example 7 (110 mg, 0.38 mmol) was converted to present title product as an oil, purified by chromatography on silica gel; 44 mg (60%); 1 H-NMR (CDCl 3 ) 4.27 (m, 1H), 3.55 (dd, 1H), 3.5 (s, 3H), 3.20 (dd, 1H), 2.84 (m, 3H), 1.92 (m, 1H), 1.71 (m, 1H); 13 C-NMR (CDCl 3 ): 63.1, 61.4, 60.6, 50.6, 40.8, 38.5, 35.7.
By the same method, the enantiomeric product of Example 7 is converted to (1R,4R)-2-(methanesulfonyl)-5-methyl-2,5-diazabicyclo[2.2.1]heptane.
EXAMPLE 10
(1S,4S)-2-Methyl-2,5-diazabicyclo[2.2.1]heptane (IX, R=CH 3 )
Title product of Example 8 (60 g, 225 mmol) was suspended in 900 ml of 30% HBr in CH 3 COOH, stirred for six hours at room temperature, then reduced to 1/4 volume at the water aspirator, the residue diluted with 1800 ml of ethyl acetate, and the resulting precipitated solids recovered by filtration. These solids were recrystallized by dissolving in the minimum necessary CH 3 OH at reflux, cooling and the addition of 400 ml of isopropyl alcohol to yield 48 g (81%) of present, purified title product; mp 258°-259° C.; 1 H-NMR (D 2 O) 4.73 (m, 1H), 4.62 (m, 1H), 3.8-3.6 (m, 4H), 3.08 (s, 3H), 2.65 (m, 1H), 2.35 (m, 1H); [alpha] D =+13.21° (c=0.946, CH 3 OH).
By the same method, the title product of Example 9 is also converted to present title product, and the enantiomeric product of Example 9 is converted to (1R,1R)-2-methyl-2,5-diazabicyclo[2.2.1]heptane.
EXAMPLE 11
trans-4-Hydroxy-L-proline Methyl Ester Hydrochloride (X, R 1 =CH 3 )
Anhydrous HCl was bubbled through a stirred suspension of trans-4-hydroxy-L-proline (80 g, 0.61 mol) in 500 ml anhydrous methanol until the mixture was homogeneous. The reaction was heated to reflux for five hours, and the volume of the solvent then reduced by one half. Ether (100 ml) was added, and the mixture kept in a freezer overnight. The resulting precipitate was filtered, washed with ether and dried under reduced pressure to yield 111 g of present title product (93% yield). mp 170°-172° C.
By the same method, trans-4-hydroxy-D-proline is converted to the enantiomer of present title product.
EXAMPLE 12
Methyl (2S,4R)-1-(4-Methylbenzenesulfonyl)-4-(4-methylbenzenesulfonyloxy)pyrrolidine-2-carboxylate (XII, R 1 =CH 3 , R 2 =R 4 =CH 3 C 6 H 4 )
Title product of the preceding Example (15 g, 83.1 mmol) was stirred with 150 ml pyridine and 11.5 ml of triethylamine at 0° C. for 30 minutes. p-Toluenesulfonyl chloride (34.8 g, 181.9 mmol) was added portionwise, maintaining a temperature of 0°-5° C. The mixture was stirred 18 hours at 0° C., then added to two volumes of ice cold water, stirred at room temperature for one hour, and present title product recovered by filtration and dried in vacuo at 30° C. for 48 hours to yield 38 g (99%) of present title product, mp 94°-95° C.
By the same method, the enantomeric product of the preceding Example is converted to the enantiomer of present title product.
Substituting methanesulfonyl chloride for p-toluenesulfonyl chloride, the same method is used to prepare methyl (2S,4S)-1-methanesulfonyl-4-methanesulfonyloxypyrrolidine-2-carboxylate.
EXAMPLE 13
(2S,4S)-N2-Methyl-1-(4-methylbenzenesulfonyl)-4-(4-methylbenzenesulfonyloxy)pyrrolidine-2-carboxamide (XIII, R=CH 3 , R 2 =R 4 =CH 3 C 6 H 4 )
Water (400 ml) was saturated with methylamine gas (20 minutes). Title product of the preceding Example (41 g, 89.4 mmol) was added and the resulting slurry stirred for 6 days. Present title product (25.2 g, 62%) was recovered as a white solid by filtration, mp 147°-149° C.; [alpha] D 25 =-80.70 (c=1.108, methanol);
Anal. C 53.25, H 5.24, N 6.05, calcd. C 53.08, H 5.35, N 6.19.
By the same method, the enantiomeric product of the preceding Example is converted to the enantiomer of present title product, and the bis-methanesulfonyl analog of the preceding Example is converted to (2S,4S)-N 2 -methyl-1-methanesulfonyl-4-methanesulfonyloxypyrrolidine-2-carboxamide.
EXAMPLE 14
(1S,4S)-2-Methyl-5-(4-methylbenzenesulfonyl)-2,5-diazabicyclo[2.2.1]heptane (VIII, R=CH 3 , R 2 =CH 3 C 6 H 4 )
To title product of the preceding Example (2.0 g, 4.42 mmol) in 20 ml tetrahydrofuran was added LiAlH 4 (750 mg, 19.9 mmol). The reaction mixture was stirred 24 hours, then quenched by the addition of 3 ml H 2 O and 0.75 ml 15% NaOH and extracted 2×15 ml CH 2 Cl 2 . The combined extracts were dried (MgSO 4 ) and stripped to yield 1 g (85%) of title product as a white solid identical with the product of Example 8.
By the same method, the enantiomeric product of the preceding Example is converted to (1R,4R)-2-methyl-5-(4-methylbenzenesulfonyl)-2,5-diazabicyclo[2.2.1]heptane, having identical physical properties except for sign of rotation; and the bis-methanesulfonyl analog of the preceding Example is converted to (1S,4S)-2-methanesulfonyl-5-methyl-2,5-diazabicyclo[2.2.1]heptane, identical in physical properties with the product of Example 9. | 1S,4S and 1R,4R-2-Alkyl-2,5-diazabicyclo[2.2.1]heptanes useful as intermediates in the synthesis of certain antibacterial quinolones, are prepared respectively, from trans-4-hydroxy-L-proline and trans-4-hydroxy-D-proline via multistep procedures. | 2 |
BACKGROUND
[0001] This disclosure relates generally to medical assemblies for the administration of fluids, and more particularly to devices for inserting an intravenous catheter into a patient for fluid administration.
[0002] Hypodermic needles are notorious for spreading blood-borne diseases such as Hepatitis B, Hepatitis C, and Human Immunodeficiency Virus (“HIV”), the virus that causes Autoimmune Deficiency Syndrome (“AIDS”). Health care workers are among those most at risk for contracting such diseases, as hypodermic needles are commonly used in medical fields. Needle stick injuries may arise during planned use and exposure, and/or as a result of carelessly or maliciously discarded needles.
[0003] The Federal Needle Stick Safety Act was enacted into law on Nov. 6, 2000, and is aimed at reducing the risk to health care workers arising from accidental needle sticks. Among other compliance mandates, the Federal Needle Stick Safety Act requires the use of needles with engineered needle injury protections. Accordingly, many hypodermic needles manufactured today include a needle tip shield or the like to protect against accidental needle sticks.
[0004] Of particular concern, however, are injuries from hollow-bore needles, especially those used for blood collection or intravenous (“IV”) catheter insertion. These devices are likely to contain residual blood and are associated with an increased risk for HIV transmission. Additionally, devices that require manipulation or disassembly after use, such as hollow-bore needles used for IV catheter insertion, have rates of injury of up to 5.3 times the rate for disposable hypodermic syringes. Such injuries most often occur during or after use and before disposal of the used needle.
[0005] IV catheters are traditionally used to infuse fluids, such as saline solution, various medicaments, and/or total parenteral nutrition into a patient. Such catheters may also be used to withdraw blood from a patient, and/or monitor various parameters of the patient's vascular system.
[0006] To introduce an IV catheter into a patient, an over-the-needle catheter may be mounted over a hollow-bore introducer needle having a sharp distal tip. The inner surface of the catheter may tightly engage the outer surface of the needle to prevent catheter peelback and facilitate insertion of the catheter into a blood vessel. The tip of the introducer needle may extend beyond the distal tip of the catheter to enable insertion of the catheter at a shallow angle through the patient's skin and into a blood vessel.
[0007] To verify proper placement of the needle and catheter in the blood vessel, the clinician may confirm the presence of “flashback” blood in a flashback chamber associated with the catheter and needle assembly. Once proper placement is confirmed, the clinician may then apply pressure to the blood vessel to occlude the vessel, thereby minimizing further blood flow through the introducer needle and catheter. The clinician must then withdraw the needle from the catheter to enable continued access to the blood vessel through the catheter as may be required to infuse fluids or the like. This process of physically manipulating and disassembling the needle and catheter after the needle has been used to position the catheter in a patient's blood vessel creates substantial risks of both accidental needle sticks and exposure to blood and blood contaminants.
[0008] From the foregoing discussion, it should be apparent that a need exists for a catheter insertion device with an automatic safety barrier to prevent injury from accidental needle sticks as well as from exposure to biological contaminants. Beneficially, such a device would enable simple and effective operation, minimize an amount of physical manipulation needed to disassemble the needle and catheter after use, and ensure that the end of the needle is properly shielded prior to such disassembly. Such a device is disclosed and claimed herein.
BRIEF SUMMARY
[0009] The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been met by currently available catheter insertion devices. Accordingly, the present invention has been developed to provide an apparatus, system, and method for shielding an end of a needle that overcomes many or all of the above-discussed shortcomings in the art.
[0010] An apparatus to shield an end of a needle in accordance with embodiments of the present invention may include a housing, a barrier member, and a biasing element. The housing may include a central bore configured to receive a needle therethrough. The housing may further include a channel extending through the housing and intersecting the central bore.
[0011] The barrier member may be hingedly coupled to the housing, and may include a leg to extend through the channel. An opening in the leg may substantially align with the central bore to accommodate the needle therethrough. In one embodiment, the leg of the barrier member includes a lock feature to prevent withdrawing the leg through the channel upon withdrawing the needle through the opening. In other embodiments, the leg further includes a single-use feature to cooperate with the lock feature to automatically limit movement between the barrier member and the housing upon withdrawing the needle through the opening.
[0012] The biasing element may bias the barrier member relative to the housing such that withdrawing the needle through the opening causes the biasing element to misalign the opening with the central bore, thereby occluding the central bore to shield an end of the needle. The needle may include a securing feature to prevent withdrawing the end of the needle through a proximal end of the housing.
[0013] In some embodiments, an apparatus in accordance with the present invention may further include a catheter to connect to a distal end of the housing such that the catheter may receive the needle through the central bore. In certain embodiments, the barrier member includes a retention hook that releasably secures the catheter to the housing. The retention hook may automatically release the catheter from the housing upon withdrawing the needle through the opening.
[0014] A method to shield an end of a needle in accordance with embodiments of the present invention is also presented. The method may include providing a housing having a central bore configured to receive a needle therethrough. A channel may be integrated into the housing to extend through the housing and intersect the central bore. A barrier member may be hingedly coupled to the housing and may include a leg to extend through the channel. An opening in the leg may substantially align with the central bore to accommodate the needle therethrough. The barrier member may be biased relative to the housing such that withdrawing the needle through the opening causes the opening to misalign with the central bore, thereby occluding the central bore to shield an end of the needle. In one embodiment, a misaligned position of the opening relative to the central bore may be substantially secured upon withdrawing the needle through the opening.
[0015] In some embodiments, the method may further include actuating the barrier member such that the leg extends through the channel. The opening in the leg may be substantially aligned with the central bore to accommodate the needle therethrough, and the needle may be inserted through the central bore and the opening.
[0016] In one embodiment, the method further includes attaching a catheter to a distal end of the housing such that the catheter communicates with the needle through the central bore. The catheter may be releasably secured to the housing via the barrier member. Specifically, a retention hook coupled to the barrier member may be actuated to secure the catheter to the housing by inserting the needle through the opening. The catheter may be automatically released from the housing upon withdrawing the needle through the opening.
[0017] A system to shield an end of a needle in accordance with the present invention may include piercing means for piercing a blood vessel to acquire intravenous access, and housing means for housing the piercing means. Barrier means may selectively occlude a portion of the housing means to shield an end of the piercing means. The barrier means may be hingedly coupled to the housing means, and may include a leg to extend through the housing means. An opening in the leg may substantially align with a bore in the housing means to accommodate the piercing means therethrough.
[0018] Biasing means may bias the barrier means relative to the housing means such that withdrawing the piercing means through the opening causes the biasing means to misalign the opening with the bore. In this manner, embodiments of the present invention may occlude a portion of the bore to shield an end of the piercing means. In some embodiments, the piercing means may include a securing feature to prevent withdrawing an end thereof through a proximal end of the housing means.
[0019] The system may further include communication means for communicating fluids between the blood vessel and an external source. The communication means may selectively connect to a distal end of the housing means such that the piercing means may communicate with the communication means through the housing means. In one embodiment, the system further includes retention means for releasably retaining the communication means with respect to the housing means in response to insertion of the piercing means through the opening. Certain embodiments of the system may also include locking means for automatically limiting movement between the barrier means and the housing means upon withdrawing the piercing means through the opening.
[0020] These and other features and advantages of the present invention may be incorporated into certain embodiments of the invention and will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. The present invention does not require that all the advantageous features and all the advantages described herein be incorporated into every embodiment of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0021] In order that the manner in which the above-recited and other features and advantages of the invention are obtained will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
[0022] FIG. 1 is an exploded cross-sectional view of a catheter insertion device with an automatic safety barrier in accordance with certain embodiments of the present invention;
[0023] FIG. 2 is a perspective view of one embodiment of a safety barrier device integral to the catheter insertion device of the present invention;
[0024] FIG. 3 is a perspective view of one embodiment of a biasing element that may be integrated into a safety barrier device in accordance with the invention;
[0025] FIG. 4 is a perspective view of a catheter insertion device armed for use in accordance with certain embodiments of the present invention;
[0026] FIG. 5 is a cross-sectional view of the catheter insertion device of FIG. 4 ;
[0027] FIG. 6 is a perspective view of one embodiment of a catheter insertion device after use in accordance with the present invention;
[0028] FIG. 7 is a cross-sectional view of the catheter insertion device of FIG. 6 ;
[0029] FIG. 8 is a cross-sectional view of an alternative embodiment of a catheter insertion device with an automatic safety barrier armed in accordance with the present invention; and
[0030] FIG. 9 is a cross-sectional view of the catheter insertion device of FIG. 7 after use.
DETAILED DESCRIPTION
[0031] The illustrated embodiments of the present invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. 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 more detailed description, as presented in the Figures, is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the invention as claimed herein.
[0032] As used in this specification, the term “needle” refers to any of various devices that may be used to pierce the skin to acquire intravenous access, such as a hypodermic needle, a hollow-bore needle, a surgical knife, a cannula, or the like.
[0033] Referring now to FIG. 1 , a catheter insertion device 100 in accordance with the present invention may include a safety barrier device 102 , a catheter 110 , and a needle 118 . The safety barrier device 102 , catheter 110 , and needle 118 may align with each other along a longitudinal axis 122 . A proximal end 112 of the catheter 110 may attach to a distal end 104 of the safety barrier device 102 by way of, for example, a threaded connection, a press fit, or by any other means known to those in the art. The needle 118 may be directed through the central bores 108 , 116 of each of the safety barrier device 102 and the catheter 110 , respectively, such that the tip 120 of the needle 118 may protrude through a distal end 114 of the catheter 110 to facilitate an intravenous catheterization process.
[0034] The central bore 116 of the catheter 110 may include a diameter 124 slightly larger than an outside diameter 126 of the needle 118 . In certain embodiments, a distal portion 126 of the central bore 116 may tightly engage the needle 118 to prevent peelback of the catheter 110 as it is inserted into a blood vessel. In some embodiments, the inside diameter 124 of the catheter 110 may increase between the distal portion 126 and the proximal end 112 , such that the diameter 124 substantially matches an inside diameter 128 of the central bore 108 of the safety barrier device 102 at a point of attachment between the two devices 110 , 102 .
[0035] In any case, the inside diameters 124 , 128 of the central bores 116 , 108 may permit the needle 118 to slide with respect to the catheter 110 and safety barrier device 102 . In some embodiments, the central bores 116 , 108 may include a substantially smooth inner surface to further facilitate relative movement between the needle 118 and the catheter 110 and safety barrier device 102 . In this manner, the needle 118 may be selectively positioned to protrude from the distal end 114 of the catheter 110 as needed to facilitate catheter 110 insertion. Likewise, the needle 118 may be selectively retracted from the proximal end 112 of the catheter 110 after use. In one embodiment, as discussed in more detail below, the needle 118 includes a securing feature 130 to prevent the tip 120 of the needle 118 from being intentionally or inadvertently withdrawn from the safety barrier device 102 after use.
[0036] Referring now to FIG. 2 , in discussing the Figures, it may be advantageous to establish a reliable coordinate system to aid in the description of several of the embodiments in accordance with the present invention. In addition to the longitudinal axis 122 discussed above with reference to FIG. 1 , coordinate axes may include a transverse axis 204 and a lateral axis 206 , where each coordinate axis 122 , 204 , 206 extends in a direction substantially orthogonal to the other.
[0037] A safety barrier device 102 in accordance with the present invention may include a housing 200 , a barrier member 212 , and a biasing element (not shown). In one embodiment, an outer surface 202 of the housing 200 may be substantially cylindrical and molded along the longitudinal axis 122 to provide a secure, comfortable grip. In some embodiments, for example, the housing 200 may include grooves, ridges or an otherwise textured outer surface 202 to facilitate a secure grip.
[0038] The central bore 108 may extend in a substantially longitudinal direction 122 from a distal end 104 to a proximal end 106 of the housing 200 . The proximal end 106 of the housing 200 may be configured to direct the needle 118 into the central bore 108 . In some embodiments, the needle 118 may extend through the central bore 108 and exit the housing 200 at its distal end 104 to communicate with a catheter 110 or other device attached thereto.
[0039] In one embodiment, a diameter 128 of the central bore 108 may taper from the distal end 104 to the proximal end 106 of the housing 200 . In other embodiments, a diameter 128 of the central bore 108 at the proximal end 106 of the housing 200 may be substantially less than its diameter 128 at the distal end 104 of the housing 200 , or at an intermediate point along its longitudinal axis 204 a . In still other embodiments, a diameter 128 of the central bore 108 may be substantially consistent along a length of the housing 200 .
[0040] The barrier member 212 may attach to a proximal end 106 of the housing 200 by way of a hinge 210 or other such device known to those in the art. In one embodiment, the barrier member 212 and housing 200 are substantially monolithic, having a living hinge 210 or flexure bearing therebetween. Alternatively, the housing 200 and barrier member 212 may constitute separate components attached by a standard hinge 210 or other suitable device known to those in the art. In any case, the hinge 210 may permit the barrier member 212 to pivot with respect to the housing 200 , such that a leg 214 of the barrier member 208 may selectively extend into a channel 208 formed within the housing 200 .
[0041] The channel 208 may extend in a substantially transverse direction 204 through the housing 200 and intersect the central bore 108 . In one embodiment, the channel 208 opens onto substantially opposite sides of the housing 200 . In other embodiments, the channel 208 extends only partially through the housing 200 such that a single point of entry on the outer surface 202 of the housing 200 provides access to the channel 208 . In any case, the channel 208 may include a length sufficient to accommodate the leg 214 of the barrier member 212 .
[0042] The leg 214 of the barrier member 212 may extend from the body 218 of the barrier member 212 such that pivoting the barrier member 212 with respect to the housing 200 may cause the leg 214 to extend into the channel 208 . The leg 214 of the barrier member 212 may include an opening 216 that may align with the central bore 108 . Further, the opening 216 may include a diameter substantially corresponding to a diameter 128 of the central bore 108 . In this manner, the needle 118 may be advanced through the opening 216 to secure the leg 214 with respect to the channel 208 , as discussed in more detail with reference to FIGS. 4 and 5 below.
[0043] The leg 214 of the barrier member 212 may include a safety barrier portion 220 to selectively block the central bore 108 , or portion thereof. In certain embodiments, as discussed in more detail below, the biasing element (not shown) may cooperate with the barrier member 212 to automatically misalign the opening 216 with the central bore 108 upon withdrawing the tip 120 of the needle 118 from the opening 216 . The safety barrier portion 220 of the leg 214 may then occlude the central bore 108 at the channel 208 to prevent access to the needle 118 through the distal end 104 of the housing 200 . In some embodiments, as discussed in more detail below, the leg 214 of the barrier member 212 may include a lock feature 222 to maintain the leg 214 within the channel 208 upon withdrawing the needle 118 from the opening 216 .
[0044] The barrier member 212 may further include a retention hook 224 extending from a distal end 226 thereof. As discussed in more detail below, the retention hook 224 may secure the catheter 110 or other device to the safety barrier device 102 by creating mechanical interference between the barrier member 212 and the proximal end 112 of the catheter 110 or other attached device.
[0045] Referring now to FIG. 3 , a biasing element 300 in accordance with the present invention may include a spring, an elastomeric material, a resilient material, or any other suitable material or device known to those in the art. The biasing element 300 may include an attachment feature 302 to attach the biasing element 300 to the safety barrier device 102 . The biasing element 300 may cooperate with the barrier member 112 to urge the barrier member 112 away from the housing 200 absent application of an opposite force. The barrier member 112 may be secured in a biased position relative to the housing 102 by extending the needle 118 through the central bore 108 and opening 216 to apply an opposite force.
[0046] Specifically, in one embodiment, the biasing element 300 includes a leaf-spring portion 306 residing substantially adjacent to the body 218 of the barrier member 212 to urge the barrier member 212 away from the housing 200 . The biasing element 300 may be attached to the housing 200 by way of an attachment feature 302 such as a retention hook or other suitable device known to those in the art. The needle 118 may extend through the central bore 108 and the opening 216 in the leg 214 of the barrier member 212 to maintain the central bore 108 and opening 216 in alignment, thereby securing the barrier member 212 in a biased position relative to the housing 200 . In certain embodiments, such as where the biasing element 300 or attachment feature 302 would otherwise obstruct the central bore 108 , the biasing element 300 may include an opening 304 to accommodate the needle 118 therethrough.
[0047] Referring now to FIGS. 4 and 5 , the catheter insertion device 100 of the present invention may be armed to effectively shield a tip 120 of a needle 118 by attaching a catheter 110 or other adapter device to a distal end 104 of the housing 200 and pivoting the barrier member 212 with respect to the housing 200 such that a leg 214 thereof may be received into the channel 208 . As previously discussed with reference to FIG. 3 above, a biasing element 300 may be integrated with the housing 200 to urge the barrier member 212 away from the housing 200 . Accordingly, pivoting the barrier member 212 towards the housing 200 to enable the leg 214 to be received into the channel 208 may require application of an opposing force. The force applied may be adjusted as needed to position the leg 214 such that an opening 216 in the leg 214 may substantially align with the central bore 108 . The needle 118 may then be inserted into the central bore 108 through a proximal end 106 of the housing 200 and advanced through the central bore 108 and opening 216 in the leg 214 .
[0048] In some embodiments, the needle 118 may be further guided through the distal end 104 of the housing and into the attached catheter 110 or other device. In one embodiment, the needle 118 protrudes through the distal end 114 of the catheter 110 to facilitate an intravenous catheterization process. In this manner, the needle 118 may maintain alignment between the central bore 108 and the opening 216 , thereby securing a position of the leg 214 with respect to the channel 208 .
[0049] Moreover, in some embodiments, the needle 118 may maintain a substantially fixed relationship between a retention hook 224 extending from a distal end 226 of the barrier member 212 and the catheter 110 or other adapter device attached to the housing 200 . Specifically, in some embodiments, the catheter 110 or other adapter device may include a lip 400 extending substantially radially from its proximal end 112 . The retention hook 224 may be molded to interlock with the lip 400 where the catheter 110 attaches to the distal end 104 of the housing 200 . As the retention hook 224 is integral to the barrier member 212 , the needle 118 may extend through the opening 216 in the leg 214 of the barrier member 212 to both maintain alignment between the central bore 108 and the opening 216 , as well as to secure an interlocked relationship between the retention hook 224 and the lip 400 of the catheter 110 . Accordingly, attachment of the catheter 110 to the housing 200 may also be reliably secured.
[0050] Referring now to FIGS. 6 and 7 , retracting the needle 118 through the opening 216 in a longitudinal direction 122 towards the proximal end 106 of the housing 200 may actuate the biasing element 300 to urge the barrier member 212 away from the housing 200 , thereby misaligning the opening 216 with the central bore 116 . As a result, a safety barrier portion 220 of the leg 214 positioned adjacent to the opening 216 may be forced to fully or partially occlude the central bore 108 . As previously mentioned, a lock feature 222 coupled to the leg 214 may abut or otherwise mechanically interfere with a portion of the housing 200 to prevent withdrawal of the safety barrier portion 220 of the leg 214 from the channel 208 . In certain embodiments, the lock feature 222 may include cooperating features 222 a , 222 b substantially adjacent either side of the opening 216 , such that withdrawing the needle 118 through the opening 216 may actuate the cooperating lock features 222 a , 222 b to limit movement of the leg 214 with respect to the channel 208 in either transverse direction 204 . In this manner, the lock feature 222 may reliably secure the safety barrier portion 220 to at least partially occlude the central bore 108 and thus prevent the retracted needle tip 120 from re-entering the central bore 108 at a position longitudinally distal from the channel 208 .
[0051] In certain embodiments, retracting the needle 118 through the opening 216 may further disengage the interlocked relationship between the retention hook 224 and the proximal end 112 of the catheter 110 . Specifically, the biasing element 300 may urge the barrier member 212 and retention hook 224 away from the housing 200 and attached catheter 110 . The retention hook 224 may thus release the proximal end 112 of the catheter 110 to enable the catheter 110 and safety barrier device 102 to be disassembled after use.
[0052] As discussed above, retracting the needle 118 through the opening 216 towards the proximal end 106 of the housing 200 effectively occludes the central bore 108 while releasing the catheter 110 from the distal end 104 of the housing 200 . As a result, embodiments of the present invention provide increased protection against accidental needle sticks and blood exposure by ensuring both proper shielding of the needle tip 120 after use, as well as by preventing disassembly of the catheter insertion device 100 prior to the needle tip 120 being properly shielded.
[0053] In certain embodiments of the present invention, the needle 118 may include a securing feature 130 to prevent complete withdrawal of the needle 118 through the proximal end 106 of the housing 200 . The securing feature 130 may include, for example, one or more protrusions from the needle 118 surface, an increased diameter of the needle 118 at a particular point along its longitudinal axis 122 , or any other suitable securing feature known to those in the art. The securing feature 130 may interfere with the central bore 108 at a proximal end 106 of the housing 200 such that the needle tip 120 may not be withdrawn from the central bore 108 at the proximal end 106 .
[0054] Referring now to FIGS. 8 and 9 , an alternative embodiment of a safety barrier device 102 in accordance with the present invention may include a housing 200 , a barrier member 212 , and a biasing element 300 , where the biasing element 300 includes a protrusion or other feature on the outer surface 202 of the housing located proximate to a hinge 210 connecting the housing 200 and barrier member 212 . The barrier member 212 may include a resilient material to enable the barrier member 212 to flex outwardly against the biasing element 300 , thereby generating spring energy. This may occur, for example, where the barrier member 212 pivots with respect to the housing 200 to enable a leg 214 thereof to extend through a channel 208 extending in a substantially transverse direction 204 through the housing 200 .
[0055] Such spring energy may be stored by the barrier member 212 as a result of the needle 118 extending through the central bore 108 of the housing, and further through the opening 216 in the leg 214 of the barrier member 212 to maintain alignment between the central bore 108 and the opening 216 . In this position, the needle 118 may further secure a proximal end 112 of the catheter 110 to a distal end 104 of the housing 200 by actuating a retention hook 224 integrated with or coupled to a distal end of the barrier member 212 . As discussed above, the retention hook 224 may interface with the proximal end 112 of the catheter 110 to secure its position relative to the distal end 104 of the housing 200 .
[0056] Referring now to FIG. 9 , withdrawing the needle 118 from the opening 216 in the leg 214 of the barrier member 212 may actuate a lock feature 222 integrated with or coupled to the leg 214 . The lock feature 222 may secure misalignment of the opening 216 and the central bore 108 within the channel 208 such that a safety barrier portion 220 of the leg 214 effectively and reliably obstructs the needle tip 120 relative to a distal end 104 of the central bore 108 .
[0057] As illustrated, the lock feature 222 may include cooperating lock features 222 a , 222 b , located substantially adjacent either side of the opening 216 . One lock feature 222 a may interface with an outer surface 202 of the housing 200 , while the other lock feature 222 b interfaces with a substantially opposite surface 202 of the housing 200 . The lock features 222 a , 222 b may be actuated in response to misalignment between the central bore 108 and the opening 216 . Specifically, the biasing element 300 may urge the barrier member 212 in a substantially transverse direction 204 away from the longitudinal axis 122 of the housing 200 , thereby misaligning the central bore 108 and opening 216 to actuate the lock features 222 a , 222 b.
[0058] In one embodiment, one lock feature 222 a may be molded to project from a distal end of the leg 214 of the barrier member 212 and abut the outer surface 202 of the housing 200 , while a second lock feature 222 b may selectively protrude from the leg 214 upon misalignment of the central bore 108 with the opening 216 . Specifically, the second lock feature 222 b may be biased with respect to the leg 214 such that the lock feature 222 b automatically protrudes outwardly from the leg 214 upon its emergence from within the channel 208 . The lock features 222 a , 222 b may thus cooperate to limit movement of the leg 214 in either transverse direction 204 relative to the housing 200 . In this manner, embodiments of the present invention may prevent complete withdrawal of the leg 214 from within the channel 208 to reliably shield a tip 120 of the needle 118 , as well as discourage re-use of the catheter insertion device 100 .
[0059] The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A catheter insertion device with an automatic safety barrier includes a housing, a barrier member, and a biasing element. The housing includes a central bore configured to receive a needle therethrough, and further includes a channel extending through the housing and intersecting the central bore. The barrier member is hingedly coupled to the housing, and includes a leg to extend through the channel. An opening in the leg substantially aligns with the central bore to accommodate the needle therethrough. The biasing element biases the barrier member relative to the housing such that withdrawing the needle through the opening causes the biasing element to misalign the opening with the central bore, thereby occluding the central bore to shield an end of the needle. | 0 |
FIELD OF THE INVENTION
[0001] The field of the invention is a lockable swivel that can be used in a drill string for rotation thereof when the swivel is locked and in wireline applications to let the drill string rotate freely when the wireline is operated.
BACKGROUND OF THE INVENTION
[0002] Previously, if the operator desired to rotate the drill string during wireline operations, the wireline was pulled from the well bore and the entry devices were disengaged from the drill string. The removal of the wireline could be avoided if an inline swivel was placed in the drill string between the wireline device and the rotary table. This arrangement would permit rotation to be accomplished with a wireline in place, but effectively disengaged the top-drive unit from its preferred role of providing both lifting power and rotation to the drill string.
[0003] Using prior conventional technology, the drill pipe was separated and raised high above the rig floor on each run in order to change out tools. Although the pipe can be rotated, the operator could not circulate or reciprocate the pipe during these periods. Circulation was achieved by adding a pump-in sub and another T.I.W. safety valve immediately above the existing T.I.W. valve; which, however, put the disconnect or break point between the upper T.I.W. valve and the swivel several feet above the rig floor creating a safety hazard while operating the rig tongs.
[0004] Further, since the tool strings must be stripped in and out beneath the upper assembly, a lubricator or tool protection device could not be used and all tools and explosives were brought onto the rig floor unshielded and unconfined. In the event of an inadvertent detonation of the explosive string shot or perforators, all personnel on the rig floor were totally exposed to this unnecessary life-threatening hazard.
[0005] Once rigged-up and going in the hole using conventional technology such as the Boyd side-entry sub, the wireline passed through the acute angle in the side entry sub. This caused excessive wearing of the wireline and creates sever grooving in the sub. The single rubber pack-off, which is commonly used with this system, is very susceptible to leaking and/or line gripping and stoppage during pump-down operations. The system cannot be used when working under surface pressure and with the need to utilize a grease injector and wireline blow out preventers (BOPs).
[0006] During pipe recovery operations, both right and left-hand torque must be worked down-hole using the rig tongs. This is a procedure has long been recognized to be one of the greatest safety hazards to be encountered during pipe recovery operations. When using this prior technology, pipe tongs were attached to the drill string and secured to the rig to hold torque that had been put into the drill string from the rotary table or top drive unit.
[0007] With the present invention, this torque can be maintained while continuing circulation and wireline operation.
[0008] USP RE41,759 FIG. 4 provided an apparatus which would allow the connection of various wireline devices 106 to be placed in the drill string 100 between the top drive unit 102 and the rotary table 114 of a conventional drilling rig throughout wireline operations. Such devices 106 as the Boyd Borehole Drill Pipe Continuous Side Entry or Exit Apparatus (such as described in U.S. Reissue Pat. No. 33,150) or the Top Entry Sub Arrangement (as described in U.S. Pat. No. 5,284,210) may both be utilized for various wireline operations.
[0009] Referring to FIG. 4 , what this reference disclosed is a lockable in-line swivel device 110 which is selectively engaged by the operator to permit or inhibit rotational movement provided by a top drive unit 102 to be transmitted through the swivel 110 to the pipe string 112 and to allow disengagement of the locked swivel 110 so that rotation may be accomplished by the rotary table 114 simultaneously with the wireline operations.
[0010] This design permitted the wireline entry devices 106 to be left in the drill string 100 during all operations involving the wireline operation avoiding the time consuming makeup and disengagement of the entry tools 106 required to safely permit entry of the wireline into the well bore. If rotation and longitudinal movement is desired, the wireline alone was removed from the wellbore, but the entry tool 106 remained in place and the swivel 110 is locked to provide transmission of all rotation through the swivel 110 into the pipe string 112 .
[0011] At other times, the operator using a top-drive unit 102 could pick up the drill string 100 and yet maintain torque which has been put into the pipe string 112 in pipe recovery operations. This was done by engaging the swivel 110 in locked position and picking up with the top drive unit 102 . As the torque is worked through the drill string 100 , additional wireline operations and the operator would set the drill string 100 down, disengage the swivel 110 , continue to rotate with the rotary table 114 and continue the wireline operations.
[0012] The swivel provided to accomplish the above operations is shown in FIGS. 1-3 of this patent. The design features a multi-component body with spaced splines with the lower spline juxtaposed in an overlapping relation to a retainer that holds the upper housing assembly of body parts to the lower housing with fairly primitive rotary bearing design and no thrust bearing capability. The present invention improves on the shortcomings of this design providing several unique features that reduce the number of housing parts to allow the use of a unitary upper and lower body with an internal retaining ring to secure the actuating piston to the upper housing. The design adds thrust bearing capability nested between pairs of tapered surfaces on one side between the housings and on the other between the lower housing and the end cap. Spherical bearings are used to facilitate relative rotation. These and other features of the present invention will be more readily appreciated by a review of the description of the preferred embodiment and the associated drawing while recognizing that the full scope of the invention is to be found in the appended claims.
[0013] Also relevant in the lockable swivel field is U.S. Pat. No. 6,378,630 FIG. 6 where flow through the swivel compresses a stack of Belleville washers to engage splines and lock the swivel as long as flow displaces a piston to overcome the resisting spring force. Other references show swivels in general and swivels that combine a wireline entry fitting into a common housing or swivels that lock in one rotational direction and allow relative rotation in an opposite direction. Some examples of these references are U.S. Pat. Nos. 6,553,825; 5,996,712; 6,796,191; 8,171,991; 6,915,865; 6,994,628; 7,793,731; 7,316,276; 7,168,498; 7,377,316; 7,392,850; 8,210,268; 4,074,775 FIG. 2B; 7,011,162 FIGS. 2 a and 2B; 4,781,359; 4,715,454 and 7,857,058.
SUMMARY OF THE INVENTION
[0014] A lockable swivel features a unitary upper housing connected to a unitary lower housing with a connector to hold the housing components together for relative or tandem rotation. A hydraulically actuated piston shifts spaced apart splines axially to selectively engage splines on both housings for the locked position and to release the splines in both housing for the unlocked position. A thrust bearing in the lower housing is disposed between two pairs of tapered surfaces with the upper pair disposed on the housings and the lower pair between the connector and the lower housing. The thrust bearing is disposed between a pair of spherical bearings with the upper radial bearing retained by the upper housing and the lower radial bearing retained by the connector. An internal ring retains the piston to the upper housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a half section half exterior view of the locking swivel in the locked piston down position; and
[0016] FIG. 2 is the view of FIG. 1 in the piston up or unlocked position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Referring to FIG. 1 upper body 12 is secured to lower body 13 by end cap or connector 15 . A screw or other fastener 4 retains a threaded connection 30 between the upper body 12 and the connector 15 . A retainer 14 is secured at thread 32 to the upper body 12 and that threaded connection is maintained by a circlip 11 . A swivel piston 19 can move down until bottoming on the retainer 14 as shown in FIG. 1 and can move axially in the opposite direction until bottoming out by essentially eliminating the volume of chamber 42 when contacting an end surface that defines that chamber. Near the upper end 36 are o-ring 22 and backup ring 25 to retain pressure in the central passage 38 . A cavity 40 that varies in volume is defined between seals 22 and 23 . Seal 23 and upper seal 24 define a variable volume cavity 42 into which a fitting 1 , 3 is connected for communicating hydraulic pressure that enlarges cavity 42 while pushing down on piston area 44 to move the piston 19 to the FIG. 1 position where it is bottomed on the retainer ring 14 . Another connection 1 , 2 extends into cavity 46 which is shown in FIG. 1 in its smallest volume position. Lower seal 24 and seal 23 mounted to the retainer 14 seal this variable volume space. Adding hydraulic pressure into fittings 1 , 2 and removing hydraulic pressure from fitting 1 , 3 advances the piston 19 up toward and into contact with a top surface that defines chamber 42 .
[0018] Piston 19 has an upper spline 48 engaged with a spline 50 on the upper body 12 in the FIG. 1 locked position. At the same time the piston 19 has a lower spline 54 that engages a mating spline 52 in the FIG. 1 position. Thus the piston 19 locks the upper housing 12 to the lower housing 13 for tandem rotation when the two spline pairs are engaged. As stated before with hydraulic pressure applied to chamber 46 and removed from chamber 42 the piston 19 rises and the spline pairs 52 , 54 disengage so that the housing components 12 and 13 can relatively rotate. Spline pairs 48 and 50 remain engaged. Such relative rotation is facilitated by the upper and lower preferably spherical bearings 9 which can also include any type of rolling element bearing such as ball, roller or needle among others, that are disposed on opposite sides of the thrust bearing 8 . The upper bearing 9 is externally retained by the lower end 56 of the upper body 12 on two adjacent sides that are perpendicular to each other and surfaces 60 and 62 on the lower body 13 . The lower bearing is retained externally by adjacent surfaces 64 and 66 on the connector 15 and surface 68 on the lower body as well as an adjacent surface on the end cap 16 that is retained with screws 6 to the connector 15 . A grease fitting 7 allows adding grease to the lower spherical bearing 9 .
[0019] Thrust bearing 8 is externally retained by adjacent perpendicular surfaces 74 and 76 on the connector 15 and 70 and 72 on the lower body 13 . Thrust bearing 8 is straddled by mating sloping surfaces on opposed sides. Above the bearing 8 surface 80 on the lower end 56 of the upper body 12 sits in opposition to surface 82 on the lower body. Below the bearing 8 surface 84 on the lower body 13 is opposed to mating surface 86 on the connector 15 . Surfaces 84 and 86 are not intended to contact. In one option the pair of mating sloping surfaces 80 and 82 above bearing 8 can contact and in that variation the upper radial bearing 9 can be replaced with a floating roller bearing to transmit the axial component of a thrust load while the radial component is absorbed by the upper body 12 .
[0020] In preferred alternative to dealing with tensile thrust, as it is very unusual to have compressive thrust loads in such devices, the surfaces 84 and 86 or 80 and 82 do not contact and the thrust load is taken by the upper spherical bearing 9 . The mating pairs of sloping surfaces allow the use of a larger thrust bearing 8 than the radial bearings 9 that straddle it above and below.
[0021] The piston 19 can be pinned at 5 to allow external indication of the position of the piston 19 . Piston 19 can also be shear pinned to the upper body 12 for run in to prevent accidental movement of the piston 19 until a predetermined force is applied in chamber 42 .
[0022] Those skilled in the art can now appreciate several features and variations thereof as depicted in FIG. 1 . FIG. 2 is identical to FIG. 1 with the piston 19 in the raised position toward a travel stop that is the top radial surface that defines chamber 42 , to permit relative rotation between the bodies 12 and 13 . The bodies 12 and 13 are each made of a single component. The piston 19 is retained by an internal ring 14 located near a thick portion of the upper body 12 . Spaced apart spherical bearings 9 straddle an even larger thrust bearing 8 . The upper splines mate adjacent a thick portion of the upper housing 12 where there are no weak points such as threaded body connections. The lower splines mate within the retainer ring 14 to lend support to the lower end of the piston 19 . The bearing assembly 8 , 9 is axially spaced from the meshing splines. The upper body takes a radial component from thrust loading and transfers the axial component to the thrust bearing 9 .
[0023] While the piston is illustrated as hydraulically externally driven in opposed directions those skilled in the art will appreciate that the piston can be alternatively actuated with flow cycles therethrough that in combination with a j-slot mechanism can put the piston 19 in the splines locked and unlocked positions in situations where hydraulic power systems are not available. In this case the piston is acted on by a spring return to work against the force generated with fluid flow. On the other hand the piston can have unequal piston areas and can be moved against a spring bias with simply applied pressure and removal of the applied pressure.
[0024] The driving force can also be locally available rig air. The spacing of the bearing assembly that comprises bearings 8 and 9 axially spaced from the retainer 14 allow the use of larger bearings without adding unduly to the diameter of the housings while at the same time providing additional supporting wall for the bearings.
[0025] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims appended hereto. | A swivel apparatus includes upper and lower housings having a passage therethrough operably connected with a coupling for selective relative rotation; at least one movable piston having a first position where the housings are rotationally locked to each other and a second position where the housings are free for relative rotation; the piston is retained to the upper housing with a retainer secured within and discrete from the upper housing, and the retainer is axially spaced from a bearing assembly. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation in part of U.S. patent application Ser. No. 11/931,393 filed Oct. 31, 2007 which claims priority to U.S. Provisional Patent Application No. 60/863,715 filed Oct. 31, 2006 and is also a continuation-in-part of U.S. patent application Ser. No. 12/421,456 filed Apr. 9, 2009 which claims priority to 61/048,176 filed Apr. 26, 2008 and is a continuation in part of U.S. patent application Ser. No. 11/931,393 filed Oct. 31, 2007 which claims priority to U.S. Provisional Patent Application No. 60/863,715 filed Oct. 31, 2006, the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention is generally related to treatments for ocular disorders and more specifically to the use of agents that lower IOP and/or treat or prevent glaucoma.
BACKGROUND OF THE INVENTION
[0003] Primary open angle glaucoma (POAG), also known as chronic or simple glaucoma, represents the majority of all glaucomas in the United States. Most forms of glaucoma result from disturbances in the flow of aqueous humor that have an anatomical, biochemical or physiological basis.
[0004] Elevated levels of plasminogen activator inhibitor-1 (PAI-1) have been detected in the aqueous humor of glaucoma patients (Dan et al., Arch Opthalmol, Vol. 123:220-224, 2005). PAI-1 levels are increased by the cytokine TGFβ (Binder et al., News Physiol Sci, Vol. 17:56-61, 2002), among other endogenous stimuli. PAI-1 inhibits the activity of both tissue plasminogen activator (tPA) and urokinase plasminogen activator (uPA). Both tPA and uPA catalyze the conversion of plasminogen into plasmin, a key intermediate in the fibrinolytic cascade (Wu et al., Curr Drug Targets, Vol. 2:27-42, 2002). Plasmin is known to promote the conversion of certain pro-matrix metalloproteinases (MMPs) into their active, extracellular matrix (ECM)-degrading, forms (He et al., PNAS, Vol. 86:2632-2636, 1989). PAI-1 also modulates the association of vitronectin, an ECM component, with cell surface integrins which act as adhesion receptors (Zhou et al., Nature Structural Biology, Vol. 10(7):541-544, 2003). Thus, PAI-1 has been linked to both decreased adhesion and increased detachment of cells in non-ocular tissues.
[0005] Drug therapies that have proven to be effective for the reduction of IOP (IOP) and/or the treatment of POAG include both agents that decrease aqueous humor production and agents that increase the outflow facility. Such therapies are in general administered by one of two possible routes; topically (direct application to the eye) or orally. However, pharmaceutical ocular anti-hypertension approaches have exhibited various undesirable side effects. For example, miotics such as pilocarpine can cause blurring of vision, headaches, and other negative visual side effects. Systemically administered carbonic anhydrase inhibitors can also cause nausea, dyspepsia, fatigue, and metabolic acidosis. Certain prostaglandins cause hyperemia, ocular itching, and darkening of eyelashes and periorbital skin. Such negative side-effects may lead to decreased patient compliance or to termination of therapy such that vision continues to deteriorate. Additionally, there are individuals who simply do not respond well when treated with certain existing glaucoma therapies. There is, therefore, a need for other therapeutic agents for the treatment of ocular disorders such as glaucoma and ocular hypertension.
[0006] Cilostazol (Pletal®) has been approved in the United States since 1999 for the treatment of intermittent claudication, i.e., leg pain due to compromised blood flow associated with peripheral vascular disorders. It has also shown efficacy in clinical trials as an inhibitor of restenosis after coronary stent placement. In the eye, cilostazol has been shown to increase the survival of retinal ganglion cells post-axotomy (Kashimoto et al., Neuroscience Letters, Vol. 436:116-119, 2008), and has been reported to enhance blood flow to the optic nerve head and retina (Suzuki et al., J. Ocular Therapy, Vol. 14(3):239-245, 1998), but has not been contemplated as a therapeutic for glaucoma or ocular hypertension. Cilostazol reportedly suppresses transforming growth factor (TGFβ2) and plasminogen activator inhibitor-1 (PAI-1) protein expression, as well as PAI-1 activity, in non-ocular tissues of rats (Mohamed, Biomed Pharmacother. 2009 Mar. 12. [Epub ahead of print]; Lee et al, Atherosclerosis, Vol. 207:391-398, 2009).
BRIEF SUMMARY OF THE INVENTION
[0007] Embodiments of the present invention recognize that the modulation of PAI-1 can be used to treat ocular disease and/or lower IOP. One embodiment provides a method for treating glaucoma or elevated IOP in a patient comprising administering to the patient an effective amount of a composition comprising an agent that modulates PAI-1.
[0008] Another embodiment of the present invention is a method of treating a PAI-1-associated ocular disorder comprising administering an effective amount of a composition comprising an agent that modulates PAI-1 binding to vitronectin.
[0009] A preferred embodiment of the present invention is a method for treating glaucoma or elevated IOP in a patient comprising administering to the patient an effective amount of a composition comprising cilostazol or an analog or metabolite thereof such as 3,4-dehydro cilostazol or cilostamide.
[0010] In certain of these embodiments, the agent is ZK4044, PAI-039, WAY-140312, HP-129, T-686, XR5967, XR334, XR330, XR5118, PAI-1 antibodies, PAI-1 peptidomimetics, and combinations thereof.
[0011] Yet another embodiment is a method of manufacturing a compound to be used as a treatment for glaucoma or elevated IOP comprising providing a candidate substance suspected of modulating PAI-1, selecting the compound by assessing the ability of the candidate substance to decrease the amount of total and/or active PAI-1 in the trabecular meshwork of a subject suffering from glaucoma or elevated PAI-1, and manufacturing the selected compound.
[0012] In certain embodiments, compositions of the invention further comprise a compound selected from the group consisting of opthalmologically acceptable preservatives, surfactants, viscosity enhancers, penetration enhancers, gelling agents, hydrophobic bases, vehicles, buffers, sodium chloride, water, and combinations thereof.
[0013] In yet other embodiments, a compound selected from the group consisting of β-blockers, prostaglandin analogs, carbonic anhydrase inhibitors, α 2 agonists, miotics, neuroprotectants, rho kinase inhibitors, and combinations thereof may be administered either as part of the composition or as a separate administration.
[0014] The foregoing brief summary broadly describes the features and technical advantages of certain embodiments of the present invention. Additional features and technical advantages will be described in the detailed description of the invention that follows. Novel features which are believed to be characteristic of the invention will be better understood from the detailed description of the invention when considered in connection with any accompanying figures. However, figures provided herein are intended to help illustrate the invention or assist with developing an understanding of the invention, and are not intended to be definitions of the invention's scope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A more complete understanding of the present invention and the advantages thereof may be acquired by referring to the following description, taken in conjunction with the accompanying drawing and wherein:
[0016] FIG. 1 is a graph of experimental results showing the concentration-dependent effect of TGFβ2 (24 h) on levels of PAI-1 in human trabecular meshwork (GTM-3) cell supernatants. Data are expressed as mean and SEM, n=3. *p<0.05 versus corresponding vehicle group by one-way ANOVA, followed by the Dunnett test;
[0017] FIG. 2 is a graph of experimental results showing PAI-1 levels in GTM-3 cell supernatants with or without treatment with TGFβ2 (5 ng/mL) for various time periods. Data are expressed as mean and SEM, n=3. *p<0.05 versus corresponding vehicle time point group, by Student's t-test;
[0018] FIG. 3 is a bar graph showing the effect of wild-type PAI-1 (1 μg/mL, 2 h) and TGFβ2 (5 ng/mL, 2 h) on adhesion of transformed (GTM-3) and non-transformed (GTM730) cells to vitronectin substrate. Data are expressed as mean and SEM, n=12-44. *p<0.05 versus corresponding untreated groups by one-way ANOVA, followed by the Dunnett test;
[0019] FIG. 4 is a graph of experimental results showing concentration-dependent effect of wild-type PAI-1 (2 h) on adhesion of GTM-3 cells to vitronectin substrate. Data are expressed as mean and SEM, n=4. *p<0.05 versus vehicle group by one-way ANOVA, followed by the Dunnett test;
[0020] FIG. 5 is a graph of experimental results showing the time-dependent effect of wild-type PAI-1 (1 μg/mL) on adhesion of GTM-3 cells to vitronectin substrate. Data are expressed as mean and SEM, n=12-44;
[0021] FIG. 6 is a bar graph of experimental results showing the effect of wild-type PAI-1 (1 μg/mL, 1 h) versus a stable, degradation-resistant PAI-1 mutant (1 μg/mL, 1 h) on adhesion of GTM-3 and GTM730 cells to vitronectin substrate. Data are expressed as mean and SEM, n=4. *p<0.05 versus corresponding untreated groups by Student's t-test. **p<0.05 versus corresponding PAI-1 (wild-type) treated groups by Student's t-test;
[0022] FIG. 7 is a bar graph of experimental results showing the effect of wild-type PAI-1 (1 μg/mL, 2 h) versus a non-vitronectin binding PAI-1 mutant (1 μg/mL, 2 h) on adhesion of GTM-3 cells to vitronectin substrate. Data are expressed as mean and SEM, n=4-24. *p<0.05 versus untreated group by one-way ANOVA, followed by the Dunnett test;
[0023] FIG. 8 is a graph of experimental results showing the concentration-dependent effect of wild-type PAI-1 (4 h) on migration of GTM-3 cells. Data are expressed as mean and SEM, n=4-32. *p<0.05 versus vehicle group by one-way ANOVA, followed by the Dunnett test;
[0024] FIGS. 9 a - 9 c are graphs showing the effect of cilostazol on TGFβ2-induced (5 ng/mL; 24 h) total PAI-1 protein in supernatants from three different human trabecular meshwork (HTM) cell lines;
[0025] FIG. 10 is a graph showing the effect of the cilostazol metabolite 3,4-dehydro cilostazol (“DHC”) on TGFβ2-induced (5 ng/mL; 24 h) total PAI-1 protein in supernatants from GTM-3 HTM cells;
[0026] FIG. 11 is a graph showing the effect of the cilostazol analog cilostamide on TGFβ2-induced (5 ng/mL; 24 h) total PAI-1 protein in supernatants from GTM-3 HTM cells; and
[0027] FIGS. 12 a - 12 b are graphs showing the effect of topical ocular administration of various concentrations of cilostazol compared to control on Ad.TGFβ2-induced ocular hypertension in mice.
DETAILED DESCRIPTION OF THE INVENTION
[0028] PAI-1 has been linked to both decreased adhesion and increased detachment of cells in non-ocular tissues. A review of the data disclosed herein leads to the conclusion that increased PAI-1 levels in glaucomatous aqueous humor may be due to actions of TGFβ2 on trabecular meshwork cells. PAI-1-induced decreases in TM cell adhesion are likely due to PAI-1 interference with attachment of cells to the extracellular matrix component vitronectin. Additionally, the PAI-1-induced decrease in TM cell adhesion may facilitate migration of TM cells from the meshwork environment. Thus, the PAI-1 induced decrease in TM cell adhesion and increase in TM cell migration may be important factors in the decrease of TM cellularity seen in glaucomatous eyes. Certain embodiments of the present invention recognize that PAI-1 may cause such effects in trabecular meshwork (TM) tissues.
[0029] Circulating PAI-1 normally exists in a latent form, due to the ability of the active PAI-1 to rapidly and spontaneously transform to its inactive conformation. However, PAI-1 bound to vitronectin becomes stabilized in its active form, resulting in a much longer half-life. Thus, one means to reduce deleterious effects of active PAI-1 is to utilize agents which modulate the interaction of PAI-1 and vitronectin. Such agents would thus allow unbound vitronectin in the ECM to associate with its cell surface (integrin) receptors, thus enhancing cellular adhesion and reducing cell loss from TM tissues. Modulation of PAI-1's expression/activity and or its ability to bind vitronectin can provide a viable therapeutic approach to the management of glaucoma.
[0030] Certain embodiments of the present invention are methods for targeting the downstream effects of PAI-1 in ocular disorders such as glaucoma by interfering with the binding of PAI-1 to vitronectin as shown in the following scheme,
[0000]
[0000] where PAI-1 decreases binding of trabecular meshwork (TM) cell surface adhesion receptors (integrins) to vitronectin, an extracellular matrix component. As a consequence, cells detach from the TM and are swept via aqueous flow into the juxtacanulicular region of TM. This accumulation of detached TM cells and their debris contributes to increased outflow resistance and elevated IOP. Modulation of PAI-1 binding to vitronectin can thus decrease the detachment of TM cells and reduce increased outflow resistance and elevated IOP. Additionally, TM tissue cellularity may be thereby increased, preserving such vital functions as phagocytosis.
PAI-1 Modulators
[0031] Various PAI-1 binding modulators are known in the art. Jensen et al, for example, describe the discovery of a small peptide with strong affinity for wild-type PAI-1 and which inhibits association of the uPA-PAI-1 complex with low density lipoprotein receptor family members (Jensen et al, Inhibition of plasminogen activator inhibitor-1 binding to endocytosis receptors of the low-density-lipoprotein receptor family by a peptide isolated from a phage display library, Biochem J., Vol. 399(3):387-396, 2006). Agents that alter PAI-1's ability to inhibit tissue plasminogen activator (tPA) and/or urokinase plasminogen activator (uPA) may modulate PAI-1 binding as well. Such agents include, but are not limited to, ZK4044 (Liang et al., Characterization of a small molecule PAI-1 inhibitor, ZK4044, Thrombosis Research, Vol. 115(4):341-50, 2005), PAI-039 (tiplaxtinin) (Weisberg et al., Pharmacological inhibition and genetic deficiency of plasminogen activator inhibitor-1 attenuates angiotensin II/salt-induced aortic remodeling. Arterioscler Thrombosis Vasc Biology, Vol. 25(2):365-71, 2005 February; Hennan et al., Evaluation of PAI-039 [{1-benzyl-5-[4-(trifluoromethoxy)phenyl]-1H-indol-3-yl}(oxo)acetic acid], a novel plasminogen activator inhibitor-1 inhibitor, in a canine model of coronary artery thrombosis., J Pharmacol Exp Ther., Vol. 314(2):710-6, 2005 Aug. Epub, 2005 Apr. 28; Elokdah et al., A novel, orally efficacious inhibitor of plasminogen activator inhibitor-1: design, synthesis, and preclinical characterization. Journal Med. Chem., Vol. 47(14):3491-3494, 2004 Jul. 1), WAY140312 (Crandall et al., Characterization and comparative evaluation of a structurally unique PAI-1 inhibitor exhibiting oral in-vivo efficacy., J Thromb Haemost., Vol. 2(8):1422-1428, August 2004; Crandall et al., WAY-140312 reduces plasma PAI-1 while maintaining normal platelet aggregation, Biochem Biophys Res Commun., Vol. 311(4):904-8, 2003 Nov. 28), HP129 (fendosal) (Ye et al., Synthesis and biological evaluation of menthol-based derivatives as inhibitors of plasminogen activator inhibitor-1 (PAI-1). Bioorg Med Chem. Lett., Vol. 13(19):3361-3365, 2003 Oct. 6), and T-686 (Murakami et al., Protective effect of T-686, an inhibitor of plasminogen activator inhibitor-1 production, against the lethal effect of lipopolysaccharide in mice, Japan Journal Pharmacol., Vol. 75(3):291-294. 1997 November); Ohtani et al., T-686, a novel inhibitor of plasminogen activator inhibitor-1, inhibits thrombosis without impairment of hemostasis in rats. Eur J. Pharmacol., Vol. 330(2-3):151-156, 1997 Jul. 9; Vinogradsky et al., A new butadiene derivative, T-686, inhibits plasminogen activator inhibitor type-1 production in vitro by cultured human vascular endothelial cells and development of atherosclerotic lesions in vivo in rabbits, Thrombosis Research., Vol. 85(4):305-14, 1997 Feb. 15; Ohtani et al., Inhibitory effect of a new butadiene derivative on the production of plasminogen activator inhibitor-1 in cultured bovine endothelial cells, Journal Biochem (Tokyo), Vol. 120(6):1203-8, 1996 Dec.). Bryans et al., Inhibition of plasminogen activator inhibitor-1 activity by two diketopiperazines, XR330 and XR334, The Journal of Antibiotics, Vol. 49(10):1014-1021, 1996 October. Einholm et al., Biochemical mechanism of action of a diketopiperazine inactivator of plasminogen activator inhibitor-1, XR5118, Biochem Journal, Vol. 373:723-732, 2003.
[0032] Additionally, PAI-1 inhibitors such as those taught by Ye (Ye et al., Synthesis and biological evaluation of piperazine-based derivatives as inhibitors of plasminogen activator inhibitor-1 (PAI-1). Bioorg Med Chem. Lett., Vol. 14(3):761-5, 2004 Feb. 9; Ye et al., Synthesis and biological evaluation of menthol-based derivatives as inhibitors of plasminogen activator inhibitor-1 (PAI-1). Bioorg Med Chem. Lett., Vol. 13(19):3361-3365, 2003 Oct. 6) and antibody-based inhibitors such as those taught by Verbeke (Verbeke et al., Cloning and paratope analysis of an antibody fragment, a rational approach for the design of a PAI-1 inhibitor. Journal Thromb Haemost., Vol. 2(2):289-297, 2004 February) and van Giezen (van Giezen et al., The Fab-fragment of a PAI-1 inhibiting antibody reduces thrombus size and restores blood flow in a rat model of arterial thrombosis. Thromb Haemost., Vol. 77(5):964-969, May 1997) may also modulate PAI-1 binding. Other PAI-1 modulators may comprise PAI-1 peptidomimetics.
[0033] As discussed above, cilostazol has been shown to inhibit PAI-1 expression and activity in rat tissue (Mohamed, Biomed Pharmacother., 2009 Mar. 12. [Epub ahead of print]; Lee et al, Atherosclerosis, Vol. 207:391-398, 2009), and is a preferred PAI-1 modulator of the present invention. The structure of cilostazol is shown below:
[0000]
[0034] Cilostazol (OPC-13013; CAS No. 73963-72-1) is metabolized by liver enzymes (primarily CYP3A4) to active metabolites such as 3,4-dehydro-cilostazol (DHC) and 4′-trans-hydroxy-cilostazol (HC). HC is much less active than cilostazol. However, the activity of DHC(OPC-13015; CAS No. 73963-62-9) is reportedly 4-7 fold greater than cilostazol, and may account for ≧50% of total activity attributed to cilostazol. The structure of 3,4-dehydro-cilostazol (DHC) is shown below:
[0000]
[0035] Cilostamide (OPC-3689; CAS No. 6855-75-4), is a cilostazol analog. The structure of cilostamide is shown below:
[0000]
[0036] The contents of all references cited in this section under heading “PAI-1 Modulators” are hereby incorporated by reference in their entirety.
Modes of Delivery
[0037] The PAI-1 modulators of the present invention can be incorporated into various types of ophthalmic formulations for delivery. The compounds may be delivered directly to the eye (for example: topical ocular drops or ointments; slow release devices such as pharmaceutical drug delivery sponges implanted in the cul-de-sac or implanted adjacent to the sclera or within the eye; periocular, conjunctival, sub-tenons, intracameral, intravitreal, or intracanalicular injections) or systemically (for example: orally, intravenous, subcutaneous or intramuscular injections; parenteral, dermal or nasal delivery) using techniques well known by those of ordinary skill in the art. It is further contemplated that the PAI-1 modulators of the invention may be formulated in intraocular inserts or implantable devices.
[0038] The PAI-1 modulators disclosed herein are preferably incorporated into topical ophthalmic formulations for delivery to the eye. The compounds may be combined with opthalmologically acceptable preservatives, surfactants, viscosity enhancers, penetration enhancers, buffers, sodium chloride, and water to form an aqueous, sterile ophthalmic suspension or solution. Ophthalmic solution formulations may be prepared by dissolving a compound in a physiologically acceptable isotonic aqueous buffer. Further, the ophthalmic solution may include an opthalmologically acceptable surfactant to assist in dissolving the compound. Furthermore, the ophthalmic solution may contain an agent to increase viscosity such as hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, methylcellulose, polyvinylpyrrolidone, or the like, to improve the retention of the formulation in the conjunctival sac. Gelling agents can also be used, including, but not limited to, gellan and xanthan gum. In order to prepare sterile ophthalmic ointment formulations, the active ingredient is combined with a preservative in an appropriate vehicle such as mineral oil, liquid lanolin, or white petrolatum. Sterile ophthalmic gel formulations may be prepared by suspending the compound in a hydrophilic base prepared from the combination of, for example, carbopol-974, or the like, according to the published formulations for analogous ophthalmic preparations; preservatives and tonicity agents can be incorporated.
[0039] PAI-1 modulators are preferably formulated as topical ophthalmic suspensions or solutions, with a pH of about 4 to 8. The compounds are contained in the topical suspensions or solutions in amounts sufficient to lower IOP in patients experiencing elevated IOP and/or maintaining normal IOP levels in glaucoma patients. Such amounts are referred to herein as “an amount effective to control IOP,” or more simply “an effective amount.” The compounds will normally be contained in these formulations in an amount 0.01 to 5 percent by weight/volume (“w/v %”), but preferably in an amount of 0.25 to 2 w/v %. Thus, for topical presentation 1 to 2 drops of these formulations would be delivered to the surface of the eye 1 to 4 times per day, according to the discretion of a skilled clinician. The PAI-1 modulators may also be used in combination with other elevated IOP or glaucoma treatment agents, such as, but not limited to, rho kinase inhibitors, β-blockers, prostaglandin analogs, carbonic anhydrase inhibitors, α 2 agonists, miotics, serotonergic agonists and neuroprotectants.
[0040] As used herein, “PAI-1 modulator” encompasses such modulators as well as their pharmaceutically-acceptable salts. A pharmaceutically acceptable salt of a PAI-1 modulator is a salt that retains PAI-1 modulatory activity and is acceptable by the human body. Salts may be acid or base salts since agents herein may have amino or carboxy substituents. A salt may be formed with an acid such as acetic acid, benzoic acid, cinnamic acid, citric acid, ethanesulfonic acid, fumaric acid, glycolic acid, hydrobromic acid, hydrochloric acid, maleic acid, malonic acid, mandelic acid, methanesulfonic acid, nitric acid, oxalic acid, phosphoric acid, propionic acid, pyruvic acid, salicylic acid, succinic acid, sulfuric acid, tartaric acid, p-toluenesulfonic acid, trifluoroacetic acid, and the like. A salt may be formed with a base such as a primary, secondary, or tertiary amine, aluminum, ammonium, calcium, copper, iron, lithium, magnesium, manganese, potassium, sodium, zinc, and the like.
[0000] Determination of Biological Activity PAI-1 modulators can be selected using binding assays or functional assays that can also be used to determine their biological activity. Such assays can be developed by those of skill in the art using previously described methods. Other assays are or can be derived from data presented infra in the Examples. For example, the TM cell migration assay later described can be used where a putative PAI-1 modulator is added as a test agent.
In Vivo Biological Activity Testing
[0041] The ability of certain PAI-1 modulators to safely lower IOP may be evaluated in certain embodiments by means of in vivo assays using New Zealand albino rabbits and/or Cynomolgus monkeys.
Ocular Safety Evaluation in New Zealand Albino Rabbits
[0042] Both eyes of New Zealand albino rabbits are topically dosed with one 30 μL aliquot of a test compound in a vehicle. Animals are monitored continuously for 0.5 hr post-dose and then every 0.5 hours through 2 hours or until effects are no longer evident.
Acute IOP Response in New Zealand Albino Rabbits
[0043] Intraocular pressure (IOP) is determined with a Mentor Classic 30 pneumatonometer after light corneal anesthesia with 0.1% proparacaine. Eyes are rinsed with one or two drops of saline after each measurement. After a baseline IOP measurement, test compound is instilled in one 30 μL aliquot to one or both eye of each animal or compound to one eye and vehicle to the contralateral eye. Subsequent IOP measurements are taken at 0.5, 1, 2, 3, 4, and 5 hours.
Acute IOP Response in Cynomolgus Monkeys
[0044] Intraocular pressure (IOP) is determined with an Alcon pneumatonometer after light corneal anesthesia with 0.1% proparacaine as previously described (Sharif et al., J. Ocular Pharmacol. Ther., Vol. 17:305-317, 2001; May et al., J. Pharmacol. Exp. Ther., Vol. 306:301-309, 2003). Eyes are rinsed with one or two drops of saline after each measurement. After a baseline IOP measurement, test compound is instilled in one or two 30 μL aliquots to the selected eyes of cynomolgus monkeys. Subsequent IOP measurements are taken at 1, 3, and 6 hours. Right eyes of all animals had undergone laser trabeculoplasty to induce ocular hypertension. All left eyes are normal and thus have normal IOP.
EXAMPLES
[0045] The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventor to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.
Example 1
TGFβ2 Increases PAI-1 Content in TM Cells
[0046] FIG. 1 presents the results of experiments showing that TGFβ2 increases the PAI-1 content in trabecular meshwork cell cultures (GTM-3). PAI-1 mediated effects may contribute to the previously observed TGFβ2-mediated accumulation of extracellular matrix materials in various tissues, including TM tissues. FIG. 2 demonstrates that such TGFβ2-mediated PAI-1 increases are persistent in cell cultures treated with TGFβ2. TGFβ2-treatment results in both concentration-dependent and time-dependent accumulation of PAI-1 in TM cell supernatants ( FIGS. 1 and 2 ). PAI-1 levels increase gradually in response to TGFβ2, reaching a constant level at approximately 24 h post-treatment.
Example 2
Wild-Type PAI-1 Decreases Adhesion of TM Cells
[0047] FIG. 3 presents experimental data demonstrating the ability of recombinant human PAI-1 (2 h treatment) to decrease adhesion of cultured human TM cells to a vitronectin substrate; in that same model, adhesion was not affected by a mutant PAI-1 which does not bind vitronectin ( FIG. 7 ). FIG. 4 shows the effect of increasing concentrations of PAI-1 on TM cell adhesion. The effect of PAI-1 on adhesion was dose-dependent, with an estimated EC 50 of approximately 0.6 μM.
[0048] Such interference with TM cell adhesion may thereby trigger accelerated TM cell loss such as that seen in glaucoma, particularly POAG. Detached TM cells may contribute to the obstruction of aqueous humor outflow, a process believed to lead to increased outflow resistance and elevated IOP. Loss of TM cells from the meshwork tissues may also lead to impaired debris clearance, as a result of reduced phagocytic capacity.
[0049] Referring again to FIG. 3 , cells that were treated with TGFβ2 for 2 hr did not experience measurable loss of adhesion when compared to controls. The lack of effect of short-term treatment with TGFβ2 is likely due to insufficient TGFβ2-mediated PAI-1 induction during the 2 hr treatment period (vis. FIG. 2 ). Responses of SV40-transformed (GTM-3) cells were highly similar to that of non-transformed (GTM730) cells.
Example 3
Wild-Type PAI-1 Degrades Over Time
[0050] FIG. 5 shows experimental data indicating that the wild type PAI-1-mediated loss of adhesion is transient, with adhesion levels returning to near-control levels after 24 h. FIG. 6 is a bar graph of experimental results showing the effect of wild-type PAI-1 (1 μg/mL, 1 h) versus a stable, degradation-resistant PAI-1 mutant (1 μg/mL, 1 h) on adhesion of GTM-3 and GTM730 cells to vitronectin substrate. Taken in context with FIG. 5 , the data demonstrate that wild-type PAI-1 appears to degrade over time. The effect of PAI-1 was therefore enhanced by use of a stable PAI-1 mutant (mixture of the K154T, Q139L, M354I, and H150H mutations) which is more degradation-resistant than the wild-type protein.
Example 4
Wild-Type PAI-1 Effects on Adhesion are Vitronectin-Mediated
[0051] FIG. 7 is a bar graph of experimental results showing the effect of wild-type PAI-1 (1 μg/mL, 2 h) versus a non-vitronectin binding PAI-1 mutant (1 μg/mL, 2 h) on adhesion of GTM-3 cells to vitronectin substrate. The mutant PAI-1, which does not bind vitronectin yet is known to be otherwise functional, was without effect on TM cell adhesion to vitronectin substrate, while the wild-type vitronectin-binding PAI-1 decreased adhesion to ca. 50% of control levels.
[0052] FIG. 8 is a graph of experimental results showing the concentration-dependent effect of wild-type PAI-1 (4 h) on migration of GTM-3 cells. Wild-type PAI-1, at concentrations similar to that which reduce TM cell adhesion, induced migration of TM cells.
Example 5
In Vitro and In Vivo Cilostazol, 3,4-Dehydro Cilostazol, and Cilostamide Experiments
[0053] Experiments were performed to examine the effects of cilostazol and a cilostazol analog and metabolite on PAI-1 expression. In addition, the intraocular pressure-lowering effects of cilostazol were examined in a mouse model.
[0054] FIGS. 9-11 present graphs showing the effect of cilostazol, 3,4-dehydro cilostazol, and cilostamide on TGFβ2-induced (5 ng/mL; 24 h) total PAI-1 protein in supernatants from human trabecular meshwork (HTM) cell lines. Cilostazol was tested against three different HTM cell lines (GTM, NTM470-05, and GTM191-04). All graphs demonstrate a dose-dependent inhibitory effect on PAI-1 protein expression by the cell cultures for cilostazol and the cilostazol analog and metabolite.
[0055] FIGS. 12 a - 12 b are graphs showing the effect of topical ocular administration of various concentrations of cilostazol compared to control on Ad.TGFβ2-induced ocular hypertension in mice. Ad.TGFβ2 viral vector was injected on Day 0. Dosing with Cilostazol or vehicle was performed on the indicated days (denoted by horizontal bars). Intraocular pressure (IOP) was monitored in conscious mice using a rebound tonometer. The data presented in FIGS. 12 a - 12 b depicts results from two independent studies and demonstrates substantial IOP-lowering effects from both the 0.3 and 1.0% cilostazol formulations relative to control (Maxidex vehicle).
Methods for Examples 1-5
[0056] Human TM cell culture: Human TM cells were isolated from post-mortem human donor tissue, characterized, and cultured as previously described. Generation and characterization of the transformed (GTM-3) cell line was also as previously described (Pang et al., Preliminary characterization of a transformed cell strain derived from human trabecular meshwork., Curr. Eye Res., Vol. 13:51-63, 1994.)
[0057] PAI-1 ELISA: 24-well plates of TM cell cultures were serum-deprived for 24 h followed by an additional 24 h (or as indicated) incubation with TGFβ2 in a serum-free medium. Aliquots of supernatants from the treated cultures were quantified for secreted PAI-1 content by means of human PAI-1 ELISA kit (American Diagnostica).
[0058] TM cell adhesion: TM cell adhesion was determined by means of InnoCyte ECM Cell Adhesion Assay (Calbiochem). TM cells (20,000/well; serum-free medium) were plated onto a vitronectin-coated 96-well plate. Test agents were then added, followed by incubation in a cell culture incubator for the times indicated. Non-adherent cells were then removed by decantation and gentle wash of the wells with PBS. Relative cell attachment was determined by means of fluorescent dye (calcein-AM) uptake.
[0059] TM cell migration: Migration of TM cells was assessed using InnoCyte Cell Migration Assay (Calbiochem). TM cells (50,000/well; serum-free medium) were plated into the upper well assembly of the migration chamber supplied with the kits. Lower wells were filled with solutions of the test agents and the chamber was then incubated in a cell culture incubator. After 4 h, the upper well assembly was removed and supernatants were gently decanted to remove unattached cells. The upper well assembly was then placed into a fresh lower plate containing a mixture of detachment buffer and calcein-AM. 60 minutes later, aliquots from each lower well were transferred to a fresh 96 well plate and relative fluorescence determined.
Example 6
[0060]
[0000]
Ingredients
Concentration (w/v %)
Cilostazol
0.01-2%
Hydroxypropyl methylcellulose
0.5%
Dibasic sodium phosphate (anhydrous)
0.2%
Sodium chloride
0.5%
Disodium EDTA (Edetate disodium)
0.01%
Polysorbate 80
0.05%
Benzalkonium chloride
0.01%
Sodium hydroxide/Hydrochloric acid
For adjusting pH to 7.3-7.4
Purified water
q.s. to 100%
Example 7
[0061]
[0000]
Ingredients
Concentration (w/v %)
Cilostamide
0.01-2%
Methyl cellulose
4.0%
Dibasic sodium phosphate (anhydrous)
0.2%
Sodium chloride
0.5%
Disodium EDTA (Edetate disodium)
0.01%
Polysorbate 80
0.05%
Benzalkonium chloride
0.01%
Sodium hydroxide/Hydrochloric acid
For adjusting pH to 7.3-7.4
Purified water
q.s. to 100%
Example 8
[0062]
[0000]
Ingredients
Concentration (w/v %)
3,4-dehydro Cilostazol
0.01-2%
Guar gum
0.4-6.0%
Dibasic sodium phosphate (anhydrous)
0.2%
Sodium chloride
0.5%
Disodium EDTA (Edetate disodium)
0.01%
Polysorbate 80
0.05%
Benzalkonium chloride
0.01%
Sodium hydroxide/Hydrochloric acid
For adjusting pH to 7.3-7.4
Purified water
q.s. to 100%
Example 9
[0063]
[0000]
Ingredients
Concentration (w/v %)
Cilostazol
0.01-2%
White petrolatum and mineral oil and lanolin
Ointment consistency
Dibasic sodium phosphate (anhydrous)
0.2%
Sodium chloride
0.5%
Disodium EDTA (Edetate disodium)
0.01%
Polysorbate 80
0.05%
Benzalkonium chloride
0.01%
Sodium hydroxide/Hydrochloric acid
For adjusting pH to 7.3-7.4
[0064] The present invention and its embodiments have been described in detail. However, the scope of the present invention is not intended to be limited to the particular embodiments of any process, manufacture, composition of matter, compounds, means, methods, and/or steps described in the specification. Various modifications, substitutions, and variations can be made to the disclosed material without departing from the spirit and/or essential characteristics of the present invention. Accordingly, one of ordinary skill in the art will readily appreciate from the disclosure that later modifications, substitutions, and/or variations performing substantially the same function or achieving substantially the same result as embodiments described herein may be utilized according to such related embodiments of the present invention. Thus, the following claims are intended to encompass within their scope modifications, substitutions, and variations to processes, manufactures, compositions of matter, compounds, means, methods, and/or steps disclosed herein. | The invention concerns in one embodiment a method for treating glaucoma or elevated IOP in a patient comprising administering to the patient an effective amount of a composition comprising an agent that modulates PAI-1 activity. In a preferred embodiment, the agent that modulates PAI-1 expression and/or activity is cilostazol or an analog or metabolite of cilostazol. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Japanese Patent Application No. 2014-059415 filed Mar. 24, 2014, the content of which is hereby incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to an apparatus and a non-transitory computer-readable medium that stores computer-readable instructions.
[0003] A known embroidery sewing machine stores sewing data and stitch data that indicates a reference position that is necessary for positioning a pattern such that aligning of a pattern to an already sewn pattern is to be performed efficiently and accurately in a case where a plurality of patterns are combined and sewn. In the embroidery sewing machine, the pattern that is sewn first and a stitch that indicates the reference position for that pattern are sewn on a cloth based on the sewing data and the stitch data. A user is therefore able to recognize the reference position.
SUMMARY
[0004] For example, a case may occur in which the user desires to sew a plurality of decorative patterns of comparatively small size on individual characters of a character pattern that is made up of a plurality of characters, in order to make the pattern more decorative. Hereinafter, the resulting pattern is called a decorated character pattern. Specifically, the decorated character pattern is an embroidery pattern that is made by combining a character pattern and a decorative pattern. In a case where a decorated character pattern is sewn by the embroidery sewing machine that is described above, the user need to manually align the sewing positions of the character pattern and the decorative pattern. That task means time and effort for the user.
[0005] Embodiments of the broad principles derived herein provide an apparatus that can easily generate sewing data for combining and sewing a plurality of patterns, and also provide a non-transitory computer-readable medium that stores computer-readable instructions.
[0006] Embodiments provide an apparatus including a processor and a memory. The memory is configured to store computer-readable instructions. The computer-readable instructions, when executed by the processor, cause the apparatus to perform processes of acquiring first pattern data and second pattern data, the first pattern data being data for sewing a first embroidery pattern, and the second pattern data being data for sewing each of at least one second embroidery pattern, identifying, based on the first pattern data, at least one characteristic point of a pattern shape describing the first embroidery pattern, setting positioning data for positioning and sewing the at least one second embroidery pattern at the respective identified at least one characteristic point, and generating sewing data, based on the first pattern data, the second pattern data, and the positioning data. The sewing data is data for sewing the first embroidery pattern and the at least one second embroidery pattern in a sewing order in which the at least one of second embroidery pattern is sewn after the first embroidery pattern is sewn.
[0007] Embodiments also provide a non-transitory computer-readable medium storing computer-readable instructions that, when executed by a processor of an apparatus, cause the apparatus to perform processes that include acquiring first pattern data and second pattern data, the first pattern data being data for sewing a first embroidery pattern, and the second pattern data being data for sewing each of at least one second embroidery pattern, identifying, based on the first pattern data, at least one characteristic point of a pattern shape describing the first embroidery pattern, setting positioning data for positioning and sewing the at least one second embroidery pattern at the respective identified at least one characteristic point, and generating sewing data, based on the first pattern data, the second pattern data, and the positioning data. The sewing data is data for sewing the first embroidery pattern and the at least one second embroidery pattern in a sewing order in which the at least one of second embroidery pattern is sewn after the first embroidery pattern is sewn.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Embodiments will be described below in detail with reference to the accompanying drawings in which:
[0009] FIG. 1 is a block diagram that shows an electrical configuration of sewing data generation device;
[0010] FIG. 2 is a conceptual diagram that shows various types of storage areas in a hard disk device;
[0011] FIG. 3 is an oblique view of a sewing machine;
[0012] FIG. 4 is a flowchart of decorated character pattern creation processing;
[0013] FIG. 5 is a figure that shows a character pattern;
[0014] FIG. 6 is a figure that shows a decorative pattern;
[0015] FIG. 7 is a conceptual diagram of a portion of block data that configure the character pattern;
[0016] FIG. 8 is a conceptual diagram of block data with a thread density of 5 ;
[0017] FIG. 9 is a flowchart of characteristic point identification processing;
[0018] FIG. 10 is a flowchart of the characteristic point identification processing, continuing from FIG. 9 ;
[0019] FIG. 11 is a figure that shows an example in which a point q 1 is on a side p 2 -p 4 in the block data;
[0020] FIG. 12 is a figure that shows a line segment of the block data in the character pattern;
[0021] FIG. 13 is a figure that shows an example in which the point q 1 is on a side p 3 -p 4 in the block data;
[0022] FIG. 14 is a figure that shows a character pattern that is configured from single-stitch data only;
[0023] FIG. 15 is a figure that shows a character pattern that is configured by intermingling the block data and the single-stitch data;
[0024] FIG. 16 is an explanatory figure of a method for determining an ending point of a character line in the character pattern;
[0025] FIG. 17 is an explanatory figure of a method for determining a vertex point of a character line in the character pattern;
[0026] FIG. 18 is a figure that shows candidate points for positioning decorative patterns in the character pattern;
[0027] FIG. 19 is a figure that shows candidate points for positioning decorative patterns in parts of the character pattern that are configured from the single-stitch data;
[0028] FIG. 20 is a flowchart of pattern positioning processing;
[0029] FIG. 21 is a figure that shows a form in which decorative patterns are positioned at a starting point and an ending point of a first character line (m=0);
[0030] FIG. 22 is a figure that shows a decorated character pattern after the pattern positioning processing;
[0031] FIG. 23 is a flowchart of thinning-out processing;
[0032] FIG. 24 is a figure that shows a surface area in which rectangular areas that are indicated by mask data for two decorative patterns partially overlap; and
[0033] FIG. 25 is a figure that shows the decorated character pattern after the thinning-out processing.
DETAILED DESCRIPTION
[0034] An embodiment will be explained with reference to the drawings. The configuration of a sewing data generation device 1 will be explained with reference to FIG. 1 . The sewing data generation device 1 is a device that is able to generate embroidery data for the forming, by a sewing machine 3 (refer to FIG. 3 ), of stitches of an embroidery pattern in a sewing workpiece (for example, a work cloth) that is held by an embroidery frame 41 .
[0035] The sewing data generation device 1 may be a device that is dedicated to generating the embroidery data. The sewing data generation device 1 may be a general-purpose device such as a personal computer or the like. In the present embodiment, the general-purpose sewing data generation device 1 is used as an example. The sewing data generation device 1 includes a CPU 11 , which is a controller that performs control of the sewing data generation device 1 . A RAM 12 , a ROM 13 , and an input/output (I/O) interface 14 are connected to the CPU 11 . The RAM 12 temporarily stores various types of data, such as computation results and the like that are produced by computational processing by the CPU 11 . The ROM 13 stores a bios and the like.
[0036] The I/O interface 14 performs mediation of data transfers. A hard disk device (HDD) 15 , an input circuit 16 , an output circuit 17 , an external communication interface 18 , and a connector 19 are connected to the I/O interface 14 .
[0037] An input portion 20 , such as a keyboard or the like, is connected to the input circuit 16 . A display 21 , which is a display device, is connected to the output circuit 17 . The external communication interface 18 is an interface that can connect to a network 25 . The sewing data generation device 1 can connect to an external device through the network 25 . A storage medium 55 , such as a memory card or the like, can be connected to the connector 19 . Through the connector 19 , the sewing data generation device 1 is able to read data from the storage medium 55 and write data to the storage medium 55 .
[0038] Various types of storage areas in the HDD 15 will be explained with reference to FIG. 2 . The HDD 15 includes various types of storage areas, including a program storage area 151 , a character pattern data storage area 152 , a decorative pattern data storage area 153 , and a sewing data storage area 154 . The program storage area 151 stores various types of programs, including a program for performing decorated character pattern creation processing (refer to FIG. 4 ).
[0039] The character pattern data storage area 152 stores character pattern data. The character pattern data include shape data for a character pattern, thread color data that indicate the color of a thread, mask data for the character pattern, and the like. The character pattern is an embroidery pattern that indicates the shape of a character, as do alphabetic character patterns 51 to 53 shown in FIG. 5 , for example. The shape data are data for creating the shape of a character. The shape data include block data, single-stitch data, and the like, for example. The block data and the single-stitch data will be explained below. The mask data for a character pattern are data that indicate the smallest rectangle that can encompass the character pattern. The center point of the character pattern is defined by the coordinates of the intersection point of the diagonals of the rectangle that is indicated by the mask data. Coordinate data are data that indicate the coordinates in an XY coordinate system (refer to FIG. 3 ) that will be described below.
[0040] The decorative pattern data storage area 153 stores decorative pattern data. The decorative pattern data include coordinate data for needle drop points of a sewing needle 44 (refer to FIG. 3 ) in a decorative pattern, stitch data that indicate types of and setting values for stitches in the decorative pattern, thread color data that indicate the color of a thread, mask data for the decorative pattern, and the like. The decorative patterns are embroidery patterns that are used when a decorated character pattern (refer to FIG. 25 ) is created by combining the decorative patterns, such as a floral decorative pattern 85 shown in FIG. 6 , with the character pattern. The stitches of the decorative pattern may be satin stitches, fill stitches, and the like, for example. The needle drop point is a point where the sewing needle 44 , which is disposed directly above a needle hole (not shown in the drawings), pierces the sewing workpiece when a needle bar 35 is moved downward from above the sewing workpiece. The setting values are setting values for stitch angles, thread density, and the like, for example. The mask data for a decorative pattern are data that indicate the smallest rectangle that can encompass the decorative pattern. The center point of the decorative pattern is defined by the coordinates of the intersection point of the diagonals of the rectangle that is indicated by the mask data. Coordinate data are data that indicate the coordinates in an XY coordinate system that will be described below. A user can use a pattern editing function of the sewing data generation device 1 to edit the character pattern and the decorative pattern, and can also generate sets of pattern data for forming the character pattern and the decorative pattern, respectively.
[0041] The sewing data storage area 154 stores various types of sewing data. The various types of sewing data include sewing data for sewing a decorated character pattern that is generated by the decorated character pattern creation processing (refer to FIG. 4 ), which will be described below. The various types of sewing data also include sewing data and the like for sewing an ordinary embroidery pattern. The sewing data are data that, in the same manner as the stitch data, indicate the coordinates of the needle drop points and the stitch order for forming the stitches of the embroidery pattern. The sewing data for the decorated character pattern will be described below.
[0042] The sewing machine 3 will be explained briefly with reference to FIG. 3 . The sewing machine 3 is capable of sewing an embroidery pattern based on the sewing data. The sewing machine 3 includes a bed 30 , a pillar 36 , an arm 38 , and a head 39 . The bed 30 is the base of the sewing machine 3 and is long in the left-right direction. The pillar 36 extends upward from the right end portion of the bed 30 . The arm 38 extends to the left from the upper end of the pillar 36 such that the arm 38 is positioned opposite the bed 30 . The head 39 is a portion that is joined to the left end of the arm 38 .
[0043] When performing embroidery sewing, the user of the sewing machine 3 may mount an embroidery frame 41 that holds a sewing workpiece onto a carriage 42 that is disposed on the bed 30 . The embroidery frame 41 is moved to the coordinates of a needle drop point by a Y axis moving mechanism (not shown in the drawings) and an X axis moving mechanism (not shown in the drawings). The Y axis moving mechanism is contained in the carriage 42 . The X axis moving mechanism is contained in a body case 43 . The coordinates of the needle drop point are indicated by an XY coordinate system that is specific to the sewing machine 3 . In the present embodiment, the X direction is the left-right direction of the sewing machine 3 . The positive X direction is the direction from left to right. The negative X direction is the direction from right to left. The Y direction is front-rear direction of the sewing machine 3 . The positive Y direction is the direction from the rear to the front. The negative Y direction is the direction from the front to the rear. In conjunction with the moving of the embroidery frame 41 , a shuttle mechanism (not shown in the drawings) and the needle bar 35 on which the sewing needle 44 is attached are driven. The embroidery pattern is thus formed on the sewing workpiece. The Y axis moving mechanism, the X axis moving mechanism, the needle bar 35 , and the like are controlled based on the sewing data by a CPU (not shown in the drawings) that is built into the sewing machine 3 .
[0044] A connector 37 is provided on a side face of the pillar 36 of the sewing machine 3 . The storage medium 55 may be mounted in and removed from the connector 37 . For example, the sewing data generated by the sewing data generation device 1 are stored in the storage medium 55 through the connector 19 , as shown in FIG. 1 . Then the storage medium 55 may be mounted in the connector 37 of the sewing machine 3 . The stored sewing data may be read and stored in the sewing machine 3 . Based on the stored sewing data, the CPU of the sewing machine 3 may control the operation of sewing the embroidery pattern. The sewing machine 3 is thus able to sew the embroidery pattern based on the sewing data generated by the sewing data generation device 1 .
[0045] The decorated character pattern creation processing that the CPU 11 performs will be explained with reference to FIGS. 4 to 25 . The sewing data generation device 1 is capable of performing both the decorated character pattern creation processing and ordinary processing. The decorated character pattern creation processing is processing that generates the sewing data for the decorated character pattern. The ordinary processing is processing that generates the sewing data for an ordinary embroidery pattern. Using the input portion 20 , the user can perform operations to select and start various types of processing. When the CPU 11 detects the operations to select and start the decorated character pattern creation processing, the CPU 11 reads into the RAM 12 the program for performing the decorated character pattern creation processing stored in the program storage area 151 of the HDD 15 , then performs the processing below by executing the instructions contained in the program.
[0046] As shown in FIG. 4 , first, the CPU 11 performs character selection processing (Step S 1 ). The character selection processing is processing that allows the user to select a character pattern. The CPU 11 displays a character pattern selection screen, for example, on the display 21 , then waits until the CPU 11 detects that a character pattern is selected by the user. A single character may be selected, and a plurality of characters may be selected. For each of the character patterns, there are a plurality of variations, in which the shape, the style, the color, and the like of the character are different. In the present embodiment, it is assumed that the user selects the three character patterns 51 to 53 shown in FIG. 5 . The character pattern 51 is the alphabetic character “K”, the character pattern 52 is the alphabetic character “S”, and the character pattern 53 is the alphabetic character “L”.
[0047] When the CPU 11 detects that the character patterns 51 to 53 is selected, the CPU 11 acquires from the character pattern data storage area 152 of the HDD 15 the character pattern data sets that correspond to the selected character patterns 51 to 53 (Step S 2 ) and stores the character pattern data sets in the RAM 12 . Each one of the character patterns 51 to 53 is configured from block data that will be described below.
[0048] The block data will be explained with reference to FIGS. 7 and 8 . The block data are coordinate data for the individual vertices of a four-sided block that is defined by four points. FIG. 7 shows two blocks that configure a portion of a character pattern 54 . One of the blocks is configured from points p 1 , p 2 , p 3 , and p 4 , and another of the blocks is configured from points p 3 , p 4 , p 5 , and p 6 . The points p 1 and p 4 are positioned at opposite ends of a diagonal of the first block. The points p 2 and p 3 are positioned at opposite ends of another diagonal of the first block. The points p 3 and p 6 are positioned at opposite ends of a diagonal of the second block. The points p 4 and p 5 are positioned at opposite ends of another diagonal of the second block. A rectangle that is indicated by mask data 57 for the character pattern 54 encompasses the two blocks. The point p 1 is the vertex that is the closest to a start point 56 of the mask data 57 . The start point 56 is a point that indicates the position where the sewing by the sewing machine 3 is to be started. For the block data for each of the four-sided blocks, the CPU 11 computes needle drop points on two opposing sides of the four-sided block such that a predetermined thread density can be achieved. The thread density is information about the number of stitches that is to be disposed within one block, and the thread density is included in the character pattern data.
[0049] FIG. 8 shows an example of block data for which the thread density is 5 . Needle drop points q 1 and q 3 are set on a side p 2 -p 4 , which is one side of one four-sided block. Needle drop points q 2 and q 4 are set on a side p 1 -p 3 , which is another side of the one four-sided block. Five stitches s 1 to s 5 are disposed within the block. The stitch s 1 data indicate a stitch that links the starting point p 1 and the ending point q 1 . The stitch s 2 data indicate a stitch that links the starting point q 1 and the ending point q 2 . The stitch s 3 data indicate a stitch that links the starting point q 2 and the ending point q 3 . The stitch s 4 data indicate a stitch that links the starting point q 3 and the ending point q 4 . The stitch s 5 data indicate a stitch that links the starting point q 4 and the ending point p 4 .
[0050] Next, as shown in FIG. 4 , the CPU 11 performs decorative pattern selection processing (Step S 3 ). The decorative pattern selection processing is processing that allows the user to select a decorative pattern that is to be disposed in combination with the character pattern. In the same manner as in the character selection processing, the CPU 11 displays a decorative pattern selection screen, for example, on the display 21 . The CPU 11 then waits until the CPU 11 detects that a decorative pattern is selected by the user. In the present embodiment, it is assumed that the user selects the floral decorative pattern 85 shown in FIG. 6 . When the CPU 11 detects that the floral decorative pattern 85 is selected, the CPU 11 acquires the decorative pattern data for the selected floral decorative pattern 85 from the decorative pattern data storage area 153 of the HDD 15 (Step S 4 ) and stores the decorative pattern data in the RAM 12 . The decorative pattern data for the decorative pattern 85 include mask data 85 A (refer to FIG. 6 ) and the like. A center point O of the decorative pattern 85 is set at the intersection point of diagonals of the mask data 85 A.
[0051] Next, as shown in FIG. 4 , the CPU 11 performs characteristic point identification processing (Step S 5 ). The characteristic point identification processing is processing that identifies characteristic points of the character pattern. The characteristic points of the character pattern are points that characterize the shape of the character pattern. The characteristic points of the character pattern include endpoints and a vertex of the character pattern, for example. The endpoints are the starting point and the ending point of at least one line segment that corresponds to one stroke of the character (and is equivalent to a character line that will be described below). The vertex may be, for example, an intersection point of two line segments that form a corner of the character. This sort of characteristic point is a candidate point for positioning the decorative pattern.
[0052] The characteristic point identification processing will be explained with reference to FIGS. 9 and 10 . First, the CPU 11 initializes to zero the values of a block counter i, a stitch counter r, a line segment counter k, and a character line counter m (Step S 10 ). The block counter i counts the number of blocks that are indicated by the block data. The stitch counter r counts the number of stitches in the single-stitch data. The line segment counter k counts the total of the number of line segments that correspond to center lines of the blocks that are indicated by the block data and the number of line segments that correspond to the stitches in the single-stitch data. The character line counter m counts the number of the character lines. The character line is the at least one line segment that corresponds to one stroke of the character, and the character line will be described in detail below. The counter values for each one of the counters i, r, k, and m are stored in the RAM 12 .
[0053] Next, the CPU 11 defines, as target data, the first set of the shape data for creating the character pattern 51 , which is the first of the character patterns 51 to 53 selected in the character selection processing at Step S 1 . The CPU 11 determines whether the target data are block data (Step S 11 ). The CPU 11 may start the processing from one of the character patterns 52 and 53 .
[0054] In a case where the target data are block data (YES at Step S 11 ), the CPU 11 sets the value of a total number of blocks imax to the number of blocks that are continuous from the block that the target data (the block data) indicate (Step S 12 ). For example, in a case where the number of continuous blocks is 3, including the block that the target data (the block data) indicate, the total number of blocks imax is set to 3. The CPU 11 initializes the block counter i to zero (Step S 13 ). From the target i-th block data, the CPU 11 acquires the coordinates of the vertices p 1 to p 4 (refer to FIG. 12 ) of the block that the block data indicate (Step S 14 ). In a case where the value of the block counter i is zero, the i-th block data are the first block data.
[0055] Next, in order to determine a direction of the block data, the CPU 11 acquires the coordinates for the point q 1 , which is the ending point of the first stitch s 1 in the block data (Step S 15 ). The direction of the block data means the direction in which the character is written. The first stitch s 1 is a stitch for which the point p 1 , which is the start point, is defined as the starting point. The CPU 11 determines whether the point q 1 is on the side p 2 -p 4 (Step S 16 ). In a case where the point q 1 is on the side p 2 -p 4 (YES at Step S 16 ), as shown in FIG. 11 , the direction of the block data is from the side p 1 -p 2 toward the side p 3 -p 4 . Accordingly, the CPU 11 defines the center point of the side p 1 -p 2 as the starting point of a k-th line segment (hereinafter called the line segment [k]) in the block data and defines the center point of the side p 3 -p 4 as the ending point of the line segment [k] (Step S 18 ). The line segment [k] is equivalent to a center line of the block data. In a case where the value of k is zero, the k-th line segment (the line segment [ 0 ]) is the first line segment. For example, in a first block 61 (i=0) of the character pattern 51 , the positions of the starting point and the ending point of a line segment 61 A (k=0) are defined, as shown in FIG. 12 .
[0056] In contrast, in a case where the point q 1 is not on the side p 2 -p 4 (NO at Step S 16 ), the CPU 11 determines whether the point q 1 is on the side p 3 -p 4 (Step S 17 ). In a case where the point q 1 is on the side p 3 -p 4 (YES at Step S 17 ), as shown in FIG. 13 , the direction of the block data is from the side p 1 -p 3 toward the side p 2 -p 4 . Accordingly, the CPU 11 defines the center point of the side p 1 -p 3 as the starting point of the line segment [k] and defines the center point of the side p 2 -p 4 as the ending point of the line segment [k] (Step S 19 ). The CPU 11 can thus determine the coordinates of the starting point and the ending point of the line segment [k] based on the block data and the coordinate data for the point q 1 , which is the ending point of the first stitch. For each line segment [k], the CPU 11 stores the coordinate data for the starting point and the ending point of the line segment [k] in the RAM 12 . In a case where the point q 1 is not on the side p 3 -p 4 (NO at Step S 17 ), the CPU 11 cannot define the starting point and the ending point of the line segment [k], so the CPU 11 forces the termination of the processing without doing anything.
[0057] In this manner, the positions of the starting point and the ending point of the line segment [k] are defined for the block data for one block. Therefore, the CPU 11 adds 1 to the block counter i and adds 1 to the line segment counter k (Step S 20 ). Next, the CPU 11 determines whether the value of the block counter i has reached the value of the total number of blocks imax (Step S 21 ). In a case where the value of the block counter i is less than the value of the total number of blocks imax (NO at Step S 21 ), the CPU 11 returns to Step S 14 and repeats the processing described above for the block data for the next block (Steps S 14 to S 20 ).
[0058] In a case where the value of the block counter i has reached the value of the total number of blocks imax (YES at Step S 21 ), the calculation of the starting points and the ending points of the line segments [k] for the blocks that are continuous from the block that the target data (the block data) indicate has been completed. Accordingly, the CPU 11 determines whether all of the calculations of the starting points and the ending points of the line segments [k] have been completed for all of the shape data for creating the character pattern 51 (Step S 27 ). In a case where the value of the line segment counter k matches the number of sets of the shape data for the character pattern, all of the calculations of the starting points and the ending points of the line segments [k] have been completed for the character pattern. The character pattern 51 is defined by the block data only. Therefore, in a case where the value of the block counter i has reached the value of the total number of blocks imax, the calculations of the starting points and the ending points of the line segments [k] have all been completed (YES at Step S 27 ). In this case, as shown in FIG. 10 , the CPU 11 advances the processing to Step S 29 , which will be described below.
[0059] The character pattern 51 shown in FIG. 12 is defined by the block data only. Depending on the style of the character pattern, the character pattern may be defined by the single-stitch data only or by a combination of the block data and the single-stitch data. The single-stitch data are coordinate data for the endpoints (the starting points and the ending points) of the stitches that form the shape of the character or the like. FIG. 14 shows character patterns 71 to 73 , which are examples of a character style that is defined by the single-stitch data only. The character pattern 71 is the alphabetic character “K”, the character pattern 72 is the alphabetic character “S”, and the character pattern 73 is the alphabetic character “L”. Where the character pattern is defined by the single-stitch data only, it is often the case that the shape of the character pattern is formed by the stitches themselves.
[0060] In contrast, FIG. 15 shows character patterns 81 to 83 , which are examples of a character style that is defined by a combination of the block data and the single-stitch data. The character pattern 81 is the alphabetic character “K”, the character pattern 82 is the alphabetic character “S”, and the character pattern 83 is the alphabetic character “L”. A character style that is defined by a combination of the block data and the single-stitch data has a different visual quality from a character style that is defined by the block data only or the single-stitch data only, making a more creative impression. In a case where the character pattern is defined by the block data only, as described above, the CPU 11 calculates the starting point and the ending point of the line segment [k], which is the center line of the block. In a case where the shape data for the character pattern include the single-stitch data, then for the part of the character pattern that is defined by the single-stitch data, the CPU 11 may calculate starting points and ending points of line segments that correspond to stitches.
[0061] Returning to Step S 9 , in a case where the target data are single-stitch data, not block data (NO at Step S 11 ), the CPU 11 sets the value of a total number of stitches rmax to the number of stitches that are continuous from the stitch that the target data (the single-stitch data) indicate (Step S 22 ). For example, in a case where the number of continuous stitches is 3, including the stitch that the target data (the single-stitch data) indicate, the total number of stitches rmax is set to 3. The CPU 11 initializes the stitch counter r to zero (Step S 23 ). Then the CPU 11 defines the starting point of the line segment [k] as the starting point of the target stitch [r] and defines the ending point of the line segment [k] as the ending point of the stitch [r] (Step S 24 ). The CPU 11 stores the coordinate data for the starting point and the ending point of the line segment [k] in the RAM 12 .
[0062] In this manner, the positions of the starting point and the ending point of the line segment [k] are defined for one stitch that the single-stitch data indicate. The CPU 11 adds 1 to the stitch counter r and the line segment counter k (Step S 25 ). The CPU 11 determines whether the value of the stitch counter r has reached the value of the total number of stitches rmax (Step S 26 ). In a case where the value of the stitch counter r is less than the value of the total number of stitches rmax (NO at Step S 26 ), the CPU 11 returns to Step S 24 and repeats the processing described above for the next set of the single-stitch data (Steps S 24 , S 25 ).
[0063] In a case where the value of the stitch counter r has reached the value of the total number of stitches rmax (YES at Step S 26 ), the calculation of the starting points and the ending points of the line segments [k] for the single-stitch data that indicate the stitches that are continuous from the stitch that the target data (the single-stitch data) indicate has been completed. Accordingly, the CPU 11 determines whether all of the calculations of the starting points and the ending points of the line segments [k] have been completed for all sets of the shape data for creating the character pattern (Step S 27 ). For example in a case where the block data follow the single-stitch data for which the calculations have been completed, the calculations of the starting points and the ending points of the line segments [k] have not all been completed for the character pattern (NO at Step S 27 ). Accordingly, the CPU 11 returns to Step S 11 and, for the block data that indicate the next continuous block (YES at Step S 11 ), repeats the processing that is described above (Steps S 12 to S 21 ). In a case where all of the calculations of the starting points and the ending points of the line segments [k] have been completed for the character pattern (YES at Step S 27 ), the CPU 11 advances the processing to Step S 29 , as shown in FIG. 10 .
[0064] As shown in FIG. 10 , the CPU 11 defines the starting point of the first character line (m=0) as the starting point of the first block (or the first stitch) (Step S 29 ). The character line is the at least one line segment that corresponds to one stroke of the character, and the character line is configured from the line segments [k]. The CPU 11 sets the value of a total number of line segments kmax to the current value of the line segment counter k (Step S 30 ). The total number of line segments kmax is the total number of the line segments [k] in the character pattern 51 . The CPU 11 once again initializes the line segment counter k to zero (Step S 31 ).
[0065] Next, the CPU 11 determines whether the coordinates of the ending point of the line segment [k] are different from the coordinates of the starting point of the next line segment [k+1] (Step S 32 ). In a case where the coordinates of the ending point of the line segment [k] are different from the coordinates of the starting point of the next line segment [k+1] (YES at Step S 32 ), the ending point of the line segment [k] and the starting point of the next line segment [k+1] are in different positions. Accordingly, the CPU 11 defines the endpoint of the line segment [k] as the endpoint of the m-th character line (hereinafter called the character line [m]) (Step S 34 ) and defines the starting point of the next line segment [k+1] as the starting point of the next character line [m+1] (Step S 35 ). The CPU 11 stores the coordinates of the ending point of the character line [m] and the coordinates of the starting point of the character line [m+1] in the RAM 12 . The CPU 11 adds 1 to the character line counter m (Step S 36 ). In a case where the value of the character line counter m is zero, the m-th character line (the character line [ 0 ]) is the first character line.
[0066] Conversely, in a case where the coordinates of the ending point of the line segment [k] and the starting point of the next line segment [k+1] are the same (NO at Step S 32 ), the positions of the ending point of the line segment [k] and the starting point of the next line segment [k+1] overlap. For example, as shown in FIG. 16 , in blocks 91 to 95 at the beginning of the top of the “S” character pattern 52 , the ending point of a line segment 91 A of the block 91 and the starting point of a line segment 92 A of the block 92 overlap at a point T 1 . The ending point of a line segment 93 A of the block 93 and the starting point of a line segment 94 A of the block 94 overlap at a point T 2 . The ending point of the line segment 94 A of the block 94 and the starting point of a line segment 95 A of the block 95 overlap at a point T 3 . In other words, two line segments are connected at each one of the point T 1 , the point T 2 , and the point T 3 . Therefore, the point T 1 , the point T 2 , and the point T 3 are not endpoints of the character pattern.
[0067] In this sort of case, the CPU 11 determines whether the overlapping point is a vertex of the character pattern. The CPU 11 determines whether an angle that is formed by the line segment [k] and the next line segment [k+1] is less than or equal to a threshold value Ta (Step S 33 ). The threshold value Ta may be 150 degrees, for example, but the threshold value Ta may be modified. In a case where the angle is greater than the threshold value Ta (NO at Step S 33 ), the angle that is formed by the line segment [k] and the next line segment [k+1] is not small enough that the overlapping point can be regarded as a characteristic point. In this case, the overlapping point is not regarded as a vertex. Accordingly, the CPU 11 adds 1 to the line segment counter k (Step S 37 ). In the example shown in FIG. 16 , the angle at each one of the point T 1 , the point T 2 , and the point T 3 is greater than the threshold value Ta. Therefore, none of the point T 1 , the point T 2 , and the point T 3 is a vertex.
[0068] On the other hand, in a case where the angle is less than or equal to the threshold value Ta (YES at Step S 33 ), the angle that is formed by the line segment [k] and the next line segment [k+1] is small enough that the overlapping point can be regarded as a characteristic point. The overlapping point is therefore regarded as a vertex. Accordingly, the CPU 11 defines the ending point of the line segment [k] as the ending point of the character line [m] (Step S 34 ) and defines the starting point of the next line segment [k+1] as the starting point of the next character line [m+1] (Step S 35 ). The CPU 11 stores the coordinates of the ending point of the character line [m] and the coordinates of the starting point of the character line [m+1] in the RAM 12 . The CPU 11 adds 1 to the character line counter m (Step S 36 ).
[0069] For example, as shown in FIG. 17 , in blocks 97 to 99 at the end of the “L” character pattern 53 , the ending point of a line segment 97 A of the block 97 and the starting point of a line segment 98 A of the block 98 overlap at a point T 4 . The ending point of the line segment 98 A of the block 98 and the starting point of a line segment 99 A of the block 99 overlap at a point T 5 . Therefore, the point T 4 and the point T 5 are not endpoints. At the point T 4 , the angle that is formed by the line segment 97 A and the line segment 98 A is greater than the threshold value Ta. Therefore, the point T 4 is not a vertex. In contrast, at the point T 5 , the angle that is formed by the line segment 98 A and the line segment 99 A is not greater than the threshold value Ta. Therefore, the point T 5 is a vertex.
[0070] Next, returning to FIG. 10 , the CPU 11 determines whether the value of the line segment counter k has reached a value that is 1 less than the value of the total number of line segments kmax (Step S 38 ). When the final line segment [k] is reached, there is no next line segment. Accordingly, there is no need to consider whether the ending point of the final line segment [k] is an endpoint. Therefore, at Step S 38 , the CPU 11 determines whether the value of the line segment counter k has reached the value that is 1 less than the value of the total number of line segments kmax. In a case where the value of the line segment counter k has not reached the value that is 1 less than the value of the total number of line segments kmax (NO at Step S 38 ), the CPU 11 returns to Step S 32 . The CPU 11 proceeds to repeat the processing (Steps S 32 to S 37 ) for determining the endpoint of the next character line. In a case where the value of the line segment counter k has reached the value that is 1 less than the value of the total number of line segments kmax (YES at Step S 38 ), the CPU 11 defines the ending point of the character line [m] as the ending point of the final block (or the final stitch, in the case of the single-stitch data) (Step S 39 ). The CPU 11 stores the coordinates of the ending point of the character line [m] in the RAM 12 . The CPU 11 sets the current value of the character line counter m to a total number of character lines mmax (Step S 40 ). The total number of character lines mmax is the total number of the character lines in the character pattern 51 . The CPU 11 processes the character patterns 52 and 53 in the same manner as the character pattern 51 . The CPU 11 terminates the characteristic point identification processing and returns to the decorated character pattern creation processing shown in FIG. 4 .
[0071] At the point when the characteristic point identification processing is terminated, the coordinate data for the starting point and the ending point of every character line [m] in each of the character patterns 51 to 53 are stored in the RAM 12 . The starting point and the ending point of each character line [m] are the candidate points for positioning the decorative pattern 85 . For example, the candidate points in the character patterns 51 to 53 , which are defined by the block data only, are the center positions of the circles shown in FIG. 18 . On the other hand, the candidate points in the character patterns 81 to 83 , which are defined by a combination of the block data and the single-stitch data, are the center positions of the circles shown in FIG. 19 . In FIG. 19 , the candidate points for the character patterns 82 and 83 is omitted from the drawing. Next, the CPU 11 performs pattern positioning processing, which is shown in FIG. 20 (Step S 6 ).
[0072] The pattern positioning processing will be explained with reference to FIG. 20 . The pattern positioning processing is processing that positions the decorative pattern at the candidate points identified by the characteristic point identification processing. First, the CPU 11 initializes the character line counter m and a positioned pattern counter n to zero (Step S 41 ). The positioned pattern counter n counts the number of decorative patterns positioned on one character pattern. As shown in FIG. 21 , the endpoints of each of the character lines [m] (refer to the broken lines in FIG. 21 ) in the character pattern 51 are candidate points for positioning the decorative pattern 85 , for example. The CPU 11 positions the decorative pattern 85 such that the center point O of the decorative pattern 85 overlaps a starting point 66 and an ending point 67 of the first character line (m=0) (Step S 42 ). The CPU 11 stores the coordinates of the mask data 85 A of the positioned decorative patterns 85 in the RAM 12 as positioning data for the decorative patterns 85 . The positioning of the decorative patterns 85 is thus completed for the one character line [m]. The CPU 11 adds 1 to the value of the character line counter m and adds 1 to the value of the positioned pattern counter n (Step S 43 ).
[0073] Next, the CPU 11 determines whether the value of the character line counter m has reached the value of the total number of character lines mmax (Step S 44 ). In a case where the value of the character line counter m is less than the value of the total number of character lines mmax (NO at Step S 44 ), the CPU 11 returns to Step S 41 and repeats the processing (Steps S 42 to S 43 ) until the positioning of the decorative patterns 85 has been completed for all of the character lines. In a case where the value of the character line counter m has reached the value of the total number of character lines mmax (YES at Step S 44 ), the positioning of the decorative patterns 85 has been completed for all of the character lines. Therefore, the CPU 11 terminates the pattern positioning processing. The CPU 11 processes the character patterns 52 and 53 in the same manner as the character pattern 51 .
[0074] At the point when the pattern positioning processing is terminated, the character patterns 51 to 53 become decorated character patterns 251 to 253 , which are shown in FIG. 22 . At this stage, the decorative patterns 85 are positioned at all of the characteristic points of the decorated character patterns 251 to 253 . Therefore, some of the decorative patterns 85 overlap one another. When the decorative patterns 85 overlap one another, the shapes of the decorative patterns 85 may be disfigured, depending on the extent of the overlapping. In such a case, the appearance of the decorated character patterns 251 to 253 therefore may be poorer. Accordingly, the CPU 11 returns to the processing shown in FIG. 4 and performs thinning-out processing (Step S 7 ).
[0075] The thinning-out processing will be explained with reference to FIG. 23 . First, the CPU 11 acquires a threshold value Tb from the ROM 13 (Step S 50 ). The threshold value Tb is a threshold value for the ratio of a surface area S where two of the decorative patterns 85 overlap one another to a total surface area of the overlapping decorative patterns 85 . For example, the threshold value Tb in the present embodiment is thirty percent. The threshold value Tb may be modified in accordance with the shape, the size, and the like of the decorative pattern. The threshold value Tb may be stored in a storage medium other than the ROM 13 . For example, the threshold value Tb may be stored in the HDD 15 .
[0076] In order to detect overlapping among all of the (fourteen) decorative patterns 85 positioned in the decorated character pattern 251 (refer to FIG. 22 ), the CPU 11 computes the amount of overlap between one target decorative pattern 85 and another of the decorative patterns 85 , then compares the result to the threshold value Tb. In the present embodiment, the one target decorative pattern 85 is defined as a first pattern, and each one of the other decorative patterns 85 is defined as a second pattern. The CPU 11 initializes a first pattern counter v to zero (Step S 51 ). The first pattern counter v counts the first patterns. Next, the CPU 11 initializes a second pattern counter w to zero (Step S 52 ). The second pattern counter w counts the second patterns. The value of each of the counters v and w is stored in the RAM 12 .
[0077] First, from among all of the (fourteen) decorative patterns 85 in the decorated character pattern 251 , the CPU 11 selects, as the first pattern, the decorative pattern 85 positioned the earliest. Then, from among the other decorative patterns 85 , the CPU 11 selects, as the second pattern, the decorative pattern 85 positioned the earliest. The CPU 11 computes the surface area S where the rectangular area that is indicated by the mask data for the first pattern overlaps the rectangular area that is indicated by the mask data for the second pattern (Step S 53 ). For example, as shown in FIG. 24 , a portion of the rectangular area that is indicated by mask data 86 A for a decorative pattern 86 , which is selected as the first pattern, overlaps a portion of the rectangular area that is indicated by mask data 87 A for a decorative pattern 87 , which is selected as the second pattern. Based on the coordinates of the mask data 86 A and the mask data 87 A, the CPU 11 computes the surface area S of the rectangular overlapping area (the rectangular area that is filled by diagonal lines in FIG. 24 ). In this manner, the CPU 11 detects that the decorative patterns 86 and 87 overlap. The larger the ratio of the surface area S to the total surface area of the overlapping decorative patterns 85 , the greater the possibility becomes that the stitches of the decorative patterns 86 and 87 is disfigured during the sewing by the sewing machine 3 . The possibility therefore exists that the shapes of the decorative patterns 86 and 87 is not identifiable.
[0078] Accordingly, the CPU 11 determines whether the ratio of the surface area S to the total surface area of the overlapping decorative patterns 85 is less than the threshold value Tb (Step S 54 ). The threshold value Tb is the threshold value acquired at Step S 50 . In a case where the ratio of the surface area S to the total surface area of the overlapping decorative patterns 85 is less than the threshold value Tb (YES at Step S 54 ), the first pattern and the second pattern are either separated from one another or the extent of the overlapping of the first pattern and the second pattern is small. Accordingly, the CPU 11 adds 1 to the second pattern counter w without deleting either one of the first pattern and the second pattern (Step S 55 ). The determining of the extent of the overlapping in the combination of the first pattern and the second pattern has thus been completed.
[0079] Next, the CPU 11 determines whether the value of the second pattern counter w has reached the value of the positioned pattern counter n (Step S 56 ). The initial value of positioned pattern counter n is the total number of the decorative patterns 85 that are positioned in the decorated character pattern 251 . For example, the value of the positioned pattern counter n when the thinning-out processing starts is 14. In this case, the number of the decorative patterns 85 that are positioned in the decorated character pattern 251 is 14. In a case where the value of the second pattern counter w is less than the value of the positioned pattern counter n (NO at Step S 56 ), the CPU 11 returns to Step S 53 . Then the CPU 11 then repeats the processing for a combination of the same first pattern as in the preceding round of the processing and a different second pattern from the second pattern in the preceding round of the processing.
[0080] In a case where the value of the second pattern counter w has reached the value of the positioned pattern counter n (YES at Step S 56 ), the determining of the extent of the overlapping has been completed for all of the combinations of the first pattern and the plurality of the second patterns that are other than the first pattern. Accordingly, the CPU 11 adds 1 to the first pattern counter v (Step S 57 ) and determines whether the value of the first pattern counter v is greater than or equal to value of the positioned pattern counter n (Step S 58 ). In a case where the value of the first pattern counter v is less than the value of the positioned pattern counter n (NO at Step S 58 ), the CPU 11 defines, as the first pattern, a decorative pattern 85 that is different from the first pattern in the preceding round of the processing. The CPU 11 returns to Step S 52 and once again initializes the second pattern counter w to zero. Next, in the same manner as described above, the CPU 11 successively determines the extent of the overlapping between the new first pattern and the second patterns, which are the other decorative patterns 85 .
[0081] In a case where the ratio of the surface area S where the first pattern and the second pattern overlap to the total surface area is not less than the threshold value Tb (NO at Step S 54 ), the extent of the overlapping of the first pattern and the second pattern is large. Accordingly, in order to delete the first pattern, which is positioned earlier, the CPU 11 deletes the positioning data for the first pattern (Step S 59 ). As described previously, the positioning data indicate the coordinates of the mask data 85 A for the positioned decorative pattern 85 . In this manner, one of the overlapping decorative patterns 85 on the character pattern is deleted. The CPU 11 then moves up by 1 the positioning order each of the remaining decorative patterns 85 that follow the deleted decorative pattern 85 . The CPU 11 selects, as the first pattern, the decorative pattern 85 positioned the earliest among the decorative patterns 85 that have not yet been selected as the first pattern (Step S 60 ). Furthermore, because one of the decorative patterns 85 has been deleted, the CPU 11 subtracts 1 from the value of the positioned pattern counter n (Step S 61 ). The CPU 11 repeats the processing at Steps S 52 to S 61 for as long as the value of the first pattern counter v has not reached the value of the positioned pattern counter n (NO at Step S 58 ).
[0082] In a case where the value of the first pattern counter v has reached the value of the positioned pattern counter n (YES at Step S 58 ), the determining of the extent of the overlapping has been completed for all of the decorative patterns 85 . Furthermore, in a case where two or more of the decorative patterns 85 overlap, the decorative patterns 85 have been thinned out appropriately. The CPU 11 also performs the processing that is described above for the decorated character patterns 252 and 253 , in the same manner as for the decorated character pattern 251 . The CPU 11 then terminates the thinning-out processing.
[0083] As shown in FIG. 25 , at the point when the thinning-out processing is completed, the decorative patterns 85 on the decorated character patterns 251 to 253 have been thinned out appropriately. Compared to the decorated character patterns 251 to 253 prior to the performing of the thinning-out processing (refer to FIG. 22 ), the decorative patterns 85 have been thinned out appropriately. Accordingly, the characters in the decorated character patterns 251 to 253 may be more easily visible, and their overall appearance may be improved.
[0084] Next, the CPU 11 returns to the decorated character pattern creation processing shown in FIG. 4 and displays the tinned-out decorated character patterns 251 to 253 on the display 21 (Step S 8 ). The user is able to check the decorated character patterns 251 to 253 on the display 21 .
[0085] The CPU 11 then generates the sewing data for sewing the decorated character patterns 251 to 253 (Step S 9 ). The sewing data include the character pattern data for each one of the character patterns 51 to 53 , the decorative pattern data for the decorative patterns 85 , the positioning data for the decorative patterns 85 , sewing order data, and the like. The character pattern data are acquired from the character pattern data storage area 152 of the HDD 15 . The decorative pattern data are acquired from the decorative pattern data storage area 153 of the HDD 15 . The positioning data are acquired from the RAM 12 . The sewing order data are data for a sewing order in which the decorative patterns are sewn after the character pattern is sewn. The CPU 11 may store the generated sewing data in the sewing data storage area 154 of the HDD 15 . The CPU 11 may store the generated sewing data in the storage medium 55 through the connector 19 . The CPU 11 terminates the decorated character pattern creation processing.
[0086] As explained above, the sewing data generation device 1 of the present embodiment is able to generate the sewing data for the decorated character pattern. The decorated character pattern is a character pattern in which a decorative pattern is combined with a character pattern. The CPU 11 of the sewing data generation device 1 acquires the shape data that are included in the character pattern data for the character pattern 51 , for example, which is the alphabetic character “K”. Based on the shape data, the CPU 11 identifies the characteristic points of the character pattern 51 . The characteristic points are the endpoints and the vertices of the character pattern 51 , for example. The CPU 11 positions the floral decorative patterns 85 , for example, at the characteristic points identified in the character pattern 51 . The CPU 11 defines the coordinates of the characteristic points where the decorative patterns 85 are positioned as the coordinates of the center points of the decorative patterns 85 that are indicated by the mask data. The CPU 11 stores the mask data coordinates in the RAM 12 as the positioning data. The CPU 11 generates the sewing data for the decorated character pattern 251 based on the character pattern data for the character pattern 51 , the decorative pattern data for the decorative patterns 85 , and the positioning data for the decorative patterns 85 . The sewing data include the sewing order data for the sewing order in which the decorative patterns 85 are sewn after the character pattern 51 is sewn.
[0087] In this manner, the sewing data generation device 1 is able to identify the characteristic points of the character pattern 51 and automatically position the decorative patterns 85 at the characteristic points. Therefore, the sewing data for sewing the decorated character pattern 251 can be generated easily. Even in a case where the user has selected a different character pattern or decorative pattern, for example, the decorative patterns are automatically positioned in relation to the character pattern. Therefore, it is not necessary for the user to reposition the decorative patterns manually. Furthermore, even in a case where the style of the character pattern is changed, the characteristic points of the character pattern that correspond to the new style are newly identified. The decorative patterns are positioned at the newly identified characteristic points. Therefore, it is not necessary for the user to reposition the decorative patterns manually.
[0088] In the present embodiment, in the characteristic point identification processing shown in FIGS. 9 and 10 , the CPU 11 identifies the characteristic points of the character pattern by referring to at least one of the block data and the single-stitch data. The block data and the single-stitch data are the shape data that are included in the character pattern data. By referring to at least one of the block data and the single-stitch data, the CPU 11 is able to identify specifically a pattern shape of the character pattern. The CPU 11 is therefore able to identify the endpoints and the vertex accurately.
[0089] In the present embodiment, in the pattern positioning processing shown in FIG. 20 , the CPU 11 stores in the RAM 12 , as the positioning data, the coordinates of the mask data for the decorative patterns that are positioned on the character pattern. Furthermore, in the thinning-out processing shown in FIG. 23 , the CPU 11 detects the overlapping of two or more of the decorative patterns, based on the positioning data for each one of the decorative patterns that are positioned on the character pattern. In a case where the overlapping of two or more of the decorative patterns is detected, the CPU 11 identifies the decorative pattern to be deleted from among of the overlapping decorative patterns, based on a specified condition. The CPU 11 deletes the positioning data for the identified decorative pattern. The decorative patterns may thus be more easily visible, and the overall appearance of the decorated character pattern may be improved.
[0090] In the present embodiment, in the thinning-out processing shown in FIG. 23 , the specified condition for deleting a decorative pattern is that, in a case where the ratio of the surface area S where two decorative patterns overlap to the total surface area of the overlapping decorative patterns is not less than the threshold value Tb, one of the overlapping decorative patterns is to be deleted. Thus, in a case where two or more decorative patterns overlap, the CPU 11 is able to thin out the decorative patterns appropriately according to the specified condition. It is therefore possible to improve the balance of the positioning of the decorative patterns in the decorated character pattern.
[0091] Various types of modifications can be made to the embodiment that is described above. In the embodiment that is described above, a general-purpose device such as a personal computer or the like is used as the sewing data generation device 1 . However, the sewing data generation device 1 may also be a device that is dedicated to generating the embroidery data. The sewing data generation device 1 may also be incorporated into a sewing machine.
[0092] In the embodiment that is described above, a mode is explained in which the decorative patterns are positioned on the character pattern. Instead of the character pattern, a different embroidery pattern, such as a pictorial figure, a symbol, or the like, for example, may be used. Instead of a design (a floral design) such as the decorative pattern 85 in the embodiment that is described above, a different embroidery pattern, such as a text character, a pictorial figure, a symbol, or the like, for example, may be used. Such an embroidery pattern may be selected from among various types of embroidery patterns.
[0093] In the decorated character pattern creation processing shown in FIG. 4 in the embodiment that is described above, the thinning-out processing (Step S 7 ) may be omitted. The sewing data generation device 1 may be configured such that the user can select whether or not to perform the thinning-out processing.
[0094] In the pattern positioning processing shown in FIG. 20 in the embodiment that is described above, the decorative patterns 85 are positioned at all of the candidate points for the decorative patterns 85 that are identified by the characteristic point identification processing shown in FIGS. 9 and 10 . However, the decorative patterns 85 may be positioned at fixed intervals (such as at every other candidate point, for example). In the embodiment that is described above, the decorative patterns 85 that are positioned on the character pattern are all the same size. However, the sizes of the decorative patterns 85 may be enlarged and reduced according to the locations where the decorative patterns 85 are positioned, for example.
[0095] In the embodiment that is described above, the endpoints and the vertex of the character pattern are both identified as the characteristic points. Then the decorative patterns are positioned at the identified characteristic points. However, it is acceptable for only the endpoints or only the vertex of the character pattern to be identified, in accordance with a selection operation by the user, for example. Then the decorative pattern may be positioned at the identified characteristic point. The sewing data generation device 1 may be configured such that the user can use the input portion 20 to delete a decorated pattern manually while checking the decorated character patterns that are displayed on the display 21 .
[0096] In the embodiment that is described above, in the characteristic point identification processing shown in FIGS. 9 and 10 , the starting points and the ending points of the line segments that correspond to the center lines of the individual blocks in the block data are determined. However, it is not always necessary for the center lines of the individual blocks in the block data to be identified. It is sufficient for a line segment that indicates the direction of the block data to be identified.
[0097] In the embodiment that is described above, in the thinning-out processing shown in FIG. 23 , in a case where the ratio of the surface area S where the first pattern and the second pattern overlap to the total surface area of the overlapping decorative patterns is not less than the threshold value Tb (NO at Step S 54 ), the positioning data for the decorative pattern 85 positioned earlier are deleted. The decorative pattern 85 that was positioned later is given priority and left in place (refer to Step S 59 ). However, it is acceptable to give priority to and leave in place either one of the decorative pattern 85 positioned earlier and the decorative pattern 85 positioned later.
[0098] In the embodiment that is described above, at Step S 59 of the thinning-out processing shown in FIG. 23 , the positioning data for the first pattern are deleted in order to delete the positioned decorative pattern 85 . However, processing that invalidates the positioning data, for example, may be performed.
[0099] The decorated character pattern creation processing in the embodiment that is described above is not limited to the example of being performed by the CPU 11 . The decorated character pattern creation processing may be performed by a different electronic part (for example, an ASIC). The decorated character pattern creation processing may be performed by distributed processing by a plurality of electronic parts (that is, a plurality of CPUs). For example, a portion of the decorated character pattern creation processing may be performed by a server (not shown in the drawings) that is connected to the sewing data generation device 1 .
[0100] The apparatus and methods described above with reference to the various embodiments are merely examples. It goes without saying that they are not confined to the depicted embodiments. While various features have been described in conjunction with the examples outlined above, various alternatives, modifications, variations, and/or improvements of those features and/or examples may be possible. Accordingly, the examples, as set forth above, are intended to be illustrative. Various changes may be made without departing from the broad spirit and scope of the underlying principles. | An apparatus includes a processor and a memory configured to store computer-readable instructions. The computer-readable instructions, when executed by the processor, cause the apparatus to perform processes of acquiring first pattern data and second pattern data, the first pattern data being data for sewing a first embroidery pattern, and the second pattern data being data for sewing each of at least one second embroidery pattern, identifying, based on the first pattern data, at least one characteristic point of a pattern shape describing the first embroidery pattern, setting positioning data for positioning and sewing the at least one second embroidery pattern at the respective identified at least one characteristic point, and generating sewing data, based on the first pattern data, the second pattern data, and the positioning data. The sewing data is data for sewing the first embroidery pattern and the at least one second embroidery pattern. | 3 |
This invention relates to a lamp. It relates more particularly to an improved utility lamp for illuminating a work site.
BACKGROUND OF THE INVENTION
Utility lamps of the general variety with which we are concerned here have been available for many years. Such lamps usually include a handle containing a lamp socket and switch and some kind of cage for protectively enclosing the lamp bulb screwed into the socket. A long electrical cord has one end extending through the handle and connected to the socket while its other end is terminated by a standard male electrical plug. To use the utility lamp, the worker inserts the electrical plug into an electrical outlet and positions the lamp in a suitable location at the work site. A hook, clip or other such fastener is often mounted to the lamp to enable the lamp to be suspended from or anchored to a suitable support at the site.
While prior lamps of this variety perform their illuminating function quite satisfactorily, they do have certain drawbacks. For example, some prior utility lamps have protective bulb cages which simply engage over the bulb and are separate from the handle. Accordingly, the cage does not adequately protect the bulb. Also when a bulb burns out and has to be replaced, the cage must be separated from the handle. Resultantly, sometimes the cage becomes lost so that the worker is forced to use the utility lamp with a completely unprotected and unshielded bulb which is a dangerous practice.
Some conventional lamps, while having an integral handle and cage construction, fabricate the cage out of metal making the overall appliance relatively expensive. Also, the cage is electrically conductive so that, when the worker is engaged in electrical repairs, the lamp cage can provide a conductive path from a "hot" conductor to ground or to the worker and therefore can cause short circuits and shocks.
Prior lamps of this type are also inconvenient to use. This is because the lamp cord often becomes twisted, tangled and knotted requiring the worker to take the time to straighten out the cord before he can use the lamp. The main reason for this is that usually no provision is made for storing the lamp cord. The cord is simply coiled up by hand or wound around the lamp handle, neither of which is a very effective procedure for maintaining a cord in a tangle-free condition. There are some prior lamps that have tried to overcome this problem by storing the cord on an integral spring-loaded reel. However, such appliances are quite expensive. Furthermore, they are quite bulky and unwieldly so that it is difficult to work in close quarters with them.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved utility lamp which is relatively inexpensive to make.
A further object is to provide a utility lamp which is easy and safe to use.
Yet another object of the invention is to provide a utility lamp which includes storage for the lamp cord.
Yet another object of the invention is to provide a utility lamp which is designed so that is can be positioned at just the right location at a work site to effectively illuminate the parts or pieces being worked on.
Other objects will, in part, be obvious and will, in part, appear hereinafter.
The invention accordingly comprises the features of construction, combination of elements and arrangement of parts which will be exemplified in the following detailed description, and the scope of the invention will be indicated in the claims.
Briefly, the utility lamp of this invention includes a bulb holder, a protective bulb shield and a lamp cord storage section which are all molded or otherwise formed of a rugged impact-resistant plastic, the latter two parts of the lamp being formed as a single unitary piece. The plastic handle is hollow to receive a standard switched lamp socket and a lamp cord connected to the socket and which extends out of the end of the handle terminating in a conventional electrical plug.
Provision is made for removably clamping the cage and cord storage sections to the handle so that the cage completely envelops and protects the bulb inserted into the lamp socket. The cage is composed of two shell-like halves connected by an integral hinge, thereby permitting the cage to be opened in order to replace the bulb in the lamp socket without having to disconnect the cage from the handle. Therefore, replacement of the bulb does not involve moving or loosening fasteners or other parts which could become lost.
The cord storage section of the lamp attached to the cage is in the form of an elongated bobbin or spool extending parallel to the lamp handle and around which the cord can be wrapped. When the lamp is not in use, the cord is wound around the spool, the lamp and wrapped cord form a compact package which can be stored in a minimum amount of space.
When using the lamp, the worker inserts the lamp plug into the nearest electrical outlet and unwraps from cord storage only sufficient cord to enable the lamp handle to be positioned at the work site. Therefore, there is little likelihood of the lamp cord becoming knotted, twisted or tangled.
The present lamp also includes provision for anchoring or supporting the lamp at the work site in a variety of different ways. In this, the cage and cord storage section cooperate to provide feet which enable the lamp to stand on end on a flat surface so as to shed of focus its light along that surface. Also, the storage section of the lamp is provided with a flat surface which permits the lamp to rest stably on its side on such a surface. Further, a special magnetic pad is incorporated into that same section to enable the lamp to be supported or suspended from a ferromagnetic surface such as a steel door or plate. Finally, a multiple-position hook is mounted to the lamp to permit the lamp to be suspended from a peg, pipe or other projection in the event that work has to be performed at an elevated location.
Thus the present lamp can be positioned in a variety of different ways at the work site depending upon the particular circumstances. Accordingly, even though the work has to be performed in very close quarters, the lamp can usually always be supported in one or another of its operative positions so as to adequately illuminate the area. By the same token, when the lamp is not in use and the cord is wound up on the storage section, the unit can be suspended or supported in a variety of ways in an out-of-the-way storage location. Accordingly my utility lamp should find wide application in the home, in the plant and in the field when work has to be performed in locations where natural light in inadequate.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view of a utility lamp made in accordance with this invention;
FIG. 2 is a fragmentary front elevational view with parts cut away of the FIG. 1 lamp;
FIG. 3 is an exploded perspective view of the lamp;
FIG. 4 is a fragmentary rear elevational view of the lamp; and
FIG. 5 is a fragmentary perspective view on a larger scale showing a portion of the FIG. 1 lamp in greater detail.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2 of the drawings, my utility lamp indicated generally at 10 comprises a handle indicated generally at 12, a protective cage shown generally at 14 and a cord spool or storage section shown generally at 16. All of these components of the lamp are molded or formed of a suitable impact-resistant plastic such as high density polyethylene, with the cage and storage section being formed as an integral unit.
A standard switched threaded lamp receptacle or socket 18 mounted in handle 12 opens into cage 14 so that it can receive a standard electrical bulb B shown in dotted lines in FIG. 2. The receptacle switch button 18a is accessible through the opposite sides of handle 12. Also the receptacle includes an integral grounded electrical outlet 22 whose openings are also accessible through the side of handle 12 adjacent switch button 18a. A three-wire electrical cord 24 extends into the handle 12 and its end 24a (FIG. 2) is connected to receptacle 18, including its outlet 22. The opposite end 24b of the cord is terminated by a standard grounded electrical plug 26.
When the lamp is not in use, the cord 24 can be wrapped around the storage section 16. If desired, a clip 28 can be attached to the end of the cord adjacent plug 26 and arranged to clip to an adjacent turn of the cord to prevent the cord from unwrapping from section 16. In this condition, as shown in FIG. 1 the overall utility lamp constitutes a compact package which can be stored in a minimum amount of space. To facilitate convenient storage, a hook 32 is mounted to the top of the lamp. This hook is arranged so that it can assume a variety of different positions, permitting the lamp to be suspended from any one of many convenient projections such as the peg P shown in FIG. 1. Alternatively, the lamp can simply repose on its side on a suitable storage shelf or surface.
When using the lamp, one simply unwraps the cord 24 from section 16 and inserts the plug 26 into the electrical outlet nearest the work site. Then the worker unwraps only enough of the cord to enable the handle to be situated in a convenient location at the work site. Then the lamp may be suspended by way of the hook 32 from any suitable elevated projection, the hook being swiveled as needed to engage over that projection. Alternatively, if there is a convenient flat surface at the work site, the lamp can repose on end as shown in FIG. 4 with the hook 32 swinging out of the way to permit that. Still further, of course, the lamp can rest on its side on any convenient surface. A special magnetic plate 38 may be incorporated into the section 16 which permits the lamp to be anchored magnetically to an upstanding ferromagnetic surface such as a steel plate, frame member or other such part.
Because the subject lamp can be secured in all of the aforementioned different ways at a work site, in all probability the lamp can be positioned so as to shed a maximum amount of light on the parts and pieces to be worked on. Furthermore, even when the work is being performed in very close quarters with energized electrical terminals, since the lamp is composed primarily of non-conductive plastic parts, there is little likelihood of the lamp causing short circuits or being a source of electrical shocks to the worker.
After the particular job is finished, the worker simply disconnects the plug 26 and rewinds the cord 24 on the storage section 16 thereby ensuring that the cord will be tangle free when he next has occasion to use the lamp.
Referring now to FIGS. 1 to 3 of the drawings, the lamp handle 12 comprises an extruded or molded plastic tube 42 having a relatively large diameter upper end section 42a and a tapered lower end section 42b. A pair of diametrically opposite longitudinal slits 44 are formed in the upper end segment of section 42a to divide the upper portion of that section into two halves which can be spread apart to permit the slidable insertion of the bulb receptacle 18 and outlet 22. The lower ends of the slits 44 are enlarged and terminate in circular cutouts 44a which accommodate the receptacle switch button 18a. Arcuate walls 47 are formed on opposite sides of each slit near the lower end thereof to shield the protruding ends of the button. Also, the handle is formed with a cross-shaped boss 46 positioned directly under one slit 44 and provided with three holes or cutouts 48 which are aligned with the three openings of the outlet 22 once the outlet is seated inside the handle.
A pair of spaced-apart circular ribs 52 are provided at the top of the tube 42 to facilitate attachment of the handle to the cage 14 as will be described later. The aforementioned slots 44 also extend through these ribs dividing each rib into two generally semi-circular sections. Another circular rib 54 is formed at the lower end of the handle 42 so that, when the user grabs the handle, it does not tend to slide out of his hand.
Still referring to FIGS. 1 to 3, the utility lamp bulb enclosure or cage 14 includes a plastic shell 56 composed of a central generally semi-cylindrical section 56a, an upper semi-spherical section 56b and a lower semi-conical section 56c. Hinged to the shell 56 by way of an integral "living" hinge 58 at one side of shell section 56a is a mating grid ir grille 62. Grid or grille 62 also has a semi-cylindrical middle section 62a and a semi-spherical upper section 62b and a semi-conical lower section 62c which are interconnected by a rectangular array of webs 64.
The grid 62 can be swung from an open position shown in FIG. 3 wherein it permits ready access into shell 56 to a closed section illustrated in FIGS. 1 and 2 wherein it mates with the shell forming an enclosure which extends all around the bulb B depicted in FIG. 2. When the grid 62 is in that closed position, the free edge of its section 62a abuts the opposing edge of the shell section 56a. Further, that edge is captured between a pair of posts 66 which project out from section 56a just inboard of that opposint edge and a resilient latch 68 molded integrally with the side edge of shell section 56a. The latch engages over the edge of the grid section to releasably lock that section in its closed position.
As best seen in FIGS. 2 and 3, the lower end of the shell section 56c is formed with a reduced diameter semi-cylindrical neck portion 72 which defines with the remainder of section 56c a semi-circular shelf 74 whose dimensions and diameter correspond to the dimensions and diameter of the uppermost rib 52 in handle 12. Furthermore, the length of the neck portion 72 corresponds to the spacing between the two ribs 52 on handle 12 permitting the handle to be positioned with respect to the cage so that its uppermost rib 52 seats in the groove 74.
A pair of diametrically opposite laterally-extending tabs 76 are formed at the opposite sides of the neck portion 72 just below the groove 74. After the handle 12 is seated as aforesaid with rib 52 positioned in groove 74, a semi-cylindrical plastic clamp member 78 having a pair of laterally-extending end extensions or tabs 78a is engaged over the upper end of the handle between the two ribs 52 so that its tabs 78a are in register with the tabs 76. Openings 80 are formed in tabs 78a for receiving self-threading screws 82 which are turned down into registering sockets 84 formed in tabs 76. When the screws are tightened, the handle 12 is securely but releasably connected to the cage 14 and the storage section 16 formed integrally therewith.
The cage section 62c has a lower semi-circular rib 62d which has an inner diameter which is more or less the same as the outer diameter of the upper handle rib 52 so that when the cage is in its closed position shown in FIG. 2, the rib 62d engages over that upper rib 52.
When the upper end of the handle 12 is clamped to the cage as aforesaid, the segments of that handle on opposite sides of the slits 44 are squeezed together, thereby securely retaining the receptacle 18 in the handle. Preferably also, a laterally-extending tooth 86 is formed in the handle between its flanges 52 which is arranged to seat in a mating notch 88 formed at the right hand side of the neck portion 72 in the cage 14 as best seen in FIG. 3. This tooth-notch engagement prevents relative rotation of the handle and the cage, thus ensuring that the switch button 18a and the electrical outlet openings 48 in the handle are readily accessible at the front of the utility lamp as shown in FIGS. 1 and 2.
As best seen in FIGS. 2 to 4, the cord storage section 16 is formed integrally with the cage 14 at the free side edge of shell 56. Section 16 is basically in the form of an I-beam. That is, it has a pair of spaced-apart generally rectangular side rails 92 and 94 connected by an intervening rectangular web 96. Also to further rigidify the section, a pair of upper and lower flanges 98 extend laterally between the two side rails 92 and 94 at the opposite ends of web 96. The side rail 94 is formed integrally with the cage 14 and to further strengthen and rigidify that connection, an upper web 102 extends laterally between the upper end of rail 94 and the edge of shell section 56b. Likewise, a lower web 104 extends laterally from that same rail 94 to the edges of the shell sections 56c and its neck 72. Actually the left hand tab 76 illustrated in FIG. 3 is formed integrally with that web 104.
Thus when the cord 24 is wound up on section 16, its various turns engage around the end flanges 98 and are captured between side rails 92 and 94 forming a tight compact package.
Referring now to FIGS. 1 and 3, the outer face of the left hand rail 92 is formed with a rectangular recess 108 which accommodates the magnetic strip 38. That strip may be secured in the recess by any suitable means such as adhesive so that its outer surface is flush with or projects slightly out from the outer surface of rail 92. Thus when the strip is positioned against a ferromagnetic object such as a steel plate, it will adhere to that object, thereby suspending the lamp as a whole.
Also as noted above, the utility lamp is formed so that it can repose on its head as shown in FIG. 4. To this end, a pair of generally triangular ribs 110 and 112 are formed integrally with the shell section 56b and the cage section 62b respectively. More particularly, the rib 110 projects out laterally at the very upper edge of cage section 56b and its upper edge 110a is flat and coplanar with the upper edge 102a of the web 102 as well as the upper edges 92a, 94a of the rails 92 and 94. Likewise, the rib 112 projects out laterally from the very top of the cage section 62b and its upper edge 112a is aligned and coplanar with rib edge 110a. Thus all of these coplanar surfaces define a two dimensional stand which enables the lamp to be positioned stably on a flat surface as shown in FIG. 4.
Referring now particularly to FIGS. 2 and 5, the hook 32 is connected to the web 102 extending between cage 14 and section 16. More particularly, a pair of spaced-apart parallel walls 123 are formed integrally with rail 94 and web 102. The walls project out on the shell side of that web, defining between them a vertical slot 124 whose width is slightly greater than the diameter of the wire hook 32. The opposing faces of the walls 123 are formed with spherical recesses or dimples 126 which are arranged to rotatively receive a bulbous or spherical hook end 32a. The walls 123 are sufficiently resilient that, when the bulb 32a is forced between the walls, the walls spread apart. Then, when the bulb is seated in the recesses 126, the walls snap together, thereby rotatively capturing the hook end between them.
With this arrangement, the hook 32 can rotate 360° about a vertical axis as indicated by the arrow A in FIG. 5. Furthermore, it can be swung up and down vertically through the slot 124 almost 180° as indicated by the arrow B in that same figure. Thus the hook can swivel as needed to enable it to hook over almost any convenient projection at the work site. Also, when the utility lamp is stood on end as shown in FIG. 4, the hook can be swung up out of the way as shown in that figure. Preferably, the walls 123 are sufficiently resilient that they grip the hook end 32a sufficiently strongly that the hook does not flop about. Therefore, when it is swung up out of the way as shown in FIG. 4, it remains in that position until forcibly displaced therefrom.
In use, the lamp 10 can be hung from an elevated support by way of its hook 32, with the hook pivoting in one direction or the other as indicated in FIG. 2 to enable the lamp to be hung so as to illuminate the object being worked on. If such a projection is not available but there is a ferromagnetic object in the vicinity, the lamp 10 can be suspended from that object by way of its magnetic strip 38. If neither of the aforesaid courses is available, but there is a flat surface at hand, the lamp can simply be rested on its side as shown in FIG. 1 (turned sideways) or the lamp can be stood on end as depicted in FIG. 4.
To use the lamp, the worker simply inserts the plug 26 into a nearby electrical outlet and unwinds only that amount of the cord 24 that enables the lamp handle 12 to be positioned at the work site. Accordingly, the lamp cord 24 remains substantially straight and untangled. The lamp, while illuminating the work site, also includes the electrical outlet 22 which permits an auxiliary device such as an electrical tool to be powered from the lamp. When the work is done, the cord 24 is rewound onto section 16 and the lamp stored away. The present lamp is formed substantially entirely of relatively inexpensive plastic material. Therefore its overall cost is kept to a minimum. Furthermore all of the various parts of the lamp are connected together and it is not even necessary to remove any fastenings in order to replace the bulb B. One simply displaces the latch 68 and swings the cage 62 to its open position shown in FIG. 3 to gain access to the bulb. For all of the aforesaid reasons, then, this electrical appliance should prove to be a very marketable item.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained. Also, certain changes may be made in the above description or shown in the accompanying drawings. For example, in some instances, it may be desirable to market the cage and integral holder section of the present lamp as a separate unit for attachment to a conventional utility lamp handle and cord. This is possible because the clamp member 78 will fit around the handles of many present-day utility lamps. Therefore, it is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described. | A utility lamp has a tubular handle for containing a bulb receptacle connected to a cord extending out of the handle and terminated by a connector. A bulb cage or guard is removably clamped to the handle to protectively enclose a bulb inserted in the receptacle. Formed integrally with the bulb guard is a cord storage section about which the length of cord extending from the handle can be wound. A stand is formed at the free end of the bulb guard permitting the utility lamp to be stood on end on a horizontal surface. Also, a hook is swively mounted to the top of the bulb guard so that the lamp can be hung from an elevated projection and a magnet is mounted to the cord storage section enabling lamp to be suspended from a ferromagnetic object. | 5 |
TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates in general, to the operation of a subsurface safety valve installed in the tubing of a subterranean wellbore and, in particular, to an apparatus and method for locking out a subsurface safety valve and communicating hydraulic fluid through the subsurface safety valve.
BACKGROUND OF THE INVENTION
[0002] One or more subsurface safety valves are commonly installed as part of the tubing string within oil and gas wells to protect against unwanted communication of high pressure and high temperature formation fluids to the surface. These subsurface safety valves are designed to shut in production from the formation in response to a variety of abnormal and potentially dangerous conditions.
[0003] As these subsurface safety valves are built into the tubing string, these valves are typically referred to as tubing retrievable safety valves (“TRSV”). TRSVs are normally operated by hydraulic fluid pressure which is typically controlled at the surface and transmitted to the TRSV via a hydraulic fluid line. Hydraulic fluid pressure must be applied to the TRSV to place the TRSV in the open position. When hydraulic fluid pressure is lost, the TRSV will operate to the closed position to prevent formation fluids from traveling therethrough. As such, TRSVs are fail safe valves.
[0004] As TRSVs are often subjected to years of service in severe operating conditions, failure of TRSVs may occur. For example, a TRSV in the closed position may leak. Alternatively, a TRSV in the closed position may not properly open. Because of the potential for disaster in the absence of a properly functioning TRSV, it is vital that the malfunctioning TRSV be promptly replaced or repaired.
[0005] As TRSVs are typically incorporated into the tubing string, removal of the tubing string to replace or repair the malfunctioning TRSV is required. As such, the costs associated with replacing or repairing the malfunctioning TRSV is quite high. It has been found, however, that a wireline retrievable safety valve (“WRSV”) may be inserted inside the original TRSV and operated to provide the same safety function as the original TRSV. These insert valves are designed to be lowered into place from the surface via wireline and locked inside the original TRSV. This approach can be a much more efficient and cost-effective alternative to pulling the tubing string to replace or repair the malfunctioning TRSV.
[0006] One type of WRSV that can take over the full functionality of the original TRSV requires that the hydraulic fluid from the control system be communicated through the original TRSV to the inserted WRSV. In traditional TRSVs, this communication path for the hydraulic fluid is established through a pre-machined radial bore extending from the hydraulic chamber to the interior of the TRSV. Once a failure in the TRSV has been detected, this communication path is established by first shifting a built-in lock out sleeve within the TRSV to its locked out position and shearing a shear plug that is installed within the radial bore.
[0007] It has been found, however, that operating conventional TRSVs to the locked out position and establishing this communication path has several inherent drawbacks. To begin with, the inclusion of such built-in lock out sleeves in each TRSV increases the cost of the TRSV, particularly in light of the fact that the built-in lock out sleeves are not used in the vast majority of installations. In addition, since these built-in lock out sleeves are not operated for extended periods of time, in most cases years, they may become inoperable before their use is required. Also, it has been found, that the communication path of the pre-machined radial bore creates a potential leak path for formation fluids up through the hydraulic control system. As noted above, TRSVs are intended to operate under abnormal well conditions and serve a vital and potentially lifesaving function. Hence, if such an abnormal condition occurred when one TRSV has been locked out, even if other safety valves have closed the tubing string, high pressure formation fluids may travel to the surface through the hydraulic line.
[0008] In addition, manufacturing a TRSV with this radial bore requires several high-precision drilling and thread tapping operations in a difficult-to-machine material. Any mistake in the cutting of these features necessitates that the entire upper subassembly of the TRSV be scrapped. The manufacturing of the radial bore also adds considerable expense to the TRSV, while at the same time reducing the overall reliability of the finished product. Additionally, these added expenses add complexity that must be built into every installed TRSV, while it will only be put to use in some small fraction thereof.
[0009] Attempts have been made to overcome these problems. For example, attempts have been made to communicate hydraulic control to a WRSV through a TRSV using a radial cutting tool to create a fluid passageway from an annular hydraulic chamber in the TRSV to the interior of the TRSV such that hydraulic control may be communicated to the insert WRSV. It has been found, however, that such radial cutting tools are not suitable for creating a fluid passageway from the non annular hydraulic chamber of a rod piston operated TRSVs.
[0010] Therefore, a need has arisen for an apparatus and method for establishing a communication path for hydraulic fluid to a WRSV from a failed rod piston operated TRSV. A need has also arisen for such an apparatus and method that do not require a built-in lock out sleeve in the rod piston operated TRSV. Further, a need has arisen for such an apparatus and method that do not require the rod piston operated TRSV to have a pre-machined radial bore that creates the potential for formation fluids to travel up through the hydraulic control line.
SUMMARY OF THE INVENTION
[0011] The present invention disclosed herein comprises an apparatus and method for establishing a communication path for hydraulic fluid to a wireline retrievable safety valve from a rod piston operated tubing retrievable safety valve. The apparatus and method of the present invention do not require a built-in lock out sleeve in the rod piston operated tubing retrievable safety valve. Likewise, the apparatus and method of the present invention avoid the potential for formation fluids to travel up through the hydraulic control line associated with a pre-drilled radial bore in the tubing retrievable safety valve.
[0012] In broad terms, the apparatus of the present invention allows hydraulic control to be communicated from a non annular hydraulic chamber of a rod piston operated tubing retrievable safety valve to the interior thereof so that the hydraulic fluid may, for example, be used to operate a wireline retrievable safety valve. This may become necessary when a malfunction of the rod piston operated tubing retrievable safety valve is detected and a need exists to otherwise achieve the functionality of the rod piston operated tubing retrievable safety valve.
[0013] The rod piston operated tubing retrievable safety valve of the present invention has a housing having a longitudinal bore extending therethrough. The safety valve also has a non annular hydraulic chamber in a sidewall portion thereof. A valve closure member is mounted in the housing to control fluid flow through the longitudinal bore by operating between closed and opened positions. A flow tube is disposed within the housing and is used to shift the valve closure member between the closed and opened positions. A rod piston, which is slidably disposed in the non annular hydraulic chamber of the housing, is operably coupled to the flow tube. The safety valve of the present invention also has a pocket in the longitudinal bore.
[0014] In one embodiment of the present invention a communication tool is used to establish a communication path between the non annular hydraulic chamber in a sidewall portion of the safety valve and the interior of the safety valve. In this embodiment, the communication tool has a first section and a second section that are initially coupled together using a shear pin or other suitable coupling device. A set of axial locating keys is operably attached to the first section of the tool and is engagably positionable within a profile of the safety valve. The tool includes a radial cutting device that is radially extendable through a window of the second section. For example, the radial cutting device may include a carrier having an insert removably attached thereto and a punch rod slidably operable relative to the carrier to radially outwardly extend the insert exteriorly of the second section.
[0015] The tool also includes a circumferential locating key that is operably attached to the second section of the tool. The circumferential locating key is engagably positionable within the pocket of the safety valve. Specifically, when the first and second sections of the tool are decoupled, the second section rotations relative to the first section until the circumferential locating key engages the pocket, thereby circumferentially aligning the radial cutting device with the non annular hydraulic chamber. A torsional biasing device such as a spiral wound torsion spring places a torsional load between the first and second sections such that when the first and second sections are decoupled, the second section rotates relative to the first section. A collet spring may be used to radially outwardly bias the circumferential locating key such that the circumferential locating key will engage the pocket, thereby stopping the rotation of the second section relative to the first section. Once the circumferential locating key has engaged the pocket, the radial cutting device will be axially and circumferentially aligned with the non annular hydraulic chamber. Through operation of the radial cutting device, a communication path is created from the non annular hydraulic fluid chamber to the interior of the safety valve.
[0016] As such, hydraulic fluid may now be communicated down the existing hydraulic lines to the interior of the tubing. Once this communication path exists, for example, a wireline retrievable safety valve may be positioned within the rod piston operated tubing retrievable safety valve such that the hydraulic fluid pressure from the hydraulic system may be communicated to a wireline retrievable safety valve.
[0017] In another embodiment of the present invention, a lock out and communication tool is used to lock out the safety valve and then establish a communication path between the non annular hydraulic chamber in a sidewall portion of the safety valve and the interior of the safety valve. In this embodiment, the lock out and communication tool is lowered into the safety valve until the lock out and communication tool engages the flow tube. The lock out and communication tool may then downwardly shift the flow tube, either alone or in conjunction with an increase in the hydraulic pressure acting on the rod piston, to operate the valve closure member from the closed position to the fully open position. Alternatively, if the safety valve is already in the open position, the lock out and communication tool simply prevents movement of the flow tube to maintain the safety valve in the open position. Thereafter, the lock out and communication tool interacts with the safety valve as described above with reference to the communication tool to communicate hydraulic fluid from the non annular hydraulic fluid chamber to the interior of the safety valve.
[0018] One method of the present invention that utilizes the communication tool involves inserting the communication tool into the safety valve, locking the communication tool within the safety valve with the safety valve in a valve open position, axially aligning the radially cutting device with the non annular hydraulic chamber, circumferentially aligning the radially cutting device with the non annular hydraulic chamber and penetrating the radially cutting device through the sidewall portion and into the non annular hydraulic chamber to create a communication path between the non annular hydraulic chamber and the interior of the safety valve.
[0019] In addition, a method of the present invention that utilizes the lock out and communication tool involves engaging the flow tube of the safety valve with the lock out and communication tool, retrieving the lock out and communication tool from the safety valve and maintaining the safety valve in the valve open position by preventing movement of the rod piston with an insert that is left in place within the sidewall portion when the remainder of the radial cutting tool is retracted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] For a more complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention, taken in conjunction with the accompanying drawings in which like numerals identify like parts and in which:
[0021] [0021]FIG. 1 is a schematic illustration of an offshore production platform wherein a wireline retrievable safety valve is being lowered into a tubing retrievable safety valve to take over the functionality thereof;
[0022] FIGS. 2 A- 2 B are cross sectional views of successive axial sections of a rod piston operated tubing retrievable safety valve of the present invention in its valve closed position;
[0023] FIGS. 3 A- 3 B are cross sectional views of successive axial sections of a rod piston operated tubing retrievable safety valve of the present invention in its valve open position;
[0024] FIGS. 4 A- 4 B are cross sectional views of successive axial sections of a communication tool of the present invention;
[0025] FIGS. 5 A- 5 B are cross sectional views of successive axial sections of a communication tool of the present invention in its running position and disposed in a rod piston operated tubing retrievable safety valve of the present invention;
[0026] FIGS. 6 A- 6 B are cross sectional views of successive axial sections of a communication tool of the present invention in its locked position and disposed in a rod piston operated tubing retrievable safety valve of the present invention;
[0027] FIGS. 7 A- 7 B are cross sectional views of successive axial sections of a communication tool of the present invention in its orienting position and disposed in a rod piston operated tubing retrievable safety valve of the present invention;
[0028] FIGS. 8 A- 8 B are cross sectional views of successive axial sections of a communication tool of the present invention in its perforating position and disposed in a rod piston operated tubing retrievable safety valve of the present invention;
[0029] FIGS. 9 A- 9 B are cross sectional views of successive axial sections of a communication tool of the present invention in its retrieving position and still substantially disposed in a rod piston operated tubing retrievable safety valve of the present invention; and
[0030] FIGS. 10 A- 10 C are cross sectional views of successive axial sections of a lock out and communication tool of the present invention disposed in a rod piston operated tubing retrievable safety valve of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
[0032] Referring to FIG. 1, an offshore oil and gas production platform having a wireline retrievable safety valve lowered into a tubing retrievable safety valve is schematically illustrated and generally designated 10 . A semi-submersible platform 12 is centered over a submerged oil and gas formation 14 located below sea floor 16 . Wellhead 18 is located on deck 20 of platform 12 . Well 22 extends through the sea 24 and penetrates the various earth strata including formation 14 to form wellbore 26 . Disposed within wellbore 26 is casing 28 . Disposed within casing 28 and extending from wellhead 18 is production tubing 30 . A pair of seal assemblies 32 , 34 provide a seal between tubing 30 and casing 28 to prevent the flow of production fluids therebetween. During production, formation fluids enter wellbore 26 through perforations 36 in casing 28 and travel into tubing 30 to wellhead 18 .
[0033] Coupled within tubing 30 is a tubing retrievable safety valve 38 . As is well known in the art, multiple tubing retrievable safety valves are commonly installed as part of tubing string 30 to shut in production from formation 14 in response to a variety of abnormal and potentially dangerous conditions. For convenience of illustration, however, only tubing retrievable safety valve 38 is shown.
[0034] Tubing retrievable safety valve 38 is operated by hydraulic fluid pressure communicated thereto from surface installation 40 and hydraulic fluid control conduit 42 . Hydraulic fluid pressure must be applied to tubing retrievable safety valve 38 to place tubing retrievable safety valve 38 in the open position. When hydraulic fluid pressure is lost, tubing retrievable safety valve 38 will operate to the closed position to prevent formation fluids from traveling therethrough.
[0035] If, for example, tubing retrievable safety valve 38 is unable to properly seal in the closed position or does not properly open after being in the closed position, tubing retrievable safety valve 38 must typically be repaired or replaced. In the present invntion, however, the functionality of tubing retrievable safety valve 38 may be replaced by wireline retrievable safety valve 44 , which may be installed within tubing retrievable safety valve 38 via wireline assembly 46 including wireline 48 . Once in place within tubing retrievable safety valve 38 , wireline retrievable safety valve 44 will be operated by hydraulic fluid pressure communicated thereto from surface installation 40 and hydraulic fluid line 42 through tubing retrievable safety valve 38 . As with the original configuration of tubing retrievable safety valve 38 , the hydraulic fluid pressure must be applied to wireline retrievable safety valve 44 to place wireline retrievable safety valve 44 in the open position. If hydraulic fluid pressure is lost, wireline retrievable safety valve 44 will operate to the closed position to prevent formation fluids from traveling therethrough.
[0036] Even though FIG. 1 depicts a cased vertical well, it should be noted by one skilled in the art that the present invention is equally well-suited for uncased wells, deviated wells or horizontal wells. Also, even though FIG. 1 depicts an offshore operation, it should be noted by one skilled in the art that the present invention is equally well-suited for use in onshore operations.
[0037] Referring now to FIGS. 2A and 2B, therein is depicted cross sectional views of successive axial sections a tubing retrievable safety valve embodying principles of the present invention that is representatively illustrated and generally designated 50 . Safety valve 50 may be connected directly in series with production tubing 30 of FIG. 1. Safety valve 50 has a substantially cylindrical outer housing 52 that includes top connector subassembly 54 , intermediate housing subassembly 56 and bottom connector subassembly 58 which are threadedly and sealing coupled together.
[0038] It should be apparent to those skilled in the art that the use of directional terms such as top, bottom, above, below, upper, lower, upward, downward, etc. are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. As such, it is to be understood that the downhole components described herein may be operated in vertical, horizontal, inverted or inclined orientations without deviating from the principles of the present invention.
[0039] Top connector subassembly 54 includes a substantially cylindrical longitudinal bore 60 that serves as a hydraulic fluid chamber. Top connector subassembly 54 also includes a profile 62 and a radially reduced area 64 . In accordance with an important aspect of the present invention, top connector subassembly 54 has a pocket 66 . In the illustrated embodiment, the center of pocket 66 is circumferentially displaced 180 degrees from longitudinal bore 60 . It will become apparent to those skilled in the art that pocket 60 could alternatively be displaced circumferentially from longitudinal bore 60 at many other angles. Likewise, it will become apparent to those skilled in the art that more than one pocket 60 could be used. In that configuration, the multiple pockets 60 could be displaced axially from one another along the interior surface of top connector subassembly 54 .
[0040] Hydraulic control pressure is communicated to longitudinal bore 60 of safety valve 50 via control conduit 42 of FIG. 1. A rod piston 68 is received in slidable, sealed engagement against longitudinal bore 60 . Rod piston 68 is connected to a flow tube adapter 70 which is threadedly connected to a flow tube 72 . Flow tube 72 has profile 74 and a downwardly facing annular shoulder 76 .
[0041] A flapper plate 78 is pivotally mounted onto a hinge subassembly 80 which is disposed within intermediate housing subassembly 56 . A valve seat 82 is defined within hinge subassembly 80 . It should be understood by those skilled in the art that while the illustrated embodiment depicts flapper plate 78 as the valve closure mechanism of safety valve 50 , other types of safety valves including those having different types of valve closure mechanisms may be used without departing from the principles of the present invention, such valve closure mechanisms including, but not limited to, rotating balls, reciprocating poppets and the like.
[0042] In normal operation, flapper plate 78 pivots about pivot pin 84 and is biased to the valve closed position by a spring (not pictured). When safety valve 50 must be operated from the valve closed position, depicted in FIGS. 2 A- 2 B, to the valve opened position, depicted in FIGS. 3 A- 3 B, hydraulic fluid enters longitudinal bore 60 and acts on rod piston 68 . As the downward hydraulic force against rod piston 68 exceeds the upward bias force of spiral wound compression spring 86 , flow tube 72 moves downwardly with rod piston 68 . As flow tube 72 continues to move downwardly, flow tube 72 contacts flapper closure plate 78 and forces flapper closure plate 78 to the open position.
[0043] When safety valve 50 must be operated from the valve open position to the valve closed position, hydraulic pressure is released from conduit 42 such that spring 86 acts on shoulder 76 and upwardly bias flow tube 72 . As flow tube 72 is retracted, flapper closure plate 78 will rotate about pin 84 and seal on seat 82 .
[0044] If safety valve 50 becomes unable to properly seal in the closed position or does not properly open after being in the closed position, it is desirable to reestablish the functionality of safety valve 50 without removal of tubing 30 . In the present invention this is achieved by inserting a lock out and communication tool into the central bore of safety valve 50 .
[0045] Referring now to FIGS. 4 A- 4 B, therein is depicted cross sectional views of successive axial sections a lock out and communication tool embodying principles of the present invention that is representatively illustrated and generally designated 100 . Communication tool 100 has an outer housing 102 . Outer housing 102 has an upper subassembly 104 that has a radially reduced interior section 106 . Outer housing 102 also has a key retainer subassembly 108 including windows 110 and a set of axial locating keys 112 . In addition, outer housing 102 has a lower housing subassembly 114 .
[0046] Slidably disposed within outer housing 102 is upper mandrel 116 that is securably coupled to expander mandrel 118 by attachment members 120 . Upper mandrel 116 carries a plurality of dogs 122 . Partially disposed and slidably received within upper mandrel 116 is a fish neck 124 including a fish neck mandrel 126 and a fish neck mandrel extension 128 . Partially disposed and slidably received within fish neck mandrel 126 and fish neck mandrel extension 128 is a punch rod 130 . Punch rod 130 extends down through communication tool 100 and is partially disposed and selectively slidably received within main mandrel 132 .
[0047] Punch rod 130 and main mandrel 132 are initially fixed relative to one another by shear pin 134 . Main mandrel 132 is also initially fixed relative to lower housing subassembly 114 of outer housing 102 by shear pins 136 . Shear pins 136 not only prevent relative axial movement between main mandrel 132 and lower housing subassembly 114 but also prevent relative rotation between main mandrel 132 and lower housing subassembly 114 . A torsional load is initially carried between main mandrel 132 and lower housing subassembly 114 . This torsional load is created by spiral wound torsion spring 138 .
[0048] Attached to main mandrel 132 is a circumferential locating key 140 on the upper end of collet spring 142 . Circumferential locating key 140 includes a retaining pin 144 that limits the outward radial movement of circumferential locating key 140 from main mandrel 132 . Disposed within main mandrel 132 is a carrier 146 that has an insert 148 on the outer surface thereof. Insert 148 includes an internal fluid passageway 150 . Carrier 146 and insert 148 are radially extendable through window 152 of main mandrel 132 . Main mandrel 132 has a downwardly facing annual shoulder 154 .
[0049] The operation of communication tool 100 of the present invention will now be described relative to safety valve 50 of the present invention with reference to FIGS. 5 A- 5 B, 6 A- 6 B, 7 A- 7 B, 8 A- 8 B and 9 A- 9 B. In FIGS. 5 A- 5 B, communication tool 100 is in its running configuration. Communication tool 100 is positioned within the longitudinal central bore of safety valve 50 . As communication tool 100 is lowered into safety valve 50 , downwardly facing annular shoulder 154 of main mandrel 132 contacts profile 74 of flow tube 72 . Main mandrel 132 may downwardly shift flow tube 72 , either alone or in conjunction with an increase in the hydraulic pressure within longitudinal chamber 60 , operating flapper closure plate 78 from the closed position, see FIGS. 2 A- 2 B, to the fully open position, see FIGS. 3 A- 3 B. Alternatively, if safety valve 50 is already in the open position, main mandrel 132 simply holds flow tube 72 in the downward position to maintain safety valve 50 in the open position. Communication tool 100 moves downwardly relative to outer housing 52 of safety valve 50 until axial locating keys 112 of communication tool 100 engage profile 62 of safety valve 50 .
[0050] Once axial locating keys 112 of communication tool 100 engage profile 62 of safety valve 50 , downward jarring on communication tool 100 shifts fish neck 124 along with fish neck mandrel 126 , fish neck mandrel extension 128 , upper mandrel 116 and expander mandrel 118 downwardly relative to safety mandrel 50 and punch rod 130 . This downward movement shifts expander mandrel 118 behind axial locating keys 112 which locks axial locating keys 112 into profile 62 , as best seen in FIGS. 6 A- 6 B.
[0051] In this locked configuration of communication tool 100 , dogs 122 are aligned with radially reduced interior section 106 of upper housing subassembly 104 . As such, additional downward jarring on communication tool 100 outwardly shifts dogs 122 which allows fish neck mandrel extension 128 to move downwardly. This allows the lower surface of fish neck 124 to contact the upper surface of punch rod 130 . Continued downward jarring with a sufficient and predetermined force shears pins 136 , as best seen in FIGS. 7 A- 7 B. When pins 136 shear, this allows punch rod 130 and main mandrel 132 to move axially downwardly relative to housing 102 and expander mandrel 118 of communication tool 100 and safety valve 50 . This downward movement axially aligns carrier 146 and insert 148 with radially reduced area 64 and axially aligns circumferential locating key 140 with pocket 66 of safety valve 50 .
[0052] In addition, when pins 136 shear, this allows punch rod 130 and main mandrel 132 to rotate relative to housing 102 and expander mandrel 118 of communication tool 100 and safety valve 50 due to the torsional force stored in torsion spring 138 . This rotational movement circumferentially aligns carrier 146 and insert 148 with longitudinal bore 60 of safety valve 50 . This is achieved due to the interaction of circumferential locating key 140 and pocket 66 . Specifically, as punch rod 130 and main mandrel 132 rotate relative to safety valve 50 , collet spring 142 radially outwardly biases circumferential locating key 140 . Thus, when circumferential locating key 140 becomes circumferentially aligned with pocket 66 , circumferential locating key 140 moves radially outwardly into pocket 66 stopping the rotation of punch rod 130 and main mandrel 132 relative to safety valve 50 . By axially and circumferentially aligning circumferential locating key 140 with pocket 66 , carrier 146 and insert 148 become axially and circumferentially aligned with longitudinal bore 60 of safety valve 50 .
[0053] Once carrier 146 and insert 148 are axially and circumferentially aligned with longitudinal bore 60 of safety valve 50 , communication tool 100 is in its perforating position, as depicted in FIGS. 8 A- 8 B. In this configuration, additional downward jarring on communication tool 100 , of a sufficient and predetermined force, shears pin 134 which allow punch rod 130 to move downwardly relative to main mandrel 132 . As punch rod 130 move downwardly, insert 148 penetrates radially reduced region 64 of safety valve 50 . The depth of entry of insert 148 into radially reduced region 64 is determined by the number of jars applied to punch rod 130 . The number of jars applied to punch rod 130 is predetermined based upon factors such as the thickness of radially reduced region 64 and the type of material selected for outer housing 52 .
[0054] With the use of communication tool 100 of the present invention, fluid passageway 150 of insert 148 provides a communication path for hydraulic fluid from longitudinal bore 60 to the interior of safety valve 50 . Once insert 148 is fixed within radially reduced region 64 , communication tool 100 may be retrieved to the surface, as depicted in FIGS. 9 A- 9 B. In this configuration, punch rod 130 has retracted from behind carrier 146 , fish neck mandrel extension 128 has retracted from behind keys 106 and expander mandrel 118 has retracted from behind axial locating keys 112 which allows communication tool 100 to release from safety valve 50 . Insert 148 now prevents the upward movement of rod piston 68 and flow tube 72 which in turn prevents closure of flapper closure plate 78 , thereby locking out safety valve 50 . In addition, flow passageway 150 of insert 148 allow for the communication of hydraulic fluid from longitudinal bore 60 to the interior of safety valve 50 which can be used, for example, to operate a wireline retrievable subsurface safety valve that is inserted into locked out safety valve 50 .
[0055] Referring now to FIGS. 10 A- 10 C, therein is depicted cross sectional views of successive axial sections a lock out and communication tool embodying principles of the present invention that is representatively illustrated and generally designated 200 . The communication tool portion of lock out and communication tool 200 has an outer housing 202 . Outer housing 202 has an upper subassembly 204 that has a radially reduced interior section 206 . Outer housing 202 also has a key retainer subassembly 208 including windows 210 and a set of axial locating keys 212 . In addition, outer housing 202 has a lower housing subassembly 214 .
[0056] Slidably disposed within outer housing 202 is upper mandrel 216 that is securably coupled to expander mandrel 218 by attachment members 220 . Upper mandrel 216 carries a plurality of dogs 222 . Partially disposed and slidably received within upper mandrel 216 is a fish neck 224 including a fish neck mandrel 226 and a fish neck mandrel extension 228 . Partially disposed and slidably received within fish neck mandrel 226 and fish neck mandrel extension 228 is a punch rod 230 . Punch rod 230 extends down through lock out and communication tool 200 and is partially disposed and selectively slidably received within main mandrel 232 and main mandrel extension 260 of the lock out portion of lock out and communication tool 200 .
[0057] Punch rod 230 and main mandrel 232 are initially fixed relative to one another by shear pin 234 . Main mandrel 232 is also initially fixed relative to lower housing subassembly 214 of outer housing 202 by shear pins 236 . Shear pins 236 not only prevent relative axial movement between main mandrel 232 and lower housing subassembly 214 but also prevent relative rotation between main mandrel 232 and lower housing subassembly 214 . A torsional load is initially carried between main mandrel 232 and lower housing subassembly 214 . This torsional load is created by spiral wound torsion spring 238 .
[0058] Attached to main mandrel 232 is a circumferential locating key 240 on the upper end of collet spring 242 . Circumferential locating key 240 includes a retaining pin 244 that limits the outward radial movement of circumferential locating key 240 from main mandrel 232 . Disposed within main mandrel 232 is a carrier 246 that has an insert 248 on the outer surface thereof. Insert 248 includes an internal fluid passageway 250 . Carrier 246 and insert 248 are radially extendable through window 222 of main mandrel 232 . Main mandrel 232 is threadedly attached to main mandrel extension 260 . In the illustrated embodiment, the lock out portion of lock out and communication tool 200 also includes a lug 262 with contacts upper shoulder 74 , a telescoping section 264 and a ratchet section 266 . In addition, a piston the lock out portion of lock out and communication tool 200 includes a dimpling member 268 that is radially extendable through a window 270 .
[0059] In operation, as lock out and communication tool 200 is positioned within the longitudinal central bore of safety valve 50 as described above with reference to tool 100 , flapper closure plate 78 is operated from the closed position, see FIGS. 2 A- 2 B, to the fully open position, see FIGS. 3 A- 3 B. Lock out and communication tool 200 moves downwardly relative to outer housing 52 of safety valve 50 until axial locating keys 212 of lock out and communication tool 200 engage profile 62 of safety valve 50 and are locked therein.
[0060] In this locked configuration of lock out and communication tool 200 , shears pins 236 may be sheared in response to downward jarring which allows punch rod 230 and main mandrel 232 to move axially downwardly relative to housing 202 and expander mandrel 218 of lock out and communication tool 200 and safety valve 50 . As explained above, this downward movement axially aligns carrier 246 and insert 248 with radially reduced area 64 . In addition, circumferential locating key 240 is both axially and circumferentially aligned with pocket 66 of safety valve 50 .
[0061] By axially and circumferentially aligning circumferential locating key 240 with pocket 66 , carrier 246 and insert 248 become axially and circumferentially aligned with longitudinal bore 60 of safety valve 50 such that additional downward jarring on lock out and communication tool 200 of a sufficient and predetermined force shears pin 234 which allow punch rod 230 to move downwardly relative to main mandrel 232 and main mandrel extension 260 . As punch rod 230 move downwardly, insert 248 penetrates radially reduced region 64 of safety valve 50 . Further travel of punch rod 230 downwardly relative to main mandrel 232 and main mandrel extension 260 causes dimpling member 268 to contact and form a dimple in the inner wall of safety valve 50 which prevents upward travel of piston 68 after lock out and communication tool 200 is retrieved from safety valve 50 .
[0062] The unique interaction of lock out and communication tool 200 of the present invention with safety valve 50 of the present invention thus allow for the locking out of a rod piston operated safety valve and for the communication of its hydraulic fluid to operate, for example, an insert valve.
[0063] While this invention has been described with a reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments. | A communication tool ( 100 ) for communicating hydraulic fluid through a tubing retrievable safety valve ( 50 ) is disclosed. The tool ( 100 ) has a first section ( 102 ) and a second section ( 132 ) that are initially coupled together. A set of axial locating keys ( 112 ) is operably attached to the first section ( 102 ) and is engagably positionable within a profile ( 62 ). A radial cutting device ( 148 ) is radially extendable through a window ( 152 ) of the second section ( 132 ). A circumferential locating key ( 140 ) is operably attached to the second section ( 132 ) and is engagably positionable within a pocket ( 66 ) of the safety valve ( 50 ) when the first and second sections ( 102, 132 ) are decoupled, thereby circumferentially aligning the radial cutting device ( 148 ) with the non annular hydraulic chamber ( 60 ). | 4 |
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FIELD OF THE INVENTION
[0002] The present invention is a method of purchasing where a person is looking to purchase normally in a local area around him, and is looking for special cost products such as blow out items and or clearance items or better price items of the same manufacturer or supplier.
BACKGROUND OF THE INVENTION
[0003] normally a consumer looking the purchase best cost items has to physically travel to the stores and retail places or make phone calls and ask specials for a given item from the retailer.
[0004] Meanwhile sometimes retailers have overstock or old items that are willing to sell for lower price, on line sales are increasing due to convenient and availability therefore more and more people are looking to purchase with more convenience and better cost.
[0005] with the advent of mobile communication devices and their capabilities, a buyer could track their selected items cost thru several retailers or simply check the availability an item or even find a deal on a product or service that he wants to take advantage of a special buy thru a retailer. But often the buyer is not aware of immediate availability of goods and the seller has no way to show the buyer what is available in the retail store unless the buyer physically travels to the store and become aware of the items for special cost.
[0006] A need therefore exists for the seller to show his inventory of goods and their costs to buyer and the buyer needs to see the items without making a special trip or phone call to the retailer. Often if a buyer becomes aware of a special on a goods or services even if not immediate needs for the item, They will make a purchase for future use. But the buyer need to have a convenient way to shop without using a computer to log on and preferably wireless mobile device that could track his location and provide to him the most convenient retailer to purchase from.
SUMMARY OF THE INVENTION
[0007] to resolve the problem of not being aware and not knowing availability of certain goods at the retailer of services or goods we provide a mobile device application with capability of checking the sellers items for sale directly from the seller, which is signed up by a third party to have an electronic media for posting the sellers items wanting to sell. The buyer accesses the electronic media and if satisfy purchase the item and have the seller to reserve the item for the buyer for pick up.
[0008] Although there are several embodiment that could present the invention we will present 4 sample embodiments:
[0009] FIG. 1 is one of the possible embodiment of the present invention, a seller posts their goods, a buyer purchases the goods the seller assigns a third party to administrate the transaction and accept the fund. The third party accepts the funds from a buyer and pays a percentage of the funds to the seller, and after the transaction is complete, the buyer meets the seller and receives the goods from a pick up location.
[0010] FIG. 2 In another embodiment, after all transactions, the 3 rd party pays for local sales and used taxes automatically.
[0011] In another embodiment, the seller gets total amount of the transaction and a software available to the seller will automatically sends a percentage of the transaction to a third party.
[0012] In another embodiment of the present invention the seller gets total amount of the transaction and, a software available to the seller will automatically sends a percentage of the transaction to a third party and another percentage to the local sales and used tax.
[0013] Above features of the current invention make it clear that the invention has a strong merit and is useful as well as novel, makes the economy between buyer an sellers move faster and create wealth for retailers that often have certain inventory that could be sold and become useful for a buyer. Meanwhile make shopping faster and more convenient between the buyers and the sellers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a block diagram of one embodiment of present invention.
[0015] FIG. 2 is a block diagram of another embodiment of the present invention.
[0016] FIG. 3 is a block diagram of another embodiment of the present invention.
[0017] FIG. 4 is a block diagram of another embodiment of present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The Block diagram of one embodiment FIG. 1 of present invention represent a seller ( 100 ) that has capability of posted items ( 101 ) wanting to sell on their electronic media platform which then interfaces with a interface ( 102 ) system that inputs this data into third party ( 105 ) that makes it visual and transaction able for purchasing. A buyer ( 104 ) then views the items using a mobile device application ( 103 ) that also interfaces with an interface ( 102 ) system that is also inputs data into a third party ( 105 ) which makes it transaction able.
[0019] The third party ( 105 ) facilitates the purchase transaction ( 107 ) and divides the fund that is received, then transfers funds to a third party percentage fund ( 108 ) and seller percentage fund ( 106 ). After the funds transferred, the seller ( 100 ) and the buyer ( 104 ) get prompt by interface ( 102 ) system. The seller ( 100 ) goes to a pick up location ( 109 ) which is normally at the seller ( 100 ) location; the buyer ( 104 ) goes to pick up location ( 109 ) to receive the items that is purchased by the buyer ( 104 ). The Transaction complete ( 110 )
[0020] The Block diagram of one embodiment FIG. 2 of present invention represent a seller ( 100 ) that has capability of posted items ( 101 ) wanting to sell on their electronic media platform which then interfaces with a interface ( 102 ) system that inputs this data into third party ( 105 ) that makes it visual and transaction able for purchasing. A buyer ( 104 ) then views the items using a mobile device application ( 103 ) that also interfaces with an interface ( 102 ) system that is also inputs data into a third party ( 105 ) which makes it transaction able.
[0021] The third party ( 105 ) facilitates the purchase transaction ( 107 ) and divides the funds that is received, then transfers funds to a third party percentage fund ( 108 ) and to 4 th party percentage fund ( 111 ) as well as seller percentage fund ( 106 ). After the funds transferred, the seller ( 100 ) and the buyer ( 104 ) get prompt by interface ( 102 ) system. The seller ( 100 ) goes to a pick up location ( 109 ) which is normally at the seller ( 100 ) location; the buyer ( 104 ) goes to pick up location ( 109 ) to receive the items that is purchased by the buyer ( 104 ). The Transaction complete ( 110 )
[0022] The block diagram form embodiment FIG. 3 of present invention represents a seller ( 202 ) being able to get an item posted ( 203 ) and interfaces with an interface ( 204 ) system that facilitates a purchase transactions ( 201 ) the buyer ( 206 ) accesses the seller ( 202 ) of the posted item ( 203 ) thru the mobile device application ( 205 ) and purchases the posted item ( 203 ) the interface ( 204 ) system facilitates the purchase transaction ( 201 ) and access 100% of the funds from a buyer ( 206 ) thru a mobile device application ( 205 ) that interfaces with the interface ( 204 ) system. The seller ( 202 ) receives 100% funds ( 200 ) and facilitates to transfer a third party percentage fund ( 207 ) and a third party ( 208 ) authorizes thru a third party authorized for pick up ( 209 ) then the seller ( 202 ) and the buyer ( 206 ) go to a pick up location which is preferably the same location as the seller ( 200 ) then the transaction completes ( 211 )
[0023] The block diagram form embodiment FIG. 3 of present invention represents a seller ( 202 ) being able to get an item posted ( 203 ) and interfaces with an interface ( 204 ) system that facilitates a purchase transactions ( 201 ) the buyer ( 206 ) accesses the seller ( 202 ) of the posted item ( 203 ) thru the mobile device application ( 205 ) and purchases the posted item ( 203 ) the interface ( 204 ) system facilitates the purchase transaction ( 201 ) and access 100% of the funds from a buyer ( 206 ) thru a mobile device application ( 205 ) that interfaces with the interface ( 204 ) system. The seller ( 202 ) receives 100% funds ( 200 ) and facilitates to transfer a third party percentage fund ( 207 ) and a 4 th party ( 212 ) and a third party ( 208 ) authorizes thru a third party authorized for pick up ( 209 ) then the seller ( 202 ) and the buyer ( 206 ) go to a pick up location which is preferably the same location as the seller ( 200 ) then the transaction completes ( 211 )
[0024] While the present invention has been described above with respect to 4 embodiments, the scope of the invention is not deemed limited to the above embodiments. Rather, the present invention covers all embodiments falling within the scope and spirit of the following claims as well as equivalent arrangements thereof. | A Method of consumer shopping where the consumer could use a Mobile device that is equipped with pin locator where the merchants could sell their goods or services thru a direct communication to a buyer of their goods and services using the capabilities of an additional software or hardware or both added to their mobile device. | 6 |
BACKGROUND OF THE INVENTION
This invention is related to the measurement of bottom hole pressures in deep bore holes in the earth. More particularly, this invention relates to the apparatus and method for filling a conventional type of Bourdon tube pressure measuring instrument with a fluid for communicating well fluid pressure to the Bourdon tube to enable the Bourdon tube to measure well fluid pressures at high temperatures.
It is well known in the art to use a Bourdon tube enclosed in a tubular housing for measuring bottom hole pressures in deep bore holes in the earth. A typical pressure measuring instrument comprises three separate sections. One section includes a recording device in which a sharp jeweled stylus scratches a line trace on the surface of a cylindrical sheet to make a record of the sensed pressure as a function of time. The second section is a pressure sensing section which generally includes a long helically wound Bourdon tube of many terms anchored at its bottom end and fastened to the recording stylus at the upper end. Pressure changes in the hydraulic fluid inside the Bourdon tube cause the upper end to rotate with respect to the fixed bottom end and, therefore, to rotate the stylus against the recording chart. A clock driven mechanism in the recording section moves the chart longitudinally so that a continuous curve is drawn of the pressure as a function of time. The third section of the instrument is devoted to means for contacting the well fluids and transmitting the pressure of the well fluids to the hydraulic liquid in the Bourdon tube. U.S. Pat. No. 3,744,307 to Harper, et al. describes a typical prior art Bourdon tube sensors for use in deep bore holes.
One method of transmitting well fluid pressure to the hydraulic liquid in the Bourdon tube is to contact the well fluids with an extensible bellows, the interior of which is filled with a clean hydraulic liquid and placed in fluid communication with the Bourdon tube. The outside of the bellows contacts the well fluids so that pressure of the well fluid is communicated to the Bourdon tube through the bellows and enclosed hydraulic liquid.
Standard Bourdon tube assembly ordinarily are filled with a liquid such as triethylene glycol, which outgasses at temperatures above 350 degrees Fahrenheit. Outgassing of the liquid in the Bourdon tube seriously degrades instrument accuracy so that it is difficult to obtain meaningful pressure measurements in well bores having ambient temperatures above 350 degrees Fahrenheit. If a bellows is used to transmit well fluid pressures to the Bourdon tube, outgassing of the fluid causes the bellows to expand; and if the temperature is sufficiently high, outgassing of the fluid will rupture the bellows.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and a method for filling a Bourdon tube with a fluid that, under proper conditions, exhibits no appreciable outgassing at temperatures up to approximately 750 degrees Fahrenheit. The invention includes the use of a liquid having a high boiling point in an ordinary Bourdon tube. A suitable hydraulic liquid is a form of modified terphenyl sold by Monsanto Industrial Chemical Company under the trademarks Therminol 66 and Santotherm Heat Transfer Fluids. The thermal expansion of the liquid is directly proportional to the volume thereof. The preferred hydraulic fluid does not begin to bubble until it is heated to approximately 625 degrees Fahrenheit. Because of initial outgassing, the fluid must be placed under a vacuum at about 300 degrees Fahrenheit before it is usable to provide an instrument of the desired accuracy over the temperature ranges encountered in deep bores. This invention provides a filling device and method for ensuring that the fluid is sufficiently outgassed before it is put into the Bourdon tube. The invention heats and evacuates the fluid and Bourdon tube simultaneously while maintaining a barrier of cool fluid over the heated fluid to prevent is exposure to oxygen, thereby reducing oxidation of the fluid.
The invention includes a bellows arrangement having a fill port that is sealed with a fill plug when the instrument is in use. The fill plug is ordinarily threadedly engaged in a cap that encloses one end of the bellows. Before filling, the length of the bellows is reduced by mechanical compression from a length of about 51/4 inches, a standard bellows length, to about 33/4 inches. The bellows includes a center post that serves as a guide for the bellows and which fills a portion of the volume thereof. The centerpost is formed of a material such as stainless steel, which experiences negligible outgassing at temperatures of up to about 750 degrees Fahrenheit. In order to fill the Bourdon tube, the plug is removed and the filling device is then threadedly engaged in the fill port. The filling device includes a hot reservoir which contains a supply of the hydraulic fluid adjacent the fill port. A valve in the filling device controls fluid flow through a passage between the filling device and the bellows. The hot reservoir preferably contains a supply of the hydraulic fluid sufficient to fill the Bourdon tube and the bellows. A vacuum line is connected to the cold reservoir above the level of the hydraulic fluid in the cold reservoir to outgas the hydraulic fluid and to evacuate the bellows and Bourdon tube. A heating shield is connected to the filling apparatus between the cold and hot reservoirs to form an air space around the hot reservoir, the bellows and the Bourdon tube. The air space is heated to facilitate outgassing of the fluid and to remove impurities from the Bourdon tube and bellows. After the outgassing of the hydraulic fluid and the heating of the Bourdon tube and bellows have been accomplished, the vacuum is removed while the valve in the hot reservoir is open to allow the fluid to flow into the bellows and Bourdon tube. After the Bourdon tube is filled, the filling apparatus is removed from the fill port, which is then plugged to prevent leakage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a Bourdon tube and bellows assembly for measuring pressures in a well bore; and
FIG. 2 is a partial cross-sectional view illustrating apparatus used to fill the bellows and Bourdon tube of FIG. 1 with an outgassed fluid.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a typical temperature measuring instrument 10 includes a helically wound Bourdon tube 12 having a closed end 14 and an open end 16, which is in fluid communication with a bellows 18 through a shield connector 20. The shield connector 20 is of a generally hollow elongate cylindrical construction having external threads at each end for connection to other apparatus (not shown) used in connection with the bellows 18 and Bourdon tube 12.
A solid rod, or center post 22 placed in the shield connector 20 extends into the bellows 18. The center post 22 serves as a guide for the bellows 18 and fills part of the space therein to reduce the amount of fluid required to fill the bellows 18 and the shield connector 20. The center post 22 is preferably formed of stainless steel to prevent outgassing in the temperature range of interest, which includes wellbore temperatures of up to 750 degrees Fahrenheit.
The bellows 18 terminates in a cap 24, which has a longitudinal passage 26 therethrough. The cap 24 also includes a fill port 28 which is in fluid communication with the passage 26. A plut 30 seals the fill port 28 when the instrument for the measuring apparatus 10 is filled with a working fluid or is in use.
When the pressure measuring apparatus 10 is in use, the well fluid pressure is applied to the cap 24, which transmits the pressure to the working fluid in the Bourdon tube 12. Increasing the fluid pressure in the Bourdon tube causes the tube 12 to unwind and drive a stylus (not shown) connected to the closed end 14 from an equilibrium position at ambient atmospheric pressure to indicate the pressure in the well bore.
It has been found that accurate pressure measurements at high temperature require the use of a working fluid which does not boil or experience appreciable outgassing at the temperature in the well bore. In order to assure the desired accuracy of pressure measurement, the working fluid must not boil or outgas over temperatures ranging from ambient atmospheric temperatures up to about 750 degrees Fahrenheit. The inventor has found that a high performance heat transfer fluid, which is a modified terphenyl sold by Monsanto Industrial Chemical Company under the trademarks Therminol 66 and Santotherm Heat Transfer Fluids is a particularly suitable working fluid for pressure measurements at high temperatures. Although Therminol 66 is a preferred working fluid for high temperature, high pressure applications, any substance having the essential outgassing and temperature-pressure-volume characteristics discussed herein is satisfactory.
Therminol 66 is an essentially colorless, oily liquid having a faint characteristic oder. The substance has a pour point of -18 degrees Fahrenheit, a thermal expansion that is essentially linear, a density at 75 degrees Fahrenheit of about 8.35 pounds per gallon, a flash point of 355 degrees Fahrenheit, or 180 degrees Celsius, a fire point of 382 degrees Fahrenheit, or 194 degrees Celsius and a boiling point of approximately 625 degrees Fahrenheit at atmospheric pressure. The substance is virtually non-toxic and non-irritating, posing no special handling problems. It is not absorbed through the unbroken skin in significant quantities, and is non-irritating to the skin and is only mildly irritating if eye contact occurs. Therefore, under ordinary conditions there are no special handling procedures that must be observed with the working fluid. At room temperatures, there is no vapor exposure problem when transferring the fluid from a shipping container into the filling apparatus 32 of the present invention. However, vapors emitted at high temperatures may be mildly irritating under prolonged exposure. In the present invention, the working substance is maintained in essentially leak-free containers so that there should be little or no opportunity for workers to come in contact with vapors.
Referring to FIG. 2, a filling mechanism 32 has a projection 34 threadedly engaged in the fill port 28. The filling apparatus 32 includes a hot reservoir 38 from which the projection 34 extends, a cold reservoir 40 in fluid communication with the hot reservoir 38 through a neck 42 and a heater shield 44 connected to the neck 42. The heater shield 44 may conveniently be of a generally cylindrical configuration having length and diameter sufficient to enclose the Bourdon tube 12, the shield connector 20, the bellows 18, the hot reservoir 38, and a portion of the neck 42. The hot reservoir 38, the bourdon tube and the bellows 18 are placed in a heater chamber 51.
The hot reservoir 38 and the neck 42 are preferably formed of a suitable metal such as stainless steel that is capable of withstanding temperatures up to at least 300 degrees Fahrenheit. The cold reservoir 40 preferably includes a bottom surface 41 formed of the same material as the hot reservoir 38 and the neck 42. The bottom surface 41 preferably has a threaded lip 43 extending perpendicularly therefrom; and a threaded, generally cylindrical portion 45 is mounted upon the lip 43. The cylindrical portion 45 is preferably formed of a transparent plastic substance to permit visual monitoring of the level 47 of working fluid in the filling apparatus 32. The heater shield 44 is preferably formed of the same metal as the neck 42 and may be conveniently connected thereto by a weldment 49. The heater shield 44 serves to prevent appreciable heat transfer from the heater chamber 52 to the plastic portion 45.
The cold reservoir 40 may also conveniently be of a generally cylindrical configuration. The cold reservoir 40 has an end 46 that is covered by a cap 48 and a vacuum outlet 50 from which a vacuum line 52 extends. An elongate rod 54 having a conical end 56 extends through a passage 58 in the cap 48 so that the conical end 56 is adjacent a correspondingly shaped recess 60 of the inside of the projection 34. The passage 58 through the cap 48 is preferably threaded and a portion of the rod 54 is also threaded so that rotation of the rod 54 selectively engages or disengages the conical end 56 of the rod 54 with the conical recess 60 in the projection 34. The conical projection 56 on the rod 54 and the conical recess 60 in the plug 34 cooperate to function as a valve 61 so that rotating the rod 54 a sufficient distance to seat the conical projection 56 in the recess 60 prevents fluid flow from the hot reservoir 38 into the passage 26 and thus into the bellows 18 and the Bourdon tube 12.
The rod 54 has an end 62 projecting out of the cap 48. The end 62 preferably has a knob 64 mounted thereto to facilitate rotation of the rod 54 to selectively seat or unseat the conical projection 56 in the recess 60.
When the filling apparatus 32 is used to fill the bellows 18 and the Bourdon tube 12, the projection 34 may be first threadedly engaged in the fill port 24 and the rod 54 is rotated so that the conical projection 56 engages the recess 60 to seal the opening 28 into the projection 34. The working fluid for filling the bellows 18 and Bourdon tube 12 is put into the cold reservoir 40 so that the level 47 of the fluid is below that of the vacuum as seen through the cylindrical portion 25. The working fluid completely fills the hot reservoir 38 and the neck 42. The working fluid may be conveniently supplied to the cold reservoir through the vacuum inlet 50 before connection of a vacuum pump (not shown) thereto.
After the desired amount of working fluid is inserted into the filling apparatus 32, the vacuum line 32 is connected to a pumping apparatus (not shown), which evacuates the bellows 18 and the Bourdon tube 12, which causes the bellows 18 to contract somewhat. The valve 61 is open so that the vacuum is applied to the bellows 18 and the Bourdon tube 12. The Bourdon tube 12, the bellows 18, the hot reservoir 38 and the heat shield remain in a heated air chamber (not shown) for about 20 minutes or more at a temperature of approximately 300 degrees Farenheit under vacuum to evacuate the bellows 18 and Bourdon tube 12 and to outgas the fluid in the hot reservoir 38. Heating the working fluid under vacuum causes the fluid to be sufficiently outgassed to provide the desired accuracy in pressure measurements. Maintaining a long fluid passage, such as the neck 42, between the hot reservoir 38 and the cold reservoir 40 causes a cover of relatively cold filling fluid to be maintained above the hot fluid, thereby preventing oxidation of the heated fluid.
The vacuum prevents the heated fluid from flowing into the bellows 18 and Bourdon tube 12. After the heated fluid has been sufficiently outgassed, the vacuum is turned off, and the fluid is allowed to flow into the bellows 18 and Bourdon tube 12. Once the bellows 18 and Bourdon tube 12 have been filled, the assembly is removed from the hot chamber, and the filling assembly 32 is disconnected from the fill port 28 of the bellows 18, and the plug 30 is inserted into the fill port 28 to seal the outgassed working fluid in the Bourdon tube 12 and bellows 18.
A preferred detailed procedure for filling the bellows 18 and Bourdon tube 12 with the working fluid is described below. It is to be understood that those skilled in the art might follow a different sequence of steps and might place some steps with other equivalent steps.
The length of a standard bellows is reduced by mechanical compression by use of a conventional vise or the like (not shown) from a typical valve of about 51/4 to 33/4 inches. The combination of the compression of the bellows 18 and inclusion of the center post 22 therein reduces the volume of a typical bellows by about fifty percent from 27.25 cc to about 14 cc. Over the temperature range of interest, the bellows 18 has a length expansion of about one inch. Even though the total volume of the system including the Bourdon tube 12 and the bellows 18 varies with the specific gauge and pressure range, the filling 10 apparatus and method provide acceptable expansion in all pressure ranges typically encountered in wellbore pressure measurement applications.
The air bath is heated to approximately 300 degrees Farenheit. The filling assembly 32 should be dimensioned so that if it is filled approximately one-third full with the working fluid, preferably Therminol 66 as explained above, the filling assembly 32 will contain sufficient fluid to fill the bellows 18 and Bourdon tube 12. When the filling assembly 32 has required amount of working fluid therein, the projection 34 is threadedly engaged in the fill port 28 with the valve 61 being closed. With the vacuum pump power being off, a suitable hose (not shown) is connected between the vacuum line 52 and the vacuum pump. After connecting the vacuum line 52 to the vacuum pump, the knob 64 is turned a sufficient amount, such as five full turns to open the valve 61. The vacuum pump is then turned on and allowed to remain on until a vacuum of 25 inches of mercury is achieved in the filling apparatus. After the desired vacuum is obtained, the vacuum pump is turned off for five to ten seconds or until the filling fluid ceases to bubble. After the bubbling has ceased, the vacuum pump is turned on until a vacuum of approximately 28 inches of mercury is achieved, after which the vacuum pump is turned off again for 5-10 seconds. The vacuum pump is then reactivated until the vacuum reaches 30 inches of mercury, at which time the vacuum pump is turned off until the bubbling subsides. The vacuum pump is then turned on and the filling apparatus is evacuated for five minutes while approximately once each minute the bellows is extended by about 0.5 inch and moved with a slight rotary motion. After the 5 minute evacuation period, the vacuum hose should be removed for approximately 30 seconds and then replaced for about 2 minutes while the bellows is extended and rotated slightly.
The vacuum hose should then be removed after the 2 minute period and the filling apparatus 32 with the bellows 18 attached thereto placed into a 300 degree Fahrenheit air bath for about 20 minutes. After the filling apparatus 32 is removed from the air bath, the system is again evacuated for about 10 minutes while pulling, rotating, and tapping on the Bourdon tube 12.
After the 10 minute evacuation period, the vacuum should be removed for approximately 30 seconds and then replaced for another 10 minutes while the assembly is allowed to remain stationary. After the second 10 minute evacuation period, the vacuum hose should be removed from the vacuum line 52 and the entire filling apparatus 32, bellows 18, and Bourdon tube 12 should be cooled with water. All water should be blown away from the fill port 26 before the projection 34 is disengaged therefrom.
With the Bourdon tube 12 being held in a vise or other suitable apparatus, the bellows 18 should be disconnected from the filling apparatus 32. The bellows 18 should then be held at a predetermined length and the plug 30 should be secured in the fill port 26 with a suitable washer (not shown), if necessary, being positioned between the bellows cap 24 and the plug 30.
The bellows 18 and the Bourdon tube 12 when filled as described herein may be used to measure well bore pressures at temperatures of up to 600 degrees Fahrenheit without special precautions. If pressures of 500 psi or more are maintained on the bellows 18 and Bourdon tube 12 while the temperature exceeds 600 degrees Fahrenheit, they may be used for pressure measurements at temperatures up to 750 degrees Fahrenheit.
Although the present invention has been described with reference to particular apparatus and process steps, it will be understood by those skilled in the art that numerous modifications may be made without departing from the scope and spirit of the invention. Accordingly, all modifications and equivalents which are properly within the scope of the appended claims are included in the present invention.
INDUSTRIAL APPLICATION
The present invention has application wherein it is necessary to fill a container, tube, or other enclosed volume with an outgassed fluid. The present invention is particularly useful in preparing Bourdon pressure gauges for use in pressure measurements in deep well bores. | This invention relates to apparatus and methods for filling a conventional Bourdon tube with an outgassed fluid to permit use of the Bourdon tube to measure fluid pressures at high temperatures. The filling device includes a hot reservoir containing hydraulic fluid that has been heated to facilitate outgassing and a cold reservoir in fluid communication with the hot reservoir to prevent exposure of the fluid in the hot reservoir to oxygen. A vacuum line connected to the cold reservoir permits evacuation of the filling apparatus, the Bourdon tube and a typical bellows that may be attached to the Bourdon tube. The bellows is mechanically compressed and provided with a center post to reduce the volume of the bellows by about fifty percent. After the Bourdon tube, the bellows and the hydraulic fluid in the hot reservoir have been heated and outgassed, the vacuum is removed from the cold reservoir to permit hydraulic fluid to flow from the hot reservoir into the bellows and Bourdon tube. After the Bourdon tube and bellows are filled, the filling apparatus is disconnected from the fill port, which is then plugged to prevent leakage. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
The invention of this application is an improvement on those of copending applications for patent, Ser. No. 370,656 filed June 18, 1973 by James W. Messerly, Joe A. Powell, and Ronald L. Shippy; and Ser. No. 594,845 filed July 9, 1975, a continuation of Ser. No. 410,695 filed Oct. 29, 1973 by James W. Messerly and Joe A. Powell and now abandoned.
BACKGROUND OF THE INVENTION
The applications for patent identified above describe the use of certain solid lubricants to perform either or both of two important functions. One such function is to seal punctures, particularly when the solid lubricants are present as coatings on a closed cell cellular rubber layer on the inside of the tire. The other function is to prevent destructive friction and thereby minimize or prevent injury to a tire in the event of loss of air and operation with the tire flat. The principal object of this invention is to provide a tire with an improved lubricant for performing either or both of the functions just mentioned.
SUMMARY OF THE INVENTION
We have discovered that a mixture of certain kinds of synthetic hydrocarbons, having molecular weights within a particular range and certain other specific physical properties, with other synthetic or natural hydrocarbon materials of a different particular kind, will have the exact properties necessary for effective functioning for the desired purposes when applied to the inner surface of pneumatic tires. The mixture is required to be a nonflowable but flexible solid at ordinary atmospheric temperatures but to be an extremely viscous liquid at normal operating temperatures of tires. It is required also to be permanently adherent to the rubber material at the inside surface of the tire and to be free from hardening such as would cause it to crack or flake off of the surface. In order to perform the function of sealing punctures, the composition should also be capable of swelling the material which is at the internal surface of the tire and which is usually made from a vulcanized composition consisting in large part of butyl rubber.
We have not found any single material which satisfactorily meets all of these requirements, but we have found that these requirements can all be met by preparing a blend of two or more different hydrocarbon materials, or materials which are chemically neutral and have the essential properties of hydrocarbons even though some atoms other than hydrogen and carbon may be present.
One of the materials must be a synthetic hydrocarbon polymer which is partially crystalline and which will melt at the temperature normally existing on the inner surface of a operating pneumatic passenger tire, but which is at least in part of such a character as to congeal as by partial crystallization to a soft, waxy solid at ordinary atmospheric temperatures. These properties are exhibited by hydrocarbon polymers of regular and essentially linear structure and moderate molecular weight in the range of about 1000 to 5000 and having melting or softening temperatures of about 75° to 110° C (165° to 230° F).
The other material which is mixed with the crystallizable polymer to produce the composition of this invention must be a material of sufficiently high molecular weight as not to flow noticeably at ordinary temperatures but which is essentially free from any tendency to crystallize at ordinary atmospheric temperatures and which permanently exhibits a tacky consistency permitting it to adhere and to remain in place on surfaces of other materials. It is preferably also a synthetic hydrocarbon polymer, but may be a suitable natural material of generally hydrocarbon character such as a heavy neutral petroleum oil. These properties are exhibited by materials consisting of molecules of generally high but quite variable molecular weight and irregular molecular structure. Thus the average molecular weights may be from about 1000 to 10,000 but the individual molecules may have molecular weights from a few hundred to over a hundred thousand. The molecular structure, too, is preferably rather irregular, and may include side chains, branches, and rings, and sometimes even some hetero atoms such as oxygen in hydroxyl or ether form.
We have discovered that neither of these two ingredients will perform satisfactorily by itself but that they will do so when mixed in suitable proportions.
The crystallizable or solid ingredient by itself will harden sufficiently to crack and flake off of the inner surface of the tire so that the handling of new tires in storage at normal low temperatures can cause loss of the material from the tires. A secondary consequence is extremely objectionable soiling of floors and handling equipment.
The noncrystallizable component by itself is not sufficiently solid to remain in the location to which it is applied. It can therefore flow to the bottom of a tire which has become heated in service and is then cooled in a stationary position, so that the concentration of material in one location will result in serious unbalance of the tire. Moreover, the noncrystallizable component is not sufficiently solid to be capable of functioning with reasonable reliability as a puncture sealant.
While neither of the ingredients alone is completely satisfactory, we have found that remarkably good performance is obtained when they are used in admixture in proper proportions. The proportions of the two ingredients required to obtain the desired results will necessarily vary somewhat with the choice of particular constituent materials.
The higher the molecular weight of the crystallizable ingredient, and the greater its crystallinity, the less of it will be required. Similarly, the molecular weight of the noncrystallizable ingredient will determine to some extent the proportion which can be used without causing excessive flow when the temperature of the tire is high. These two ingredients are obtainable in many different grades made from various raw materials in different ways.
They may each be made from olefins singly or mixed and polymerized in various ways using a variety of catalysts to produce polymers varying not only in molecular weight but also in molecular structure. Thus varying degrees of branching or cyclization may occur and, in addition, when made from olefin monomers which contain three or more carbon atoms a variety of molecular structures are possible such as atactic or syndiotactic or isotactic arrangements of the side chains, and with olefinic raw materials having more than three carbon atoms an even greater variety of structures is possible.
We have found that the suitability of materials for use in this invention is not dependent primarily on the particular base material from which each one is produced, but rather on fairly easily measured physical properties. We prefer to use mixtures of a partially crystallizable polyethylene with either atactic low molecular weight polypropylene or low molecular weight polyisobutylene, but polymers made from other olefins or mixtures of olefins may be used provided the requirements as to physical properties of the components are met, and the proportions are chosen so as to provide the required physical properties in the product.
The physical requirements for highway tires in passenger car sizes are essentially that the blend of hydrocarbon materials be free from brittleness at low winter temperatures, free from flow at temperatures somewhat above high summer temperatures, yet be semiliquid at normal operating temperatures of the tires, and be completely fusible at somewhat higher temperatures for convenient application in a molten condition. Preferably, the composition should remain flexible down to about -35° C (-30° F) and remain nonflowable up to 90° C (195° F), although a narrower range from about 0° C (32° F) at the low end may be satisfactory under some conditions, and to about 65° C (150° F) at the high end may be satisfactory in a mild climate or under only moderately severe service conditions. In any event, the compositions should fuse to a liquid of a viscosity suitable for brushing or spraying at a temperature not over about 115° to 130° C (240° to 265° F). In addition, the compositions should exhibit a distinct tack over all or at least the greater part of the range of service temperatures so that they will cling to the inner surface of the tire and remain in the position in which originally placed. These requirements are met by the compositions described below.
THE DRAWINGS
In the accompanying drawings,
FIG. 1 is a sectional view of a pneumatic passenger car tire, and
FIG. 2 is a partial section of the crown or tread portion of an enlarged scale.
DETAILED DESCRIPTION
The compositions which have been described in general terms are intended for use in conventional pneumatic tires, which may be bias carcass tires, or belted bias carcass tires, but are preferably radial carcass tires with the nearly inextensible belts which provide the essential lateral stability. They may be tires intended for almost any kind of service, but are preferably tires intended for highway passenger automobiles. Such tires are made with relatively thin walls, but operate at rather high speeds so that internal temperatures of 30° C (54° F) above ambient temperatures are commonplace.
In the drawings, FIG. 1 is a sectional view across a radial cord tire of low aspect ratio intended for passenger automobile service. Such a tire contains inextensible wire bead grommets 10 to hold the tire in place on the bead seats of a conventional flanged rim. One or two plies of rubberized inextensible cords 11 are provided to withstand the inflation pressure and have their margins wrapped around and vulcanized to the bead grommets 10. These plies 11 extend directly transverse of the tire and therefore lie in radial planes from one bead grommet 10 along the adjacent sidewall 12, across the crown region 13, along the other sidewall 14, and around the second bead grommet 10. To provide for lateral stability and to restrict the tread diameter so as to provide the desired low aspect ratio, a nearly inextensible belt outward of the carcass plies 11 is made up of strong cords 15 extending about the tire in a circumferential direction or at a small angle to the circumferential direction. Outward of the belt cords 15 is a thick layer 16 of tread rubber which extends across the entire crown 13 merging with a thinner rubber sidewall cover 17.
On the inside of the tire is a thin layer of essentially air-impervious material such as butyl rubber or chlorinated butyl rubber functioning as a liner 18 of about 1 to 3 mm (0.04 to 0.12 inches) thickness to prevent loss of inflation air by diffusion through the tire. Under the crown portion only of the tire is provided a layer of closed cell cellular rubber 19 of a thickness comparable to that of the liner or slightly greater, up to about 5 mm (0.20 inches), for the purpose of sealing punctures. The tire so far described, except for the presence of the cellular rubber 19, is a conventional tire. With the addition of the cellular rubber 19, it is the tire described in prior application, Ser. No. 370,656, cross referenced above.
In accordance with this invention, a composition is prepared from two commercially available materials. In a specific embodiment, one of them is a particular grade of polyethylene; the other is a particular grade of polypropylene.
The polypropylene is an amorphous noncrystallizable material made by polymerizing propylene with a redox catalyst to a moderate molecular weight of about 900. This polypropylene has a softening temperature of 82° to 95° C determined by the ball and ring laboratory method, and at 190° C is a liquid with a viscosity of 49 to 90 centipoises.
The polyethylene is a grade which is a soft solid of average molecular weight between about 1000 and 5000, a density of 0.88, and which becomes liquid at 85° C. It is mostly amorphous but contains a significant proportion of crystallizable material. It is sometimes called polyolefin grease.
In this particular example 100 parts of the polypropylene are melted with 30 to 50 parts and preferably about 35 parts of the partly crystalline polyethylene and intimately mixed.
The temperature is adjusted to about 120° C and the liquid mix is forced through a spray nozzle to produce a coarse spray of about 110° included angle directed to the inner surface of the crown portion of the tire, which requires a pressure of about 6 atmospheres. The amount applied should be sufficient to produce a coating of 1 to 2 mm thickness and preferably 1.5 mm, which requires in the neighborhood of 200 grams for a medium-sized passenger automobile tire.
The composition immediately solidifies to form a smooth, soft, greasy surface on the inside of the tire, which remains flexible and tacky over the entire normal range of operating temperatures so as to retain its position unchanged. A portion of the liquid material is absorbed by the underlying rubber surface which in the preferred form of the invention is the cellular rubber material. This action contributes to the firm retention of the coating in position and also somewhat swells the rubber material, which enhances the ability of the cellular rubber to seal small punctures.
As was pointed out in the prior application, Ser. No. 370,656, a thin cellular rubber layer on the inside of a tire is very effective in sealing small punctures, particularly when coated with low molecular weight polyethylene. The puncture sealing ability is even more effective with the mixed polymers of this invention.
Moreover, as pointed out in the other prior application, Ser. No. 410,695, an internal layer of low molecular weight polyethylene is an excellent internal lubricant for preventing destructive friction when a tire becomes deflated so that the weight of the vehicle is borne by small areas of the inner surface of the tire in moving apposition. This function is also more effectively performed by the mixed polymers of this invention.
Both of these benefits are obtained either with or without the presence of the cellular rubber layer.
In the absence of a cellular rubber layer, the polymer composition of this invention, because of its softness and plasticity, is readily smeared into a small puncture to reduce or prevent further escape of air, and if the temperature is so high as to cause the polymer composition to be semi-liquid, it tends to be absorbed rapidly by the surface of the rubber so as to swell the puncture shut. In the presence of a cellular layer the puncture closing actions are enhanced and made more certain by the expansion of the compressed gas in the closed cells toward the lower pressure of the outside atmosphere.
Again in the absence of a cellular rubber layer, the new polymer composition functions as a very effective lubricant during operation of a vehicle with a flat tire, eliminating or minimizing the rubbing forces which otherwise tend to tear or shred the inner surface of the flat tire. In the presence of a cellular rubber layer, which acts as a cushion to distribute radial forces which would otherwise be concentrated in a very small area and tend to cut the tire structure, the chances of injury during operation of a vehicle on a flat tire are still further reduced.
Similar excellent results are obtained with many other specific combinations of the kind outlined above.
Thus, with the partly crystalline, low molecular weight polyethylene described above, additions of the following materials have been found to give good results. For each 100 parts of the polyethylene:
a. 35 parts poly-isobutylene of average molecular weight about 890 and density 0.890.
b. 25 parts of the poly-isobutylene and 10 parts of paraffin base partly naphthenic petroleum oil of density 0.890 pour point -10° C (+14° F) and viscosity 100 secs SUS at 38° C (100° F).
c. 13 parts of the petroleum oil used in b. above and 20 parts of rosin oil of viscosity 95 to 130 secs SUS at 99° C (210° F).
Also, a mixture of 100 parts of a partly crystallizable polypropylene which becomes fluid at 95° C (200° F) with 40 parts of the same poly-isobutylene used in a. above gives similar good results both in sealing punctures and in protection against damage when run flat. | An internal tire lubricant which minimizes or prevents injury to a pneumatic tire when it runs flat, and which also assists in sealing small punctures, consists of a mixture of liquid or easily fusible materials, one of which is a partially crystalline solid olefine polymer, and another of which is an essentially noncrystalline liquid or solid hydrocarbon or analogous material. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/530,343, filed Oct. 31, 2014, which is a continuation of U.S. application Ser. No. 13/156,529, filed Jun. 9, 2011, now U.S. Pat. No. 8,913,172, issued Dec. 16, 2014, which is a divisional of U.S. application Ser. No. 12/243,355, filed Oct. 1, 2008, now U.S. Pat. No. 8,149,315, issued Apr. 3, 2012, which claims priority to Japanese Patent Application No. 2008-155446, filed Jun. 13, 2008, Japanese Patent Application No. 2008-171276, filed Jun. 30, 2008 and Japanese Patent Application No. 2008-241660, filed Sep. 19, 2008. The entire disclosures of each of these applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an information processing apparatus and an information processing program, and more particularly, to a openable/closeable information processing apparatus and an information processing program for displaying an image on a display screen of the information processing apparatus.
[0004] 2. Description of the Background Art
[0005] Conventionally, an information processing apparatus displays images by a so-called slide show function and the like. For example, Japanese Laid-Open Patent Publication No. 2005-184108 discloses a digital camera which displays a plurality of taken images by a slide show function. In the case of reproducing a plurality of images by the slide show, the user can input a reproducing time for each image and the like. Japanese Laid-Open Patent Publication No. 2006-230340 discloses a camera with a switch by which frame-by-frame advance and return are performed for changing a taken image to be displayed. Japanese Laid-Open Patent Publication No. 11-331739 discloses a technique to change a taken image to be displayed by automatically reproducing a plurality of images in a predetermined order.
[0006] Japanese Laid-Open Patent Publication No. 11-41339 discloses a method for displaying an image of a person who a phone call is being made to as a method for displaying an image in a mobile phone. In the mobile phone, when making a phone call using a telephone book function, an image of a person who the phone call is being made to is displayed together with the telephone number and the name of the person.
[0007] As described above, an image to be displayed in the conventional arts is changed at predetermined time intervals or by a switch operation of the user, thereby lacking interest for the user.
SUMMARY OF THE INVENTION
[0008] Therefore, an object of the present invention is to provide an information processing apparatus and an information processing program which are capable of changing an image to be displayed by a novel method.
[0009] The present invention has the following features to attain the object mentioned above. It is noted that reference characters and supplementary explanations in parentheses in this section are merely provided to facilitate the understanding of the present invention in relation to the later-described embodiment, rather than limiting the scope of the present invention in any way.
[0010] A first aspect is an information processing apparatus ( 10 ) capable of being opened and closed. The information processing apparatus comprises storage means (a stored data memory 34 , a memory card 28 ), display means (a lower LCD 12 or an upper LCD 22 ), and taken image display control means (a CPU 31 executing a step S 5 and a step S 73 ; hereinafter, step numbers are merely described in this section). The storage means is means for storing a taken image therein. The display means has a display screen provided in a surface which is located inside when the information processing apparatus is closed and which is located outside when the information processing apparatus is opened. The taken image display control means is for displaying a taken image on the display screen, and changing a taken image to be displayed between before and after closing and opening the information processing apparatus when the information processing apparatus is closed and opened again.
[0011] It is noted that the phrase “capable of being opened and closed” means that the surface in which the “display screen” of the present invention is provided can be located inside (hidden by the other housing) and outside by relative movement of two housings, and a foldable type, a slide type, a rotary type, and a complex type of them can be exemplified.
[0012] Further, the “taken image” in the above is an image taken by imaging means, but in the first aspect, the information processing apparatus may not comprise imaging means. In other words, a taken image stored in the storage means may be an image taken by imaging means of another apparatus. In addition, the “taken image” may be a still image or a moving image including a plurality of images. Further, the information processing apparatus may comprise at least one display screen. In a later-described embodiment, the information processing apparatus may display a taken image on a lower LCD 12 .
[0013] According to the first aspect, a taken image to be displayed is changed by closing and opening the information processing apparatus capable of being opened and closed. In other words, since photograph data is changed when the display screen is hidden and then exposed, a taken image to be displayed can be changed by a novel method for changing a taken image to be displayed by closing and opening the information processing apparatus.
[0014] Further, the information processing apparatus may further comprise imaging means (cameras 23 and/or, 24 ). In this case, the storage means stores therein an image taken by the imaging means.
[0015] According to the above, the user can display taken images which are taken by the information processing apparatus while changing the taken images by a novel operation of closing and opening the information processing apparatus.
[0016] Further, the information processing apparatus may further comprise storing means (S 26 , S 54 ) for storing an image taken by the imaging means in the storage means in accordance with a predetermined photographing operation. In this case, when the predetermined photographing operation is performed, the taken image display control means may change the taken image to be displayed on the display screen to a taken image to be stored in the storing means (S 27 ).
[0017] According to the above, when photographing is performed (a taken image by the imaging means is stored), the image obtained by the photographing is displayed on the display screen. Thus, the user can quickly view the image obtained by the photographing, and can confirm the photographed content.
[0018] Further, when changing the taken image to be displayed between before and after closing and opening the information processing apparatus, the taken image display control means may determine a taken image after the change in accordance with a predetermined order ( FIG. 17 ). In this case, when the information processing apparatus is closed and opened again in a state where a taken image to be stored by the storing means is displayed by performing the predetermined photographing operation while a first taken image is displayed, the taken image display control means displays a second taken image which is to be displayed after the first taken image if obeying the predetermined order, as a taken image after the change, on the display screen.
[0019] According to the above, the user can confirm the photographed content, and can view the taken image, which is the continuation of the taken image which had been displayed prior to the photographing operation, by closing and opening the information processing apparatus after the photographing operation.
[0020] Further, the information processing apparatus may further comprise imaging state setting means (S 10 ) for enabling imaging by the imaging means in accordance with a predetermined operation being performed while a taken image is displayed by the taken image display control means.
[0021] According to the above, the photographing function is quickly activated by performing the predetermined operation when a taken image is displayed. In other words, in a state where the photographing function is allowed to be activated, the taken image is displayed. Thus, by displaying the taken image in the state where the photographing function is allowed to be activated, the user can be prompted to use the photographing function. Further, since the user can be made to comprehensively recognize the state where the photographing function is allowed to activated by displaying the taken image, the configuration to further comprise the imaging state setting means is particularly advantageous when the information processing apparatus has many functions in addition to the photographing function.
[0022] Further, the information processing apparatus may store a first photographing program (a simplified photographing program) for performing photographing processing of storing an image taken by the imaging means in the storage means and a second photographing program (a multifunctional photographing application) for performing the photographing processing, and the second photographing program has a function different from the first photographing program. In this case, the taken image display control means sets both a taken image stored in the storage means by execution of the first photographing program and a taken image stored in the storage means by execution of the second photographing program as objects to be displayed on the display screen.
[0023] According to the above, a taken image stored by either of two types of photographing programs can be set as an object to be displayed on the display screen. Thus, since a taken image by either photographing program can be displayed, a limitation regarding which photographing program to be used is not given to the user, and a user-friendly photographing function can be provided.
[0024] Further, the information processing apparatus may further comprise selection image display control means (S 5 ) for displaying, on the display screen or another display screen (a lower LCD 12 ) of the information processing apparatus, a selection image (a menu screen) for causing a user to select an application program to be launched from a plurality of application programs. In this case, the taken image display control means displays the taken image while displaying the selection image.
[0025] According to the above, the information processing apparatus displays a taken image in a state where a plurality of application programs are allowed to be activated. Thus, a menu screen (including the selection image and the taken image) which is uniform in the conventional arts can be different for each user, thereby providing individuality to the menu screen. Further, it is thought that the user causes the information processing apparatus to display the selection image because of user's interest that “what taken image will be displayed”, thereby prompting the user to select an application program and to use a function other than a function of displaying a taken image.
[0026] Further, when the application program is terminated, the taken image display control means may select a taken image to be displayed from taken images stored in the storage means in a random manner, and may display the taken image (S 3 ).
[0027] According to the above, a taken image is displayed when the application program is terminated. Thus, since the taken image motivates the user to continue to use the information processing apparatus even when the application program is terminated, use of the information processing apparatus can be prompted.
[0028] Further, when the information processing apparatus is started up, the taken image display control means selects a taken image to be displayed from taken images stored in the storage means in a random manner, and displays the taken image (S 3 ).
[0029] According to the above, when the information processing apparatus is started up, a taken image to be displayed is selected in a random manner. Thus, since a different taken image is displayed every time the power of the information processing apparatus is turned on, it is thought that the user turns on the power of the information processing apparatus because of user's interest that “what taken image will be displayed”, thereby prompting the user to use the information processing apparatus.
[0030] Further, when changing the taken image between before and after closing and opening the information processing apparatus, the taken image display control means may select a taken image after the change from taken images stored in the storage means in accordance with a predetermined order, and may display the taken image (S 73 , FIG. 17 ).
[0031] According to the above, taken images are sequentially changed and displayed in accordance with a predetermined order by closing and opening the information processing apparatus. Thus, the user can view a four-panel cartoon of which a graphic (a taken image) is changed every time the information processing apparatus 10 is opened, and can successionally view a series of photographs arranged in chronological order.
[0032] Further, the information processing apparatus may further comprise setting means (S 46 ) for setting, among taken images stored in the storage means, a taken image designated by a user as a candidate image. In this case, the taken image display control means selects a taken image to be displayed from a plurality of the candidate images.
[0033] According to the above, only user's favorite taken image can be set as an object to be displayed. Further, since the configuration to comprise the setting means can easily exclude taken images which the user does not want to display, it is particularly convenient when taken images are changed and displayed in accordance with a predetermined order (since it becomes easy to display taken images in user's favorite order).
[0034] Further, when there is no taken image set as the candidate image, the taken image display control means may select a taken image to be displayed on the display screen from taken images stored in the storage means (S 3 ).
[0035] According to the above, a taken image can be displayed even when no candidate image is set, thereby motivating the user to use the imaging apparatus.
[0036] Further, the information processing apparatus may further comprise sleep means (S 71 ) for, when the information processing apparatus is closed, shifting at least a part of functions of the information processing apparatus to a sleeping state or a power-saving operation state.
[0037] According to the above, a taken image is changed every return from a sleeping state or a power-saving operation state. Thus, by the taken image changed every time the information processing apparatus is closed and opened, the user can be prompted to return the information processing apparatus from a sleeping state or a power-saving operation state, and to use (open) the information processing apparatus again.
[0038] In the first aspect, in addition to the above description, the information processing apparatus may store a launch program for selectively launching an application program desired by the user among a plurality of application programs. In this case, the taken image display control means may change a taken image to be displayed in accordance with launching of the launch program. The taken image after the change may be determined among taken images stored in the storage means in a random manner or in accordance with a predetermined order. It is noted that “launching of the launch program” includes turning on the power of the information processing apparatus and launching the launch program (so called cold start), and launching the launch program while the power of the information processing apparatus is ON (so called hot start, including the case of return from a sleep state, and the like).
[0039] Further, in the first aspect, an order of taken images sequentially displayed by closing and opening the information processing apparatus may be set by the user. In other words, the information processing apparatus may further comprise order setting means for setting an order of taken images to be displayed in accordance with an instruction from the user. In this case, the taken image display control means determines a taken image after the change in accordance with an order set by the order setting means.
[0040] Further, in the first aspect, the information processing apparatus may further comprise acceptance means for accepting, from the user, an instruction to designate a taken image to be displayed on the display screen. In this case, the taken image display control means displays the taken image designated by the instruction on the display screen in accordance with acceptance of an instruction by the acceptance means.
[0041] A second aspect is an information processing apparatus ( 10 ) capable of being opened and closed. The information processing apparatus comprises storage means (a stored data memory 34 , a memory card 28 ), display means (a lower LCD 12 or an upper LCD 22 ), selection image display control means (S 5 ), and taken image display control means (S 5 ). The storage means is means for storing a taken image therein. The display means has a display screen provided in a surface which is located inside when the information processing apparatus is closed and which is located outside when the information processing apparatus is opened. The selection image display control means is means for displaying, in accordance with start-up of the information processing apparatus, a selection image for causing a user to select an application program to be launched from a plurality of application programs. The taken image display control means is means for displaying the taken image while the selection image is displayed.
[0042] According to the second aspect, the information processing apparatus displays a taken image in a state where a plurality of application programs are allowed to be activated. Thus, a menu screen (including the selection image and the taken image) which is uniform in the conventional arts can be different for each user, thereby providing individuality to the menu screen.
[0043] Further, in accordance with the start-up of the information processing apparatus, the taken image display control means may select a taken image to be displayed from taken images stored in the storage means in a random manner, and may display the taken image (S 3 ).
[0044] According to the above, when the information processing apparatus is started up, a taken image to be displayed is selected in a random manner. Thus, since a different taken image is displayed every time the power of the information processing apparatus is turned on, it is thought that the user turns on the power of the information processing apparatus because of user's interest that “what taken image will be displayed”, thereby prompting the user to use the information processing apparatus.
[0045] Further, the information processing apparatus may further comprise imaging means (cameras 23 and/or 24 ) and imaging state setting means (S 10 ). The imaging state setting means is means for enabling imaging by the imaging means in accordance with a predetermined operation being performed while a taken image is displayed by the taken image display control means. In this case, the storage means stores therein an image taken by the imaging means.
[0046] According to the above, the photographing function is quickly activated by performing the predetermined operation when a taken image is displayed. In other words, in a state where the photographing function is allowed to be activated, the taken image is displayed. Thus, by displaying the taken image in the state where the photographing function is allowed to be activated, the user can be prompted to use the photographing function. Further, since the user can be made to comprehensively recognize the state where the photographing function is allowed to activated by displaying the taken image, the configuration to further comprise the imaging state setting means is particularly advantageous when the information processing apparatus has many functions in addition to the photographing function.
[0047] Further, the information processing apparatus may further comprise imaging means (cameras 23 and/or 24 ), the information processing apparatus stores a first photographing program (a simplified photographing program) for performing photographing processing of storing an image taken by the imaging means in the storage means and a second photographing program (a multifunctional photographing application) for performing the photographing processing, and the second photographing program has a function different from the first photographing program. In this case, the taken image display control means sets both a taken image stored in the storage means by execution of the first photographing program and a taken image stored in the storage means by execution of the second photographing program as objects to be displayed on the display screen.
[0048] According to the above, a taken image stored by either of two types of photographing programs can be set as an object to be displayed on the display screen. Thus, since a taken image by either photographing program can be displayed, a limitation regarding which photographing program to be used is not given to the user, and a user-friendly photographing function can be provided.
[0049] Further, when the information processing apparatus is closed and opened again, the taken image display control means may change a taken image to be displayed between before and after closing and opening the information processing apparatus.
[0050] According to the above, similarly as in the first aspect, a taken image to be displayed can be changed by a novel method for changing a taken image to be displayed by closing and opening the information processing apparatus.
[0051] Further, the present invention can be provided in the form of an information processing program which causes a computer of the information processing apparatus to function as the above means.
[0052] As described above, according to the first aspect, a taken image to be displayed can be changed by a novel method for changing a taken image to be displayed by closing and opening an information processing apparatus capable of being opened and closed. Further, according to the second aspect, a menu screen which is uniform in the conventional arts can be different for each user, thereby providing individuality to the menu screen.
[0053] These and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] FIG. 1 is a view showing an external view of an information processing apparatus;
[0055] FIG. 2 is a view showing an external view of the information processing apparatus;
[0056] FIG. 3 is a block diagram showing an internal configuration of the information processing apparatus;
[0057] FIG. 4 is a view for explaining a method of launching each application program in the information processing apparatus;
[0058] FIG. 5 is a view showing main data stored in a main memory 32 of the information processing apparatus;
[0059] FIG. 6 is a main flow chart showing a procedure of processing in the information processing apparatus;
[0060] FIG. 7 is a view showing an example of a menu screen in a present embodiment;
[0061] FIG. 8 is a flow chart showing a procedure of simplified photographing processing (a step S 10 ) shown in FIG. 6 ;
[0062] FIG. 9 is a view showing an example of images displayed in a photographing enabled state;
[0063] FIG. 10 is a flow chart showing a procedure of multifunctional photographing processing in the present embodiment;
[0064] FIG. 11 is a flow chart showing a procedure of photograph display mode processing (a step S 34 ) shown in FIG. 10 ;
[0065] FIG. 12 is a view showing an example of images displayed in a photograph display mode in the present embodiment;
[0066] FIG. 13 is a flow chart showing a procedure of photographing mode processing (a step S 36 ) shown in FIG. 11 ;
[0067] FIG. 14 is a view showing an example of an image displayed in a photographing mode in the present embodiment;
[0068] FIG. 15 is a flow chart showing a procedure of photographing leading processing (a step S 2 ) shown in FIG. 6 ;
[0069] FIG. 16 is a flow chart shown a detail of opening-closing time processing in the present embodiment; and
[0070] FIG. 17 is a view showing a method of changing a display image at a step S 73 shown in FIG. 16 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0071] [Configuration of Information Processing Apparatus]
[0072] The following will describe an information processing apparatus according to an embodiment of the present invention. FIGS. 1 and 2 are views each showing an external view of an information processing apparatus 10 . FIG. 1 is an external view of the information processing apparatus 10 as viewed from a side, and FIG. 2 is an external view of the information processing apparatus 10 as viewed from the opposite side. The hand-held information processing apparatus 10 shown in FIGS. 1 and 2 takes an image with imaging means (a camera), displays the taken image on a screen, and stores data of the taken image. Further, the information processing apparatus 10 is capable of executing various application programs such as a game, and the like in addition to an application program for executing photographing processing. With reference to FIGS. 1 and 2 , the following will describe an external configuration of the information processing apparatus 10 .
[0073] The information processing apparatus 10 is a foldable apparatus, and includes two housings, namely, a lower housing 11 and an upper housing 21 as shown in FIGS. 1 and 2 . The lower housing 11 and the upper housing 21 are connected to each other so as to be capable of being opened or closed (foldable). In other words, axial portions 11 A are provided at both ends of an upper side (a side on an x-axis positive side in the drawing) of the lower housing 11 in a left-right direction (in a y direction in the drawing), respectively, as shown in FIG. 1 (the axial portions 11 A are structurally integral with the lower housing 11 ). Further, an axial portion 21 A is provided in a center portion of a lower side (a side on an x-axis negative side in the drawing) of the upper housing 21 in the left-right direction (in the y direction in the drawing) as shown in FIG. 1 (the axial portion 21 A is structurally integral with the upper housing 21 ). The axial portions 11 A and the axial portion 21 A are connected to each other by a hinge provided therein so as to be pivotable about an axis in the left-right direction. Thus, the lower housing 11 and the upper housing 21 are connected to each other so as to be pivotable about an axis in the left-right direction. FIGS. 1 and 2 show the information processing apparatus 10 in an opened state. In an alternative embodiment, the information processing apparatus 10 may not be of a foldable type, and may include one housing.
[0074] As shown in FIG. 1 , the information processing apparatus 10 includes two display devices, namely, an upper LCD (Liquid Crystal Display) 22 and a lower LCD 12 . The upper LCD 22 is mounted in an inner surface of the upper housing 21 (which is a surface located on the inside of the information processing apparatus 10 in a closed state), and the lower LCD 12 is mounted in an inner surface of the lower housing 11 . Although an LCD is used as a display device in the present embodiment, any other display devices such as a display device using an EL (Electro Luminescence) may be used. In addition, the information processing apparatus 10 can use a display device of any resolution. Although a case where the information processing apparatus 10 includes the two display devices is described as an example in the present embodiment, in an alternative embodiment, the information processing apparatus may include any number of display devices.
[0075] As shown in FIGS. 1 and 2 , the information processing apparatus 10 includes two cameras 23 and 24 as the imaging means. Each of the cameras 23 and 24 is accommodated in the upper housing 21 . As shown in FIG. 1 , the inner camera 23 is mounted in the inner surface of the upper housing 21 . In the present embodiment, the inner camera 23 is mounted in the axial portion 21 A of the upper housing 21 . On the other hand, as shown in FIG. 2 , the outer camera 24 is mounted in a surface opposite to the surface in which the inner camera 23 is mounted, namely, in an outer surface of the upper housing 21 (which is a surface located on the outside of the information processing apparatus 10 in the closed state). In other words, in the present embodiment, the two cameras 23 and 24 are provided such that imaging directions thereof are opposite to each other. Thus, a user can take images in two different directions without changing a manner of holding the information processing apparatus 10 . For example, the user can take an image of a view seen from the information processing apparatus 10 toward the user with the inner camera 23 as well as an image of a view seen from the information processing apparatus 10 in a direction opposite to the user with the outer camera 24 .
[0076] Although the case where the information processing apparatus 10 includes the two cameras 23 and 24 as the imaging means is described as an example in the present embodiment, the information processing apparatus 10 may include one camera, or three or more cameras. Further, a position at which a camera is mounted may be any position.
[0077] The information processing apparatus 10 includes a plurality of buttons 14 A to 14 J as input devices. As shown in FIG. 1 , the direction input button 14 A, the button 14 B, the button 14 C, the button 14 D, the button 14 E, the power button 14 F, the start button 14 G, and the select button 14 H are provided on the inner surface of the lower housing 11 . Each of the buttons 14 A to 14 E, the start button 14 G, and the select button 14 H is used for performing various operations with respect to the information processing apparatus 10 . The power button 14 F is used for turning on or off the power of the information processing apparatus 10 . Further, as shown in FIG. 2 , the L button 14 I is provided at a left end of the upper side of the lower housing 11 (at a left end as viewed from the inner surface side; on a y-axis negative side in the drawing), and the R button 14 J is provided at a right end of the upper side (at a right end as viewed from the inner surface side; on a y-axis positive side in the drawing). The L button 14 I and the R button 14 J are used for performing a photographing operation (a shutter operation). Although not shown in the drawings, the information processing apparatus 10 includes a volume button for adjusting volume of later-described speakers. For example, the volume button is provided on a left side surface of the lower housing 11 .
[0078] The information processing apparatus 10 further includes a touch panel 13 , as shown in FIG. 1 , as another input device in addition to the above buttons. The touch panel 13 is mounted on a screen of the lower LCD 12 . The touch panel 13 may be of any type such as a resistive film type, an optical type (infrared type), or a capacitive coupling type. The touch panel 13 used in the present embodiment has the same resolution (detection accuracy) as that of the lower LCD 12 . However, the resolution of the touch panel 13 and the lower LCD 12 may not necessarily be the same as each other. A touch pen 27 is usually used for performing an input with respect to the touch panel 13 , but a finger of the user can be used for operating the touch panel 13 instead of the touch pen 27 . In the present embodiment, the information processing apparatus 10 determines a later-described dividing line in accordance with an input with respect to the touch panel 13 . In a right side surface of the lower housing 11 , an insertion opening 17 (indicated by a dotted line in FIGS. 1 and 2 ) is provided for accommodating the touch pen 27 .
[0079] The information processing apparatus 10 includes a microphone (a microphone 43 shown in FIG. 3 ) as a voice input device. The microphone 43 is accommodated in the upper housing 21 . In the present embodiment, the microphone 43 is disposed in the axial portion 21 A of the upper housing 21 . In the inner surface of the upper housing 21 , a microphone hole 21 C is provided to allow the microphone to detect sound outside the information processing apparatus 10 . The microphone hole 21 C is provided in the axial portion 21 A of the upper housing 21 .
[0080] The information processing apparatus 10 includes the speakers (not shown) as sound output means. The speakers are accommodated in the upper housing 21 . In the upper housing 21 , sound holes 21 D are provided for releasing sound from the speakers therethrough. The sound holes 21 D are provided on both left and right sides of the upper LCD 22 , respectively.
[0081] Further, as shown in FIG. 2 , a cover 18 is provided on the right side surface of the lower housing 11 so as to be capable of being opened or closed. Inside the cover 18 , an insertion opening (indicated by a two-dot chain line in FIG. 1 ) is provided so as to be capable of receiving a memory card 28 therein. In the insertion opening, a connector (not shown) is provided for electrically connecting the information processing apparatus 10 to the memory card 28 . The memory card 28 is inserted into the insertion opening to be connected to the connector. The memory card 28 is used, for example, for storing data of a taken image. Further, an application program (a later-described selected application program) which is executable by the information processing apparatus 10 may be stored in the memory card 28 .
[0082] Further, as shown in FIG. 2 , on the upper side of the lower housing 11 , an insertion opening (indicated by a chain line in FIG. 1 ) is provided so as to be capable of receiving a cartridge 29 therein. In the insertion opening, a connector (not shown) is provided for electrically connecting the information processing apparatus 10 to the cartridge 29 . The cartridge 29 is inserted into the insertion opening to be connected to the connector. For example, an application program (a later-described selected application program) which is executable by the information processing apparatus 10 may be stored in the cartridge 29 .
[0083] [Internal Configuration of Information Processing Apparatus 10 ]
[0084] With reference to FIG. 3 , the following will describe an internal configuration of the information processing apparatus 10 . FIG. 3 is a block diagram showing the internal configuration of the information processing apparatus 10 . As shown in FIG. 3 , the information processing apparatus 10 includes electronic components including a CPU 31 , a main memory 32 , a memory control circuit 33 , a stored data memory 34 , a preset data memory 35 , a memory card interface (memory card I/F) 36 , a cartridge interface (cartridge I/F) 37 , a wireless communication module 38 , a local communication module 39 , a real time clock (RTC) 40 , a power circuit 41 , an interface circuit (I/F circuit) 42 , and the like. These electronic components are mounted on an electronic circuit substrate and accommodated in the lower housing 11 . It is noted that various electronic circuits and a battery of the information processing apparatus 10 may be accommodated in either the upper housing 21 or the lower housing 11 .
[0085] The CPU 31 is information processing means for executing various programs (a later-described launch program, selected application programs, and the like). The main memory 32 , the memory control circuit 33 , and the preset data memory 35 are connected to the CPU 31 . Further, the stored data memory 34 is connected to the memory control circuit 33 .
[0086] The main memory 32 is storage means used as a work area and a buffer area of the CPU 31 . In other words, the main memory 32 stores a (application) program executed by the CPU 31 , and also stores various data used in processing executed by executing the program. In the present embodiment, for example, a PSRAM (Pseudo-SRAM) is used as the main memory 32 . The stored data memory 34 is storage means for storing a program executable by the CPU 31 , data of images taken by the cameras 23 and 24 , and the like. The stored data memory 34 is constructed of, for example, a NAND flash memory. In the present embodiment, the above various programs are stored in the stored data memory 34 , and when the CPU 31 executes a program, the program to be executed is read out therefrom into the main memory 32 . It is noted that the program executed by the CPU 31 may not be stored in advance in the stored data memory 34 , may be obtained from the memory card 28 , or may be obtained from a later-described external apparatus by means of communication with the external apparatus.
[0087] The memory control circuit 33 is a circuit for controlling reading of data from the stored data memory 34 or writing of data to the stored data memory 34 in accordance with an instruction from the CPU 31 . The preset data memory 35 is storage means for storing data (preset data) of various parameters which are set in advance in the information processing apparatus 10 , and the like. A flash memory connected to the CPU 31 via an SPI (Serial Peripheral Interface) bus can be used as the preset data memory 35 .
[0088] The memory card I/F 36 is connected to the CPU 31 . The memory card I/F 36 reads out data from the memory card 28 mounted to the connector or writes data to the memory card 28 in accordance with an instruction from the CPU 31 . In the present embodiment, data of images taken by the cameras 23 and 24 are written to the memory card 28 , and image data stored in the memory card 28 are read out from the memory card 28 to be stored in the stored data memory 34 .
[0089] The cartridge I/F 37 is connected to the CPU 31 . The cartridge I/F 37 reads out data from the cartridge 29 mounted to the connector or writes data to the cartridge 29 in accordance with an instruction from the CPU 31 . In the present embodiment, an application program (a later-described selected application program) which is executable by the information processing apparatus 10 is read out from the cartridge 29 to be executed by the CPU 31 , and data regarding the application program (e.g. saved data of a game, and the like) is written to the cartridge 29 .
[0090] The wireless communication module 38 functions to connect to a wireless LAN device by a method conformed to the standard of IEEE802.11.b/g. The local communication module 39 functions to wirelessly communicate with an information processing apparatus of the same type by a predetermined communication method. The wireless communication module 38 and the local communication module 39 are connected to the CPU 31 . The CPU 31 is capable of receiving data (data of taken images, an application program, and the like) from and sending data (data of taken images, an application program, and the like) to another apparatus via the Internet by using the wireless communication module 38 , and capable of receiving data from and sending data to another information processing apparatus of the same type by using the local communication module 39 .
[0091] The RTC 40 and the power circuit 41 are connected to the CPU 31 . The RTC 40 counts a time, and outputs the time to the CPU 31 . The CPU 31 calculates a current time (date) based on the time counted by the RTC 40 . The power circuit 41 controls electric power from a power supply (the battery) of the information processing apparatus 10 to supply the electric power to each electronic component of the information processing apparatus 10 .
[0092] The information processing apparatus 10 includes the microphone 43 and an amplifier 44 . The microphone 43 and the amplifier 44 are connected to the I/F circuit 42 . The microphone 43 detects sound, and outputs a sound signal to the I/F circuit 42 . The amplifier 44 amplifies the sound signal from the I/F circuit 42 , and causes the speakers (not shown) to output the sound signal. The I/F circuit 42 is connected to the CPU 31 . The touch panel 13 is connected to the I/F circuit 42 . The I/F circuit 42 includes a sound control circuit for controlling the microphone 43 and the amplifier 44 (the speakers) and a touch panel control circuit for controlling the touch panel. The sound control circuit performs A/D conversion or D/A conversion on the sound signal, and converts the sound signal into sound data in a predetermined format. The touch panel control circuit generates touch position data in a predetermined format based on a signal from the touch panel 13 , and outputs the touch position data to the CPU 31 . The touch position data indicates coordinates of a position (input position) on an input surface of the touch panel 13 at which an input is performed. The touch panel control circuit reads a signal from the touch panel 13 and generates touch position data every a predetermined time period. The CPU 31 can recognize an input position with respect to the touch panel 13 by obtaining the touch position data.
[0093] An operation section 14 includes the above buttons 14 A to 14 J and the above volume button, and is connected to the CPU 31 . The operation section 14 outputs operation data indicative of an input state with respect to each button (whether or not each button is pressed) to the CPU 31 . The CPU 31 obtains the operation data from the operation section 14 , and executes processing in accordance with an input with respect to the operation section 14 .
[0094] The cameras 23 and 24 are connected to the CPU 31 . Each of the cameras 23 and 24 takes an image in accordance with an instruction from the CPU 31 , and outputs data of the taken image to the CPU 31 . In the present embodiment, the CPU 31 gives an imaging instruction to the camera 23 or 24 , and the camera which has received the imaging instruction takes an image and sends image data to the CPU 31 every a predetermined time period.
[0095] The LCDs 12 and 22 are connected to the CPU 31 . Each of the LCDs 12 and 22 displays an image thereon in accordance with an instruction from the CPU 31 . In the present embodiment, the CPU 31 causes a taken image obtained from the camera 23 or 24 and an explanation image for explaining a manner of operation, and the like to be displayed on the LCDs 12 and 22 .
[0096] [Outline of Processing in Information Processing Apparatus 10 ]
[0097] With reference to FIG. 4 , the following will describe an outline of processing executed by the information processing apparatus 10 . The information processing apparatus 10 is capable of executing various processing using a plurality of application programs having various functions, in addition to executing the photographing processing. The following will describe a method of launching each application.
[0098] FIG. 4 is a view for explaining a method of launching each application program in the information processing apparatus 10 . The information processing apparatus 10 selectively launches an application program desired by the user among a plurality of application programs 53 to 56 . The application programs 53 to 56 which are selectively launched by the information processing apparatus 10 may be referred to as selected application programs.
[0099] The above plurality of selected application programs includes the photographing application program 53 . The photographing application program 53 is an application program for performing photographing with the camera 23 or 24 . The photographing application program 53 is stored in advance (pre-installed) in the information processing apparatus 10 .
[0100] Further, the above plurality of selected application programs includes application programs having various functions in addition to the above photographing application program 53 . As shown in FIG. 4 , for example, the above plurality of selected application programs includes the setting application program 54 for performing various settings of the information processing apparatus 10 , the communication application program 55 for the information processing apparatus 10 to perform communication with an external apparatus, and the game application program 56 for performing a predetermined game. Further, in the present embodiment, the information processing apparatus 10 stores other selected application programs in addition to the four selected application programs 53 to 56 as shown in FIG. 4 .
[0101] The above plurality of selected application programs may include a program which is not pre-installed in the information processing apparatus 10 . When executed, for example, a selected application program may be downloaded from another apparatus via a network such as the Internet, and the like, or may be read from a detachable storage medium such as the memory card 28 or the cartridge 29 into a memory within the information processing apparatus 10 .
[0102] Further, in the present embodiment, processing of selectively launching the selected application programs 53 to 56 is executed by a launch function program 51 . The launch function program 51 is one of programs included in a launch program (a launch program 61 shown in FIG. 5 ) according to the present invention. The launch function program 51 is a program for selecting a selected application program to be launched among the plurality of selected application programs 53 to 56 . The launch function program 51 is a program called as launcher. The selected application programs 53 to 56 become objects for a selection operation which can be performed by the user by executing the launch function program 51 , and are selected by the selection operation to be executed.
[0103] In addition, the information processing apparatus 10 includes (1) first launch operation acceptance means, (2) first launch means, (3) photographing processing means, (4) photographing enabling operation acceptance means, (5) state setting means, (6) second launch operation acceptance means, (7) second launch means, and (8) cancellation means. In the present embodiment, each of these means is realized by a program (the launch program 61 ), which is executed by a computer (the CPU 31 ) of the information processing apparatus 10 , causing the computer to function as the means. In an alternative embodiment, the information processing apparatus 10 may not include each means of the above (6) to (8).
[0104] (1) First Launch Operation Acceptance Means
[0105] The first launch operation acceptance means accepts a first launch operation for selectively launching the above plurality of application programs (later-described steps S 6 and S 11 ). Thus, the user can select a selected application program to be desired to be launched (executed) for execution. The first launch operation is an operation for selectively launching the selected application program, and thus, hereinafter, the first launch operation may be referred to as a “selection launch operation”. It is noted that a state of accepting the first launch operation (a state where it is possible to perform the first launch operation) is referred to as a “launch acceptance state” ( FIG. 4 ).
[0106] (2) First Launch Means
[0107] When the first launch operation is performed, the first launch means launches an application program which is selected by the first launch operation among the above plurality of application programs (a later-described step S 12 ). In other words, for example, when the photographing application program 53 is selected by the first launch operation, the photographing application program 53 is launched.
[0108] In the present embodiment, the launch acceptance state corresponds to a state where a so-called menu screen is displayed, and the information processing apparatus 10 is initially in the launch acceptance state after being started up (a power is turned on) (except for start-up for the first time). Although details will be described later, the menu screen ( FIG. 7 ) showing icons indicating the selected application programs 53 to 56 , respectively, is displayed on the lower LCD 12 in the launch acceptance state in the present embodiment. The user can launch a selected application program by performing an operation of touching a position of the icon with respect to the touch panel 13 as the first launch operation.
[0109] (3) Photographing Processing Means
[0110] The photographing processing means executes photographing processing (a later-described step S 10 ). The photographing processing is processing of storing a taken image by the camera 23 or 24 in storage means of the information processing apparatus in accordance with a predetermined photographing operation. In the present embodiment, the photographing operation is an operation of pressing a predetermined button (more specifically, the L button 14 I or the R button 14 J). The above photographing processing means is means realized by executing the launch program 61 according to the present invention by the CPU 31 of the information processing apparatus 10 , and is different from means realized by the above photographing application program 53 . It is noted that the photographing processing means only has to have at least a function to execute photographing processing (a function to store a taken image by the camera 23 or 24 in the storage means of the information processing apparatus 10 ), but may have other functions regarding photographing (e.g. a function to display a stored image, and a function to edit a stored image).
[0111] In the present embodiment, the launch program 61 according to the present invention includes a photographing function program 52 shown in FIG. 4 . The above photographing processing means is realized by executing the photographing function program 52 by the CPU 31 of the information processing apparatus 10 . In other words, in the present embodiment, the information processing apparatus 10 stores two types of programs for executing photographing processing, namely, the photographing function program 52 and the photographing application program 53 .
[0112] Further, although, in the present embodiment, the launch program 61 includes the two types of programs, the launch function program 51 and the photographing function program 52 , the launch function program 51 and the photographing function program 52 may be incorporated into one program. The launch program 61 (the launch function program 51 and the photographing function program 52 ) is pre-installed in the information processing apparatus 10 .
[0113] Here, a function by the photographing processing means is different from a function which is enabled by executing the photographing application program 53 . In the present embodiment, the photographing processing means has only a part of the function which the photographing application program 53 has. In an alternative embodiment, the photographing processing means may have a function which the photographing application program 53 does not have.
[0114] (4) Photographing Enabling Operation Acceptance Means
[0115] In the launch acceptance state, the photographing enabling operation acceptance means accepts a photographing enabling operation for causing (a state of the information processing apparatus 10 to be) a photographing enabled state (the later-described steps S 6 and S 9 ). The photographing enabled state is a state where it is possible to execute photographing processing by the above photographing processing means in accordance with the above photographing operation (a state of accepting the photographing enabling operation). In other words, in the launch acceptance state, the user can launch the selected application programs 53 to 56 by the first launch operation, and can also activate a photographing function by the photographing processing means by the photographing enabling operation ( FIG. 4 ). In the present embodiment, the photographing enabling operation is the same as the above photographing operation. More specifically, the photographing enabling operation and the photographing operation each are a single operation with respect to a predetermined button (an operation of once pressing the L button 14 I or the R button 14 J). In an alternative embodiment, the predetermined button is not limited to a button provided in the information processing apparatus 10 , and may be a button (a button image) displayed on the touch panel 13 (the first LCD 12 ) of the information processing apparatus 10 .
[0116] In the present embodiment, the photographing enabled state is a state in which photographing processing is executed in accordance with a photographing operation being performed. However, as an optional additive configuration, the information processing apparatus 10 may perform the following processing in the photographing enabled state. In the photographing enabled state, the information processing apparatus 10 may display a live image (an image taken in real time; see FIG. 9 ) and/or an image for explaining an operation regarding photographing. Further, in the photographing enabled state, the information processing apparatus 10 may stop processing of launching an application by the first launch operation acceptance means.
[0117] In the present embodiment, the photographing enabling operation is an operation of which an operation manner is different from an operation manner of the first launch operation. More specifically, in the present embodiment, the first launch operation is an input operation with respect to the touch panel 13 while the photographing enabling operation is an operation of pressing a predetermined button (more specifically, the L button 14 I or the R button 14 J). It is noted that the phrase “an operation manner is different” means that “an input device to be operated is different”, and also means that an operation performed with respect to the same input device is different. In an alternative embodiment, the first launch operation and the photographing enabling operation may be operations of touching different positions on the touch panel 13 , may be operations of inputting different lines with respect to the touch panel 13 , or may be operations of pressing different buttons. For easily and quickly performing activation of the photographing function (launch of the photographing function program 52 ) by the photographing processing means, the photographing enabling operation is preferably an simple operation such as an operation of pressing a predetermined button.
[0118] (5) State Setting Means
[0119] When the above photographing enabling operation is performed, the state setting means sets the state of the information processing apparatus 10 to the photographing enabled state (a step S 10 which is executed in the case of YES at a later-described step S 9 ). In other words, when the photographing enabling operation is performed, the state of the information processing apparatus 10 becomes the photographing enabled state ( FIG. 4 ). Thus, a photographing operation by the user is possible. Therefore, the user can take a photograph (can cause the information processing apparatus 10 to execute the photographing processing) by performing the photographing operation after the photographing enabling operation is performed.
[0120] In the present embodiment, the launch acceptance state and the photographing enabled state have an exclusive relation with each other, and the information processing apparatus 10 is alternatively in either the launch acceptance state or the photographing enabled state. In other words, the photographing operation (in the photographing enabled state) is not accepted in the launch acceptance state while the first launch operation (in the launch acceptance state) is not accepted in the photographing enabled state. However, in an alternative embodiment, the launch acceptance state and the photographing enabled state may not have an exclusive relation with each other, and it may be possible for the information processing apparatus 10 to be in the launch acceptance state and in the photographing enabled state. For example, the information processing apparatus 10 may accept the first launch operation in the photographing enabled state.
[0121] As described above, according to the present embodiment, by the configurations of the above (1) to (5), the information processing apparatus 10 is capable of executing two types of photographing functions, namely, a photographing function by executing the photographing application program 53 and a photographing function by the photographing processing means. For performing photographing by the photographing processing means from the launch acceptance state, the user only has to perform the photographing enabling operation and the photographing operation which are the same as each other. In other words, the user can perform photographing only by performing the same operation twice (typically, only by pressing the same button twice), and can perform photographing by an exceedingly simple operation.
[0122] Further, in the case where the photographing enabling operation is a single operation with respect to a predetermined button, the photographing function by the photographing processing means can be executed from the launch acceptance state by a single operation with respect to a predetermined button, and hence can be executed by an exceedingly simple operation. Thus, when the user desires to perform photographing using the information processing apparatus 10 , the use can quickly set the state of the information processing apparatus 10 to a state where photographing is possible by once pressing the predetermined button.
[0123] (6) Second Launch Operation Acceptance Means
[0124] In the above photographing enabled state, the second launch operation acceptance means accepts a second launch operation for launching the photographing application program 53 (the later-described steps S 24 and S 28 ). Thus, in the photographing enabled state, the user can perform the second launch operation in addition to the photographing operation. The second launch operation is an operation for launching the photographing application program 53 directly from the photographing enabled state without returning to the launch acceptance state, and thus may be referred to as a “shortcut launch operation”.
[0125] In the present embodiment, in the photographing enabled state, an image being taken by the camera 23 or 24 is displayed on the lower LCD 12 while a button image (a button image 78 shown in FIG. 9 ) for performing the second launch operation is displayed on the lower LCD 12 ( FIG. 9 ). The user can perform the second launch operation by performing an operation of touching the button image. For easily and quickly performing launch of the photographing application program 53 , the second launch operation is preferably a simple operation.
[0126] (7) Second Launch Means
[0127] When the above second launch operation is performed, the second launch means launches the photographing application program 53 (a later-described step S 30 ). Thus, the user can launch the photographing application program 53 in either the launch acceptance state or the photographing enabled state. The photographing application program 53 is launched (executed) by either the first launch operation in the launch acceptance state or the second launch operation in the photographing enabled state.
[0128] (8) Cancellation Means
[0129] In the above photographing enabled state, the cancellation means automatically cancels the photographing enabled state in accordance with satisfaction of a predetermined condition (simplified photographing processing is terminated in the case of Yes at a later-described S 25 ). The predetermined condition is, for example, a photographing operation being performed a predetermined number of times in the photographing enabled state (execution of photographing processing a predetermined number of times), elapse of a predetermined time period from a time of start of the photographing enabled state, and the like. In the present embodiment, the photographing enabled state is automatically cancelled in accordance with a single execution of photographing processing in the photographing enabled state. In other words, when a photographing operation is performed in the photographing enabled state, the photographing enabled state is cancelled (after the photographing processing is terminated). In the present embodiment, as a result of cancellation of the photographing enabled state, the state of the information processing apparatus 10 is shifted to the launch acceptance state.
[0130] According to the above cancellation means, the photographing enabled state is automatically cancelled without performing a (dedicated) operation for canceling the photographing enabled state. Especially, in the present embodiment, when the user performs a photographing operation once in the photographing enabled state, the state of the information processing apparatus returns to the launch acceptance state. Thus, even a novice user who has not read an instruction manual, and the like can naturally return to the launch acceptance state by performing a photographing operation. Therefore, a state that “the user does not know how to return from the photographing enabled state to the launch acceptance state” can be prevented, and a user-friendly information processing apparatus can be provided.
[0131] As described above, according to the present embodiment, in the launch acceptance state, the user can launch the selected application programs 53 to 56 by the selection launch operation (the first launch operation), and also can execute the photographing function by the photographing processing means by the photographing enabling operation. In addition, in the photographing enabled state where it is possible to perform photographing by the photographing function, the user can launch the photographing application program 53 by the shortcut launch operation (the second launch operation). Thus, even while performing photographing by the photographing processing means, the user can easily and quickly launch the photographing application program 53 by the shortcut launch operation. In other words, according to the present embodiment, in the case where the user desires to use a function (of the photographing application program 53 ) which the photographing processing means does not have during photographing by the photographing processing means, the user can easily and quickly use the function by the shortcut launch operation.
[0132] [Detail of Processing in Information Processing Apparatus 10 ]
[0133] With reference to FIGS. 5 to 17 , the following will describe a detail of the processing executed by the information processing apparatus 10 . First, with reference to FIG. 5 , data used in the processing in the information processing apparatus 10 will be described.
[0134] FIG. 5 is a view showing main data stored in the main memory 32 of the information processing apparatus 10 . As shown in FIG. 5 , a program storage region 60 and a data storage region 64 are provided in the main memory 32 .
[0135] In the program storage region 60 , various programs (application programs) executed by the CPU 31 are stored. More specifically, the launch program 61 , the photographing application program 53 , and other selected application programs 62 , and the like are stored in the program storage region 60 . These programs are read out from the stored data memory 34 , the memory card 28 , or the cartridge 29 to be stored in the main memory 32 at an appropriate timing after start-up of the information processing apparatus 10 (e.g. at a timing of launching a program).
[0136] The launch program 61 is a program for executing main processing in the information processing apparatus 10 . The launch program 61 is read into the main memory to be executed after the start-up of the information processing apparatus 10 . The launch program 61 includes the above launch function program 51 and the above photographing function program 52 .
[0137] The launch function program 51 is a program for selecting a selected application program to be launched as described above.
[0138] The photographing function program 52 is a program which is not a selected application program, and is a program for executing the photographing processing. In the present embodiment, the photographing function program 52 has only a part of the function which the photographing application program 53 has. In other words, in the present embodiment, the photographing function program 52 is a relatively simple functional photographing processing program, and the photographing application program 53 is a relatively multifunctional photographing processing program. Further, the photographing function program 52 has a data size which is smaller than that of the photographing application program 53 . It is noted that since the programs 52 and 53 have a common function, a part of their data may be commoditized and stored. Hereinafter, the relatively simple functional photographing function program 52 may be referred to as a “simplified photographing program 52 ”, and the relatively multifunctional photographing application program 53 may be referred to as a “multifunctional photographing application program 53 ”.
[0139] In the present specification, the phrase “(relatively) simple functional” includes both meaning of having (relatively) few functions and meaning of having a (relatively) low function, and the phrase “(relatively) multifunctional” includes meaning of having relatively many functions as well as meaning of having a (relatively) high function. In other words, the simplified photographing program 52 may have a relatively low function (e.g. photographing with a small number of pixels, a small number of types of stamps which can be used in editing a taken image, and the like) while the multifunctional photographing application program 53 may have a relatively high function (e.g. photographing with a large number of pixels, a large number of types of stamps which can be used in editing a taken image, and the like). Further, the simplified photographing program 52 may have relatively few functions (e.g. adjustment of exposure and white balance is impossible, a predetermined editing operation with respect to a taken image is impossible, and the like) while the multifunctional photographing application program 53 may have relatively many functions (e.g. adjustment of exposure and white balance is possible, a predetermined editing operation with respect to a taken image is possible, and the like).
[0140] Further, the other selected application programs 62 are selected application programs other than the multifunctional photographing application program 53 , and include the above setting application program 54 , the above communication application program 55 , the above game application program 56 , and the like.
[0141] The selected application programs (including the multifunctional photographing application program 53 ) are stored in the stored data memory 34 or the memory card 28 , and read out into the main memory 32 when launched. It is noted that the selected application programs may be obtained (downloaded) from an external apparatus by means of communication to be stored in the stored data memory 34 .
[0142] Meanwhile, in the data storage region 64 , display image data 65 , setting data 66 , and the like are stored. In addition to these data 65 and 66 , various data used in the processing in the information processing apparatus 10 are stored in the data storage region 64 .
[0143] The display image data 65 is data indicative of a display image. Here, in the present embodiment, one of stored images which are taken in the past is displayed on the menu screen, and a image being displayed is referred to as a display image. More specifically, the display image data 65 indicates a file name, and the like, of a display image. Although a detail of a method of selecting a display image will be described later, a later-described favorite image, an image immediately after photographing (storing) is performed by the simplified photographing program 52 , and the like are selected as a display image in the present embodiment.
[0144] The setting data 66 is data indicative of setting information used in each program for photographing (the simplified photographing program 52 and the multifunctional photographing application program 53 ). The setting data 66 is passed as an argument to each of the programs 52 and 53 at a time of launching each of the programs 52 and 53 for photographing. The setting data 66 includes a camera change data 67 and a storage destination data 68 .
[0145] The camera change data 67 indicates a camera for taking an image among the inner camera 23 and the outer camera 24 . In other words, the camera change data 67 is data indicative of either the inner camera 23 or the outer camera 24 .
[0146] The storage destination data 68 indicates a storage destination of a taken image (referred to as a stored image) to be stored by the photographing operation. In the present embodiment, a taken image to be stored by the photographing operation is stored in the stored data memory 34 or the memory card 28 . Thus, the storage destination data 68 indicates either the stored data memory 34 or the memory card 28 .
[0147] It is noted that information such as a file name, and the like is attached to the stored image, and information regarding favorite is also attached to the stored image. Here, in the present embodiment, the user can set some of stored images as “favorite” (a later-described step S 46 ). Hereinafter, a stored image which is set as favorite is referred to as a “favorite image”. Information indicative of “favorite” is added to data of a favorite image. In addition, in the present embodiment, information indicative of any of first to third groups is added to the data of the favorite image. In other words, in the present embodiment, favorite images can be divided into the first to third groups, and managed ( FIG. 17 ).
[0148] With reference to FIGS. 6 to 17 , the following will describe a procedure of the processing in the information processing apparatus 10 . FIG. 6 is a main flow chart showing the procedure of the processing in the information processing apparatus 10 . When the power is applied to the information processing apparatus 10 by pressing the power button 14 F, the CPU 31 of the information processing apparatus 10 initializes the main memory 32 , and the like, and then starts executing the launch program 61 . Thus, processing at subsequent steps S 1 to S 13 is started.
[0149] At the step S 1 , the CPU 31 determines whether or not the information processing apparatus 10 is started up for the first time. The determination at the step S 1 can be made, for example, by storing time and date of starting up the information processing apparatus 10 last time. In other words, if time and date of the last start-up have been stored, it can be determined that the start-up of the information processing apparatus 10 this time is not a start-up for the first time. On the other hand, if the time and the date of the last start-up have not been stored, it can be determined that the start-up of the information processing apparatus 10 this time is the start-up for the first time. When a result of the determination at the step S 1 is positive, the processing at the step S 2 is executed. On the other hand, when the result of the determination at the step S 1 is negative, the processing at the step S 2 is skipped, and the processing at the step S 3 is executed.
[0150] At the step S 2 , the CPU 31 executes photographing leading processing. The photographing leading processing is processing for leading the user to experience a photographing operation with a simple function. In other words, in the photographing leading processing, the user is caused to select whether to perform photographing processing using the above simplified photographing program 52 . When the user selects to perform the photographing processing, the user is caused to experience a simple photographing operation by the above simplified photographing program 52 . A detail of the photographing leading processing will be described later using FIG. 15 . The CPU 31 executes the processing at the step S 3 subsequent to the step S 2 .
[0151] At the step S 3 , the CPU 31 selects a display image among favorite images in a random manner. More specifically, the CPU 31 selects one favorite image among favorite images stored in the stored data memory 34 in a random manner, and stores data indicative of information (e.g. a file name) identifying the selected favorite image as the display image data 65 in the main memory 32 . When there is no favorite image (when there is no favorite image stored in the stored data memory 34 ), one image is selected from the stored images stored in the stored data memory 34 in a random manner (or in accordance with a predetermined order). Further, when no stored image (when there is no image stored in the stored data memory 34 ), a display for notifying that there is no stored image and/or a display for prompting the photographing processing are performed at the later-described step S 5 . Subsequent to the step S 3 , the processing at the step S 4 is executed.
[0152] At the step S 4 , the CPU 31 launches the launch function program 51 . In other words, the CPU 31 reads out the launch function program 51 from the stored data memory 34 to be stored in the main memory 32 , and executes the launch function program 51 . The processing at the step S 5 and thereafter is executed by the CPU 31 executing the launch function program 51 . Further, in the present embodiment, the CPU 31 reads out the simplified photographing program 52 into the main memory 32 along with the launch function program 51 at a timing of reading out the launch function program 51 . In an alternative embodiment, the simplified photographing program 52 may be read out into the main memory 32 at a timing of executing later-described simplified photographing processing (the step S 11 ). Subsequent to the step S 4 , the processing at the step S 5 is executed.
[0153] At the step S 5 , the CPU 31 displays a menu screen. The menu screen is a screen (an image) for causing the user to select a selected application program to be launched among the selected application programs. The launch acceptance state shown in FIG. 4 is a state where the menu screen is displayed. The following will describe the menu screen in the present embodiment using FIG. 7 .
[0154] FIG. 7 is a view showing an example of the menu screen. As shown in FIG. 7 , at the step S 5 , the image for causing the user to select a selected application program to be executed is displayed on the lower LCD 12 . More specifically, icon images 71 a to 71 c , a scroll bar 72 , a marker 73 , and scroll buttons 74 a and 74 b are displayed on the lower LCD 12 .
[0155] Each of the icon images 71 a to 71 c is an image indicating a selected application program. In FIG. 7 , the three icon images corresponding to three selected application programs, namely, the icon image 71 a indicating the setting application program 54 , the icon image 71 b indicating the multifunctional photographing application program 53 , and the icon image 71 c indicating the communication application program 55 , are displayed. The user can launch a selected application program indicated by the touched icon image by performing an operation of touching the icon image (the icon image 71 b in FIG. 7 ) displayed at a center of the screen (in the left-right direction) as the above first launch operation.
[0156] In the present embodiment, three icon images (the icon images 71 a to 71 c in FIG. 7 ) among icon images corresponding to a plurality of application programs, respectively, are displayed on the screen. The three icon images being displayed (types of the three icon images being displayed) are changed in accordance with an operation of scrolling the screen. In other words, although icon images indicating selected application programs other than these three selected application programs are not displayed in FIG. 7 , the icon images are displayed by scrolling the screen of the lower LCD 12 . The scrolling of the screen of the lower LCD 12 can be performed by an operation of touching an icon image other than the icon image displayed at the center of the screen, or by an operation of touching the marker 73 or the scroll button 74 a or 74 b . In other words, when the user touches the icon image (the icon image 71 a or 71 c in FIG. 7 ) other than the icon image displayed at the center of the screen, the screen of the lower LCD 12 is scrolled, and the touched icon image is displayed at the center of the screen. Or, the user can move the marker 73 along the scroll bar 72 by performing an operation of moving a touched position along the scroll bar 72 right and left while touching the marker 73 , thereby scrolling the screen of the lower LCD 12 in accordance with the movement of the marker 73 . Or, the screen of the lower LCD 12 can be scrolled leftward by an operation of touching the scroll button 74 a on the left side of the scroll bar 72 , and the screen of the lower LCD 12 can be scrolled rightward by an operation of touching the scroll button 74 b on the right side of the scroll bar 72 . As described above, in the state where the menu screen is displayed, the user can change the icon image displayed at the center of the screen by the operation of scrolling the screen, and also can launch the selected application program indicated by the icon image by the operation of touching the icon image displayed at the center of the screen.
[0157] In the present embodiment, the scrolling of the screen of the lower LCD 12 is performed by an operation of touching an icon image other than the icon image displayed at the center of the screen, or by an operation of touching the marker 73 or the scroll button 74 a or 74 b . However, the scrolling of the screen of the lower LCD 12 may be performed by another operation. For example, the screen of the lower LCD 12 may be scrolled rightward by pressing a right side portion of the direction input button 14 A, and the screen of the lower LCD 12 may be scrolled leftward by pressing a left side portion of the direction input button 14 A.
[0158] In the present embodiment, all of the plurality of selected application programs are not concurrently displayed, but a part of the plurality of selected application programs is displayed in the form of a list and interchanged with the rest so as to be displayed. Here, in an alternative embodiment, all of the plurality of selected application programs may be concurrently displayed. Alternatively, (icon images of) selected application programs to be displayed as a list may be displayed in a line as in the present embodiment or may be displayed in a matrix state of 2×2 or more.
[0159] Meanwhile, as shown in FIG. 7 , at the step S 5 , on the upper LCD 22 , a display image 75 and photographing button images 76 a and 76 b are displayed. The display image 75 is a stored image which is stored in the main memory 32 , indicated by the display image data 65 , and selected at the step S 3 , and the like. In other words, in the present embodiment, an image taken in the past is displayed on the menu screen. Thus, a user who uses the information processing apparatus 10 for the first time is caused to be aware that the information processing apparatus 10 has the photographing function. Further, the menu screen of the information processing apparatus 10 is different for each user (each information processing apparatus), and thus the menu screen can have individuality. When there is no stored image at the step S 5 , a display for notifying that there is no stored image and/or a display for prompting the photographing processing (e.g. displaying of a message that “Press L button or R button to photograph”) are performed at the later-described step S 5 .
[0160] Further, the photographing button images 76 a and 76 b are images indicating an operation for shifting the state of the information processing apparatus 10 to a state where it is possible to perform photographing by the simplified photographing program 52 (the photographing enabled state shown in FIG. 4 ), namely, the above photographing enabling operation. Thus, in the present embodiment, by displaying the operation for shifting the state of the information processing apparatus 10 to the photographing enabled state on the menu screen (a launch acceptance state), it can be clearly displayed to the user that it is possible to perform photographing by the simplified photographing program 52 from the menu screen (without selecting a selected application program). As shown in FIG. 7 , in the present embodiment, the photographing enabling operation is an operation of pressing the L button 14 I or the R button 14 J. Thus, the user can shift the state of the information processing apparatus 10 to the state where it is possible to perform photographing by the simplified photographing program 52 by once pressing a button (the L button 14 I or the R button 14 J) in the launch acceptance state. In the present embodiment, the photographing enabling operation is an operation of pressing a predetermined button (the L button 14 I or the R button 14 J) provided in the information processing apparatus 10 . However, in an alternative embodiment, the photographing enabling operation may be an operation of touching a predetermined button image displayed on the lower LCD 12 .
[0161] It is noted that in the present embodiment, except for the start-up for the first time (the case of Yes at the step S 1 ), a screen displayed initially after the start-up of the information processing apparatus 10 is the menu screen. In other words, in the present embodiment, the information processing apparatus 10 sets an initial state after the start-up of the information processing apparatus 10 to the launch acceptance state. Thus, the user can launch the simplified photographing program 52 immediately after the start-up.
[0162] Referring back to FIG. 6 , subsequent to the step S 5 , the processing at the step S 6 is executed. At the step S 6 , the CPU 31 accepts an input with respect to each input device. In other words, the CPU 31 obtains operation data from the operation section 14 , and also obtains input position data from the touch panel 13 . The obtained operation data and input position data are stored in the main memory 32 . In the launch acceptance state, the processing at the step S 6 is executed every a predetermined time period (e.g. every a one-frame time period ( 1/60 sec.)). Subsequent to the step S 6 , the processing at the step S 7 is executed.
[0163] At the step S 7 , the CPU 31 determines whether or not an operation of scrolling the screen of the lower LCD 12 has been performed. The determination at the step S 7 can be made by referring to the input position data stored in the main memory 32 at the step S 6 . In other words, in the determination processing at the step S 7 , the CPU 31 determines whether or not an input of touching a region where the marker 73 or the scroll button 74 a or 74 b is displayed has been performed. When a result of the determination at the step S 7 is positive, the processing at the step S 8 is executed. On the other hand, when the result of the determination at the step S 7 is negative, the processing at the later-described step S 9 is executed.
[0164] As described above, in the present embodiment, the step S 7 of determining existence/nonexistence of a scrolling operation is executed prior to the step S 9 of determining existence/nonexistence of a photographing enabling operation (i.e. detection of a scrolling operation is performed preferentially over detection of a photographing enabling operation). Thus, while a scrolling operation is performed, the state of the information processing apparatus is not shifted to the photographing enabled state even when a photographing enabling operation is performed. For example, even when an operation of pressing the L button 14 I or the R button 14 J is performed while a operation of scrolling the screen of the lower LCD 12 right or left is performed by touching the scroll button 74 a or 74 b on the left or right side of the scroll bar 72 or by pressing the direction input button 14 A, the state of the information processing apparatus is not shifted to the photographing enabled state.
[0165] At the step S 8 , the CPU 31 scrolls a display of the icon images (the screen of the lower LCD 12 ). In other words, when a touch input is performed with respect to the scroll button 74 a , the icon images are scrolled rightward. Thus, an icon image which has not been displayed on the screen of the lower LCD 12 can be displayed. Subsequent to the step S 8 , the processing at the step S 5 is executed again.
[0166] Meanwhile, at the step S 9 , the CPU 31 determines whether or not the photographing enabling operation has been performed. The determination at the step S 9 can be made by referring to the operation data stored in the main memory 32 at the step S 6 . In other words, in the determination processing at the step S 9 , the CPU 31 determines whether or not the L button 14 I or the R button 14 J has been pressed. When a result of the determination at the step S 9 is positive, the processing at the step S 10 is executed. On the other hand, when the result of the determination at the step S 9 is negative, the processing at the later-described step S 11 is executed.
[0167] At the step S 10 , the CPU 31 executes the simplified photographing processing. The simplified photographing processing is processing for causing the user to perform photographing with a simple function by the simplified photographing program 52 . With reference to FIG. 8 , the following will describe a detail of the simplified photographing processing.
[0168] FIG. 8 is a flow chart showing a procedure of the simplified photographing processing (the step S 10 ) shown in FIG. 6 . In input image generation processing, first, at a step S 21 , the CPU 31 launches the simplified photographing program 52 . In the present embodiment, since the simplified photographing program 52 has been read into the main memory 32 along with the launch function program 51 , the CPU 31 starts executing the simplified photographing program 52 . At this time, the data 67 and 68 included in the setting data 66 stored in the main memory 32 are inputted (set) as arguments with respect to the simplified photographing program 52 . Processing at steps S 22 to S 28 after the step S 21 is executed using the simplified photographing program 52 (by executing the simplified photographing program 52 ).
[0169] At the step S 22 , the CPU 31 obtains data of an image taken by the inner camera 23 or the outer camera 24 . In the present embodiment, an image is taken by only one of the cameras 23 and 24 , and the CPU 31 obtains image data only from the camera. It is noted that which an image is taken by the camera 23 or 24 is determined in accordance with content of the camera change data 67 which is passed as the argument at a time of the launch of the simplified photographing program 52 (the step S 21 ). Subsequent to the step S 22 , the processing at the step S 23 is executed.
[0170] At the step S 23 , the CPU 31 executes display processing. At the step S 23 which is in the photographing enabled state, an image taken by the camera 23 or 24 , and the like are displayed. The following will describe images displayed in the photographing enabled state using FIG. 9 .
[0171] FIG. 9 is a view showing an example of the images displayed in the photographing enabled state. As shown in FIG. 9 , at the step S 23 , a taken image 77 by the camera 23 or 24 which is obtained at the step S 22 is displayed on the lower LCD 12 . The processing at the steps S 22 and S 23 is repeatedly executed every a predetermined time period (e.g. 1/60 sec.). By repeatedly executing the processing at these steps S 22 and S 23 , a real-time image taken by the camera 23 or 24 is displayed on the lower LCD 12 . In an alternative embodiment, the real-time image may be displayed on the upper LCD 22 . In this case, an image stored by the photographing operation may be also displayed on the lower LCD 12 .
[0172] In addition, a button image 78 for performing an operation for executing the multifunctional photographing application program 53 (the above second launch operation) is displayed on the lower LCD 12 . Unlike the icon images displayed on the menu screen, the button image 78 is fixedly displayed at a predetermined position (at an upper right position in FIG. 9 ) on the screen. Although detail will be described later, the user can easily shift the state of the information processing apparatus 10 from a state of executing the simplified photographing program 52 to a state of executing the multifunctional photographing application program 53 by pressing the button image 78 .
[0173] Further, similarly as in FIG. 7 , the display image 75 and the photographing button images 76 a and 76 b are displayed on the upper LCD 22 . In the present embodiment, similarly as the photographing enabling operation, the photographing operation is an operation of pressing the L button 14 I or the R button 14 J (see the photographing button images 76 a and 76 b shown in FIG. 9 ). In an alternative embodiment, the photographing operation may not be the same as the photographing enabling operation, and, for example, a button image for performing the photographing operation may be displayed on the lower LCD 12 , and an operation of touching the button image may be the photographing operation. Further, the information processing apparatus 10 may accept both the operation of pressing the L button 14 I or the R button 14 J and the operation of touching the button image as the photographing operation.
[0174] Referring back to FIG. 8 , subsequent to the step S 23 , the processing at the step S 24 is executed. At the step S 24 , the CPU 31 accepts an input with respect to each input device. The processing at the step S 24 is the same as the processing at the above step S 6 . Subsequent to the step S 24 , the processing at the step S 25 is executed.
[0175] At the step S 25 , the CPU 31 determines whether or not the photographing operation has been performed. The determination at the step S 25 can be made by referring to operation data stored in the main memory 32 at the step S 24 . In the present embodiment, since the first launch operation and the photographing operation are the same as each other, the processing at the step S 25 can be executed similarly as the processing at the step S 9 . When a result of the determination at the step S 25 is positive, the processing at the step S 26 is executed. On the other hand, when the result of the determination at the step S 25 is negative, the processing at the later-described step S 27 is executed.
[0176] At the step S 26 , the CPU 31 stores a taken image. In other words, the CPU 31 stores the taken image obtained at the step S 22 in the stored data memory 34 or the memory card 28 . A storage destination of the taken image is determined in accordance with content of the storage destination data 68 which is passed as the argument at the time of the launch of the simplified photographing program 52 (the step S 21 ). It is noted that the storage destination of the taken image can be changed by the user in the multifunctional photographing processing by the later-described multifunctional photographing application program 53 . In an alternative embodiment, the storage destination of the taken image to be stored at the step S 26 may be fixedly set as the stored data memory 34 or the memory card 28 (regardless of the storage destination data 68 ). Subsequent to the step S 26 , the processing at the step S 27 is executed.
[0177] At the step S 27 , the CPU 31 selects the stored image which is stored at the last step S 26 as a display image. More specifically, the CPU 31 stores data indicative of the stored image which is stored at the last step S 26 as the display image data 65 in the main memory 32 . After the processing at the step S 27 , the CPU 31 terminates the execution of the simplified photographing program 52 , and terminates the simplified photographing processing. Then, the processing at the step S 4 shown in FIG. 6 is executed again.
[0178] As described above, in the present embodiment, in accordance with the photographing operation being performed in the photographing enabled state (the simplified photographing processing), the simplified photographing processing is terminated, and the state of the information processing apparatus 10 is shifted from the photographing enabled state to the launch acceptance state. In other words, when the user once performs the photographing operation in the simplified photographing processing, a screen display of the information processing apparatus 10 is returned to the menu screen, and thus even a novice user who has not read an instruction manual, and the like can naturally return to the launch acceptance state. Further, in the present embodiment, since the photographing enabling operation and the photographing operation are the same as each other, a shift from the launch acceptance state to the photographing enabled state and a shift from the photographing enabled state to the launch acceptance state can be performed by the same operation. Thus, even if the user accidentally presses the L button 14 I or the R button 14 J or presses the L button 14 I or the R button 14 J without fully understanding a manner of operation to shift the state of the information processing apparatus 10 to the photographing enabled state, the user can return to the original state (the launch acceptance state) by pressing the same button. Thus, the information processing apparatus 10 which is easy for the novice user to operate can be provided. In an alternative embodiment, the photographing enabling operation and the photographing operation may be different from each other. Even in this case, an operation for shifting the state of the information processing apparatus 10 from the photographing enabled state to the launch acceptance state and the photographing enabling operation may be the same as each other. For example, the photographing enabling operation may be an operation of pressing the L button 14 I or the R button 14 J, the photographing operation may be an operation of touching a predetermined button image displayed on the lower LCD 12 , and the operation for shifting the state of the information processing apparatus 10 from the photographing enabled state to the launch acceptance state may be an operation of pressing the L button 14 I or the R button 14 J.
[0179] Further, in the present embodiment, as described above, the state of the information processing apparatus 10 is shifted to the launch acceptance state after the photographing operation is performed. Thus, the state of the information processing apparatus 10 is shifted to the launch acceptance state without displaying the image stored in the processing at the above step S 26 by the simplified photographing program 52 . Here, in the present embodiment, in the processing at the step S 27 , the CPU 31 sets the image stored in the processing at the step S 26 as a display image after the shift to the launch acceptance state. Thus, the stored image taken by the simplified photographing program 52 is displayed as the display image immediately after the shift to the launch acceptance state. As a result, according to the present embodiment, although the state of the information processing apparatus 10 is shifted to the launch acceptance state by performing the photographing operation, the user can quickly confirm the image taken by the simplified photographing program 52 .
[0180] Meanwhile, at the step S 28 , the CPU 31 determines whether or not the second launch operation has been performed. The determination at the step S 28 can be made by referring to input position data stored in the main memory 32 at the step S 24 . In other words, in the determination processing at the step S 28 , the CPU 31 determines whether or not an input of touching a region where the button image 78 for performing the second launch operation is displayed has been perfumed. When a result of the determination at the step S 28 is positive, the later-described multifunctional photographing processing ( FIG. 10 ) is executed. On the other hand, when the result of the determination at the step S 28 is negative, the processing at the step S 22 is executed again. This is the end of the description of the simplified photographing processing shown in FIG. 8 .
[0181] Referring back to FIG. 6 , at the step S 11 , the CPU 31 determines whether or not the first launch operation has been performed. The determination at the step S 11 can be made by referring to the input position data stored in the main memory 32 at the step S 6 . In other words, in the determination processing at the step S 11 , the CPU 31 determines whether or not an input of touching a region where the icon image is displayed has been performed. When a result of the determination at the step S 11 is positive, the processing at the step S 12 is executed. On the other hand, when the result of the processing at the step S 11 is negative, the processing at the later-described step S 13 is executed.
[0182] At the step S 12 , the CPU 31 executes processing of executing a selected application program. In other words, the CPU 31 reads a selected application program corresponding to the icon image selected by the first launch operation into the main memory 32 , and executes the selected application program. Thus, the selected application program is started, and the user can use the selected application program. The processing at the step S 12 is terminated by terminating the selected application program, and the processing at the step S 3 is executed again subsequent to the step S 12 .
[0183] Here, a case where the multifunctional photographing application program 53 is executed as the selected application program at the above step S 12 will be described in detail. FIG. 10 is a flow chart showing a procedure of processing by the multifunctional photographing application program 53 (the multifunctional photographing processing). In the multifunctional photographing processing, first, at a step S 30 , the CPU 31 launches the multifunctional photographing application program 53 . In other words, the CPU 31 reads the multifunctional photographing application program 53 into the main memory 32 , and starts executing the multifunctional photographing application program 53 . At this time, the data 67 and 68 included in the setting data 66 stored in the main memory 32 are inputted (set) as arguments with respect to the simplified photographing program 52 . Subsequent to the step S 30 , processing at a step S 31 is executed. The processing at the steps S 31 to S 39 after the step S 30 is executed using the multifunctional photographing application program 53 (by executing the multifunctional photographing application program 53 ).
[0184] At the step S 31 , the CPU 31 executes display processing. Here, in the present embodiment, in the multifunctional photographing processing, there are a photographing mode for performing photographing using the imaging means and a photograph display mode for displaying an image (a stored image) taken in the past. In the display processing at the step S 31 , an image for causing the user to select either one of the two modes (the photograph display mode and the photographing mode) in the multifunctional photographing processing, and an image for setting a storage destination of a taken image to be stored by the photographing operation are displayed on at least one of the LCDs 12 and 22 . Although not shown in the drawings, in the present embodiment, an image indicating each of the photograph display mode and the photographing mode, and an image indicating an instruction to change a storage destination of a taken image are displayed on the lower LCD 12 . It is noted that a method for causing the user to select a mode and a method for causing the user to change a storage destination may be any methods, and the user may be caused to perform selection and changing with a button instead of the touch panel 13 .
[0185] At the step S 32 , the CPU 31 accepts an input with respect to each input device. The processing at the step S 32 is the same as the processing at the above step S 6 . Subsequent to the step S 32 , the processing at the step S 33 is executed.
[0186] At the step S 33 , the CPU 31 determines whether or not the photograph display mode has been selected. The determination at the step S 33 can be made by referring to input position data stored in the main memory 32 at the step S 32 . In other words, in the determination processing at the step S 33 , the CPU 31 determines whether or not an input of touching a region where the image indicating the photograph display mode is displayed has been performed. When a result of the determination at the step S 33 is positive, the processing at step S 34 is executed. On the other hand, when the result of the determination at the step S 33 is negative, the processing at the later-described step S 35 is executed.
[0187] At the step S 34 , the CPU 31 executes processing to be executed in the photograph display mode (photograph display mode processing). With reference to FIG. 11 , the following will describe a detail of the photograph display mode processing.
[0188] FIG. 11 is a flow chart showing a procedure of the photograph display mode processing (the step S 34 ) shown in FIG. 10 . In the photograph display mode processing, first, at a step S 41 , the CPU 31 executes display processing. At the step S 41 in the photograph display mode, a stored image taken in the past, and the like are displayed. With reference to FIG. 12 , the following will describe images displayed in the photograph display mode.
[0189] FIG. 12 is a view showing an example of the images displayed in the photograph display mode. As shown in FIG. 12 , at the step S 41 , a plurality of stored images 81 to 83 (three in the drawing), cursors 84 , scroll buttons 85 and 86 , a setting button 87 , and an end button 88 are displayed on the lower LCD 12 .
[0190] In FIG. 12 , the stored images 81 to 83 are (a part of) stored images which are stored in the stored data memory 34 or the memory card 28 . The stored image 82 surrounded by the cursors 84 is an image which is currently selected by the cursors 84 . The scroll buttons 85 and 86 are buttons for scrolling the stored images 81 to 83 right and left. In other words, when a touch input is performed with respect to the scroll button 85 on the right side of the screen, the stored images 81 to 83 are scrolled rightward, and when a touch input is performed with respect to the scroll button 86 on the left side of the screen, the stored images 81 to 83 are scrolled leftward. When the stored images are scrolled rightward or leftward, the stored images being displayed on the lower LCD 12 are changed, and the stored image selected by the cursors 84 is also changed.
[0191] It is noted that in the present embodiment, in the photograph display mode, a taken image which is stored in either the simplified photographing processing or the multifunctional photographing processing is displayed. In the present embodiment, a stored image which is stored in the simplified photographing processing, and a stored image which is stored in the multifunctional photographing processing are stored without distinguishing therebetween. More specifically, for either stored image, a rule for attaching a file name to a data file of the stored image (e.g. attaching a file name using time and date to be photographed, a total number of images taken by the information processing apparatus 10 , and the like) is the same. Since the stored images which are stored in either photographing processing are stored without distinguishing therebetween, the stored image which is stored in each photographing processing can be displayed in the photograph display mode.
[0192] The setting button 87 is a button image for performing an operation for newly setting the stored image selected by the cursors 84 as a favorite image. In other words, when a touch input is performed with respect to the setting button 87 , the stored image selected by the cursors 84 is set as a favorite image.
[0193] The end button 88 is a button image for performing an operation for terminating the photograph display mode. In other words, when a touch input is performed with respect to the end button 88 , the photograph display mode is terminated, and the processing by the CPU 31 is returned to the processing at the step S 31 .
[0194] It is noted that at the step S 41 , some information may be displayed on the upper LCD 22 or may not be displayed on the upper LCD 22 . In the present embodiment, the CPU 31 displays the stored image selected by the cursors 84 on the upper LCD 22 .
[0195] Referring back to FIG. 11 , subsequent to the step S 41 , processing at a step S 42 is executed. At the step S 42 , the CPU 31 accepts an input with respect to each input device. The processing at the step S 42 is the same as the processing at the step S 6 . Subsequent to the step S 42 , processing at a step S 43 is executed.
[0196] At the step S 43 , the CPU 31 determines whether or not an operation of scrolling the stored images being displayed on the lower LCD 12 has been performed. The determination at the step S 43 can be made by referring to input position data stored in the main memory 32 at the step S 42 . In other words, in the determination processing at the step S 43 , the CPU 31 determines whether or not an input of touching a region where the scroll button 85 or 86 is displayed has been performed. When a result of the determination at the step S 43 is positive, processing at a step S 44 is executed. On the other hand, when the result of the determination at the step S 43 is negative, processing at a later-described step S 45 is executed.
[0197] At the step S 44 , the CPU 31 scrolls the stored images being displayed on the lower LCD 12 . In other words, when a touch input is performed with respect to the scroll button 85 , the CPU 31 scrolls the stored images rightward, and when a touch input is performed with respect to the scroll button 86 , the CPU 31 scrolls the stored images leftward. Thus, a stored image which has not been displayed on the screen of the lower LCD 12 is displayed. Subsequent to the step S 44 , the processing at the above step S 41 is executed again.
[0198] Meanwhile, at the step S 45 , the CPU 31 determines whether or not an operation for setting a stored image as a favorite image has been performed. The determination at the step S 45 can be made by referring to the input position data stored in the main memory 32 at the step S 42 . In other words, in the determination processing at the step S 45 , the CPU 31 determines whether or not an input of touching a region where the setting button 87 is displayed has been performed. When a result of the determination at the step S 45 is positive, processing at a step S 46 is executed. On the other hand, when the result of the determination at the step S 45 is negative, the processing at the above step S 41 is executed again.
[0199] At the step S 46 , the CPU 31 sets a stored image which is currently selected by the cursors 84 as a favorite image. More specifically, the CPU 31 adds information indicative of the favorite image to data of the stored image which is stored in the stored data memory 34 or the memory card 28 . In addition, in the present embodiment, at the step S 46 , the CPU 31 causes the user to select which the stored image is to be set to the first, second, or third group. Thus, information indicative of a group selected by the user among the first to third groups is added to the data of the stored image. Subsequent to the step S 46 described above, processing at a step S 47 is executed.
[0200] Although the method for causing the user to select a group to which favorite images belong to is any method, the method may be as follows in an alternative embodiment. The CPU 31 displays an image indicating each group in addition to the image shown in FIG. 12 . When the user performs touch inputs with respect to the image indicating a group and a stored image, respectively, the CPU 31 sets the stored image as a favorite image of the group. The CPU 31 may accept the touch input with respect to the stored image after accepting the touch input with respect to the image indicating the group, or may accept the touch input with respect to the image indicating the group after accepting the touch input with respect to the stored image. The CPU 31 may set the stored image as a favorite image of the group even if either the image indicating a group or a stored image is touched earlier than the other.
[0201] At the step S 47 , the CPU 31 determines whether or not to terminate the photograph display mode. The determination at the step S 47 can be made by referring to the input position data stored in the main memory 32 at the step S 42 . In other words, in the determination processing at the step S 47 , the CPU 31 determines whether or not an input of touching a region where the end button 88 is displayed has been performed. When a result of the determination at the step S 47 is positive, the CPU 31 terminates the photograph display mode processing shown in FIG. 11 . On the other hand, when the result of the determination at the step S 47 is negative, the processing at the above step S 41 is executed again.
[0202] In the photograph display mode described above, the user can view the stored images taken in the past, and also can set the stored image as a favorite image. As described above, at the above step S 3 , the display image displayed on the menu screen (the display image 75 shown in FIG. 7 ) is selected among the favorite images. Thus, the user can select an image to be displayed as a display image by himself or herself.
[0203] Referring back to FIG. 10 , when the processing at the above step S 34 is terminated, the processing at the step S 31 is executed again. Thus, when the photograph display mode is terminated, the screen for causing the user to select either the photograph display mode or the photographing mode is displayed again (the step S 31 ).
[0204] Meanwhile, at the step S 35 , the CPU 31 determines whether or not the photographing mode has been selected. The determination at the step S 35 can be made by referring to the input position data stored in the main memory 32 at the step S 32 . In other words, in the determination processing at the step S 35 , the CPU 31 determines whether or not an input of touching a region where the image indicating the photographing mode is displayed has been performed. When a result of the determination at the step S 35 is positive, the processing at the step S 36 is executed. On the other hand, when the result of the determination at the step S 35 is negative, the processing at the later-described step S 37 is executed.
[0205] At the step S 36 , the CPU 31 executes processing to be executed in the photographing mode (photographing mode processing). With reference to FIG. 13 , the following will describe a detail of the photographing mode processing.
[0206] FIG. 13 is a flow chart showing a procedure of the photographing mode processing (the step S 36 ) shown in FIG. 11 . In the photographing mode processing, first, at a step S 50 , the CPU 31 obtains data of an image taken by the inner camera 23 or the outer camera 24 . The processing at the step S 50 is the same as the processing at the above step S 22 ( FIG. 8 ). Subsequent to the step S 50 , processing at a step S 51 is executed.
[0207] At the step S 51 , the CPU 31 executes display processing. At the step S 51 which is in the photographing mode, the taken image by the camera 23 or 24 , and the like are displayed. The following will describe an image displayed in the photographing mode using FIG. 14 .
[0208] FIG. 14 is a view showing an example of the image displayed in the photographing mode. As shown in FIG. 14 , at the step S 51 , in addition to the taken image 77 similarly as in FIG. 9 , various buttons 91 to 99 are displayed on the lower LCD 12 . Each of the buttons 91 to 99 is an image for performing an instruction with respect to the information processing apparatus 10 by the user performing a touch input with respect to a position of the image. The following will describe the buttons 91 to 99 .
[0209] The photographing button 91 is a button image for performing the photographing operation. In other words, when a touch input is performed with respect to the photographing button 91 , processing of storing a taken image is executed. It is noted that the photographing button 91 is preferably displayed substantially at a center of the lower housing 11 (in the left-right direction) for the user to easily operate the photographing button 91 with either a right hand or a left hand.
[0210] The camera change button 92 is an image for performing a camera change operation. In other words, when a touch input is performed with respect to the camera change button 92 , a camera for taking an image is changed between the inner camera 23 and the outer camera 24 .
[0211] The end button 93 is a button image for performing an operation for terminating the photographing mode. In other words, when a touch input is performed with respect to the end button 93 , the photographing mode is terminated, and the processing by the CPU 31 is returned to the processing at the step S 31 .
[0212] Each of the buttons 94 to 99 is a button image for performing an instruction in editing processing. The pen mode button 94 , the eraser mode button 95 , and the stamp mode button 96 are button images for performing an operation for changing an editing mode. Here, in the present embodiment, three modes, namely, a pen mode, a stamp mode, and an eraser mode, are prepared in advance. In the pen mode, an image of an input line which is inputted with respect to the touch panel 13 can be added to a taken image. In the stamp mode, a stamp image which is prepared in advance can be added to a taken image. In the eraser mode, an image added in the pen mode or the stamp mode can be deleted. The pen mode button 94 is an image for performing an instruction to change the editing mode to the pen mode. The eraser mode button 95 is an image for performing an instruction to change the editing mode to the eraser mode. The stamp mode button 96 is an image for performing an instruction to change the editing mode to the stamp mode.
[0213] The thickness change button 97 is an image for performing an instruction to change a thickness of a line to be inputted in the pen mode. The color change button 98 is an image for performing an instruction to change a color of a line to be inputted in the pen mode. An all deletion button 99 is an image for performing an instruction to delete all images added in the pen mode or the stamp mode.
[0214] By performing an instruction using each of the above buttons 94 to 99 , the user can input an image on the taken image displayed on the lower LCD 12 (so as to be superimposed on the taken image). It is noted that FIG. 14 shows an image in the case where there is no image inputted by the user in the later-described editing processing. Further, in the present embodiment, an image for explaining a manner of operation in the photographing mode to the user is displayed on the upper LCD 12 .
[0215] Referring back to FIG. 13 , at a step S 52 , the CPU 31 accepts an input with respect to each input device. The processing at the step S 52 is the same as the processing at the above step S 6 . Subsequent to the step S 52 , processing at a step S 33 is executed.
[0216] At the step S 53 , the CPU 31 determines whether or not the photographing operation has been performed. The determination at the step S 53 can be made by referring to operation data and input position data which are stored in the main memory 32 at the step S 52 . In other words, in the determination processing at the step S 53 , the CPU 31 determines whether or not the L button 14 I or the R button 14 J has been pressed, or whether or not an input of touching a region where the photographing button 91 is displayed has been performed. Thus, in the multifunctional photographing processing, the user can perform an operation which is the same as the photographing operation in the simplified photographing processing (the operation of pressing the L button 14 I or the R button 14 J) as the photographing operation, and also can perform an operation of touching the photographing button 91 as the photographing operation. When a result of the determination at the step S 53 is positive, processing at a step S 54 is executed. On the other hand, when the result of the determination at the step S 53 is negative, processing at a later-described step S 55 is executed.
[0217] As described at the above step S 53 , in the present embodiment, the photographing processing function which is owned in common by the simplified photographing program 52 and the multifunctional photographing application program 53 is executed in accordance with the same operation (the operation of pressing the L button 14 I or the R button 14 J). Since it is possible to perform the same operation regarding the same function even when a program is changed, a user-friendly operation system can be provided. It is noted that the phrase “the function owned in common is executed in accordance with the same operation” means that the same function may be executed by an operation in either the simplified photographing program 52 or the multifunctional photographing application program 53 , and does not mean to exclude a meaning that in either the simplified photographing program 52 or the multifunctional photographing application program 53 , the function is executed by an operation different from the operation. In other words, as in the present embodiment, in the multifunctional photographing application program 53 , the photographing processing may be executed by the operation of touching the photographing button 91 in addition to the operation of pressing the L button 14 I or the R button 14 J.
[0218] At a step S 54 , the CPU 31 stores a taken image. The processing at the step S 54 is the same as the processing at the step S 26 in the above simplified photographing processing. Thus, in the present embodiment, processing of storing a taken image is similarly executed in the simplified photographing processing and the multifunctional photographing processing. More specifically, a method of deciding a camera used for taking an image and a method of deciding a storage destination in the simplified photographing processing are the same as those in the multifunctional photographing processing. Subsequent to the step S 54 , processing at a later-described step S 59 is executed.
[0219] At the step S 55 , the CPU 31 determines whether or not the camera change operation has been performed. The determination at the step S 55 can be made by referring to the input position data stored in the main memory 32 at the step S 52 . In other words, in the determination processing at the step S 55 , the CPU 31 determines whether or not an operation of touching a region where the camera change button 92 is displayed has been performed. When a result of the determination at the step S 55 is positive, processing at a step S 56 is executed. On the other hand, when the result of the determination at the step S 55 is negative, processing at a later-described step S 57 is executed.
[0220] At the step S 56 , the CPU 31 changes the camera for taking an image. In other words, when the camera for taking an image is the inner camera 23 , the CPU 31 changes the camera for taking an image to the outer camera 24 . When the camera for taking an image is the outer camera 24 , the CPU 31 changes the camera for taking an image to the inner camera 23 . More specifically, the CPU 31 gives an instruction to stop an operation to one of the cameras 23 and 24 taking an image, and gives an instruction to perform imaging to the other camera. When the processing at the above step S 56 is executed, at the step S 50 executed the next time, data of an image taken by the camera after the change is obtained by the CPU 31 , and at the step S 51 executed the next time, the image taken by the camera after the change is displayed on the lower LCD 12 . Further, at the step S 56 , the CPU 31 stores data of indicative of the camera after the change as the camera change data 67 in the main memory 32 . Thus, when the multifunctional photographing processing is executed the next time, or when the simplified photographing processing is executed the next time, imaging is performed by the camera after the change. Subsequent to the step S 56 , the processing at the later-described step S 59 is executed.
[0221] At the step S 57 , the CPU 31 determines whether or not an editing operation has been performed. The determination at the step S 57 can be made by referring to the input position data stored in the main memory 32 at the step S 52 . In other words, in the determination processing at the step S 57 , the CPU 31 determines whether or not an input of touching a region where any of the buttons 94 to 99 is displayed or a region where the taken image 77 is displayed has been performed. When a result of the determination at the step S 57 is positive, processing at a step S 58 is executed. On the other hand, when the result of the determination at the step S 57 is negative, the processing at the later-described step S 59 is executed.
[0222] At the step S 58 , the CPU 31 executes various editing processing in accordance with a touch input performed by the user. For example, when any of the buttons 94 to 98 is touched, the CPU 31 changes settings (the editing mode, settings regarding the thickness or the color of a line) in accordance with a touched button. When the region of the taken image 77 is touched, the CPU 31 executes processing according to the editing mode with respect to a touched position. In other words, when the editing mode is the pen mode, an image of a line by a touch input is added to the taken image 77 , when the editing mode is the stamp mode, a stamp image which is prepared in advance is added to the taken image 77 at the touch position, and when the editing mode is the eraser mode, the image added at the touched position in the pen mode or the stamp mode is deleted. When the all deletion button 99 is touched, all images added to the taken image 77 in the pen mode or the stamp mode are deleted. Subsequent to the step S 58 described above, the processing at the step S 59 is executed.
[0223] At the step S 59 , the CPU 31 determines whether or not to terminate the photographing mode. The determination at the step S 59 can be made by referring to the input position data stored in the main memory 32 at the step S 452 . In other words, in the determination processing at the step S 59 , the CPU 31 determines whether or not an input of touching a region where the end button 93 is displayed has been performed. When a result of the step S 59 is positive, the CPU 31 terminates the photographing mode processing shown in FIG. 13 . On the other hand, when the result of the determination at the step S 59 is negative, the processing at the above step S 50 is executed again. This is the end of the description of the photographing mode processing shown in FIG. 13 .
[0224] Referring back to FIG. 10 , when the processing at the above step S 36 is terminated, the processing at the step S 31 is executed again. Thus, when the photographing mode is terminated, the screen for causing the user to select either the photograph display mode or the photographing mode is displayed again (the step S 31 ).
[0225] Meanwhile, at the step S 37 , the CPU 31 determines whether or not an operation for changing a storage destination of a stored image has been performed. The determination at the step S 37 can be made by referring to the input position data stored in the main memory 32 at the step S 32 . In other words, in the determination processing at the step S 37 , the CPU 31 determines whether or not an input of touching a region where the image indicating the instruction to change a storage destination of a taken image has been performed. When a result of the determination at the step S 37 is positive, the processing at the step S 38 is executed. On the other hand, when the result of the determination at the step S 37 is negative, the processing at the later-described step S 39 is executed.
[0226] At the step S 38 , the CPU 31 changes a storage destination of a taken image. In other words, when a current storage destination is the stored data memory 34 , the storage destination is changed to the memory card 28 , and when the current storage destination is the memory card 28 , the storage destination is changed to the stored data memory 34 . More specifically, the CPU 31 stores data indicative of the storage destination after the change as the storage destination data 68 in the main memory 32 . Subsequent to the step S 38 , the processing at the step S 31 is executed again.
[0227] At the step S 39 , the CPU 31 determines whether or not to terminate the multifunctional photographing processing. The determination is made by determining whether or not an instruction to terminate the multifunctional photographing processing has been performed by the user. For example, a button image for performing an operation for terminating the multifunctional photographing processing may be displayed in the display processing at the step S 31 , the instruction to terminate the multifunctional photographing processing may be performed by touching the button image. Alternatively, the instruction may be performed by pressing a predetermined button. When a result of the determination at the step S 39 is negative, the processing at the step S 31 is executed again. On the other hand, when the result of the determination at the step S 39 is positive, the CPU 31 terminates the execution of the multifunctional photographing application program 53 , and terminates the multifunctional photographing processing. Then, the processing at the step S 3 shown in FIG. 6 is executed again.
[0228] Referring back to FIG. 6 , at the step S 13 , the CPU 31 determines whether or not to terminate the processing in the information processing apparatus 10 . The determination at the step S 13 is made by determining whether or not a predetermined termination instruction operation (more specifically, an operation of pressing the power button 14 F, and the like) has been performed by the user. When a result of the determination at the step S 13 is negative, the processing at the step S 5 is executed again. On the other hand, when the result of the determination at the step S 13 is positive, the CPU 31 terminates the processing shown in FIG. 6 .
[0229] As described above, according to the present embodiment, in the state where the menu screen is displayed (in the launch acceptance state; at the step S 5 ), the information processing apparatus 10 accepts the first launch operation for launching a selected application program (the steps S 11 and S 12 ), and also the photographing enabling operation for launching the simplified photographing program 52 (the steps S 9 and S 10 ). Thus, since the simplified photographing program 52 is quickly launched by the photographing enabling operation from the state where the menu screen is displayed, the user can easily launch the simplified photographing program 52 . Particularly, in the present embodiment, in order to launch a desired selected application program, the user has to perform the first launch operation after performing a scrolling operation according to need, while the user only has to perform the photographing enabling operation in order to launch the simplified photographing program 52 . Thus, in the present embodiment, it is possible to launch the simplified photographing program 52 more easily than the selected application program.
[0230] In addition, according to the above embodiment, during the execution of the simplified photographing program 52 (in the photographing enabled state; at the steps S 22 to S 28 ), the CPU 31 accepts the second launch operation for launching the photographing application program 53 (the step S 28 ). According to this, the user can launch the multifunctional photographing application program 53 by the second launch operation even while performing photographing by the simplified photographing program 52 . Therefore, even when the user desires to use a function of the multifunctional photographing application program 53 which the simplified photographing program 52 does not have while performing photographing by the simplified photographing program 52 , the user can easily and quickly use the function by the second launch operation.
[0231] Further, in the present embodiment, it is possible to quickly launch the simplified photographing program 52 having a relatively simple function from the menu screen, and it is possible to launch the multifunctional photographing application program 53 having more functions during the execution of the simplified photographing program 52 . Thus, according to the present embodiment, the user can be caused to use the information processing apparatus 10 in a usage manner in which “the information processing apparatus 10 is initially operated by a photographing program having a simple function, and then various photographing functions of the information processing apparatus 10 are used by a photographing program having more functions”, and the user can be caused to use the information processing apparatus 10 so as to get used to an operation of the information processing apparatus 10 . Further, the simplified photographing program 52 can be assumed as an introduction (a trial version) for the multifunctional photographing application program 53 , and from the viewpoint of a supplier of the information processing apparatus 10 , the user can be prompted to use the multifunctional photographing application program 53 by allowing the simplified photographing program 52 to be quickly launched from the menu screen.
[0232] Further, in the present embodiment, since the function of the simplified photographing program 52 is a part of the function of the multifunctional photographing application program 53 , the data size of the simplified photographing program 52 is smaller than that of the multifunctional photographing application program 53 . Thus, by setting a program launched by the above photographing enabling operation from the menu screen to the simplified photographing program 52 having the smaller data size, it is possible to quickly launch a program for photographing from the menu screen.
[0233] (Photographing Leading Processing)
[0234] The following will describe a detail of the photographing leading processing at the above step S 2 . FIG. 15 is a flow chart showing a procedure of the photographing leading processing (the step S 2 ) shown in FIG. 6 . In the photographing leading processing, first, at a step S 61 , the CPU 31 displays a selection screen for causing the user to select whether or not to perform photographing (whether or not to shift the state of the information processing apparatus 10 to the photographing enabled state). For example, along with a message saying “Why don't you take a photograph?”, a button image for performing an instruction to perform photographing, and a button image for performing an instruction not to perform photographing are displayed on the lower LCD 12 . Subsequent to the step S 61 , processing at a step S 62 is executed.
[0235] At the step S 62 , the CPU 31 accepts an input with respect to each input device. The processing at the step S 62 is the same as the processing at the above step S 6 . Subsequent to the step S 62 , processing at a step S 63 is executed.
[0236] At a step S 63 , the CPU 31 determines whether or not the instruction to perform photographing has been selected. The determination at the step S 63 can be made by referring to input position data stored in the main memory 32 at the step S 62 . In other words, in the determination processing at the step S 63 , the CPU 31 determines whether or not an input of touching a region where the button image for performing the instruction to perform photographing has been performed. When a result of the determination at the step S 63 is positive, processing at a step S 64 is executed. On the other hand, when the result of the determination at the step S 63 is negative, processing at a later-described step S 65 is executed.
[0237] At the step S 64 , the CPU 31 executes simplified photographing processing. This simplified photographing processing is the same as the processing at the above step S 10 , and thus the detailed description thereof will be omitted. Since the state of the information processing apparatus 10 is shifted to the photographing enabled state by the simplified photographing processing, the user can perform the photographing operation. After the simplified photographing processing at the step S 64 is terminated, the CPU 31 terminates the photographing leading processing shown in FIG. 15 . It is noted that in the present embodiment, since the processing at the step S 64 is the same as the processing at the step S 10 , it is possible to launch the multifunctional photographing application program 53 during the simplified photographing processing at the step S 64 , similarly as at the step S 10 . However, in an alternative embodiment, in the simplified photographing processing at the step S 64 , the button image 78 for performing the second launch operation may not be displayed such that it is impossible to launch the multifunctional photographing application program 53 .
[0238] On the other hand, at the step S 65 , the CPU 31 displays an image for introducing a photographing function. For example, the CPU 31 displays an image for explaining functions regarding the simplified photographing program 52 and the multifunctional photographing application program 53 , and the like on the LCDs 12 and 22 . After the step S 65 , the CPU 31 terminates the photographing leading processing shown in FIG. 15 .
[0239] As described above, in the present embodiment, the information processing apparatus 10 determines whether or not the start-up of the information processing apparatus 10 is for the first time (the step S 1 ). When the information processing apparatus 10 is started up for the first time (Yes at the step S 1 ), the information processing apparatus 10 performs a display for causing the user to select whether or not to shift the state of information processing apparatus 10 to the photographing enabled state (the step S 61 ). Then, when the user selects to perform photographing (Yes at the step S 63 ), the information processing apparatus 10 causes the user to actually experience the photographing operation (the step S 64 ). Thus, the user can be led to initially experience the photographing operation in the information processing apparatus 10 . In other words, by the photographing leading processing, a user who uses the information processing apparatus 10 for the first time can be caused to initially perform the photographing operation to get used to the photographing operation. Further, in the present embodiment, since the user is caused to experience the simple photographing operation by the above simplified photographing program 52 at the step S 64 , the user can easily perform the photographing operation as compared with the case where the user is caused to initially experience the photographing operation by the multifunctional photographing application program 53 . Further, from the viewpoint of a manufacturer of the information processing apparatus 10 , the photographing function of the information processing apparatus 10 can be comprehensively introduced to the user by causing the user to initially experience the simple photographing operation.
[0240] In the present embodiment, the user is caused to select whether or not to shift the state of the information processing apparatus 10 to the photographing enabled state at the step S 61 . However, in an alternative embodiment, in the photographing leading processing, the state of the information processing apparatus 10 may be shifted to the photographing enabled state without causing the user to make the selection. In other words, the photographing processing by the photographing program 52 or 53 may be executed without causing the user to make the selection.
[0241] (Regarding Change of Display Image)
[0242] In the present embodiment, the information processing apparatus 10 changes content of the display image on the menu screen at a predetermined timing (automatically without an instruction from the user). This produces change in the menu screen, and the user can be prevented from getting bored.
[0243] Further, in the present embodiment, the above predetermined timing includes a timing of starting up the information processing apparatus 10 , and a timing of terminating the selected application program. More specifically, as described above, when the information processing apparatus 10 is started up, or when a selected application program is terminated, the display processing at the step S 5 is executed after the processing at the step S 3 is executed. Thus, the display image on the menu screen is changed. In other words, every time the information processing apparatus 10 is started up, or every time a selected application program is executed, the display image is changed. According to this, the user has things to look forward to (about “which image is displayed”) at the start-up and at the time of terminating the execution of the selected application program, and hence, from the viewpoint of the supplier of the information processing apparatus 10 , there arises an effect of prompting the user to start up the information processing apparatus 10 and to execute a selected application program (i.e. to use the information processing apparatus 10 ).
[0244] In addition, in the present embodiment, the predetermined timing includes a timing of opening the foldable information processing apparatus 10 . In the present embodiment, since the information processing apparatus 10 in the closed state is also in a state of a sleep mode, the above “timing of starting up the information processing apparatus 10 ” includes a “timing of opening the information processing apparatus 10 in the closed state (sleep mode) (restarting the information processing apparatus 10 from the sleepmode). When the information processing apparatus 10 is opened again after the information processing apparatus 10 in the opened state is closed, the CPU 31 changes the display image between before and after the closing. Thus, the user has things to look forward to when opening the information processing apparatus 10 , and hence, from the viewpoint of the supplier of the information processing apparatus 10 , there arises an effect of prompting the user to use the information processing apparatus 10 by making the user open the information processing apparatus 10 . In the present embodiment, at the timing of opening the information processing apparatus 10 in the closed state, the display image is not changed in a random manner, and is changed in accordance with a predetermined order. With reference to FIG. 16 , the following will describe a detail of processing of changing the display image according to opening and closing.
[0245] FIG. 16 is a flow chart showing a detail of processing (opening-closing time processing) executed when the information processing apparatus 10 is closed and opened. The processing shown in FIG. 16 is started by closing the information processing apparatus 10 at any timing during the processing shown in FIG. 6 .
[0246] In the opening-closing time processing, first, at a step S 71 , the CPU 31 shifts the information processing apparatus 10 to the sleep mode. More specifically, the CPU 31 stops an image display on each of the LCDs 12 and 22 , and temporarily stops processing in an application program being executed. The sleep mode indicates a state where at least a part of functions of the information processing apparatus 10 is in a sleeping state or in a power-saving operation state. Subsequent to the step S 71 , processing at a step S 72 is executed.
[0247] At the step S 72 , the CPU 31 determines whether or not the information processing apparatus 10 is opened. When a result of the determination at the step S 72 is positive, processing at a step S 73 is executed. On the other hand, when the result of the determination at the step S 72 is negative, the processing at the step S 72 is executed again. In other words, the CPU 31 waits until the information processing apparatus 10 is opened.
[0248] At the step S 73 , the CPU 31 changes the display image in a state before the opening-closing time processing is started. At the step S 73 , the display image is changed by sequentially selecting a display image among the favorite images in accordance with a predetermined order. The following will describe a method of changing the display image with reference to FIG. 17 .
[0249] FIG. 17 is a view showing the method of changing the display image at the step S 73 . FIG. 17 shows a case where the first group includes three favorite images, the second group includes two favorite images, and the third group includes four favorite images. In the present embodiment, the favorite images included in each group are arranged in a predetermined order, and managed. The predetermined order may be an order of time and date to be photographed (stored), an order of time and date to be set as a favorite image, or an order set arbitrarily by the user. At the step S 73 , a favorite image is sequentially changed in accordance with this order. In other words, the CPU 31 sets a favorite image next to a display image before change (in the state before the opening-closing time processing is started) as a display image after change. Further, when a display image before change is a final favorite image in a group, a first favorite image in a group next to the group is set as a display image after change. Further, when a display image before change is a final favorite image in the third group, a first favorite image in the first group is set as a display image after change. As described above, at the step S 73 , the display image is changed in accordance with an order indicated by arrows in FIG. 17 . When there is no favorite image, one image is selected from the stored images in the stored data memory 34 in a random manner every time the information processing apparatus 10 is closed and opened. In this case, the display image may be changed in accordance with a predetermined order (e.g. an order of time and date to be photographed, an order of time and date to be set as a favorite image, an order set arbitrarily by the user). Subsequent to the step S 73 , the CPU 31 terminates the opening-closing time processing, and returns to a state immediately before the opening-closing time processing is started.
[0250] In the present embodiment, when the stored image immediately after photographing is performed with the simplified photographing processing is displayed in the processing at the step S 27 described above, the stored image breaks into the predetermined order and is displayed. In other words, when a photographing operation is performed with the simplified photographing processing (the step S 27 is executed), changing of the display image in accordance with the predetermined order is interrupted. However, when the information processing apparatus 10 is closed and opened later, the predetermined order is returned to, and a display image after change is displayed. For example, the case where the information processing apparatus 10 is folded and opened again after a photographing operation is performed in a state where a favorite image 1 - 2 is displayed to display a taken image stored by the photographing operation is considered. In this case, the CPU 31 displays the favorite image to be displayed after the favorite image 1 - 2 if obeying the predetermined order, namely, a favorite image 1 - 3 , as a display image after change, on the display screen.
[0251] As described above, in the present embodiment, every time the information processing apparatus 10 is opened, the display image is changed in the predetermined order. Thus, the user can enjoy changing display images one after another by an operation of opening and closing the information processing apparatus 10 . For example, the user can create a four-panel cartoon of which a graphic (a display image) is changed every time the information processing apparatus 10 is opened, and can successionally view a series of photographs arranged in chronological order by repeatedly opening and closing the information processing apparatus 10 . It is noted that at this time, at the above step S 3 , the CPU 31 may select a display image among a first favorite image in each group in a random manner. Thus, all images included in each group can be successionally displayed in a predetermined order.
[0252] In an alternative embodiment, the information processing apparatus 10 may change the display image in a predetermined order in accordance with a predetermined operation (e.g. an operation of pressing a predetermined button). In other words, the above predetermined timing may be a timing of performing a predetermined operation.
[0253] In an alternative embodiment, in the launch acceptance state, the information processing apparatus 10 may accept an instruction to display a taken image desired by the user on the upper LCD 22 . In other words, the information processing apparatus 10 may accept, from the user, an instruction to designate a taken image to be displayed on the display screen, and may display the taken image designated by the instruction on the upper LCD 22 in accordance with the acceptance of the instruction. This makes it possible to easily display a user's favorite image any time.
[0254] In the embodiment described above, when favorite images are set, the image to be displayed is changed in accordance with a predetermined order (e.g. an order of time and date to be photographed, an order of time and date to be set as a favorite image, an order set arbitrarily by the user). In an alternative embodiment, when favorite images are set, an image may be selected from the favorite images in a random manner and displayed.
[0255] In the embodiment described above, every time the information processing apparatus 10 is closed and opened, the taken image to be displayed is changed. In an alternative embodiment, “every time the launch program is launched”, the information processing apparatus 10 may perform processing of changing the image to be displayed as described above. Further, “every time the information processing apparatus 10 is closed and opened” or “every time the launch program is launched”, the information processing apparatus 10 may perform processing of changing the image to be displayed as described above.
Modified Example
[0256] In the above embodiment, predetermined information (data) is commonly used in the simplified photographing program 52 and the multifunctional photographing application program 53 . More specifically, the two programs 52 and 53 commonly use information of the camera for taking an image, and information of a storage destination of a stored image. In an alternative embodiment, the two programs 52 and 53 may commonly use other information. For example, in the case where a file name of a stored image is determined based on a total number of images taken by the information processing apparatus 10 , information of the total number of images may be commonly used.
[0257] Further, in an alternative embodiment, the information processing apparatus 10 may cause content of an argument to be passed to the multifunctional photographing application program 53 to be different between when the multifunctional photographing application program 53 is launched in the photographing enabled state (the case of Yes at the step S 28 ) and when the multifunctional photographing application program 53 is launched in the launch acceptance state (the case of Yes at the step S 11 ).
[0258] For example, information indicative of a mode at a time of starting executing the multifunctional photographing application program 53 may be the above argument. In other words, the mode at the time of starting executing the multifunctional photographing application program 53 may be different between when the multifunctional photographing application program 53 is launched in the photographing enabled state and when the multifunctional photographing application program 53 is launched in the launch acceptance state. More specifically, when the multifunctional photographing application program 53 is launched in the launch acceptance state, similarly as in the above embodiment, the mode at the time of starting executing the multifunctional photographing application program 53 may be set to a mode for causing the user to select either the photographing mode or the photograph display mode. When the multifunctional photographing application program 53 is launched in the photographing enabled state, the mode at the time of starting executing the multifunctional photographing application program 53 may be set to the photographing mode. When the multifunctional photographing application program 53 is launched in the photographing enabled state, it can be assumed that the user launches the multifunctional photographing application program 53 for performing photographing with a function which the simplified photographing program 52 does not have. Further, in an alternative embodiment, when the multifunctional photographing application program 53 is launched in the photographing enabled state, the mode at the time of starting executing the multifunctional photographing application program 53 may be set to the photograph display mode, and an image regarding a display image which has been displayed in the photographing enabled state (e.g. a favorite image in the same group as the display image, an image taken on the same day as the display image, and the like) may be displayed.
[0259] Further, in the above embodiment, a button image for launching the multifunctional photographing application program 53 in the photographing enabled state (the button image 78 shown in FIG. 9 ) is one. However, in alternative embodiment, two button images may be displayed. Here, one of the two button images is a button for launching the multifunctional photographing application program 53 with the mode at the time of starting executing the multifunctional photographing application program 53 being set to the photographing mode, and the other button image is a button for launching the multifunctional photographing application program 53 with the mode at the time of starting executing the multifunctional photographing application program 53 being set to the photograph display mode. Thus, in an alternative embodiment, the information processing apparatus 10 may prepare a plurality of types of second launch operations, and the mode at the time of start of execution (of the multifunctional photographing application program 53 ) may be different depending on a type of a second launch operation being performed.
[0260] Further, in the above embodiment, the simplified photographing program 52 is different from the launch function program 51 , and launched by the launch program independently of the launch function program 51 . Here, in an alternative embodiment, the simplified photographing program 52 may be a part of the launch function program 51 (i.e. the launch function program 51 and the simplified photographing program 52 may be incorporated into one program in the launch program 61 ). In an alternative embodiment, the launch function program 51 may launch the simplified photographing program 52 . In other words, as long as an instruction (an operation) for launching the simplified photographing program 52 is different from that for launching the multifunctional photographing application program 53 , the simplified photographing program 52 and the multifunctional photographing application program 53 may be launched by the same program or by different programs.
[0261] While the invention has been described in detail, the foregoing description is in all aspects illustrative and not restrictive. It is understood that numerous other modifications and variations can be devised without departing from the scope of the invention. | An example information processing apparatus includes a display; storage configured to store one or more applications; and a hardware processor configured to control the display to display a menu screen, including one or more selection images operable for launching applications, both when the information processing apparatus is started and when executing of a launched application is stopped. The processor is further configured to automatically change an aspect of the menu screen after the information processing apparatus is turned off and re-started. | 8 |
This is a division of application Ser. No. 210,472, filed June 23, 1988, now abandoned.
BACKGROUND OF THE INVENTION 1. Field of the Invention
This invention relates to a mineral fiberboard, and, more particularly, a mineral fiber acoustical board or unit. 2. Description of the Prior Art
Mineral fiberboards (e.g., acoustical panels) are of commercial value, compared to vegetable fiberboards, because of the incombustibility of the mineral fiber. The acoustical panels are conventionally made with mineral wool fibers and a starch binder. It is customary to impart a desired acoustical rating to these panels by mechanically punching or fissuring them. While, in many conventional ceiling products, the board perforations are necessary for sound absorption and are sometimes decorative, there are certain instances where the perforations detract from the appearance. In these instances, it would be desirable to utilize a ceiling panel which is not perforated but still has high sound-absorption properties.
OBJECTS OF THE INVENTION
It is therefore an object of the present invention to provide an improved mineral fiber containing composition from which a highly sound-absorptive ceiling panel can be produced without any need to mechanically punch or fissure the panel.
It is another object of the present invention to provide an improved mineral fiber-containing board which is characterized by a combination of desirable physical properties, including good strength and sound-absorption properties and a highly decorative surface.
Other objects and advantages of the present invention will become apparent to those skilled in the art when the instant disclosure is read in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
The above objects have been achieved in the mineral fiberboard of the present invention, which comprises sufficient mineral materials to render the board highly sound-absorbing without the need for mechanical punching or fissuring. The preferred mineral materials are mineral fibers, e.g., mineral wool, and perlite, but other mineral fillers can also be used. However, clay is not included in the board and its omission, together with the use of a relatively small amount of cellulosic material, e.g., newsprint, results in the attainment of a particularly high noise reduction coefficient (NRC). The board advantageously comprises mineral wool, Perlite, cellulosic fibers and binder in suitable proportions to give a high NRC without the need for a multiplicity of holes from the surface to the interior of the board.
While any conventional method for making an acoustical mineral fiberboard may be employed, the high sound-absorbing board of the present invention is preferably made by conventional wet processes wherein a water slurry of mineral fibers and a binder such as starch is deposited continuously upon a moving wire screen and the water is removed by drainage and suction. The mat thus formed is dried and the binder set, after which the mat is cut into units of desired dimensions for installation. In order to improve appearance and further enhance sound-absorption properties, the product can be fissured or punched to provide a perforated surface.
In an advantageous embodiment of the invention, the fiberboard is produced from a slurry containing mineral fibers which are nodulated during wet mixing of the slurry's ingredients. The ingredients, together with the water necessary to make up the required high slurry consistency (e.g., greater than 5%) for extensive mineral fiber nodulation, are added to conventional mixing and holding equipment from which they are flowed onto the board-forming wire of a machine such as a Fourdrinier through a conventional head box. The water-laid mat which is thus formed is compressed and dried. The resulting dried board surface is then advantageously modified to yield a finished product having a combination of desirable properties, including a visually appealing surface. The surface modification may include abrasion, such as by surface brushing or surface blasting (e.g., by a centrifugal force blasting machine), or any other treatment which results in a decorative appearance.
DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a diagrammatic, side elevational view of a fiberboard forming process in accordance with the present invention;
FIG. 2 is a triangular graph showing the relative percentages of perlite, newsprint and clay in a series of mineral fiberboards--mineral wool and starch concentrations held constant; and
FIG. 3 is a triangular graph showing the relative percentages of perlite, newsprint and mineral wool in another series of mineral fiberboards starch concentration held constant and clay omitted.
DETAILED DESCRIPTION OF THE INVENTION
The sound absorption properties of a mineral fiberboard made from mineral wool or the like with a binder are greatly enhanced by utilizing in the board-forming composition a specific quantity of perlite, and no more than about 10% by weight (dry solids basis) of cellulosic material, and by excluding clay from the composition. The quantities of materials employed have been found to be critical for the attainment of a high noise reduction coefficient in conjunction with the other properties required in a commercially acceptable acoustical board, such as sag and fire resistance, and adequate strength for large panel sizes. The following table sets forth the amounts of solid materials in terms of percent by weight on a dry basis of the preferred formulation used in the formation of the acoustical panel of the present invention.
______________________________________ PreferredIngredient Typical (%) Range (%) Range (%)______________________________________Mineral Wool 65.0 50-70 64-66Perlite 25.5 15-35 21-28Cellulosic Fibers 3.0 1-10 2-5Starch 6.5 4-15 4-10Retention Aid 0.03 0-1 0-0.1______________________________________
The mineral fiber component of the acoustical board of the invention includes wool or fibers formed from rock, slag, fused glass, glass mixtures thereof and other heat liquefiable raw materials capable of being converted into fibers. The mineral fibers usually have a ratio of length to diameter which is equal to 10 or higher, with lengths which vary between 0.1 and 100 mm, more typically between 1 and 10 mm, and diameters within the range of 0.1 to 25 microns. The mineral wool employed in the process of the invention typically has fiber diameters from about 4 to 8 microns, an acid/base ratio (molar) of about 0.80 to 1.10 and the following composition:
______________________________________Mineral Wool Composition Typical (%) Range (%)______________________________________SiO.sub.2 45 42-48Al.sub.2 O.sub.3 8 7-9CaO 37 36-38MgO 7 6-9______________________________________
The slurry also may contain cellulosic fibers and a binder. The solids of the slurry may comprise about 50% to 5% mineral fibers and about 1% to 10%, preferably 1% to 8%, cellulosic fibers, and the binding agent in an amount sufficient to form the board of the invention, as, e.g., about 5% to 15% .
The cellulosic fibers may be wood fibers, primary or secondary paper fibers, cotton linters or the like. The fiber length will generally be up to about 1/4 inch in length. Highly desirable fibers for use in the present invention are newsprint fibers which will generally have a length of from about 1/4 millimeter to about 5 millimeters with an average length of about 1 millimeter.
Numerous materials may be used as binding agents in the board-forming composition of the invention. Useful binders include starch, chemically modified starches, phenol-formaldehyde or other artificial resin binders, sodium silicate, glue, casein, rubber latex, aqueous rubber dispersions or emulsions, asphalt emulsions, or combinations thereof. The binder may include a minor amount of virgin kraft pulp, as disclosed in U.S. Pat. No. 2,773,764.
A wide variety of fillers can be employed in the mineral fiber containing composition of the invention. The preferred fillers are those which are inorganic. It is desirable to avoid mineral fillers which are too fine such as those having an average particle size of less than 5 microns.
Advantageously, the composition contains about 15 to 35, preferably 21 to 28, and more preferably 23 to 26, wt % (dry solids basis) of expanded perlite particles, which suitably have a density in the range from about 3.0 to 8.0, preferably 5.0-8.0, pcf. The expanded perlite used in the present invention has a typical screen analysis as follows:
______________________________________Expanded Perlite Typical Sieve Analysis % RetainedU. S. Sieve No. Typical Range______________________________________ 8 0 016 0 0-230 8 4-2050 55 35-60100 27 15-40pan 10 10-20______________________________________
The composition additionally may contain other auxiliary substances useful in conventional mineral fiberboard-forming compositions, such as preservatives, wetting agents, defoamers, retention aids, sizing agents, and broke. The amounts of such auxiliary additives can be readily determined by those skilled in the art.
In the preferred wet process for making the mineral fiberboard, the solid materials, including mineral wool, perlite, starch, and cellulosic fibers, are slurried and commingled with water in a suitable container 1 provided with agitation means 2. The mineral wool-containing slurry can have a consistency or solids content of from about 2-8 wt % . Advantageously, the consistency is sufficiently high (e.g., 5-8 wt % ) to bring about substantial formation of nodulated wool upon mixing of the slurry. The formation of nodules of mineral fiber during mixing of the slurry is brought, about as described in U.S. patent application Ser. No. 210,446 of William D. Pittman, Alan Boyd, and Fred L. Migliorini, entitled: "Method of Wet-Forming Mineral Fiberboard with Formation of Fiber Nodules" and filed on the same date as the present application. Alternatively, the mineral wool may be introduced to the slurry in the form of pellets of previously nodulated mineral wool.
After the mineral wool containing slurry is agitated sufficiently to uniformly distribute the solids and, when appropriate, to nodulate the wool, the slurried composition is transferred by pump 3 through pipe 4 to head box 5. The slurry is subsequently deposited on Fourdrinier wire 7 through orifice 6 of head box 5. The first section 8 of the Fourdrinier wire permits free drainage of water from the material and further drainage is promoted by suction boxes 9 in section 10. As the slurry is brought in contact with the Fourdrinier machine and water of the slurry drains therefrom, a wet felted mat of the mineral fiber composition forms on the machine. The wet laid mat is dewatered by the Fourdrinier machine to a solids content of about 20 to 40 weight percent.
The partially dried material is then prepressed to a thickness of about 0.4 to 0.8 inch by a plurality of press rolls 11. It will be appreciated that a single set of press rolls could be employed if desired. After being pressed, the sheet product will generally have from about 60 to about 75% water. A coating may be applied to the pressed mat by means of feed-pipe 13 and coater 14.
After passing through press rolls 11, the wet mat is transferred into dryer 12. At the outlet of the dryer, there is obtained a board having a moisture content of less than about 1.0% . The board is cut into smaller panels by saw arrangement 15. The dried product can be subjected to any suitable conventional finishing apparatus, depending on the applications for which it is intended. Such apparatuses may include applicators for applying coatings to protect and/or decorate the product surface, such as bevel coaters, finish spray coaters, printers, multi-color decorative coaters, and the like, and further drying equipment.
A fine-textured appearance can be created on one of the two major surfaces of the dried board by any suitable texturing means 17, such as by abrading, scoring, brushing, etc. The board may be advantageously turned over by an inverter 16 to present the smooth screen side for surface treatment. It has been found that a wheel blaster, such as that supplied by Wheelabrator-Frye, Inc., and known as a Tile Etch Machine, produces a surface which is fine-textured and visually appealing.
The wheel blaster uses centrifugal force to propel abrasive material against the board surface. Suitable abrasive material for eroding the surface includes metal grit, plastic abrasive, and walnut shells. Typically, the surface abrasion removes only about 0.01-0.04 inch of the board surface in producing the desired look. The finish coat is suitably applied to the board after its treatment by the blasting machine.
In accordance with the process of the present invention, the mineral fiber-containing slurry is typically formed into a textured fiberboard of from about 0.4 to 0.8 inch thick, preferably from about 0.5 to 0.8 inch thick, and having a density of from about 10 to 25 pounds per cubic foot, preferably from about 10 to 20 pounds per cubic foot. The noise reduction coefficient (NRC) of the board is generally from about 0.50-0.70, and preferably greater than 0.55, and can be secured without the use of mechanical punching or fissuring, although, if desired, the latter means can be employed to further enhance the NRC.
The present invention is further illustrated by the following examples in which all percentages are on a dry weight basis.
EXAMPLE 1
Mineral wool fiberboards 1 to 11 were each prepared from a slurry consisting of approximately 551.0 g solids uniformly dispersed in 2.0 gal water, with the concentrations of the mineral wool and a gelatinized starch binder being held constant at 55% and 9.5% , respectively, and the concentrations of the remaining ingredients being adjusted as shown in Table 1 below. The minor amount of retention aid (0.08% ) employed in preparing each board is not shown in the table.
The ingredients were diluted with water and mixed to form a homogeneous slurry. The water was drained away by pouring the slurry on a screen, and the resulting wet mat was pressed to the thickness and density shown in Table 1 and dried. Measurement of the porosity of the boards gave the air flow resistivity results presented in Table 1. In this type of comparative study of fiberboards prepared from similar ingredients, the measured air flow resistivity is found to provide a reasonable estimation of the board's noise reduction coefficient (NRC), with the air flow resistivity and NRC being inversely related.
The effect on NRC of varying the content of the perlite, newsprint and clay ingredients while keeping the mineral wool and binder constant may be seen from Table 1 considered in connection with FIG. 2 of the drawings which is a triangular graph showing for each of fiberboards 1 to 11 the percentages of the three varied ingredients vis-a-vis one another. As clearly seen from the table and graph, the lowest air flow resistivities and hence highest NRCs are attained when no clay is included in the board-forming composition (boards 1 and 4). Additionally, it is seen that board 1, having a greater content of perlite than board 4, has a lower air flow resistivity (higher NRC) than the latter board. The import of the testing is that mineral fiberboards prepared without clay and with relatively high perlite and low newsprint contents are preferred acoustical products.
TABLE 1__________________________________________________________________________ Air FlowPercent by Weight.sup.1 Thickness Density Resistivity.sup.2Board No. Perlite Newsprint Clay (in) (lb/ft.sup.3) (MKS rayls/M)__________________________________________________________________________1 35.5 0 0 0.569 16.6 931,0252 0 35.5 0 0.385 26.0 8,255,8943 0 0 35.5 0.512 23.1 13,347,2974 17.75 17.75 0 0.536 19.4 1,764,6585 17.75 0 17.75 0.587 20.1 5,232,3316 0 17.75 17.75 0.466 25.6 18,331,0527 11.8 11.8 11.8 0.547 21.7 7,458,6668 23.7 5.9 5.9 0.595 19.4 2,734,6209 5.9 23.7 5.9 0.503 23.5 4,985,73110 5.9 5.9 23.7 0.531 21.7 12,256,86711 15.2 15.2 5.1 0.580 18.1 1,771,880__________________________________________________________________________ .sup.1 Of total boardforming composition. .sup.2 According to ASTM C522.
EXAMPLE 2
The board-forming procedure of Example 1 was repeated for mineral fiberboards 12 to 22 of Table 2 below, except for the omission of clay and use of the mineral wool, perlite and newsprint ingredients at the levels shown in the table. The gelatinized starch binder was again held constant at 9.5% .
The relative percentages of perlite, newsprint and mineral wool--the total quantity of these 3 ingredients being taken as 100% for purposes of the graph--are shown in FIG. 3 of the drawings for each of boards 12 to 22. Consideration of Table 2 in connection with FIG. 3 clearly shows that boards made with a newsprint content of less than 5 weight % constitute superior acoustical products.
TABLE 2__________________________________________________________________________ Air FlowPercent by Weight.sup.1 Thickness Density Resistivity.sup.2Board No. Mineral Wool Perlite Newsprint (in) (lb/ft.sup.3) (MKS rayls/M)__________________________________________________________________________12 65.0 14.5 11.0 0.644 16.3 1,144,09913 65.0 21.5 4.0 0.644 14.5 504,03814 55.0 24.5 11.0 0.664 16.0 1,367,69315 58.5 28.0 4.0 0.643 15.6 655,06516 60.0 19.5 11.0 0.673 16.2 1,285,34917 60.9 22.1 7.5 0.686 15.5 957,86818 57.7 29.0 1.8 0.642 14.6 493,94819 65.0 23.7 1.8 0.644 15.0 473,72820 62.9 26.7 0.9 0.653 14.3 347,10721 62.0 25.8 2.7 0.651 15.3 510,82322 69.2 18.6 2.7 0.689 14.6 460,253__________________________________________________________________________ .sup.1 Of total board forming composition. .sup.2 According to ASTM C522.
EXAMPLE 3
This example illustrates, with reference to FIG. 1 of the drawings, the large-scale production of a wet-felted ceiling product of the present invention.
The formulation utilized in manufacturing the product consisted of the following ingredients in the listed percentages by weight:
______________________________________ Ingredient %______________________________________ Mineral Wool 67.0 Perlite 22.7 Newsprint 8.4 Starch 7.3 Retention Aid 0.05______________________________________
The ingredients were diluted with water to form a slurry in machine chest 1. Wet mixing of the slurry, which had a stock consistency of 5.5 wt % , nodulated the mineral wool. The slurry was transferred to head box 5 and next deposited on Fourdrinier wire 7. The slurry was dewatered in a conventional manner on the Fourdrinier machine to form a wet felt or mat of interlocked fibers. The partially dewatered fibrous mat was next passed through a press section comprising pressing rolls 11, which densified the mat and provided a wet mat of uniform thickness (about one inch) with a moisture content of about 65% . After leaving the press section, the wet mat was conveyed to dryer 12.
After being dried, the board product was subjected to various conventional finishing steps, which included cutting into appropriate sizes and cleaning. After being flipped over by inverter 16, the board product was then abraded on the screen side by a wheel blaster, and this side was coated to produce textured fiberboards of the invention.
The process was repeated except that feed-pipe 13 and coater 14 were employed to coat the mat and thus provide, after the coated mat was turned upside down by inverter 16, a backsizing on the finished fiberboards.
Backsized and unbacksized mineral ceiling panels made in accordance with the foregoing procedures had the physical characteristics reported in the following Table 3:
TABLE 3______________________________________Evaluation of FiberboardsPhysical Property Value______________________________________ASTM E-84 Tunnel Test Rating Class I with a 20 Flame Spread and 10 Smoke DevelopedAverage Thickness, in 0.739Average Density, lb/cu ft 13.3Transverse Strength, backsized, lb 26.9Transverse Strength, unbacksized, lb 19.0NRC2' × 2' backsized 502' × 2' unbacksized 502' × 4' backsized 552' × 4' unbacksized 50______________________________________ | A rigid, self-supporting, acoustical mineral fiberboard comprising a mixture of about 50 to 70 weight percent of mineral fibers, 15 to 35 weight percent of perlite, 1 to 10 weight percent of cellulosic fibers, and 4 to 15 weight percent of a binder with the proviso that the board forming solids do not include any clay filler. A pattern is formed on the fiberboard after the fiberboard has been dried. | 3 |
BACKGROUND OF INVENTION
This invention relates to towing of vehicles, in particular towing of trailers, and more specifically to towing of semitrailers. It also relates to truck bodies, more specifically to removable and interchangeable truck bodies, and still more specifically to “hook lift”, cable hoist, and chain hoist “roll-off” loaders, and other specific types of trucks constructed to handle such bodies.
Relevant background in the field of trailer towing is as follows: A tractor for pulling semitrailers is commonly equipped rearwardly with a support bearing called a “fifth wheel”, which engages a pin called a “kingpin” on the forward end of the trailer. When so engaged, the tractor-trailer combination comprises an articulating vehicle in which the trailer can rotate about a vertical axis relative to the tractor. Trailers can be towed in similar fashion using other mating bearing combinations such as ball hitches. Ease of hitching and unhitching trailers is an important factor for logistical reasons in the design of tractors, trailers, and hitching mechanisms.
Background in the other related field is as follows: In the handing of bulk materials such as solid waste, it is common to use so-called “roll-off” containers to collect and transport the materials. These containers, called “bodies”, come in various shape and capacities and are adapted to be loaded onto and transported by shuttle trucks specially configured to load and unload them. Some roll-off bodies are more specialized, such as a fat bed for carrying earth-moving machinery. There are various types of shuttle trucks for roll-off containers. A hoist roll-off shuttle of the cable or chain variety comprises a chassis with a hydraulic lift bed, a hoist and a cable or chain. The bed comprises rollers to enable roll-off bodies to be hoisted onto and off of the bed. The hook lift truck also comprises a chassis with a hydraulic lift bed, but instead of hoist, it uses a hydraulically-articulated arm ad hook to grasp a hook lift body and pull it onto or lower it from the bed.
The present invention relates these two fields in a novel way as summarized below.
SUMMARY OF INVENTION
The present invention is a removable, e.g., hook lift, body for a shuttle truck, which has been specially constructed to comprise a trailer-towing bearing such as a fifth wheel or a hitch ball. Such construction further comprises means for securely fastening the body to the shuttle so as to maintain the body in rigidly fixed relation to the chassis of the shuttle at all times. The virtue of such a body is that it enables roll-off shuttles to be used temporarily as tractors for semitrailers. This has the potential to reduce or eliminate the need for owning and maintaining dedicated tractors for semitrailers. Conversely, it can expand the capabilities of a fleet of roll-off shuttle vehicles to include trailer towing.
The towing of trailers typically requires the capability of providing certain utilities to the trailer from the tractor. Most commonly this is a source of compressed air for the trailer brakes and electricity for the trailer lights. Other utilities such as hydraulic pressure may also be desirable.
It is therefore a primary object of this invention to provide new means for towing trailers. It is a further object of this invention to provide a method of manufacturing or modifying roll-off shuttle beds for the secure installation and placement of such means. It is yet another object of this invention to provide a method of installing such means on such shuttle beds. Other objects of this invention are to expand the uses for roll-off shuttle trucks and to reduce the overall capital and maintenance costs for truck fleets. Yet another object of this invention is to provide trailers towed with the invention with connections to necessary and optional utilities available on the tractor, such as compressed air, electricity, and hydraulic fluid under pressure. Specifically, it is an object of this invention to provide, along with the new trailer towing means, means for moving sources of brake air and electricity from the rear of a shuttle truck to a location on the shuttle truck accessible to brake air and electricity connections on the trailer being towed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of a hook lift roll-off shuttle known in the art, without a body in place.
FIG. 2 is a perspective view of a portion of the shuttle of FIG. 1 with a prior art dump body in place.
FIG. 3 is a perspective view of the first embodiment of the present invention configured to comprise a fifth wheel.
FIG. 4 is a side view of the first embodiment.
FIG. 5 is a front view of the first embodiment.
FIG. 6 is a perspective view of the locking pin mechanism of the present invention in the retracted (unlocked) position.
FIG. 7 is a perspective view of the locking pin mechanism of the present invention in the advanced (locked) position.
FIG. 8 is a perspective view of a portion of the chassis of the shuttle of FIG. 1 modified to accommodate the first embodiment of the present invention.
FIG. 9 is a perspective view of the shuttle of FIG. 1 with hydraulic sections raised and hook attached for installation of the first embodiment of the present invention.
FIG. 10 is a perspective view of the shuttle of FIG. 1 with the first embodiment of the present invention secured in place.
FIG. 11 is a perspective view of a second embodiment of the present invention.
FIG. 12 is a perspective view of a cable hoist roll-off shuttle known in the art, without a body in place.
FIG. 13 is a perspective view of a third embodiment of the present invention.
FIG. 14 is a perspective view of the third embodiment shown in FIG. 13 about to be installed on the cable hoist roll-off shuttle of FIG. 12 .
FIG. 15 is a perspective view of a hook lift roll-off shuttle known in the art, without an embodiment of the present invention in place, showing utility hook-up locations.
FIG. 16 is a perspective view of a fifth embodiment of the present invention showing common utilities and connections.
FIG. 17 is a side view of the fifth embodiment.
FIG. 18 is a front view of the fifth embodiment.
FIG. 19 is a perspective view of a sixth embodiment of the present invention also showing desirable utilities and connections.
FIG. 20 ( a-d ) show additional embodiments of the invention having alternative mating parts for trailer towing.
DETAILED DESCRIPTION
Referring now in greater detail to the drawings, in which like numerals refer to like elements in all of the figures, FIG. 1 is a perspective view of a hook lift shuttle known in the art. The shuttle shown is typical of the hook lift type but there are other shuttles with dissimilar shapes also used to handle interchangeable bodies. The present invention is a body not to be construed to operate only with the shuttle depicted in FIG. 1 . This will become apparent in further discussion.
The shuttle of FIG. 1 is shown without any body in place on the bed. It comprises a multi-axle truck with a specialized hydraulically-actuated bed 101 affixed to its chassis. The bed 101 further comprises in relevant part four interconnected sections: a base section 102 fixed to the truck chassis 114 ; a primary or dump section 103 rotatably attached to the base section 102 along axis A; a secondary section 104 also rotatably attached to the base section 102 along axis B; and a tilt section 105 rotatably attached to the secondary section 104 along axis C.
The dump section 103 , secondary section 104 , and tilt section 105 may be locked into rigid relationship by remote-controlled dump latches 107 . An operator can then move all three bed sections into dumping position (about axis A) by actuating hydraulic lift cylinder 108 . If dump latches 107 are unlocked, lift cylinder 108 can rotate secondary section 104 and tilt section 105 independently of dump section 103 about axis B. The tilt cylinder 109 , by expanding hydraulically along its own axis, can rotate tilt section 105 about axis C as desired. The operation and function of the various parts are further illustrated in FIG. 9 .
Other relevant parts of the prior art shuttle are body latches 110 , which hold the rear of a shuttle body in fixed relation to the rest of the truck while the truck is in motion, rear rollers 111 , which guide a body into position on the bed when it is being loaded, and saddles 112 , which provide further resistance to side-to-side shifting of the load in transit. Also note hook assembly 113 , which is used to grasp, move, and hold lift bodies designed to be handled by such shuttles.
FIG. 2 is a perspective view of a portion of the shuttle of FIG. 1 with a prior art dump body 201 in place. Note curved pin 202 , rigidly attached to the upper front of the body 201 , passing through hook assembly 113 .
FIG. 3 is a perspective view of the first embodiment of the present invention, a fifth wheel support. It comprises a rigid rectangular frame 301 having one open end 302 at its front. Four legs 303 are attached to the frame near its corners and depend from it. The open end 302 of the frame 301 has attached to either side of it the lower ends of two pin supports 304 which extend upward from the plane of the frame 301 and diagonally towards each other. The upper ends of the pin supports are joined together by a curved pin 202 . Spanning the middle of frame 301 is platform 306 , which supports a fifth wheel trailer hitch 307 . Also spanning the underside of the platform 306 is an optional cross member 308 for further body attachment security.
When this fifth wheel support is installed on a shuttle truck, as described further in subsequent figures, pin 202 is encircled by a hook assembly 113 (not shown) and the bottom edges 309 of frame 301 rest upon saddles 112 (not shown) and upon other horizontal members of the truck (not shown). Each leg 303 provides a further means of securement to the truck chassis 114 (not shown) by a tubular locking pin mechanism 310 consisting of a pin 311 , a pin tab 312 , and a tongue 313 at each of the four legs. This means of attachment is more clearly illustrated in FIGS. 6 and 7.
FIG. 4 is a side view of the first embodiment. Note that curved pin 202 lies in a plane that is not vertical; i.e., the apex of the pin is forward (to the left of) the pin supports 304 so that it can be held on a truck bed without interfering with the tilt section 105 (not shown) of the truck bed.
FIG. 5 is a front view of the first embodiment. Note that in this prototypical example, the pin support 304 consists of two pieces of rigid material welded together for ease of assembly. Also it can be seen in this view that the platform 306 is even with the top of frame 301 , and the cross member 308 is even with the bottom. These locations are a fit with the shuttle depicted in FIG. 1, but many other configurations are possible within the scope of this invention.
FIG. 6 is a perspective view of the locking pin mechanism 310 of the present invention in the retracted (unlocked) position. The mechanism 310 is installed at the lower end of each leg 303 of the fifth wheel support. In this illustration, the leg consists of two plates 601 and 602 depending from frame 301 , although the leg could be made from other elongate materials such as, for one example, a single solid piece of rigid material, or for another example, a piece of rigid material having a hollow rectangular cross section. In this illustration, a circular hole 603 is cut horizontally through both plates so that tubular pin 311 can slide smoothly though it. The pin is of a length that when one end of the pin is flush with one side of the leg, the pin projects outward from the other side of the leg by several inches. An elongate tongue 313 is fixedly attached to the bottom of the leg so that it extends outwardly from the frame 301 and at least as far beyond one side of the leg as the pin 311 does. A pin tab 312 is fixedly attached to one end of the pin so that the tab 312 is on the same side of the leg 303 as the tongue 313 . The tongue 313 further comprises a proximal notch 604 and a distal notch 605 , both cut downward from the top edge of the tongue 313 . By use of these notches, the tubular pin 311 can be locked into either of two horizontal positions. If pin tab 312 is lowered into distal notch 605 (as shown), it is held there by gravity and pin 311 will be held in its farthest displacement away from the truck body until the tab is lifted. If the tab 312 is lowered into the proximal notch 604 , the pin 311 will project inwardly from the frame.
This is shown in FIG. 7, which is a perspective view of the locking pin mechanism 310 of the present invention in the advanced (locked) position. Note that the tubular pin 311 projects inwardly some distance from the leg 303 . If the truck chassis (not shown) has a collinear round cavity of the same diameter of leg hole 603 (not visible), pin 311 can fit into this cavity and resist motion of the frame 301 in any direction relative to the truck chassis other than coaxial to the tubular pin.
FIG. 8 is a perspective view of a the left side of the truck bed 101 of the shuttle of FIG. 1 modified to accommodate the first embodiment of the present invention depicted in FIGS. 3, 4 , and 5 . The modifications shown, which are duplicated in mirror image on the right side of the bed, comprise a forward ear 801 , a forward pin socket 802 , a rearward ear 803 , and a rearward pin socket 804 . The ears are fixedly attached to the truck chassis 114 at an angle towards the truck centerline. As will become clear in the next figure, the invention is installed on top of the truck bed 101 shown here. The two left legs of the invention (not shown) fit alongside (Oust to the left of) the visible side of the chassis 114 . In like manner, the two right legs of the invention (not shown) fit alongside the right side (not shown) of the chassis. The final positioning of the first embodiment of the invention is shown more clearly in FIG. 10 .
FIG. 9 is a perspective view of the shuttle of FIG. 1 with the secondary bed section 104 and tilt section 105 raised and the hook assembly 113 attached to the first embodiment of the present invention. The invention is prepared for installation by making sure the locking pins 311 are in their retracted (fully out) positions, and that the curved pin 202 is grasped by the hook assembly 113 . The invention is installed by using hydraulic cylinders 108 and 109 to lift the forward end 901 of the invention over the rear of the truck chassis so that forward legs 303 are above and forward of rollers 111 . As the invention is pulled hydraulically farther forward, the rearward ears 803 serve to align the lower edges 309 of frame 301 onto the rollers 111 . As the invention is pulled still farther forward, the forward end 901 of the invention must be held above the truck bed until the forward end 901 is near to contacting the rearward vertical face 902 of the tilt section 105 of the shuttle. The forward end 901 of the invention is then lowered into final position. Forward ears 801 serve to prevent forward legs 303 from hanging up on top of the chassis 114 . At this point, tubular pins 311 will line up with pin sockets 802 and 804 . The pins 311 can then be advanced into the sockets and locked.
FIG. 10 is a perspective view of the shuttle of FIG. 1 with the first embodiment of the present invention secured in place. Note that rectangular frame 301 rests in saddle 301 and rollers 111 . Note further that cross member 308 is secured under body latches 110 . Thus the invention is fixedly secured to the truck chassis by four pins 311 , cross member 308 , and curved pin 202 . Fifth wheel 307 is now ready for engagement to the kingpin of a trailer (not shown).
FIG. 11 is a perspective view of a second embodiment of the present invention, configured to comprise a hitch ball. In this embodiment, a hitch ball assembly 1101 is substituted for fifth wheel assembly 307 in FIG. 3 . Other embodiments of the invention substitute alternative hitch parts for the ball as shown in FIGS. 20 ( a-d ).
FIG. 12 is a perspective view of a cable hoist roll-off shuttle known in the arm without a body in place. It comprises in pertinent part a dump section 1201 capable of being raised as shown by pallel hydraulic cylinders 1202 . A hoist drum (not visible) pulls a cable 1203 over a sheave 1204 . (Some versions of this shuttle utilize a sprocket and chain mechanism in place of a cable and sheave, but the applicability of the present invention to it is identical.) When clevis 1205 is attached to a hook (not shown) on a body made for use on such a shuttle (not shown), the body cam be pulled onto the dump section by sliding over rails 1206 and rollers 1207 and way be secured to the shuttle by clamps 1208 and/or other securing devices such as straps (not shown).
FIG. 13 is a perspective view of a third embodiment of the present invention, which has the frame of the second embodiment reconfigured to permit installation on the cable roll-off shuttle of FIG. 12 . For clarity it is shown facing the opposite direction as the embodiment shown in FIG. 11 . Note that unlike the first two embodiments, the frame 301 encloses all four sides including forward end 901 . An upward facing hook 1301 replaces the curved pin 202 of FIGS. 3 and 11. Note that the bottom edges of the forward and rearward ends 1302 of the frame 301 are recessed upward from the sides of the frame. This helps this embodiment straddle the rails 1206 of the dump section 1201 as it is being installed (shown in more detail in FIG. 14 ). Any method of alignment and fastening of bodies consistent with safety and the proper operation of the trailer hitch is acceptable.
FIG. 14 is a perspective view of the third embodiment shown in FIG. 13 being installed on the cable hoist roll-off shuttle of FIG. 12, Note that clevis 1205 of the shuttle has been attached to hook 1301 , and cable 1203 has been hoisted upward to slide the third embodiment onto the dump section 1201 of the shuttle. Note that the right-hand rail 1206 of the dump section has been placed under the forward end 1302 of the frame, and the same is true of the left-hand rail and forward bar although not visible in this view. This centers the invention on the dump section as it is don upward by the hoist. At a certain point in its upward travel, the frame 301 comes in contact with rollers 1207 on either side of the dump section, reducing the frictional load on the hoist. If the dump section has been configured with body latches 110 (only one is visible), cross member 308 will engage them as the body nears the top of its travel, creating security against all motion of the body relative to the Suck except rearward. Rearward motion of the body is prevented by the tension of cable 1203 .
A fourth embodiment of the present invention combining the fifth wheel hitch assembly of the first embodiment (element 307 of FIG. 3) and the cable roll-off frame adaptations of the third embodiment (FIG. 13) is evident from these illustrations without an illustration of its own and is included within the scope of the present invention.
FIG. 15 is a perspective view of a hook lift roll-off shuttle 1501 known in the art, without an embodiment of the present invention in place, showing utility hook-up locations. (This illustration is meant to show the characteristics of a generic hook lift shuttle, even though a real shuttle may not have the same shape.) Utility hook-ups are sometimes needed on various hook lift bodies, including embodiments of the present invention. Typically, for example, a semi tractor must provide brake air to the trailer so that the trailer brakes will function. This compressed air is generated on the tractor and provided to the trailer through mating tubing connections completed by the driver between the rear of the tractor and the front of the trailer. Trailers must have running lights, and it is also typical for them to be powered by the tractor's electrical system. The shuttle shown in FIG. 15 is also equipped with a hydraulic power take-off control box 1502 , capable of supplying hydraulic power for a variety of purposes.
This shuttle comprises all of the features shown in FIG. 1 plus the power takeoff control box 1502 . In this Figure, the control box 1502 is located between the bed 101 and the truck cab 106 . The control box 1502 comprises a hydraulic fluid supply connection 1503 , which is available on the truck to supply hydraulic fluid under pressure to other equipment having hydraulic drive motors and cylinders, including disabled trucks. Typically, the hydraulic fluid pump on the vehicle is driven by the truck engine and also supplies fluid to the cylinders 108 and 109 of the bed 101 , although the source of the hydraulic fluid on the shuttle could just as well be a hydraulic pump driven by another engine. A hydraulic fluid return connection 1504 is also provided on the control box 1502 . Another utility feature of the depicted shuttle is compressed air. Compressed air supply and return are provided at the rear of the shuttle by pigtails 1505 and 1506 , respectively, and glad hands 1507 and 1508 , respectively. Also provided at the rear of the shuttle is an electric power point 1509 .
FIG. 16 is a perspective view of a fifth embodiment of the present invention having special utilities features for attachment to a shuttle represented by FIG. 15 . In addition to all of the trailer hitch features shown in FIG. 3, this hook lift body further comprises a winch 1601 , pneumatic tubes 1602 and 1603 , and electrical conduit 1604 . In this embodiment, winch 1601 is a hydraulically driven winch, shown with supply hose 1605 and return hose 1606 attached. A crane (not shown ) could likewise be attached to the invention. (Neither winch or crane is necessary for trailer hauling per se, but some heavy duty semitrailer tractors are equipped with such for added versatility.) The pneumatic tubes are equipped with pigtails 1607 , 1608 , 1609 , and 1610 and corresponding glad hands 1611 , 1612 , 1613 , and 1614 , respectively. Electric power plugs 1615 and 1616 are provided at either end of conduit 1604 .
The aforementioned utility conduits and tubes are shown in the Figures attached to the side of the trailer hitch support body. They need not be attached outside the frame as shown; it is possible, even desirable, to route them inside the frame. They are shown outside in these figures mainly for clarity. Similar to routing the utilities inside the frame is building the conduits into the frame itself. By way of example of this and not limitation would be a) to utilize box beams in a frame's construction and route electric conductors through them, or b) to cast compressed air passageways into portions of a cast frame.
There are two other features shown in this illustration which can be options on all embodiments. One is sliding hitch capability, denoted by track 1617 , key 1618 , and keyways 1619 (which have corresponding parts on the opposite side of the body, not shown in this view). It is often desirable to be able to adjust the position of the fifth wheel backwards or forwards along the tractor axis to improve the stability of the truck and trailer combination. Platform 306 can be positioned at various points along track 1617 corresponding to the keyways. This illustration shows a manual positioning means, but powered positioning means (e.g., pneumatic) that currently exist in the art are considered within the scope of the invention without limitation. Not shown here but also available in the art are height adjustment means which can also readily be incorporated into the present invention.
After installing this embodiment on the hook lift shuttle shown in FIG. 15 and securing it in place, compressed air can be provided to the trailer hitch body by attaching pigtails 1611 and 1612 to pigtails 1508 and 1507 in FIG. 15 . Electric power can be provided by inserting plug 1615 into power point 1509 in FIG. 15 . This provides brake air and electricity for lights at the same locations on the shuttle that they would be in on an ordinary semitrailer tractor, and a semitrailer can then be connected in the normal way.
If needed, winch 1601 can be powered by connecting supply hose 1605 to supply connection 1503 (FIG. 15) and return hose 1606 to return connection 1504 (FIG. 15) on the shuttle. Other winches besides hydraulically-powered ones, such as manual, pneumatic, electric, and combustion engine-driven are within the scope of the present invention without limitation.
FIG. 17 is a side view of the fifth embodiment of the present invention. Note that the forward pigtails 1609 and 1610 are supported by a bracket 1701 as would ordinarily be found on a semitrailer tractor. FIG. 18 is a front view of the fifth embodiment. All of the pneumatic and electric parts are shown here installed on the left side of the body (right side of this figure) but sufficient flexible tube and wire are intended to be provided on the invention to reach the central location for attachment normally found on the front of trailers. FIG. 19 is a perspective view of a sixth embodiment of the present invention also showing common utilities and connections. This embodiment is basically the third embodiment as shown in FIG. 13 (for use on a cable hoist roll-off shuttle) with the added utility adaptations of the fifth embodiment shown in FIG. 16 . In this illustration, the body is turned 180 degrees from the orientation in FIG. 13 to more clearly show the parts corresponding to the same reference characters in FIG. 16 .
The present invention is not meant to be limited to structures that conform solely to the three prior art shuttles shown in FIGS. 1, 12 , and 15 , or these shuttles as modified for greater security in FIGS. 8 and 14. The present invention can be configured to fit securely virtually any truck chassis capable of loading assorted bodies.
There are also a number of other hitch systems that can be substituted for the (fifth wheel or ball) on the loadable bodies, and they are included within the claimed scope of this invention. Either mating part of any hitch system can be substituted for the ones shown and suitably affixed to the frame of the loadable body. Examples include, but are not limited to, the pintle hitch, in which a the fifth wheel plate or hitch ball of the present invention could be replaced by a vertical pin or mating eye bolt; and the clevis hitch, in which case it could be replaced by a clevis or a mating hook.
FIGS. 20 ( a ) and ( b ) are insets of FIG. 19 showing an eye 2001 or a pintle 2002 , respectively, substituted for the hitch ball. Either an eye can be fixed to the loadable bony to mate with a pintle on the trailer, or vice versa,
FIGS. 20 ( c ) and ( d ) a insets of FIG. 19 showing a hook 2003 or a clevis 2004 respectively, substituted for the hitch ball. Either a hook can be fund to the loadable body to mate with a clevis on the trailer, or vice versa. | Bodies for hook lift shuttles and other roll-off loaders are fitted with trailer towing hitches, such as fifth wheels and hitch balls, so that when one of these bodies is loaded onto a shuttle or loader, the shuttle or loader can be used temporarily as a tractor for a trailer. Means are provided for connecting truck utilities such as brake air and electricity to the invention and thence to a trailer. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119( a ) of Korean Patent Application No. 2004-62013 , filed on Aug. 6, 2004, in the Korean Intellectual Property Office, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a disk player, and more particularly, to a disk chucking apparatus for a small-sized disk player.
[0004] 2. Description of the Related Art
[0005] A disk player records data on a disk such as a compact disk (CD), a CD-ROM, a digital video disk (DVD), or a DVD-ROM and/or reproduces data from the disk. And the disk player has a disk loading apparatus to load the disk to a position for recording or reproducing the data. A disk is inserted into the disk player and conveyed to a chucking position by a disk conveyance apparatus. After arriving at the chucking position, the disk is rotatably clamped on a turntable by a disk chucking apparatus.
[0006] FIGS. 1A and 1B are side section views showing a conventional disk chucking apparatus before chucking and after chucking, respectively. Referring to FIGS. 1A and 1B , the conventional disk chucking apparatus has a clamper 52 , a magnet 92 , a yoke 93 , a holder 10 , and a turntable 90 .
[0007] The clamper 52 consists of an upper clamper 54 and a lower clamper 58 . The upper clamper 54 and the lower clamper 58 are assembled with each other such that a hook 56 formed on the lower clamper 58 is hooked into a hook recess 57 formed in the upper clamper 54 . The magnet 92 is interposed between the upper clamper 54 and the lower clamper 58 . The yoke 93 is disposed on the top of the magnet 92 to reinforce a magnetic force between the magnet 92 and the turntable 90 . The holder 10 is located between the upper clamper 54 and the lower clamper 58 to support the clamper 52 , and moves up and down in relation to the movement of a slider (not shown) disposed on a main chassis (not shown). The turntable 90 is rotated by a spindle motor 94 to rotate a disk D seated thereon. The turntable 90 has a magnetic substance 70 disposed thereon to generate an attraction with respect to the magnet 92 .
[0008] Operation of the disk chucking apparatus having the above construction will now be described. The holder 10 descends in relation to the movement of the slider (not shown). The clamper 52 moves down a predetermined distance together with the holder 10 . The clamper 52 further descends due to a magnetic attraction between the magnet 92 and the magnetic substance 70 . The disk D conveyed and positioned between the clamper 52 and the turntable 90 is clamped to the turntable 90 by the clamper 52 . Then, the holder 10 further descends and is located between the upper clamper 54 and the lower clamper 58 without contacting either the upper clamper 54 or the lower clamper 58 , so that a space is formed to allow the clamper 52 to be rotated. Through the above-described process, operation of chucking the disk D is completed as shown in FIG. 1B . After that, the clamped disk D rotates together with the turntable 90 and the clamper 52 .
[0009] At this time, the disk D may be eccentrically rotated due to an eccentricity of the disk D, which causes a wobble of the disk D. To prevent the wobble, the disk D has to be clamped with a predetermined clamping force. The predetermined clamping force is maintained by the attraction between the magnet 92 and the magnetic substance 70 . The magnet 92 is required to have a magnetic force sufficient to maintain the clamping force constantly.
[0010] To release the disk D from the chucking state, a driving motor (not shown) is rotated in a reverse direction to the direction of the loading process, and moves the slider (not shown) on the main chassis (not shown) in an unloading direction. Then, the holder 10 ascends in relation to the movement of the slider (not shown). The clamper 52 is distanced from the disk D as the holder 10 ascends. At this time, the holder 10 has to overcome the magnetic force to move the clamper 52 upwardly.
[0011] In chucking the disk D or releasing the disk D from the chucking state, the magnet 92 is required to have a high magnetic force sufficient to prevent the wobble, which is caused by the rotation of the disk D. But the magnet 92 having the high magnetic force is expensive, and when the disk D is released from the chucking state, the high magnetic force generates a load that hinders the ascending movement of the holder 10 to distance the clamper 52 from the disk D.
[0012] Also, since the magnet 92 is interposed between the upper clamper 54 and the lower clamper 58 , it increases the height of the clamper 52 , which causes an increase of a size of the disk player.
[0013] But since a compact-sized or a slim-type disk player is preferred recently, there is a demand for a compact-sized disk player.
SUMMARY OF THE INVENTION
[0014] The present invention has been developed to solve the above problems in the related art. Accordingly, an aspect of the present invention is to provide a disk chucking apparatus for a disk player having an improved construction capable of reducing a load in releasing a disk from a chucking state.
[0015] Another aspect of the present invention is to provide a disk chucking apparatus of an improved construction for a compact-sized disk player and a slim-type disk player.
[0016] The above and other aspects of the present invention are achieved by providing a disk chucking apparatus for a disk player, having: a turntable on which a disk is seated; a clamper unit to clamp the disk to the turntable; and a holder unit, disposed on a main chassis to be approachable to and separable from the turntable, and pressing the clamper unit when the disk is clamped to the turntable, the clamper unit being rotatable.
[0017] According to one aspect, the holder unit has a holder plate disposed on the main chassis, and a press member disposed on the holder plate to press a contact part upwardly protruding from a center of the clamper unit when the disk is clamped to the turntable.
[0018] According to one aspect, the press member is a plate spring. According to one aspect, the contact part is dome-shaped.
[0019] The above and other aspects are also achieved by providing a disk chucking apparatus for a disk player, having: a turntable on which a disk seated, the turntable having a magnet disposed thereon; a holder unit disposed on a main chassis to be approachable to and separable from the turntable; a clamper disposed at the holder unit, to clamp the disk seated on the turntable; and a magnetic substance disposed on the clamper to generate an attraction with respect to the magnet so that the clamper clamps the disk to the turntable by the attraction, the clamper rotatably contacting the holder unit when the disk is clamped.
[0020] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings, of which:
[0022] FIGS. 1A and 1B are cross-section views showing a conventional disk chucking apparatus before chucking and after chucking, respectively;
[0023] FIG. 2 is a top view showing a disk loading apparatus according to an embodiment of the present invention;
[0024] FIG. 3 is an exploded perspective view showing the disk chucking apparatus of FIG. 2 ; and
[0025] FIGS. 4 and 5 are cross-section views taken along lines IV-IV of FIG. 3 to explain the operation of chucking a disk according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0026] Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described to explain the present invention by referring to the figures.
[0027] Referring to FIG. 2 , the disk loading apparatus according to an embodiment of the present invention has a main chassis 100 , a first slider 110 and a second slider 112 , a connection member 114 , and a chucking apparatus 200 .
[0028] The first and the second sliders 110 and 112 are disposed on opposite sides of the main chassis 100 , and move forwardly and backwardly. The connection member 114 connects the first and the second sliders 110 and 112 , and is rotatably supported by a hinge portion 102 provided on the main chassis 100 . When the first slider 110 receives a driving force from a driving motor (not shown) and reciprocates on the main chassis 100 , the connection member 114 moves the second slider 112 in relation to the movement of the first slider 110 , in the same direction the movement of the first slider 110 .
[0029] The chucking apparatus 200 is disposed on the main chassis 100 . The chucking apparatus 200 has cam pins 214 inserted into cam recesses (not shown) formed in the first and the second sliders 110 and 112 . The cam pins 214 , which are inserted into the cam recesses, move in relation to a loading or unloading movement of the first and the second sliders 110 and 112 , so that a holder unit 210 (see FIG. 3 ) and a clamper unit 250 (see FIG. 3 ) of the chucking apparatus 200 ascend or descend on an upper portion of the main chassis 100 .
[0030] FIG. 3 is an exploded perspective view showing the disk chucking apparatus and FIG. 4 is a cross section view taken along line IV-IV of FIG. 3 . Referring to FIGS. 3 and 4 , the disk chucking apparatus has a turntable 290 , the holder unit 210 , and the clamper unit 250 .
[0031] The turntable 290 rotates together with a disk D loaded thereon, and is driven by a spindle motor 294 mounted on the main chassis 100 (see FIG. 2 ).
[0032] An annular magnet 292 is press-fitted or caulked onto the turntable 290 .
[0033] The holder unit 210 is disposed on the main chassis 100 and is ascendable and descendible. The holder unit 210 supports the clamper unit 250 so that the clamper unit 250 is attachable to and separable from the turntable 290 . The holder unit 210 includes a holder plate 212 and a plate spring 230 acting as a pressing member.
[0034] The holder plate 212 is provided with cam pins 214 , plate spring connection holes 218 , plate spring support projections 216 , and a middle hole 220 . Two pairs of the cam pins 214 are provided at opposite sides of the holder plate 212 . The cam pins 214 are inserted into the cam recesses (not shown) so that the holder plate 212 ascends and descends in relation to the movements of the first and the second sliders 110 and 112 (see FIG. 2 ). Two pairs of the connection holes 218 are defined in the holder plate 212 symmetrically with respect to the middle portion of the holder plate 212 . The plate spring support projections 216 are positioned over the connection holes 218 . The plate spring support projections 216 may be integrally formed with the holder plate 212 or attached to the holder plate 212 by welding. The middle hole 220 is defined in the middle portion of the holder plate 212 . The plate spring 230 is connected with the clamper unit 250 through the middle hole 220 . According to one embodiment, the holder plate 212 and the plate spring 230 are integrally formed.
[0035] When a clamper 252 of the clamping unit 250 clamps the disk D, the plate spring 230 presses the clamper unit 250 , thereby preventing a wobble from being caused by an eccentric rotation of the disk D. The plate spring 230 is provided with connection pieces 232 and support pieces 234 . Two pairs of the connection pieces 232 are formed at opposite ends of the plate spring 230 . The connection pieces 232 downwardly bend from the plate spring 230 and are inserted into the connection holes 216 provided in the holder plate 212 . According to one embodiment, two support pieces 234 are separated from each other by a predetermined distance, and are oppositely disposed with respect to the middle portion of the plate spring 230 . Each support piece 234 downwardly bends from the plate spring 230 to support the clamper unit 250 . The plate spring 230 presses the clamper 252 and may use a coil spring for pressing the clamper 252 .
[0036] When clamping the disk D, the clamper unit 250 has a bottom thereof press-contact the disk D and rotates together with the disk D. The clamper unit 250 includes the clamper 252 and a magnetic substance 270 .
[0037] The clamper 252 includes an upper flange part 254 , a lower flange part 258 , a connection part 256 , a plate spring contact part 264 , and a magnetic substance mounting part 260 . The upper flange part 254 is formed on an upper portion of the clamper 252 and has an annular shape. The upper flange part 254 is supported on the support piece 234 of the plate spring 230 . The lower flange part 258 is formed on a lower portion of the clamper 252 and has an annular shape. The lower flange part 258 has a larger diameter than the upper flange part 254 . A lower surface of the lower flange part 258 contacts the disk D when clamping the disk D, and has a hole 259 defined in a center thereof corresponding to the turntable 290 , to allow the turntable 290 to be inserted therethrough. The connection part 256 connects the upper flange part 254 and the lower flange part 258 .
[0038] The contact part 264 is shaped in a hemisphere that protrudes from the center of the clamper 252 . According to one embodiment, since the contact part 264 has a hemisphere shape, it is brought into point-contact with the plate spring 230 . The point-contact allows the plate spring 230 , which is fixed to the holder plate 212 to press the rotating clamper 252 . The contact part 264 may be dome-shaped, or may take various configurations if it is made of a material having low friction.
[0039] The magnetic substance mounting part 260 is depressed in an annular shape with respect to the contact part 264 . Due to this shape, the magnetic substance 270 can be mounted on the magnetic substance mounting part 260 without increasing the height of the clamper 252 . The magnetic substance mounting part 260 has a connection protrusion 262 to be engaged with the magnetic substance 270 . According to one embodiment, the connection protrusion 262 is formed in a “ ” shape, and there are three connection protrusions 262 formed at a predetermined interval along a radial direction. The number of connection protrusions 262 increases or decreases depending on the size or thickness of the magnetic substance 270 . The connection protrusion 262 has an insert protrusion 262 a and a locking protrusion 262 b . The insert protrusion 262 a protrudes toward a center of the magnetic substance mounting part 260 , and the locking protrusion 262 b downwardly protrudes from an end of the insert protrusion 262 a.
[0040] The magnetic substance 270 generates a magnetic attraction with respect to the magnet 292 disposed on the turntable 290 , thereby allowing the clamper 252 to press the disk D. The magnetic substance 270 has an annular shape so that it is mounted on the magnetic body mounting part 260 . The magnetic substance 270 has three connection recesses 272 formed therein to be connected with the connection protrusions 262 . Each connection recess 272 is divided into an insert part 272 a and a locking part 272 b.
[0041] The insert part 272 a is formed toward a center portion of the magnetic substance 270 . The insert protrusion 262 a of the connection protrusion 262 is inserted into the insert part 272 a when the magnetic substance 270 is mounted on the magnetic substance mounting part 260 downwardly. The locking part 272 b is formed from an end of the insert part 272 a in a radial direction of the magnetic substance 270 . The locking protrusion 262 b of the connection protrusion 262 is locked into the locking part 272 b when the magnetic substance 270 rotates after the insert protrusion is inserted into the insert part 272 a . Accordingly, by simply rotating the magnetic substance 270 , the magnetic substance 270 is securely mounted on the magnetic substance mounting part 260 .
[0042] Hereinafter, operation of the disk chucking apparatus according to an embodiment of the present invention will now be described.
[0043] FIG. 4 is a cross-section view showing the clamper and the disk before chucking, and FIG. 5 is a cross-section view showing the clamper and the disk after chucking. Referring to FIGS. 4 and 5 , the first and the second sliders 110 and 112 (see FIG. 2 ) slide on the main chassis 100 (see FIG. 2 ). In relation to the sliding movements of the first and the second sliders 110 and 112 , the holder plate 212 descends. At the same time, the plate spring 230 disposed on the holder pate 212 and the clamper 252 having the upper flange part 254 supported on the support pieces 234 descend. As the holder plate 212 and the plate spring 230 descend by a predetermined distance, the clamper 252 is brought into contact with the disk D so that the disk D is seated on the turntable 290 . After that, the holder plate 212 and the plate spring 230 further descend and the plate spring 230 presses the contact part 264 . At this time, as the plate spring 230 descends, the support pieces 234 of the plate spring 230 are positioned between the upper flange part 254 and the lower flange part 258 of the clamper 252 . That is, the support pieces 234 do not contact the clamper 252 , so that the clamper 252 can be rotated.
[0044] When the chucking operation is completed as described above, the clamper 252 presses the disk D onto the turntable 290 due to a magnetic attraction exerted between the magnetic substance 270 and the magnet 292 and a pressure of the plate spring 230 exerted to the contact part 264 . After that, when the turntable 290 is rotated by the spindle motor 294 , the disk D and the clamper 252 are rotated. Also, since the contact part 264 of the clamper 252 point-contacts the plate spring 230 , the clamper 252 can be rotated in a state that the plate spring 230 is fixed to the holder plate 212 . As described above, the clamper 252 is rotated while pressing the disk D, thereby preventing a wobble from being caused by an eccentric rotation of the disk D.
[0045] As noted previously, the conventional disk chucking apparatus has to use a magnet having a high magnetic force to prevent the wobble of the disk D. In contrast, according to an embodiment of the present invention, since the clamper 252 presses the disk D with the pressure of the plate spring 230 and the magnetic attraction, the magnet is not required to have a high magnetic force.
[0046] To release from the chucking state, the driving motor (not shown) is rotated in a reverse direction to that of the above loading process. When the first and the second sliders 210 and 212 (see FIG.2 ) move on the main chassis 100 (see FIG. 2 ) in an unloading direction, the holder plate 212 ascends in relation to the sliding movements of the first and the second sliders 210 and 222 and the plate spring 230 ascends together with the holder plate 212 . As the support pieces 234 of the plate spring 230 ascend, they raise the upper flange part 254 of the clamper 252 , thereby distancing the clamper 252 from the disk D and the turntable 290 . At this time, the clamper 252 must overcome the magnetic attraction exerted between the magnetic substance 270 and the magnet 292 to ascend. Differently from the conventional apparatus, since the plate spring 230 presses the clamper 252 , the magnet 292 is not required to have a high magnetic force. Accordingly, the magnetic force that must be overcome to distance the clamper 252 from the disk D and the turntable 290 can be reduced, and thus a load generated in releasing the disk D from the chucking state can be reduced.
[0047] In contrast to the conventional disk chucking apparatus, in the disk chucking apparatus 200 , since the magnet 290 is disposed on the turntable 290 , the height of the clamper 252 can be reduced. Accordingly, a compact-sized disk player or a slim type disk player can be realized.
[0048] As described above, due to the presence of the plate spring 230 , a clamping force sufficient to prevent the wobble is generated, and a magnet having a reduced magnetic force can be employed. And thus, a load generated in releasing the disk from the chucking state can be reduced.
[0049] Also, since the magnet 292 is disposed on the turntable 290 , the height of the clamper 252 can be reduced, and thus, the compactness and slimming of the disk player can be achieved.
[0050] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | A disk chucking apparatus for a disk player, having: a turntable on which a disk is seated; a clamper unit to clamp the disk to the turntable; and a holder unit, disposed on a main chassis to be approachable to and separable from the turntable, and pressing the clamper unit when the disk is clamped to the turntable, the clamper unit being rotatable. | 6 |
FIELD OF THE INVENTION
The present invention relates to a method of automatically milking animals, such as cows, in which the animals are milked by one or more milking robots, and in which milk obtained from an udder quarter is discharged to a collector element, such as a milk claw or a milk jar.
BACKGROUND AND SUMMARY OF THE INVENTION
Such constructions are known. But they may not always be satisfactory for the prevention of illnesses such as mastitis. It is thus an object of the present invention to prevent mastitis and other illnesses to the extent possible. To that end, if in an early stage an illness has been detected in an adder quarter and the milk flow has fallen to below a defined threshold value (D1), this udder quarter is automatically stripped, If so desired, this threshold value (D1) may be different for various animals.
When the milk flow has fallen to below a predetermined threshold value, it is considered that the milking operation should cease; the udder quarter is assumed to have been more or less stripped at much as it should be. More specifically, to prevent mastitis, it is important for the milking operation to be stopped when the milk flow has become quite weak. If then the milking operation is continued, the teats may be irritated to such an extent that the risk of mastitis is increased. However, once mastitis has been detected in an udder quarter, it may be of importance nevertheless to continue milking. Therefore, once mastitis has been detected in an udder quarter and after the milk flow originating therefrom, possibly combined with that from one or more other udder quarters, has fallen to below aforesaid threshold value (D1), the udder quarter or udder quarters involved are automatically stripped.
In a first method, when mastitis has been detected in an udder quarter and after the milk flow therefrom has decreased to less than said threshold value (D1), this udder quarter is stripped further for a defined time interval. In a second alternative method, when mastitis has been detected in an udder quarter and after the milk flow originating therefrom decreases to below said threshold value (D1), the udder quarter is stripped further until an additional, predetermined quantity of milk has been withdrawn from this udder quarter. In yet another feasible method, when mastitis has been detected in an udder quarter and after the milk flow originating therefrom decreases to below said threshold value (D1), the udder quarter is stripped further until the milk flow from this udder quarter falls below a second threshold value (D2), lower than the first-mentioned threshold value (D1). In this method, the second threshold value (D2) may depend on the extent to which mastitis has been detected. Another option is to continue the milking operation until all or substantially all the milk has been withdrawn from an udder quarter affected by mastitis. To discontinue the stripping operation it is sufficient to reduce the degree of vacuum in the relevant teat cup, it not being absolutely necessary for the teat cup to be disconnected or removed at the same time. The question as to which method is to be used, depends to a significant extent on whether the teat cups are individually disconnectable or can only be disconnected and removed collectively. In addition, it should be noted that the above method can be applied to each udder quarter separately or in pair, for example the two front udder quarters and the two rear udder quarters. The two front, and also the two rear udder quarters are comparable to each other to a significant extent in respect to their milk yield. It is possible that mastitis is detected in the joint milk flow from the two front or from the two rear udder quarters or from both. In this situation, after the milk flow originating from the two front or rear udder quarters decreases to below a first threshold value, the two udder quarters continue to be stripped further, although mastitis may have occurred in only one of the two udder quarters.
According to the invention, a mastitis sensor may be incorporated in each of the milk lines, which causes a signal M to be derived in a computer, indicating that mastitis has occurred in a given udder quarter, while furthermore, with the aid of this signal M, a threshold value for the milk flow in the milk line connected to the udder quarter affected by mastitis is derived in the computer in accordance with the Booleam expression D=D1.M+D2.M. More in particular, a milk flow sensor is incorporated in each of the milk lines, each milk flow sensor supplying to the computer a signal S, indicating the quantity of the milk flow, the relevant milk line under a teat cup being closed as soon as the computer has determined that the milk flow S has decreased to less than the threshold value D. The aforementioned methods may, of course, also be combined. This combined method is then characterized in that, after mastitis has been detected in an udder quarter and after the milk flow originating therefrom has decreased to less than the said threshold value (D1), this udder quarter, depending on the progression of the milk yield versue time, is either stripped further during a predetermined time interval, or is stripped further until the milk flow from this udder quarter has fallen to below a second threshold value (D2), the second threshold value (D2) being lower than the first-mentioned threshold value (D1), or is stripped further until an additional, predetermined quantity of milk has been taken from this udder quarter.
A mastitis detection which has proved to be reliable in actual practice, is obtained when milk conductivity sensors are used as mastitis sensors. The milk conductivity sensed in a milk line is compared to the milk conductivity, updated in a computer on the basis of a progressive weighted or non-weighted average of previous milking turns, of a relevant animal on the basis of this comparison it is ascertained whether the relevant udder quarter, after the milk flow originating therefrom has decreased to less than said first threshold value (D1), should or should not be stripped further. The decision of whether or not mastitis is assumed to be present, is animal-dependent; the milk conductivity last measured is compared to the historical data previously recorded in the form of a progressive, weighted or non-weighted average. On the basis of the said comparison, the computer can produce an attention signal, which can be displayed on a display screen and/or be printed, this attention signal indicating to what extent the last-measured milk conductivity exceeds that ascertained in the computer. On the basis of this attention signal, by means of a command manually entered into the computer or by means of a command already previously recorded in the computer, a relevant udder quarter can be stripped further or be stripped further at least during the subsequent milking turn as soon as it is learned that the milk flow in the relevant milk line has decreased to less than the first-mentioned threshold value (D1). In practice, this will mean that on the basis of the attention signal the farmer can make the decision further to strip the relevant udder quarter in, for example the subsequent milking turn, although such a command may have already been stored in the computer, so that at the proper instant the relevant udder quarter can be stripped still further.
Instead of milk conductivity sensors, it is alternatively possible to incorporate filters in the milk lines, the mastitis detection then being based on resistance measurements. The filter has a higher resistance to the milk flow passing therethrough when this flow has been infected by mastitis and consequently is somewhat cloudy.
Instead of stripping a mastitis-affected udder quarter further than is usually customary, a mastitis in its initial stage can also be counteracted by milking the animals more frequently. Hence, the invention also relates to a method of automatically milking animals, such as cows, in which the milk obtained per udder quarter is discharged through separate milk lines to a collector element, such as, for example, a milk claw or a milk jar, and in which, when the milk flow originating from one or more udder quarters has fallen to below a threshold value (D1), the degree of vacuum in the teat cup or cups connected to the udder quarter or quarters is reduced or eliminated, which method is then characterized in that, when mastitis has been detected in an udder quarter and after the milk flow originating therefrom, possibly combined with that from one or more other udder quarters, has decreased to below said threshold value (D1), the relevant animal is admitted a more times per 24 hours than other animals into the area arranged for automatic milking.
When mastitis has been diagnosed for an animal, it may be important to prevent the animal, after having been milked, from mingling with the other animals. Therefore, according to the invention, it is possible that, after mastitis has been diagnosed in an udder quarter, the relevant animal is transferred to an isolation area contiguous to the area arranged for automatic milking. This isolation area may also be used are an area in which the animals can be isolated for other reasons. The isolation area may thus be used to separate animals to be inseminated or animals whose hoofs must be clipped.
The isolation area can also serve for collecting animals which report to the milking robot to be milked again too early after their previous milking turns. When these animals have to wait for some length of time, it would not be wise to send them back to the pasture: it might then be too long before they would report again to the milking robot, so that the time elapsed between successive milking turns would be too long. The invention, therefore, further relates to an apparatus for automatically milking animals, including an area comprising a milking robot and arranged for automatic milking, characterized in that, contiguous thereto, there is provided an isolation area in which animals, which report to the milking robot at such an instant that it must be assumed that the quantity of milk to be supplied by them will be less than a desired value, are detained until they can indeed be milked. The isolation area can then be in connection with a pasture, so that animals can be admitted from the pasture into the isolation area, optionally via the area arranged for automatic milking, and animals which need not be detained for specific reasons can go from the isolation area to the pasture.
Among the animals to be milked there may be "animals which are difficult to be milked automatically"; they may be animals having only three teats or animals with very unequal teat heights with such animals, it may happen that the milking robot does not succeed, or even cannot succeed--also after repeated efforts--in connecting the teat cups to the teats of the animals. A signal indicating this is usually provided, so that the farmer can then act to milk the animal, if due, himself. Since, however, the milking robot may be in operation for the full 24 hours, the farmer might find himself alerted at any moment during these 24 hours. According to the invention, this inconvenience to the farmer is avoided when the animals which are difficult to be milked automatically are detained in the isolation area for predetermined periods of time, such as nighttime, during which access to the milking area is to be denied to them. More in particular, the invention, therefore, also relates to an apparatus for automatically milking animals, including an area comprising a milking robot and arranged for automatic milking, characterized in that animals which are difficult to be milked automatically, such as those having only three teats, those having very unequal teat heights, etc., are denied access to the area arranged for automatic milking, for example, during the night, or are removed from this area without being milked if they had obtained access thereto in one way or another. More in particular, alarm means may be provided, with the aid of which it can be indicated that milking of the animal present in or at a milking compartment could not be accomplished because, for example, the milking robot cannot successfully connect the teat cups to the teats of the animal. Use of the alarm means can be avoided at least for animals which are difficult to be milked automatically during the periods of time that access to an area from which they can enter the milking compartment is denied to them.
According to the invention, the number of animals transferred from the milking area to the isolation area will be updated in the computer. The number of animals present in the isolation area can be updated both in the computer and in counting means provided for the purpose at or near the entrance and/or exit of the isolation area. When the animals enter the isolation area from the milking area, this can be recorded directly into the computer; when, however, the animals are guided by the farmer via a further door from the isolation area or predetermined animals are led therein, then the farmer can further update the number of animals present in the isolation area with the aid of the counting means. When the number of animals present in the isolation area exceeds a predetermined value, then the farmer may be warned.
Mastitis can not only be treated by further stripping of an udder quarter affected by mastitis and/or by more frequent milking of an animal, but also by rubbing an anti-mastitis ointment on at least the teat of the relevant udder quarter. The invention, therefore, also relates to a method of automatically milking animals, such as cows, characterized in that, when mastitis has been detected in an udder quarter, an anti-mastitis ointment is automatically applied, after milking, on at least the teat of the relevant udder quarter.
The invention does not only relate to a method, but also to an apparatus for automatically milking animals, in which the afore-described method can be applied. The apparatus then includes teat cups and a collector element, such as a mild claw or a milk jar, to which receives the milk obtained from each udder quarter through separate lines, and a mastitis sensor and a milk flow sensor incorporated in one or more of these lines and, in addition, means are present for breaking or reducing the vacuum in the teat cups and/or means for disconnecting the teat cups. The apparatus is then characterized in that there is present a computer, which, in response to signals coming from the milk flow sensor and the mastitis sensor, applies a control signal to the said vacuum breaking or reducing means, when the milk flow in a relevant milk line decreases to below a mastitis-depending threshold value or when a predetermined time interval has elapsed after this milk flow has decreased to less than a fixed or udder quarter-dependent threshold value. As a result, the vacuum in a relevant teat cup is broken or sufficiently reduced the teat cups for disconnecting. More specifically, when the milk flow sensors used are of the type in which the through-flow of a given quantity of milk is indicated by means of electrodes, it is, in accordance with the invention, important for the milk flow sensors to be provided in the milk lines near the connection of the milk lines to the collector element. The milk lines themselves then act as a kind of buffer, via which the milk obtained from the udder quarters is supplied in a pulsed mode. When at consecutive pulsed strokes less milk is fed through the line to a milk flow sensor, it takes a longer period of time before the volume between the two electrodes is filled with milk and the period of time between the signals supplied by the electrodes will increase. This period of time, which becomes longer towards the end of the milking operation, is a measure of the rate of milk flow. The predetermined threshold values then are in a direct relationship with the length of the time interval between consecutive signals produced by the electrodes.
Furthermore, according to the invention, a shut-off element for the milk lines connected to the teat cups may be provided under each of the teat cups, each of the shut-off elements closing a milk line after said control signal has been provided. Furthermore, according to the invention, a pulsator is usually provided for producing in each of the teat cups a pulsating vacuum, which in the relevant teat cup is broken after the said control signal has been applied, by admitting ambient pressure therein.
The afore-mentioned method can more in particular be applied in an advantageous manner in an above-described apparatus, which is not only arranged for automatic milking, but which is also provided with a milking robot for automatically connecting the teat cups to the teats of an animal to be milked and automatically disconnecting same, as soon as the milk flow in a given milk line has decreased to less than a mastitis-depending threshold value, preset in the computer, or as soon as a predetermined time interval has elapsed after the milk flow has decreased to below a fixed or udder quarter-depending threshold value. In this situation, the milking robot may comprise means for, when mastitis has been detected in an udder quarter after milking, automatically applying an anti-mastitis ointment on at least the teat of the relevant udder quarter.
According to the invention, the above-described apparatus may further include both an area arranged for automatic milking and an isolation area contiguous thereto, to which latter area the animals can be transferred for special reasons, such as because mastitis has been detected, or because the animals are to be inseminated, or because the hoofs of the animals must be clipped, etc. In or near this isolation area there may be arranged counting means, by means of which the number of animals present in the isolation area can be updated manually, more in particular when the animals are led into or from the isolation area via a separate passage. These counting means may be connected to a computer for a computerized updating of the number of animals present in the isolation area as indicated by the counting means, when the animals enter the isolation area from the milking area.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
FIG. 1 illustrates a shed organization, in which the apparatus for automatically milking animals in accordance with the invention is accommodated;
FIG. 2 illustrates schematically a portion of the apparatus for automatically milking animals, and
FIGS. 3A to 3E illustrate schematically positions of the various doors to and from the milking area and the isolation area in a specific embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a plan view of a shed or housing 1, in which a feeding area 2 is present which extends centrally in the longitudinal direction thereof. At both sides of feeding area 2, a plurality of cubicles 3 are located along substantially the overall length of housing 1 along the sides of its outer wall and, along the sides of feeding area 2 a plurality of feeding stations 4 located. Via doors 5 and 6 in shed 1, fodder in the form of hay can be transferred by means of a tractor driving into feeding passage 2 to feed channels and/or concentrate to feeding troughs for the feeding stations 4. Cubicles 3 and feeding stations 4 are arranged so that sufficient room remains for the animals to walk between the cubicles and the feeding stations, and so that they can move about and exercise to a sufficient extent and basically can walk around the shed. Near a shorter side of the shed is a milking area or compartment 7, in which a machine or apparatus for automatically milking animals is positioned. This milking machine includes a milking robot 8 for automatically connecting teat cups to the teats of an animal to be milked and subsequently disconnecting then. Between milking area 7 and the nearby side of shed 1 is a computer area 9, in which a computer 10 is located together with all the equipment that is part of the milking apparatus but is not disposed in milking area 7 proper. The milking compartment 7 has an entrance door 11 and two exit doors 12 and 13. The animals can enter the milking area from the exercise area via the door 11, whilst the animals can enter the exercise area again from the milking area via the door 12. As soon as an animal has entered the milking area from the exercise area or, via the exercise area, from the pasture, the animal's identity is ascertained in the customary manner. By means of the cow recognition system used therefor, assess is obtained to a data file present in the computer of the system for this animal. Recorded in this file inter alia is how much time has elapsed since her previous milking turn. From the subsequently established time differences between the moment when an animal enters the milking compartment, or at least reports at the milking compartment (in case the animal is identified prior to entering same), and the previous milking turn, an average value of these time differences can be determined. Preferably, this is done on the basis of a progressive average, based on each milking turn over say the last seven days. Furthermore the spreading in this average is determined. The said average value and the spreading therein are recorded in the memory file for the relevant animal and serve as a basis for a possible warning or placing the animal on an attention list, when an animal does not report in time at the milking compartment. When since the previous milking turn there has elapsed a period of time corresponding to the said average value plus a certain additional time determined by the said spreading without the animal having reported, then the animal must be brought in to be milked.
Next to milking area 7 there is an isolation area 14, which can be reached from the milking area via door 13. In addition, isolation area 14 is accessible via doors 15 and 16. In area 14, animals can be separated from the animals present in the exercise area of shed 1. This may be necessary because the animals have an udder shape that the teat cups cannot be connected automatically, because they are to be inseminated or because their hoofs are to be clipped, in which event the farmer can lead the animals via door 15 into isolation area 14, but also if mastitis has been detected in animals present in the milking area 7, those animals are then led from there via door 13 into isolation area 14 instead of into the exercise area of shed 1. The farmer can fetch animals from isolation area 14 via door 16. Using computer 10, which is further used for controlling the automatic milking procedure and the automatic connecting of the teat cups to the teats and disconnecting same therefrom, and also for performing all possible actions that are also of importance to the milking operation, the number of animals which are led from milking area 7 to isolation area 14 can be updated. When, however, the farmer himself leads animals into the isolation area via the door 15, or removes animals therefrom via the door 16, then the number of animals in the isolation area, as recorded in computer 10, will not correspond to the actual number. To prevent this error, counting means 17 are provided which are connected to computer 10. These counting means are preferably disposed near doors 15 and 16 and can be operated manually by the farmer. When the farmer leads an animal via one of doors 15 or 16 into the isolation area, then, by operating counting means 17, he can cause the number of animals indicated thereby to correspond to the actual number. Likewise, when he fetches an animal from isolation area 14 via one of the doors 15 or 16 the farmer can adjust, by operating the counting means, the number of animals present in the isolation area, so that, since counting means 17 are connected to the computer 10, the correct number of animals present in the isolation area is updated at all times in computer 10 and, if so desired, can be displayed on a display screen provided on the counting means. When in the absence of the farmer too many animals are passed from milking area 7 to isolation area 14, an alarm can be triggered to warn the farmer that the number of animals in isolation area is too high.
As has already been stated before, there may be present an isolation area for animals which have such an udder shape that the teat cups cannot be connected automatically. After these animals have been identified, they can be passed on to the isolation area, without the milking robot trying to connect the teat cups. Also animals, whose connection of the teat cups has failed even after repeated efforts, can be guided via the milking compartment to the isolation area, certainly during the so-called curfew times, such as during the night. The animals guided to the isolation area for the above reasons should be subsequently milked. For this purpose they are guided from the isolation area to the milking compartment, where the teat cups usually will have to be connected manually. To do this, the dispositions of various gates or doors into and from milking compartment 7 and isolation area 14 are represented in FIGS. 3A to 3E. In these Figures, the milking area is indicated again by reference numeral 7 and the isolation area by reference numeral 14. The entering and leaving of these areas is effected by means of, preferably computer-controlled, doors 28, 29, 30 and 31. In position of the doors as shown in FIG. 3A, an animal can enter the milking compartment 7 from the exercise area in the shed; doors 28 and 29 are subsequently closed (see FIG. 3B). When thereafter the connection of the teat cups fails or connection is not attempted due to the deviating udder shape, then door 30 is opened and the animal is guided to isolation area 14 (see FIG. 3C). Then door 30 is closed. When in this manner a certain number of non-automatically to be milked animals have been collected in the isolation area, then these will be admitted from isolation area 14 to the milking compartment in the presence of the farmer and at a moment to be decided by him. After the door 29 has opened (see FIG. 3D), an animal can enter the milking compartment from the isolation area, after which the door 29 is closed again, the animal is subsequently milked and dismissed from the milking compartment by opening doors 30 and 31 (see FIG. 3E) and guided to the exercise area of the shed. Then doors 30 and 31 close, while the door 29 is opened again in order to admit the next animal from the isolation area to the milking compartment.
The apparatus for automatically milking animals, which is partially and schematically shown in FIG. 2, includes teat cups 18 which are automatically connected to the teats of an animal to be milked by milking robot 8. Each of the milk lines 19 connected to teat cups 18 extends individually into a milk jar 20, from which, each time when a predetermined quantity of milk is received therein. The milk is pumped by means of a pump 22 via a shut-off device 21 into a line 23 leading to a milk tank (not shown). Under teat cups 18, each milk line 19 includes a shut-off device 24. Also a mastitis sensor 25 and a milk flow sensor 26 are incorporated in each of the milk lines 19. Milk flow sensors 26 are accommodated in milk lines 19 near the region where these milk lines end in the milk jar 20. FIG. 2 shows computer 10 which is also shown in FIG. 1. Signals S from individual milk flow sensors 25 are applied to this computer 10, each of these signals S being indicative of the milk flow in a relevant milk line 19. In addition, signals M supplied by each of the mastitis sensors are transmitted to computer 10. In the present embodiment, the mastitis sensors are milk conductivity sensors. The signals supplied by these sensors, which signals are a measure of the conductivity of the milk, are compared in the computer 10 to progressive, weighted or non-weighted average of the milk conductivity recorded during previous milking turns, whereupon, when the last-measured milk conductivity exceeds the progressive, weighted or non-weighted average to an excessive extent, an attention signal is displayed on display screen of the computer 10, on the basis of which signal the farmer can decide whether or not it is a matter of mastitis and if measures to counteract it must be taken. These data, and other data relevant to the milking of the animal or to her health, can not only be displayed on the display screen of the computer, but also be shown on attention lists to be printed out or even on a display screen to be arranged in the shed or elsewhere in the farm, so that the farmer can see the relevant data from a distance and at a single glance, without him having to strain his eyes on a computer display screen. By keying-in an affirmation in computer 10 a signal is received by computer 10 that it is indeed a matter of mastitis. This signal can, of course, also be produced automatically when the last-measured milk conductivity has exceeded the progressive, weighted or non-weighted average recorded in the computer by a predetermined extent. In computer 10, threshold values D1 and D2 may have been recorded in a program for the milk flow in the lines 19, or these threshold values may be entered via a keyboard. In the computer 10, a threshold value D is derived from the signal M and the threshold values D1 and D2, for which it holds that, as soon as the signal S from a milk flow sensor 26 has decreased to less than threshold value D, computer 10 produces a control signal. This control signal can be applied to a shut-off device 24 for closing the relevant milk line and for thereafter breaking the vacuum of the relevant teat cup and for optionally disconnecting the teat cup immediately thereafter. For the benefit of the milking operation there is present a pulsator 27, which is controlled by computer 10 and which produces a pulsating vacuum in each of the teat cups. After the said control signal has been applied, pulsations in the relevant teat cup to cease by admitting air at ambient pressure therein. The threshold value D, such as it is established in the computer 10, satisfies the Boolean expression D=D1.M+D2.M. In other words, in computer 10 there is determined a mastitis-dependent threshold value for the milk flow in a milk line 19, and as soon as the milk flow has decreased to a level below the predetermined threshold value D, milking of the relevant udder quarter is to be stopped. Since the second threshold value, i.e. the threshold value which holds for the case when mastitis has been found in an udder quarter, is less than the first threshold value, the relevant udder quarter is milked for a longer period of time than would be the case when no mastitis was detected in an udder quarter.
Instead of the second threshold value D2 it is also possible to utilize a predetermined time interval, which starts after the milk flow in the relevant line has decreased to less than the threshold value D1, for stripping the udder quarter.
The invention is not limited to the embodiment described in the foregoing, but includes further modifications, insofar as they are within the scope of the accompanying claims. | In a method of automatically milking animals, such as cows, the milk obtained from each udder quarter is discharged through separate milk lines to a collector element. When the milk flow from one or more udder quarters has decreased to less than a threshold value, the vacuum in the teat cup or cups connected to the udder quarter is broken. When mastitis has been detected in an udder quarter and after the milk flow originating therefrom, possibly combined with that from one or more other udder quarters, has decreased to below said threshold value, the udder quarter or quarters involved are automatically stripped, either during a predetermined period of time or for receiving a predetermined quantity of milk, or until the milk flow has decreased to less than a second threshold value which is lower than said first threshold value. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 139,881, filed Feb. 19, 1980 now U.S. Pat. No. 4,338,297, in the names of the same inventors.
BACKGROUND OF THE INVENTION
Numerous polypeptide molecules cause an allergic reaction in man and animals. Hay fever, more particularly ragweed sensitivity, characterized classically by itching of the mucosa of the nose, mouth, pharynx and eyes, lacrimation, sneezing, watery nasal discharge, coughing and sometimes asthmatic wheezing afflicts a considerable number of humans. Sensitivity to bee venom is characterized classically by a wheal and flare reaction, swelling, anaphylaxis and occasionally death. Food allergies classically are manifested by urticaria, perhaps nausea, diarrhea, and hives.
It is known that the appearance of allergy or atopy is involved with production of a tissue-sensitizing immunoglobulin (IgE) antibody. These IgE antibodies have an affinity for receptors on cells in various body tissues. The receptors on mast cells and basophils are of special significance since these cells contain pharmacologically-active mediators, such as histamine, serotonin, and kinins concentrated in cytoplasmic granules. When IgE antibodies are fixed to mast cells and basophils, contact with antigens can result in cross-linking. This cross-linking causes degranulation of mast cells and basophils which in turn release the pharmacologically active mediators (particularly histamine) and which are responsible for manifestations of the allergic response.
Thus, these disturbances are caused by immunoglobulin E reacting with specific polypeptide molecules in these substances. Untreated, these disturbances can lead to asthma in the case of hayfever, disabling reactions in the case of insect venom and limited dietary intake in the case of foods. Treatment for hayfever usually entails trial of orally active antihistamines, sometimes in combination with sympathomimettes such as phenylpropanolamine or phenylephrine. The symptoms may thus be partially suppressed, but the basic physiological difficulty, the histamine release by the antibody antigen reaction, persists. Treatment of insect stings by these agents is not practical since it is not possible to know when the event may occur and the reaction can be very severe if treatment is not immediate. Similarly the food reaction must have immediate treatment to achieve its effect. Commonly these treatments are inadequate or unsatisfactory and resort must be had to a more fundamental treatment, particularly for the pollen and venom allergies, namely desensitization.
One of the conventional and widely used methods of treating allergy is by immunizing or desensitizing a patient by repeated injections of small, gradually increasing amount of antigen, which is believed to increase the levels of blocking immunoglobulin G (IgG) antibodies and at the same time to arrest the production of IgE antibodies. This apparently conflicting effect of antigen administration is not fully understood but apparently involves differences in immunoregulation of two different classes of antibodies, viz. IgG and IgE.
This desensitization is undertaken with extreme caution. Commencing with a very dilute preparation of ragweed allergen or bee venom allergen, injected subcutaneously, if there is no local reaction within an hour of injection, the next dose is doubled and administered in 3 or 4 days. To be used in the event of an anaphylactic reaction, there must be available for emergency administration, adrenaline, antihistamines and intravenously administrable antiinflammatory corticosteroids during the testing and desensitization procedures. Both the time and precautions accompanying the conventional ragweed desensitization procedures are inconvenient. Benefits obtained by such treatments are frequently inconsistent.
This invention is concerned with the discovery, manufacture and method of use of a new and specific polypeptide immunosuppressant fraction produced by controlled proteolytic digestion of a polypeptide allergen which, upon administration for the specific allergic reaction in mammals, including humans, effects protection against said allergens without the accompanying and dangerous possibility of anaphylactic shock and other disadvantages indicated above. Pollen allergen preparations of this invention are made, illustratively, from common ragweed, giant ragweed, rye (Groups I, II and III), June grass, orchard grass, sweet vernal grass, red top, timothy, yellow dock, wheat, corn, sagebrush, blue grass, California annual grass, pig weed, Bermuda grass, Russian thistle, mountain cedar, oak, box elder, sycamore, maple, elm, etc. Ragweed constitutes the most prevalent and noxious of these and is the primary example illustrated herein. However, the pollen allergens of grasses and trees are chemically similar to ragweed pollen, the major alergens being acidic proteins of varying molecular weights within the range of about 20,000 to 40,000, as described by T. P. King, Advances In Immunology, 77-105, 1976, Academic Press, New York, N.Y. This publication further characterizes bee venom allergens (principally phospholipase and hyaluronidase) and food allergens (e.g. ovalbumin and ovomucoid) as being similar to the inhalant allergens, all being globular proteins.
According to King antigen E of short ragweed pollen comprises two non-identical polypeptide chains held together in the native molecule by noncovalent forces, the chains having molecular weights of about 26,000 and 13,000 daltons, respectively. Ovalbumin is reported as having a molecular weight of 44,000, while ovamucoid is a glycoprotein having a molecular weight of about 27,000. Bee venom phospholipase has a molecular weight of about 15,800, and hyaluronidase has a molecular weight of about 50,000. Both are basic glycoproteins.
King further reports that ragweed pollen antigen E is stable toward proteolytic digestion at neutral pH by trypsin, chymotrypsin and papain, but is digested by nagarase at neutral pH. Nagarase-digested antigen E showed less than 0.001% of the allergenic activity of intact antigen E. Ryegrass allergens Groups I and II are readily digested by trypsin and chymotrypsin, with complete removal of the antigenic and allergenic activities as well as haptenlike inhibitory activity, in the case of Group I.
The purpose of the proteolytic digestion reported by King was to show that allergens were polypeptides. The products of digestion described by King exhibited entirely different properties from those of the present invention.
As a general observation King states:
"The dominant antigenic determinants of the major allergens of ragweed and ryegrass pollens, codfish, and bee venom are dependent on both the primary structure and the conformation of the molecule, a property in common with the other globular protein antigens."
An article by L. Berrens, Annuals New York Academy of Sciences, 221: 183-198, 1974, attributes allergenic activity to lysine-sugar Amadori products which were present in all the allergens examined by him, based on the following observations: "Mild oxidation of these atopic allergens, using alkaline potassium ferric cyanide, hydrogen peroxide, or ultraviolet radiation, which selectively destroyed the highly vulnerable 1-amino-1-deoxy-2 ketose side chains, caused allergenic activity to diminish, without serious damage to the antigenic integrity of the carrier molecule.
The synthetic introduction of (lysine)-sugar structures of the above configuration into inactive carrier proteins led to the production of allergenically active preparations, featuring all the characteristic chemical properties of `natural` allergens.
In the light of these results, we have gradually come to regard the `lysine-sugar` site as essential in priming the allergic reaction."
Insect venom allergen preparations of this invention are made, illustratively, from bee venom, yellow jacket venom and other insects of the Hymenoptera order.
Food allergen preparations of this invention are made from egg, milk, and other sources of similar allergenic proteins.
The process of the present invention, involving controlled proteolytic enzyme digestion, is operable with all allergens of the above types of which applicants are aware. The polypeptide active immunosuppressant fractions of this invention, in contrast to prior art allergens, can be administered without likelihood of anaphylaxis.
Attempts to achieve separation of protective and allergic inducing activities for the treatment of pollen sensitivities, particularly in ragweed-sensitive individuals, have been reported. For example, Ishizaka, K., et al, J. Immunol. 113: 70-77, 1974, prepared four modification of the active allergenic fraction of ragweed pollen extract, antigen E, namely urea denatured antigen E (UD), its alpha and beta polypeptide chains and a reduced carboxymethylated antigen E (RC). All modifications lost antigenic determinants present in the unmodified antigen E and accordingly could not be used to achieve satisfactory antibody production against antigen E in humans. Each of the four preparations failed to combine with human gamma globulin, human IgG, against the original native antigen, and did not induce erythema wheal reactions in ragweed sensitive individuals. Since modified antigens do not induce allergenic reactions in the patients but are capable of stimulating T cells, carrier-specific helper cells, Ishizaka speculated that such modified antigens may change the T cell population without side effects. Subsequently, Ishizaka, et al., J. Immunol., 114: 110-115, 1975, reported that test results collectively indicate that a major population of B cells stimulated by native antigen is different from the majority of B cells stimulated by the urea-modified antigen. Further work on UD or the alpha-polypeptide chain isolated from the denatured molecule provided additional evidence that these materials prime T cells specific for native antigen E (Takatsu, et al., J Immunol., 115: 1469-1476, 1975 and 116: 1257-1264, 1976). It must be recognized that the denatured protein and polypeptide chains obtained from the denatured protein themselves introduce foreign material which could aggravate allergic sensitivity by providing yet another foreign sensitizing material, over and above ragweed antigen, to which the body may react.
In addition to urea-denatured antigens described by Ishizaka et al, which do not react with antibodies to native antigen molecules, the literature has disclosed other modified antigen preparations. These may be summarized as follows:
Glutaraldehyde polymerized antigen: R. Patterson, J. Allergy and Clinical Immunology, 68: 85-90, 1981 immunogenic, but reactive and administrable only in small amounts.
Formaldehyde treated antigen: D. G. Marsh et al, J. Allergy and Clinical Immunology, 68: 449-459, 1981--non-reactive but ineffective in immunosuppression.
Antigen conjugated with d-amino acids or polyethylene glycol: F. Liu et al, Proc. National Academy of Sciences USA, 76: 1430-1434, 1979; and A. H. Sehon et al, J. Allergy and Clinical Immunology, 64: 242-250, 1979--immunosuppressive, reactivity similar to unmodified antigenic extracts.
The art has thus failed to show or suggest the preparation of a pollen desensitizing agent free of anaphylactic reactivity, such as could be used therapeutically.
SUMMARY OF THE INVENTION
We have now found that a safe and effective pollen, venom, and food desensitizing material is preparable from pollen, venom, and food extracts treated with proteolytic enzyme inclusive of exopeptidases e.g. carboxypeptidase A, and endopeptidases, e.g. trypsin, chymotrypsin, papain, particularly, bacterial protease, nagarase, or pepsin, and preferably then detoxified by molecular exclusion chromatography, molecular filtration or affinity absorption to remove fractions exacerbating the allergy to be treated, to produce a product which possesses ability to suppress the immune response to said antigens, thereby avoiding dangers normally associated with attempted desensitization by use of said antigens. The polypeptide allergen desensitizing product is obtained by proteolytic digestion of the primary allergen to produce an antigen-specific polypeptide fraction apparently having only one functional antigenic valence on each molecule, thereby not participating in reactions involving antigen bridging, including antibody formation and anaphylactic response. The polypeptide fraction has a molecular weight of less than 10,000. The product of this invention does not give a positive wheal and flare reaction in sensitive individuals, nor will it react in the passive cutaneous anaphylaxis reaction (PCA) in rats sensitized by specific illustratum with ragweed antigen, bee venom antigen or egg white ovalbumin antigen. These polypeptide fragments have been found effective in suppressing immune response by activating T suppressor cells and/or inactivating B cells.
According to the invention there is thus provided an allergen desensitizing polypeptide fraction derived by proteolytic enzymatic digestion from a specific allergen causing the allergic reaction to be treated, said fraction consisting essentially of a degraded polypeptide having a molecular weight of less than about 10,000, a nominal molecular radius not greater than about 15 angstroms, an inability to precipitate with specific antibodies, an inability to induce substantial passive cutaneous anaphylaxis reaction in a sensitized mammal, an inability to release histamine from sensitized mast cells or basophils, an inability to induce substantial antibody response, a capability of significantly inhibiting immunological reactions between a whole allergen and its antibody, and a capability of inducing antigen-specific suppression.
The invention further provides a method of producing an allergen desensitizing polypeptide fraction which comprises subjecting an aqueous extract of a native allergen to digestion by a proteolytic enzyme and obtaining a reaction product consisting essentially of a degraded polypeptide fraction having a molecular weight of less than about 10,000 and a nominal molecular radius not greater than about 15 angstroms.
A method of desensitizing mammals against allergic reaction, in accordance with the invention, comprises administering to an atopic mammal, prior to or after exposure to an antigen, a dosage of a polypeptide fraction derived by proteolytic enzymatic digestion from a specific allergen causing said allergic reaction in an amount effective to inhibit significantly immunological reactions without inducing anaphylaxis in said mammal, said fraction consisting essentially of a degraded polypeptide having a molecular weight of less than about 10,000, and a nominal molecular radius not greater than about 15 angstroms.
All large polypeptide molecules including ragweed antigen, bee venom phospholipase A, and egg white ovalbumin are complex immunologic entities. They contain a large number of possible sites which are recognized as foreign by the host animal or human, and the immunologic response is to produce antibodies which will react with many of these epitopes. In order to obtain an immunologic response a minimum of two binding sites on the antigen are necessary. This same requirement for a minimum of two binding sites is also necessary for an allergic response, e.g. anaphylaxis. Thus there is a relationship between immunologic response and immunologic reactivity. The products of this invention are a series of polypeptide fractions which are assumed to have only one functional binding site on each molecule. Thus the epitopes on this molecule can only have partial recognition or reactivity. Although not wishing to be bound by theory, it is believed that it is this inability to form the complete reaction which confers the unique properties.
Polypeptide molecules, when degraded by proteolytic enzymes, form a series of products of varying molecular size. Short degradation times or very small amounts of enzyme degrade the molecule partially, yielding large fragments. In contrast, large amounts of enzyme or long digestion times result in more completely degraded polypeptide. The product of this invention results from the choice of the appropriate enzyme to form polypeptides which have the unique immunological properties. Too little degradation would result in polypeptides having properties similar to the native molecules, while too much degradation would result in fragments which have no immunologic or immunochemical reactivity. In the case of ragweed pollen it has been found that fragments having a molecular weight of less than about 2,000 have no immunologic or immunochemical reactivity.
Purification of the product may be needed to remove those allergenic molecules with too great an immunologic reactivity. This is accomplished by selecting polypeptide fragments having a molecular weight less than about 10,000 and a nominal molecular radius not greater than about 15 angstroms. If still present, strongly reacting polypeptides can be removed by affinity chromatography of allergen specific antibody columns.
It is within the scope of the invention to control carefully the digestion of the allergen by proteolytic enzymes in such manner that substantially no residual reactive antigens remain, thus making it unnecessary to carry out a purification or selection step by means of molecular exclusion chromatography, molecular filtration or affinity absorption. A purification or detoxification step in the present method is thus considered to be optional but preferred for safety.
DETAILED DESCRIPTION OF THE INVENTION
Preparation I
Short Ragweed Extract and Fraction A
Defatted short ragweed pollen, 10 g, was added to distilled water, 50 ml, and stirred for 48 hours at 4° C., or optionally as little as 2 hours at 25° C. The slurry was filtered through paper on a Buchner funnel, the filtrate being whole ragweed pollen aqueous extract. To this extract, solid ammonium sulfate was added to 90% saturation and the mixture was maintained for 2 to 3 hours at 4° C. and centrifuged. The precipitate was separated and dissolved in 3.5 ml of 0.1 M TRIS buffer and 0.06 HCL (pH 7.9). This buffered solution was run through a Sephadex G-25 polydextran molecular sieve column 95 cm high and 4 cm in diameter which had been equilibrated with 0.025 M TRIS and 0.015 M HCL (pH 7.9). The first peak raffinate from the column was fraction A. To assure purification, Fraction A was optionally again passed through the column. The raffinate was centrifuged and the supernatant portion was lyophilized.
EXAMPLE 1
Lyophylized Fraction A from Preparation I was dissolved in 0.1 M sodium bicarbonate buffer, pH 8.0, at a concentration of 20 mg/ml. Nagarase proteolytic enzyme from B subtilis was dissolved in 0.1 M sodium bicarbonate buffer, pH 8.0, to make a concentration of 20 mg/ml. The nagarase solution was added to the Fraction A solution to give a final ratio of Fraction A 100 parts to nagarase 1 part. After incubation for 24 hours at room temperature the enzyme digestion was stopped by the addition of PMSF stock solution, 190 mg per ml in 0.1 M sodium bicarbonate (pH 8.0), added to the enzyme digest to produce a molarity ratio of PMSF to nagarase of 1.5:1. This was the crude polypeptide active ragweed pollen immunizing fraction.
EXAMPLE 2
Lyophilized Fraction A from Preparation I was dissolved in 0.1 M citrate phosphate buffer, pH 3.0, at a concentration of 200 mg of Fraction A per 10 ml of buffer solution and repeatedly slowly passed through a column of immobilized pepsin enzyme on glass beads. After 20 passages at room temperature the digest was removed from the column and lyophilized.
EXAMPLE 3
A citrate-phosphate buffer (pH 3.0) was prepared from 39.8 ml of 0.1 M citric acid and 10.2 ml of 0.2 M dibasic sodium phosphate diluted to 100 ml with distilled water. The lyophilized Fraction A from Preparation 1 was dissolved in this buffer solution in a proportion of 20 mg of Fraction A per ml of buffer. To this was added an aliquot of 5 mg of pepsin in 1 ml of distilled water to give a ratio of Fraction A to pepsin of 100 to 1. The solution was maintained for 24 hours at room temperature and then brought to pH 7.4 by the addition of 0.1 M sodium hydroxide. The resulting product was the crude ragweed polypeptide active immunosuppressant fraction.
EXAMPLE 4
Bee venom phospholipase A, (Sigma Chemical Co., St. Louis, Mo. #P2509) 100 mg, was dissolved in citrate phosphate buffer, pH 3.0, 10 ml, and stirred for 1 hour at 25° C. The pH was adjusted to 3.0 by addition of 1 N HCl. Digestion was performed by adding 5 mg of pepsin (bovine) and the reaction was allowed to proceed for 6 hours at 25° C. The reaction was terminated by the addition of 1 N NaOH to bring the pH to 8.0. This destroyed any residual pepsin activity. The resulting product was the crude phospholipase A polypeptide active immunosuppressant fraction.
EXAMPLE 5
Ovalbumin (Sigma Chemical Co. Fraction V) 1 g was added to distilled water, 100 ml, and stirred for 1 hour at 25° C. The pH was adjusted to 3.0 by addition of 1 N HCl. Digestion was performed by adding 50 mg of pepsin (bovine) and the reaction was allowed to proceed for 6 hours at 25° C. The reaction was terminated by the addition of 1 N NaOH to bring the pH to 8.0. This destroyed any residual pepsin activity. The resultant product was the crude ovalbumin polypeptide active immunosuppressant fraction.
EXAMPLE 6
The products of Examples 1 through 5 were further purified by passing each of them through an affinity absorption column prepared as follows: Sepharose CL-4B polydextran was washed with distilled water. Sepharose CL-4B washed, 0.5 volume and distilled water 0.5 volume were added to 1 volume of 2 M sodium carbonate and stirred slowly. To this slurry, 0.5 volume of 2 g per ml of cyanogen bromide in acetonitrile was added all at once. The slurry was stirred vigorously for 2 minutes. The Sepharose was then washed with 10 volumes of 0.1 M sodium bicarbonate, pH 9.5. The slurry was filtered under vacuum and the filter cake was transferred to a flask containing 100 ml of 1 percent of a gamma globulin antibody to the specific allergen, for example human ragweed gamma globulin in 2 M sodium bicarbonate. Coupling of the Sepharose and globulin was effected by maintaining the preparation at 4° C. for 20 hours. After coupling, the Sepharose beads were washed successively with 20 volumes each of 0.1 M sodium acetate, pH 4.0, 0.1 M sodium bicarbonate, and physiological saline. Lowry determinations done before and after coupling demonstrated 86.3% efficiency of coupling of human gamma globulin to Sepharose beads.
The purified products of each of Examples 1 through 5 obtained in this Example have substantially identical biochemical and immunological properties. The resulting unabsorbed allergen digest, the polypeptide active immunosuppressive fraction, is used for the treatment of allergy. If desired, the raffinate may be lyophilized to produce a dry solid product which keeps well and may be resuspended in saline for therapeutic use.
The material prepared from ragweed pollen has a molecular weight of less than about 10,000 but not less than about 2,000. The antigenic determinants not absorbed out by antibodies are still retained.
EXAMPLE 7
The products of Examples 1 through 5 were further purified by passing each of them through a molecular sieve or gel filtration column prepared as follows:
Sepharose G-50, 500 g, was allowed to swell overnight in 2 liters of phosphate buffered saline, pH 7. The resulting slurry was stirred, allowed to settle and the fine particles decanted. A column of the material was made by adding the slurry carefully to a 10 cm×200 cm glass column. The polypeptide fractions of ragweed, bee venom or ovalbumin respectively, eluted in the fraction of less than about 10,000 molecular weight.
EXAMPLE 8
The products of Examples 1 through 5 were further purified by passing each of them through a molecular sieve such as the Millipore immersible CX-10, Amicon PM-10, UM-10, UM-5. The fractions were purified by ultrafiltration either by vacuum or pressure. The filters did not allow passage of molecules greater than a nominal molecular radius of about 15 angstroms.
As an aid in interpreting the data of Tables I through XIII hereinafter, the following definitions are set forth:
(1) Non-immunogenic Substance: When administered by injection in the presence of an adjuvant, there is no or a very poor immune response. This is accomplished by one or several injections of the polypeptide fractions. Testing for the immune response is done by using the passive cutaneous anaphylaxis (PCA) reaction.
(2) Non-antigenic Substance: When administered to an animal sensitized by antibodies to the specific antigen, the polypeptide fraction causes no allergic reaction. This is accomplished by injecting antibody subdermally where it adheres to host mast cells followed by a challenge with the antigen. This treatment normally results in a passive cutaneous anaphylaxis (PCA) reaction. No reaction indicates loss of antigenicity.
(3) Immunosuppressive Substance: When administered prior to or after the antigen, the polypeptide fraction reduces or eliminates the allergic response. Thus treatment with the polypeptide fraction lowers or eliminates the expected or ongoing IgE response as tested by PCA.
(4) Passive Cutaneous Anaphylaxis (PCA): A highly sensitive and reliable test of immediate hypersensitivity based on measuring titers of antibodies that sensitize mast cells and basophils. PCA is equivalent to PK reaction in humans.
(5)
Primary Response: Following first exposure to the antigen.
Secondary response: Following second or multiple exposures to antigen.
The tests reported in Tables I through XIII are averages based on either two or three experiments.
EXAMPLE 9
BDF 1 mice were injected intraperitoneally with ragweed extract and alum as an adjuvant. Immune response was measured by passive cutaneous anaphylaxis (PCA) reaction in rat skin. The PCA challenge consisted of 1 mg ragweed extract dissolved in 1 ml of 1% Evans blue. Polypeptide active pollen immunosuppressive fraction (PAPIF) was also injected, with results summarized in Table I.
TABLE I______________________________________IMMUNOGENIC PROPERTIES OF PAPIF Primary Response Secondary Response at 10 days at 40 days*Preparation** PCA Titer PCA Titer______________________________________Ragweed Ext. 10 μg 1:320 dilution 1:1620 dilutionRagweed Ext. 100 μg 1:160 dilution 1:1620 dilutionPAPIF 10 μg 0 0PAPIF 100 μg 0 0______________________________________ Titer represents mean of sera pooled from 5 mice *Second injection was given at 30 days **Dose i.p. in alum.
The above data show complete lack of immunogenicity of PAPIF in both primary and secondary immune responses are compared with ragweed extract which effected responses at dilutions of 1:160 and 1:1620.
EXAMPLE 10
To test the effect of ragweed PAPIF as an immunosuppressant, mice were injected I.V with PAPIF of Examples 3 and 6 prior to immunization with ragweed extract in accordance with Table II.
TABLE II______________________________________IMMUNOSUPPRESSIVE PROPERTIES OF PAPIFPretreatment Challenge with PCA Titerwith PAPIF* Ragweed Ext.** Day 10______________________________________100 μg day 0 100 μg day 1 010 μg day 0 " 01 μg day 0 " 1:10100 μg day 1 " 1:1010 μg day 1 " 1:201 μg day 1 " 1:400 " 1:160______________________________________ Titer represent mean of sera pooled from 5 animals *i.v. adm. in saline **i.p. in alum.
The data of Table II clearly show the immunosuppressive effect of PAPIF on the immune response to ragweed antigen in the primary immune response.
A similar degree of suppression by I.V. injection of the product of Examples 2 and 6 was observed during the secondary immune response to ragweed antigen in accordance with Table III.
TABLE III______________________________________IMMUNOSUPPRESSIVE PROPERTIES OF PAPIF INSECONDARY RESPONSEPretreatment with Challenge withPAPIF* Ragweed Ext.** PCA day 40______________________________________100 μg day 0, day 29 100 μg day 1, day 30 1:1010 μg day 0, day 29 " 1:401 μg day 0, day 29 " 1:800 " 1:3200______________________________________ Titer represents mean of sera pooled from 5 animals *i.v. in saline **i.p. in alum.
The effects of PAPIF prepared in accordance with Example 2 in the inhibition of ongoing immune response to ragweed antigen was also demonstrated. After IgE response became evident the animals were injected I.V. with PAPIF in accordance with Table IV.
TABLE IV______________________________________EFFECT OF PAPIF ON ONGOING RESPONSETreatment With Treatment WithPAPIF on Ragweed Ext. on PCADay 6, 7, 8* Day 1** Day 20______________________________________-- 100 μg 1:160100 μg 100 μg 1:10100 μg -- 0______________________________________ Titer represents mean of sera pooled from 5 animals *i.v. in saline **i.p. in alum.
Thus administration of PAPIF was suppressive even to ongoing IgE response.
EXAMPLE 11
The PAPIF material of Example 8 was tested in humans either non-sensitive or sensitive specifically to ragweed antigen.
Fraction A and purified PAPIF were prepared at a concentration of 1 mg per ml in non-pyrogenic saline and filtered through a 0.25μ Millipore bacterial filter. The filtrate was further diluted with sterile isotonic saline to 10 -3 to 10 -6 dilutions and skin reactivity tested to intradermal injection of 0.02 ml per injection as follows:
In three non-atopic individuals, the 10 -3 to 10 -6 dilutions caused no skin reaction. This shows PAPIF at these concentrations to have no inherent reactivity in normal individuals.
In three atopic individuals, the following reactions were observed with the intensity of wheal graded from a maximum of plus four down to zero as reported in Table V. These data demonstrate that PAPIF was almost non-reactive even in the most concentrated solution tested in atopic individuals.
TABLE V______________________________________REACTIVITY OF PAPIF IN RAGWEEDSENSITIVE PATIENTSDilu-tionof Patient A Patient B Patient CPrep- Fraction Fraction Fractionarat.* A PAPIF A PAPIF A PAPIF______________________________________10.sup.-3 ++++ +,0 ++++ 0 ++++ +,010.sup.-4 ++++ 0 ++ 0 ++++ 010.sup.-5 ++ 0 ++ 0 +++ 010.sup.-6 + 0 + 0 ++ 0______________________________________ *Undiluted preparation contained 1 mg/ml of the fraction.
EXAMPLE 12
Table VI demonstrates blocking activity of PAPIF in rats intradermally sensitized with reaginic IgE anti ragweed antibodies prepared in BDF 1 mice. PAPIF was administered I.V. 15 min. prior to I.V. challenge with Fraction A and Evans Blue. As shown, Table VI PAPIF substantially reduced reactivity between IgE antibody and antigen.
TABLE VI______________________________________BLOCKING ACTIVITY OF PAPIFAnti Ragweed PCAIgE Serum NoDilution PAPIF* PAPIF______________________________________1:10 +++ +++1:20 +++ +++1:40 +++ +++1:80 +++ +1:160 +++ -1:320 + -1:640 - -______________________________________ *Fraction A 100 μg in 1.0 Ml 0.5% Evans Blue given I.V. 15 min. after PAPIF
EXAMPLE 13
Table VII demonstrates that fragments having molecular weight less than 10,000 are not reactive in PCA challenge.
Rats were sensitized intradermally with anti ragweed IgE antibodies prepared in BDF 1 mice. 24 hours later they were challenged I.V. with 1 mg of the appropriate fragments purified by ultrafiltration (Example 8) in 1 ml 0.5% Evans Blue. It is evident that fragments having a molecular weight less than 10,000 were not reactive in PCA.
TABLE VII______________________________________PCA REACTIVITY OF FRAGMENTSApproximate MolecularWeight of Fragments PCA*______________________________________20,000- 30,000 +++10,000- 20,000 +++ 2,000- 10,000 -<2,000 --- -______________________________________ *Sensitizing antiserum 1:50 dilution
EXAMPLE 14
The immunosuppressant activity of the fragments separated by ultrafiltration (see Example 8) is shown in Table VIII.
The fragments were administered I.V. to groups of BDF 1 mice which were subsequently immunized with Fraction A in alum. Fragments having a molecular weight less than 2,000 were found not to be immunosuppressive.
TABLE VIII______________________________________Approx. Molecular Pretreat- ChallengedWeight of Fragmts. ment With Ragweed** PCA______________________________________20,000- 30,000 10 μg (3X) 100 μg 1:510,000- 20,000 10 μg (3X) 100 μg 1:10 2,000- 10,000 10 μg (3X) 100 μg 1:10<2,000 10 μg (3X) 100 μg 1:320-- -- 100 μg 1:320______________________________________ *Mice pretreated by intravenous injection 24, 48 and 72 hours before challenge with ragweed **In 1 mg of alum injected intraperitoneally
EXAMPLE 15
The immunogenic, immunosuppressive and antigenic properties of phospholipase A fragments (Fr 1) are demonstrated in Tables IX, X and XI. The properties of these fragments are identical to those of PAPIF described in Examples 9 and 10.
TABLE IX______________________________________IMMUNOGENICITY OF PHOSPHOLIPASE FRAGMENTSPreparation* 14 d. PCA 21 d. PCA______________________________________PS A** 160 320PS A 320 640Fr. 1*** 0 0Fr. 1 0 0______________________________________ *Administered i.p. in alum. **phospholipase A ***Fragment 1 Titer represents mean from 5 pooled sera.
TABLE X______________________________________SUPPRESSION BY PHOSPHOLIPASE FRAGMENTSPretreatment* Immunization** 21 d. PCA______________________________________Fr. 1 10 μg (3X) PS 10 μg 0Fr. 1 10 μg (3X) -- 0-- PS 10 μg 640______________________________________ *i.v. in saline **i.p. in alum. Titers means from 5 pooled sera.
TABLE XI______________________________________ANTIGENICITY OF PHOSPHOLIPASE FRAGMENTSSensitiz. With* Challenge PCA______________________________________Anti Ps IgE PS 100 μg 160Anti PS IgE Fr 1 100 μg 0Anti PS IgE Saline 0______________________________________ *Antibody injected intradermally 24 hours prior to i.v. challenge with antigen dissolved in 10 ml of .5% Evans blue dye.
EXAMPLE 16
The phospholipase A fragments (Fr 1) of Examples 4 and 6 were tested in humans non-sensitive or sensitive to bee venom. Table XII shows results of testing which demonstrate that Fr 1 is non-reactive in bee venon sensitive patients at concentration of 1 μg.
TABLE XII______________________________________SKIN TESTING OF BEE VENOM SENSITIVE PATIENTS ReactionTest Material Patient #1 Patient #2 Patient #3______________________________________Bee venom 1 μg ++++ ++ 0Phospholipase 1 μg ++++ +++ 0Fraction I 1 μg 0 0 0Saline 0 0 0______________________________________
EXAMPLE 17
Ovalbumin fragments (OVA Fr) prepared as described in Example 5 were tested for their immunogenic, suppressive and antigenic properties. The properties of these fragments were identical to those of PAPIF and phospholipase A fragments as described in Examples 9, 10 and 15.
Table XIII shows immunosuppressive properties of OVA fragments in BDF 1 mice.
TABLE XIII______________________________________SUPPRESSION BY OVA FRAGMENTSPretreatment* Immunization** 21 d. PCA______________________________________OVA Fr. 10 μg (3x) OVA 10 μg 0OVA Fr. 10 μg (3x) -- 0-- OVA 10 μg 320______________________________________ *i.v. in saline **i.p. in alum Titers means from 5 pooled sera
By way of summary, Table I discloses that the fragments were quite non-immunogenic even when administered in an adjuvant.
Immunosuppressive activity of these fragments is documented in Tables II, III and IV. These data show that the fragments were effective when administered prior to primary or secondary response or even after the response was ongoing.
Table V shows that ragweed fragments were quite non-reactive in ragweed sensitive patients when administered intradermally.
Tables VI to VIII demonstrate the blocking, and molecular weight dependency of the properties of the ragweed fragments.
Tables IX to XI demonstrate properties of fragments (Fr1) prepared from phospholipase A (PSA), the major component of bee venom in accordance with Examples 4 and 6. These tables clearly show that phospholipase A fragments were effective immunosuppressants.
Table XII shows that phospholipase A fragments were quite non-reactive in individuals sensitive to bee venom.
Table XIII shows results of experiments in which hen albumin (OVA) and its fragments (Fr OVA) prepared in accordance with Examples 5 and 6 were administered prior to parenteral challenge with OVA in alum. A high degree of suppression was achieved.
The above test data demonstrate that the polypeptide fractions of the present invention have lost the ability to cause allergic reaction, i.e. release of vasoactive amines from antibody-sensitized mast cells and basophils. However, the polypeptide fractions retain their immunoregulatory properties, and administration of the product of the invention to experimental animals parenterally inhibits initiation or continuation of ongoing IgE immune response to the specific allergen being treated.
In a typical case of pollen or ragweed allergy, desensitization is accomplished by treating the patient biweekly with the appropriate fragments. Since these fragments are relatively non-exacerbating, relatively large doses of it can be injected subcutaneously to achieve fast desensitization safely. For example, injection of 0.1 ml of 10 -3 dilution of PAPIF (basic solution containing 1 mg of PAPIF per ml) is instituted biweekly for several weeks, desirably within three months prior to the beginning of the patient's ragweed sensitivity season. At the same time, the patient is tested by radioimmunoassay for concentration of specific antiragweed IgE as well as for the skin reactivity to ragweed antigen. As a result of desensitization there is no increase in levels of antiragweed IgE upon exposure of the individual to the ragweed. In addition, the reactivity of the desensitized individual to ragweed extract is significantly reduced.
The present invention represents an advance in two areas from the standpoint of processing and ease of administration. First, it has been found that digestion of an allergen by proteolytic enzymes can be controlled to such a degree that it is not necessary to remove residual reactive antigens. Thus the step of controlled enzymatic digestion of the allergen results in the desired final product. Second, it has been found that parenteral administration of the product to mice in relatively large doses results in suppression of the IgE immune response. | Immunosuppressive polypeptide fractions prepared by enzymatic digestion of specific allergens are non-reactive in animals and humans and effective by parenteral administration, the immunosuppression being antigen specific, affecting production of immunoglobulins. A method of producing immunosuppressive polypeptide fractions and a method of desensitizing mammals therewith are disclosed. | 8 |
PRIORITY
[0001] This application claims the benefit of German Patent Application No. 102015122069.5, filed on Dec. 17, 2015, which is hereby incorporated herein by reference in its entirety.
FIELD
[0002] The present invention relates to an injection device for administration of an injection to an animal, which comprises a main body and a contact device. The main body comprises an injection instrument and the contact device has a contact area which is shaped in conformity with a body part of an animal to which the injection is to be administered.
BACKGROUND
[0003] In the keeping and rearing of animals, it is often necessary to administer an injection to the animals. This can be carried out manually with a conventional syringe. In larger enterprises, for example in poultry farming, many animals are present, to which an injection has to be administered in as short a time as possible. Hence in the prior art there are injection devices by means of which an injection to an animal can be carried out more rapidly.
[0004] For example, U.S. Pat. No. 8,211,058 B2 discloses a device for injection into the breast muscle of a chicken. For this, the device has a pressure application surface which is matched to the anatomy of the chicken in the region of the breast muscle. Through the shaping of the pressure application surface, correct positioning of the bird is facilitated. In addition, three contact sensors are provided in the pressure application surface, which are activated on correct positioning of the chicken on the pressure application surface. If all three contact sensors are activated by the presence of the chicken, a control device triggers the injection into the breast muscle of the chicken.
[0005] However, there is a continuing need to provide an improved injection device for administration of an injection to an animal.
SUMMARY
[0006] The disclosure includes an injection device for administration of an injection to an animal. The device can include a main body with an injection instrument, a contact device, a support device, a force measurement device and a control device. The contact device comprises a contact area which is shaped in conformity with a body part of the animal to which the injection is to be administered. The support device supports the contact device on the main body movable in a pressure application direction. The force measurement device has at least one force sensor and is designed to measure the force (preferably in the pressure application direction) with which the contact device acts on the main body. The control device activates the injection instrument if the force measured by the force measurement device lies in the specified range.
[0007] The injection device serves in particular for the administration of a great variety of active substances which have to be administered subcutaneously and/or intramuscularly. For example by means of the injection device vaccines or medicaments can be administered to the animal. In particular, by means of the injection device medicaments for the treatment of a great variety of diseases can be administered.
[0008] The injection device, in particular the contact device, can be designed for the injection of a great variety of animals. The contact device is differently shaped depending on the animal to be treated (and optionally on its age). In particular, the injection device is intended for administration of an injection to poultry, such as for example chickens, ducks, turkeys, quail, geese, pigeons or other farmed poultry.
[0009] The main body may comprise in particular a housing and a stand device by means of which the injection device can be put down on a support. A recess in the housing, which for example provides an access to the injection instrument, can be closed by a cover. Furthermore, the control device is preferably arranged on or in the main body. In addition, a power supply such as for example a transformer or a battery can be provided for the injection instrument, the control device and/or the force measurement device. The injection instrument is in particular positioned in the main body, especially within the housing of the main body.
[0010] The injection instrument can be configured as a syringe, such as for example a self-filling syringe. The syringe can have a syringe cylinder, in which a plunger is movably located, and a cannula whereby by movement of the plunger in the direction towards the cannula the fluid present in the syringe cylinder (i.e. for example the vaccine or the desired medicament) can be discharged via the cannula. The injection instrument further preferably comprises an actuator which can move the syringe in the direction of the contact device, so that the cannula can be inserted into the part of the animal which is adjacent to the contact area, for example through an opening in the contact area. After this insertion process, the medicament or the active substance can then be administered by movement of the plunger. In particular, the cannula can be inserted into the breast muscle of the bird.
[0011] The injection instrument can include one or more syringes. In particular, it can have two syringes so that two different medicaments can be administered simultaneously to an animal.
[0012] The injection instrument can be designed such that the several syringes can be moved in the direction of the contact device simultaneously or independently of one another.
[0013] The injection instrument can however additionally or alternatively have any other type of injection device with which the desired injection can be administered to the animal lying against the contact area.
[0014] By means of the actuator, an end of the injection device on the discharge side can be moved to the animal lying against the contact area. Contact with the animal may or also may not be achieved. It is in particular essential that the desired injection can be carried out reliably.
[0015] The injection device can be configured such that the injection devices (e.g. syringes) are controllable independently of one another. Thus for example for a first injection procedure only one of the injection devices may be used. For a second injection procedure, two or more devices may then be used. During each injection procedure the relevant fluids (e.g. medicaments) can each be administered to several animals. The injection device can have an input interface via which the desired injection procedure is adjustable and/or selectable.
[0016] The contact area of the contact device can be shaped like the body part of the animal to which the injection is to be administered. For example, the injection can be administered into the breast muscle of a bird, in which case the contact area is then shaped like the breast of the bird. Alternatively, the contact device can be designed for injection into the neck or the foot of a bird. Then the contact area has a shape adapted thereto.
[0017] In particular, several contact devices can be assigned to the injection device, so that by means of one injection device injections can be administered to several different animal species or at different sites. For this, the contact device is in particular designed such that it can be detachably secured to the main body. The contact area of the contact devices is for example designed appropriately adapted with regard to the animal species, the animal breed, the age of the animal and/or the size of the animal.
[0018] The support device preferably makes it possible to secure the contact device to the main body, in particular detachably. The support device makes it possible for the contact device to be arranged movable on the main body, so that the contact device, preferably for the determination of the pressing force, can be moved towards the main body in a pressure application direction. This pressure application is in particular carried out in that the animal is pressed against the contact device and thereby the contact device is moved towards the main body.
[0019] The force measurement device can be provided to measure the force which the contact device exerts on the main body. In particular, the force measurement device serves to determine the pressing force of the animal against the contact device. The force measurement device is in particular provided on the main body. The contact device can thus be designed free from electrical components, since the force measurement device and also the control device is arranged on the main body. The contact device is thus in particular a pure molded component. The contact device can be produced by injection molding or deep-drawing.
[0020] The control device can for example be realized by means of a microprocessor or an electrical switching circuit. The control device activates the injection instrument, which for example takes place through the triggering of the actuator of the injection instrument, so that after the activation of the injection instrument, the needle is moved outwards from the main body and the injection preparation is conveyed through the needle.
[0021] The activation of the injection instrument can then take place when the measured force lies in a specified range. This means in particular that an injection is carried out if the pressing force of the animal against the contact device lies in a specified range. The specified range can for example comprise those forces which are greater than a specified threshold value. Alternatively the specified range can represent a lower and upper limit for the pressing force of the animal against the contact device. The specified range can thus be a range open at one end and also a range bounded at both ends.
[0022] The invention in certain embodiments has the advantage that all electrical components are preferably arranged on the main body, so that the contact device is free from electrical devices. Thus the production of the contact device is possible particularly economically, since only the contact area has to be shaped in conformity with the body parts of the animal, without in comparison to the prior art further pressure sensors and their wiring having to be provided on the contact device. In addition, in the injection device according to the present invention it is not necessary to make an electrical connection between the main body and the contact device, since in particular all electrical components are arranged on the main body. This also simplifies the production of the injection instrument.
[0023] A further advantage of certain embodiments is that the force measurement device makes it possible for a user of the injection device to simplify the injection. For only when the pressing force of the animal lies in the specified range is the injection administered. Since the pressing force is a measure of the fact that the animal has been correctly positioned in the contact area of the contact device, the injection takes place at the correct site. Thus with appropriate choice of the specified range, too light a pressing, which as a rule corresponds to unsatisfactory pressing of the animal on to the contact area, and/or too firm a pressing, which can result in deformations of the animal by the pressing and hence an unplaced injection, can be avoided.
[0024] The force measurement device can comprise a first force sensor and a second force sensor at a distance therefrom, wherein the control device can only activate the injection instrument if the difference between the force measured by the first force sensor and the second force sensor lies below a specified value. In particular, both force sensors can be positioned at a distance in a horizontal direction from a midline of the contact area. In particular, the support device comprises three support elements, wherein the first support element comprises the first force sensor and/or the second support element comprises the second force sensor.
[0025] The support elements can be configured as projections on which the contact device, with in particular correspondingly shaped recesses, can move in the pressure application direction. For example, the support elements are designed as rods, pillars or cylinders, while the contact device has a corresponding, in particular cylindrical, cavity, so that the contact device can be moved towards the main body in the pressure application direction. In particular, the axial orientation of the cavity and of the support elements corresponds to the pressure application direction. Alternatively, one or more support elements can lie against a contact surface of the contact device, wherein the contact surface is preferably bounded in the circumferential direction at least in certain areas by a side wall. The side walls serves in particular for the positioning of the contact device on the main body.
[0026] The first force sensor and the second force sensor, which can measure the pressing force, can be incorporated in a first support element and a second element respectively. Preferably the first support element and the second support element, and thus also the first force sensor and the second force sensor, are arranged in a horizontal direction on the main body, so that it is possible with the first and the second force sensor to determine a force difference in a horizontal direction. The horizontal direction is in particular perpendicular to the orientation of the animal in the contact area. For example, the first support element and the second support element are arranged left and right of a vertical midline. The midline can represent the axis of symmetry of the contact area, wherein the first force sensor and the second force sensor are arranged symmetrically to this midline. With the force sensors it is thus possible to determine a balance of the pressing force in the horizontal direction. Horizontal and vertical relate for example to the base on which the main body stands and thus also to a floor area of the stand device.
[0027] The first and/or the second force sensor can be configured to measure a force acting thereon. The force sensor can be designed as a spring force transducer or as a piezo force transducer. In particular, the first and/or the second force sensor are designed as weighing cells, as is known from the prior art. The first and the second force sensor are preferably identically designed. Depending on the type of the force sensor, the required movability of the contact device relative to the main body in the pressure application direction varies. With use of a weighing cell, the contact device only has to be moved slightly in the pressure application direction.
[0028] The force sensor can be disposed on an end of the respective support element facing the contact device. Depending on the design of the force sensor, the contact device is moved in the direction of the main body, and thus the force sensor compressed, by the pressing force. Alternatively, by pressing of the contact device onto the main body the force sensor changes in its extension only slightly, wherein the pressing force is detected at the same time.
[0029] The control device preferably only activates the injection instrument if the difference between the force measured by the first force sensor and the second force sensor lies below a specified value. For example, the control device does not activate the injection instrument until the total force of the pressing of the animal against the contact device exceeds a certain threshold value and/or at the same time the difference between the force measured by the first and the second force sensor lies below a certain limit value. It is thus ensured that the total pressing force lies above a threshold value, so that it can be assumed that the animal is lying correctly in the contact area, wherein a different pressing onto one side of the contact area is at the same time avoided. This represents a further indication that the animal has been correctly positioned on the contact device, so that the injection is administered at the intended site. Thus an advantage of the provision of two force sensors claimed is that it can be better determined that the animal is lying correctly against the contact device, in particular as regards the balance of force in the horizontal direction.
[0030] The injection device can comprise a capacitive sensor for detecting the presence of the animal at the contact area, wherein preferably the control device can only activate the injection instrument if the capacitive sensor detects the presence of the animal. In particular a third support element of the support device comprises the capacitive sensor.
[0031] The capacitive sensor can operate on the basis of the change in the capacity of a single condenser or a whole condenser system. For example, the capacitive sensor is such as is known from the prior art. In a preferred embodiment the capacitive sensor is provided at an end of the third support element facing the contact device, so that it is designed to detect the proximity or presence of an animal. In particular, the contact device in the vicinity of the third support element is designed such that the measurement of the capacitive sensor is not affected. This can for example be carried out by appropriate choice of the material of the contact area in the region of the third support element.
[0032] The capacitive sensor, in particular the third support element, is preferably positioned such that it is in the vicinity of an upper region of the contact area. In particular, the capacitive sensor is positioned such that with its aid it can be determined whether the animal is present in a peripheral region, in particular the upper peripheral region of the contact area. For example, the third support element is arranged displaced in a vertical direction relative to the first and/or second support element. Preferably the third support element and/or the capacitive sensor are positioned on the midline of the contact device.
[0033] Through the preferred arrangement of the capacitive sensor such that it corresponds to a peripheral region of the contact area, it can with its aid be determined whether the animal is correctly lying against a peripheral region of the contact area. In particular, the control device activates the injection instrument if the capacitive sensor detects the presence of the animal, the total force lies above a specified threshold value and/or the measured force difference between the first force sensor and the second force sensor lies below a certain limit value. The result of this is that the correct positioning on the contact device can be especially well determined, which results in an injection at the desired site.
[0034] The contact area can comprise a contact section and a pressure application area which is movable towards the contact section in the pressure application direction. The pressure application area can for example have a movement range in the direction of the pressure application direction of at most 1 mm, 2 mm, 3 mm, 4 mm, 5 mm or at most 10 mm.
[0035] The pressure application area corresponds in particular to a part of the animal for which it is especially important that it is lying against the contact device. For example, the pressure application area serves for the contact of the breastbone and a part of the breast muscle of a bird or poultry. The correct positioning of the breastbone is an important indication that the injection can be carried out at the correct site of the breast muscle.
[0036] The contact section and the pressure application area together form the contact area, so that the contact section is also shaped in conformity with the anatomy of the animal to be pressed on. In particular, the contact section surrounds the pressure application area. The contact section in particular together with the pressure application area forms an essentially continuous contact surface for the animal to be treated (apart from a small gap between the outer contact section and the inner pressure application area).
[0037] The relative movability of the pressure application area relative to the contact section makes it possible to determine the correct positioning of the animal at the pressure application area separately from the positioning of the animal at the contact section. In particular, the movability of the pressure application area relative to the contact section provides a further parameter by means of which the positioning of the animal against the contact device can be determined.
[0038] The movability of the pressure application area relative to the contact section is preferably free from initial tension. For example, the pressure application area is mounted with play at the contact section. The pressure application area is in particular moved from the contact section towards the main body by the pushing of the animal against the contact device.
[0039] The contact section and/or the pressure application area can be produced from plastic or metal. In particular, these are produced by injection molding, wherein other production methods, such as for example deep-drawing, are also possible.
[0040] The pressure application area can sit in a recess of the contact section.
[0041] The contact section can surround the recess completely, so that the pressure application area can be supported only on the contact section. In this way, it is possible to produce a relative movement of the pressure application area with respect to the contact section.
[0042] The pressure application area can be attached to the contact section by means of a snap connection. This is preferably designed such that the snap connection cannot be non-destructively separated. Alternatively, the snap connection can be non-destructively released. The snap connection can be produced as known from the prior art. The snap connection enables the movability of the pressure application area relative to the contact section in the pressure application direction. Preferably, snap connections are provided at three sites along the recess.
[0043] The pressure application area can include at least one projection or one slot, wherein the contact section comprises at least the other of the projection and the slot, wherein the projection and the slot are provided with play in the pressure application direction.
[0044] The pair of projection and slot represents an example of a snap connection. Preferably, three pairs of projections and slots are provided. The slot can be designed as a recess into which the projection engages. For example, the pressure application area has three projections which engage with play in the slots of the contact section. The play is provided in particular in the pressure application direction, so that the pressure application area can move freely in the pressure application direction relative to the contact section.
[0045] The pair of projection and slot can also be designed circumferential around the pressure application area. The provision of a movable connection by means of projection and slot has the advantage that for attachment the pressure application area can be clicked into the contact section.
[0046] The force measurement device can include a third force sensor arranged on the main body, wherein the third force sensor is preferably designed to measure the force acting on the pressure application area. In this case, the first and second force sensor can measure the forces of the contact section.
[0047] The third force sensor can be provided separately from the support elements of the support device. In a preferred embodiment, the third force sensor does not contribute to the support of the contact device on the main body. Rather it serves for the measurement of a force which acts on the pressure application area. Thus with the aid of the third force sensor in conjunction with the movable arrangement of the pressure application area on the contact area it is possible additionally to check whether the animal is correctly positioned at the pressure application area.
[0048] The third force sensor can be a force sensor similar to the first and/or second force sensor. The third force sensor is preferably arranged opposite the pressure application area.
[0049] The control device can be configured to only activate the injection instrument if the force measured by the third force sensor lies in a specified range. Preferably, the specified range is a force range bounded at both ends. It can therefore be established by means of the third force sensor that the force acting on the pressure application area is not too great and not too small, which indicates the correct positioning of the animal against the pressure application area.
[0050] The control device can be configured to only activate the injection instrument when the force measured by the first and the second force sensor lies above a certain threshold value, the difference between the force measured by the first force sensor and the second force sensor lies below a certain limit value, the capacitive sensor detects the presence of an animal and/or the force measured by the third force sensor lies within the specified force range. This criterion is particularly well suited to indicating the correct positioning of the animal against the contact device. In particular, the positioning of the animal against the contact device takes place in that firstly the force balance in the horizontal direction is determined by means of the first and second force sensor. Then the pressing force is increased so that the animal lies against the pressure application area with appropriate force.
[0051] The control device can also be configured to activate the injection instrument if one of the aforesaid conditions or any combination of these conditions is fulfilled.
[0052] If the force measurement does not fulfil the specified condition, the control device can cause the injection instrument to travel back immediately to its original, non-activated position. Alternatively, the control device can discontinue the injection depending on the progress of the injection if the force measurement and/or the capacity measurement indicates a no longer correct positioning of the animal. For example, even with an incorrect positioning of the animal the injection can be continued if almost the whole of the injection preparation has been injected into the animal.
[0053] The control device can also continue the injection to the end irrespective of whether the previously occupied correct positioning has been vacated, since the animal by movements temporarily causes a deviating force during the injection. For example, the injection is only discontinued if the deviation of the measured forces and/or the measurement of the capacity sensor deviates from the limit values by a specified amount.
[0054] The third force sensor preferably has a bar projecting perpendicular to the pressure application direction, whereby the pressure application area lies against the bar. The bar is preferably made elongated, in particular rectangular. The third force sensor preferably has a base part projecting from the main body in the pressure application direction from which the bar projects sideways. The bar serves in particular for the force transfer of the force acting on the pressure application area to the sensor of the third force sensor. For example, the sensor of the third force sensor is provided on the base part which is arranged offset with respect to the pressure application area. The pressure application area is preferably arranged opposite the injection instrument, so that no space is available on the main body for the attachment of the third force sensor. With the aid of the bar, the offset between base part and pressure application area can be bridged.
[0055] The contact area can include at least one opening for the passage of a needle (or optionally several needles) of the injection instrument (or of another discharge-side end of the injection instrument), with the opening preferably being arranged in the pressure application area.
[0056] The opening can be configured such that the injection instrument, in particular the needle thereof, can be introduced into the animal through the opening. For example, the opening is made elongated in a horizontal direction, so that even with an arrangement in which the needle is arranged inclined relative to the surface of the main body and/or the contact device, the needle can be passed through the opening.
[0057] Since the pressure application area represents a particularly important indicator of the correct positioning of the animal against the contact device, the pressure application area is in particular selected such that it is located at the site of the injection to be carried out, which is represented by the opening. When it is now determined by the third force sensor that the pressing force in the pressure application area is in the specified correct force range, it can be assumed that the injection takes place at the correct site on the animal.
[0058] Preferably, two openings are provided in the contact area, wherein each opening is assigned to one needle of the injection instrument. Both the openings are preferably arranged in a horizontal direction, in particular symmetrically to the midline of the contact device. It is however also possible to provide a single opening for both needles.
[0059] The injection instrument can be arranged on the main body such that in the non-activated state the needle does not project from the opening. In particular, the injection instrument can be positioned such that after the activation, that is after the operation of the actuator of the injection instrument, its needle protrudes through the opening from the contact area, so that it has been inserted into the animal. Thus the injection takes place through the movement of the needle of the injection instrument and not through a displacement of the contact device. The contact device is preferably mounted movable on the main body in such a manner that when the contact device has been moved completely towards the main body, the needle does not protrude into the opening if the injection instrument is not activated.
[0060] Certain embodiments include the advantage that the needle of the injection instrument does not protrude from the contact device, so that there is a low risk of injury (in particular of the persons who push the animals onto the contact area) by the needle of the injection instrument. The injection instrument only moves out from the opening when an animal is correctly positioned, so that there is then also no risk of injury to the user.
[0061] The injection device can include a display device on which information concerning the actual positioning of the animal against the contact area based on the measurements of the force measurement device is displayed. The display device can display whether the difference between the force measured by the first force sensor and the second force sensor lies below a specified value and/or whether the force measured by the third sensor lies in the specified range and/or whether the capacitive sensor detects the presence of the animal.
[0062] The display device gives the user a visual feedback as to whether the respective measured forces indicate a correct positioning of the animal against the contact device. For example, the user immediately sees whether the force difference lies below the defined limited value, and can thus maintain this positioning and adapt the positioning appropriately with respect to the capacitive sensor and the third force sensor in order also to fulfil the conditions specified there. Thus the correct positioning of the animal against the contact device is facilitated.
[0063] The display device preferably displays the difference between the force measured by the first force sensor and the second force sensor and/or the force measured by the third force sensor. For example, the difference between the force measured by the first force sensor and the second force sensor can be displayed by a bar which is elongated in its extent depending on the side of the force excess and its height. Alternatively, the difference can also be represented by a point which, depending on the difference between the force measured by the first force sensor and the second force sensor, moves away from a zero point at which the force measured by the first force sensor and the second force sensor is the same.
[0064] The force measured by the third force sensor can be displayed as a bar, wherein a region corresponding to a specified force range is displayed at the same time. Presence in the appropriate force range can for example be additionally emphasized by a changing bar color. The display device accordingly helps the user to implement the correct pressing force and hence the correct positioning of the animal against the contact device.
[0065] It is understood that the features named above and those yet to be explained below can be used not only in the stated combinations but also in other combinations or alone, without departing from the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0066] FIG. 1 is a schematic perspective representation of one embodiment of the injection device according to the invention, wherein for better clarity of representation the contact device is shown detached from the main body.
[0067] FIG. 2 is a top view of a main body of the injection device according to FIG. 1 .
[0068] FIG. 3 is a top view of the front side of the contact device of the injection device according to FIG. 1 .
[0069] FIG. 4 is a top view of the rear side of the contact device of the injection device according to FIG. 1 .
[0070] FIG. 5 is an enlarged cross-section view of the contact device of the injection device according to FIG. 1 along the cut line V-V drawn onto FIG. 4 .
[0071] FIG. 6 is a top view of a display device of the injection device according to FIG. 1 .
[0072] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular example embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0073] In the following descriptions, the present invention will be explained with reference to various exemplary embodiments. Nevertheless, these embodiments are not intended to limit the present invention to any specific example, environment, application, or particular implementation described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration rather than to limit the present invention.
[0074] In the embodiments represented in FIGS. 1 to 6 , the injection device 10 comprises a main body 12 , a contact device 14 , a support device 16 , a force measurement device 18 , a control device S and a display device 20 . The control device S is shown dotted in FIG. 1 , since it is positioned within the main body 12 .
[0075] The injection device 10 serves for administration of injections to an animal. In the embodiment shown, vaccines or medicaments for the treatment of diseases can be administered intramuscularly to a chicken by means of the injection device 10 .
[0076] The main body 12 has a housing 22 with a cover 24 attached thereon. The cover 24 can be removed from the housing 22 in order to access an injection instrument 26 arranged in the housing 22 .
[0077] As can be seen particularly clearly in FIG. 2 , the injection instrument 26 comprises two syringes 28 (e.g. self-filling syringes), which each have a needle 30 and an actuator. The actuator moves the needle 30 out from the housing 22 of the main body 12 when the control device S activates the injection instrument 26 . In addition, the injection instrument 26 can have a pump or refilling device, not shown, with which injection preparation can be pumped through the needle 30 or which after each injection fills the syringe 28 with the injection preparation for the next injection.
[0078] The contact device 14 is arranged movable relative to main body 12 on the basis of the support device 16 . In particular, the contact device 14 is assembled removable from the main body 12 . Thus different contact devices 14 can be successively attached to the main body 12 , with the different contact devices 14 being matched for example to the animal species or breed to be treated, the age of the animals and/or their size.
[0079] The contact device 14 has a shaped contact area 34 , which is shaped in conformity with the animal and in particular in conformity with the anatomy in the region of the desired injection site. In the embodiment described here, the contact area 34 is shaped in conformity with the breast region of a chicken. The contact area 34 is made in two parts and comprises an outer contact section 34 ′ and an inner pressure application area 36 . The outer contact section 34 ′ has a recess 36 ′, in which the pressure application area 36 is positioned such that the outer contact section 34 ′ together with the inner pressure application area 36 form an essentially continuous contact surface for the chicken to be inoculated (apart from a small gap between the outer contact section 34 ′ and the inner pressure application area 36 ). The pressure application area 36 is shaped in conformity with the size of a breastbone of the chicken and thereby helps to determine the correct positioning of the breastbone of the chicken against the contact device 14 , as is further described below. In the pressure application area 36 , two openings 38 are provided, as for example is clear from FIG. 3 . The openings 38 are positioned corresponding to the syringes 28 of the injection instrument 26 in a horizontal direction symmetrically to a midline M of the contact device 14 . After their activation by the control device S, the needles 30 of the syringes 28 move into the breast muscle of the chicken through the openings 38 .
[0080] The pressure application area 36 is arranged movable relative to the contact section 34 ′ in a pressure application direction D ( FIG. 1 ). For this, the pressure application area 36 has three separate projections 35 , which project on the rear side R of the contact section 34 ′ over the recess 36 ′ and are guided in three slots 37 , which are made on the rear side R. The slots 37 are made such that the pressure application area 36 is held and that a movement of the projections 35 and thus of the pressure application area 36 in the pressure application direction D is possible. The possible travel is 2 mm.
[0081] The support device 16 has three pillar-shaped support elements 40 a , 40 b , 40 c . As can be seen clearly in FIG. 2 , the support elements 40 a - 40 c have a cylindrical shape, so that the contact device 14 can be pushed onto the support elements 40 a - 40 c . For this, the contact device 14 has two cylindrical cavities 39 a and 39 b , shown in FIG. 4 , which are matched to the size of the support elements 40 a and 40 b . The length of the support elements 40 a and 40 b and the depth of the cavities 39 a and 39 b in the contact device 14 are selected such that at the maximum push-in depth of the contact device 14 this is at a distance from the main body 12 . The contact device 14 is lies against the third support element 40 c by means of a contact surface 41 .
[0082] In the representation of FIG. 1 , for better clarity the contact device 14 is shown, in the form of an exploded view, at a distance from the main body 12 . Naturally, during the operation of the injection device 10 the contact device 14 sits on the support elements 40 a , 40 b and 40 c and is guided by these such that the contact device 14 is movable along the pressure application direction D.
[0083] The first support element 40 a is positioned at a distance from the second support element 40 b in a horizontal direction, in particular symmetrically to the injection instrument 26 . On the axis of symmetry of the first support element 40 a and the second support element 40 b , the third support 40 c is arranged offset in a vertical direction which is perpendicular to the horizontal direction. The axis of symmetry coincides with a midline M of the contact device 14 .
[0084] The force measurement device 18 comprises three force sensors 42 a , 42 b and 42 c , which are each designed as a weighing cell known from the prior art. A first force sensor 42 a is built into the first support element 40 a , while a second force sensor 42 b is positioned in the second support element 40 b.
[0085] A third force sensor 42 c is positioned on the midline M. The third force sensor 42 c has a base part 43 and a bridge or bar 44 . The bridge 44 extends up to the openings 38 , while its free end lies somewhat below the openings 38 . The bridge 44 is provided since, because of the anatomy of the chicken and in particular the breastbone, for which the pressure application area 36 is provided, the section projecting the furthest in the direction of the main body 12 lies in the region of the two openings 38 . In this region, because of the two syringes 28 , there is not sufficient space in the main body 12 for the third force sensor 42 c . The bridge 44 is therefore provided for force transfer from the pressure application area 36 to the third force sensor 42 c . As can be seen from FIG. 5 , the pressure application area 36 has a projecting contact section 44 ′, which during the operation of the injection device presses against the bridge 44 at the free end of the bridge 44 .
[0086] The injection device 10 further has a capacitive sensor 46 , which is positioned at the end of the third support element 40 c facing the contact device 14 . The capacitive sensor 46 detects the presence of an animal in its vicinity. For this, in the region adjacent to the capacitive sensor 46 the contact device 14 is designed in such a manner that it does not interfere with the capacity measurement of the capacitive sensor 46 . By means of the capacitive sensor 46 , it can be determined whether the animal is positioned in an upper peripheral region of the contact area 34 .
[0087] As can be seen in FIG. 6 , the display device 20 shown enlarged in FIG. 6 has a display 50 for the force measured by means of the third force sensor 42 c , a display 52 for the difference of the force measured by means of the first force sensor 42 a and the second force sensor 42 b and a display 54 for the capacitive sensor 46 .
[0088] The display 50 shows the force measured by means of the force sensor 42 c in the form of a point the vertical positioning whereof indicates the magnitude of the force. The display 50 further has markings which correspond to the specified force range. In the embodiment shown, the point is located in the specified force range, so that the force applied to the pressure application area 36 lies in the specified range.
[0089] In the case of the display 52 , it is shown by means of the position of a point whether the force applied to the first force sensor 42 a or to the second force sensor 42 b is greater than the force applied to the respective other force sensors. In the embodiment shown, the point is located in the middle of the display 52 , which indicates that the force applied to the first force sensor 42 a or to the second force sensor 42 b is of equal magnitude. The display 54 is designed as a lamp, wherein the illumination of the display 54 indicates that the capacitive sensor 56 has detected the presence of the animal.
[0090] The mode of functioning of the injection device 10 is explained below:
[0000] A user of the injection device 10 holds an animal against the contact device 14 . By correct positioning of the animal against the contact area 34 , that is by application of the appropriate pressing force, the control device S triggers an injection. For this, the force difference between the force measured by the first force sensor 42 a and the second force sensor 42 b must lie below a certain limit value, that is, the force balance in the horizontal direction must be present. This indicates that the animal is not being pushed on obliquely. If the force balance is present and a force in the specified range is present on the third force sensor 42 c , the control device S activates the injection instrument 26 and the injection is performed, if further the presence of the animal is detected by means of the capacitive sensor 46 .
[0091] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. Moreover, features or aspects of various example embodiments may be mixed and matched (even if such combination is not explicitly described herein) without departing from the scope of the invention. | An injection device for administration of an injection to an animal can include a main body, which contains an injection instrument, a contact device, which has a contact area which is shaped in conformity with a body part of the animal to which the injection is to be administered. A support device which supports the contact device on the main body can be movable in a pressure application direction. A force measurement device including at least one force sensor can be designed to measure at last one force with which the contact device acts on the main body. A control device can activate the injection instrument if the force measured by the force measurement device lies in a specified range. | 0 |
COPYRIGHT NOTIFICATION
A portion of the disclosure of this patent document and its attachments contain material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyrights whatsoever.
BACKGROUND
Touch sensors are common in electronic displays. Many mobile smartphones and tablet computers, for example, have a touch screen for making inputs. A user's finger touches a display, and a touch sensor detects the input.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The features, aspects, and advantages of the exemplary embodiments are better understood when the following Detailed Description is read with reference to the accompanying drawings, wherein:
FIGS. 1 and 2 are simplified schematics illustrating an environment in which exemplary embodiments may be implemented;
FIG. 3 is a more detailed block diagram illustrating the operating environment, according to exemplary embodiments;
FIGS. 4-5 are schematics illustrating a gesture detector, according to exemplary embodiments;
FIGS. 6-7 are circuit schematics illustrating a piezoelectric transducer, according to exemplary embodiments;
FIGS. 8-11 are more schematics illustrating the gesture detector, according to exemplary embodiments;
FIGS. 12-14 are schematics illustrating a learning mode of operation, according to exemplary embodiments;
FIG. 15 is an exploded component view of an electronic device, according to exemplary embodiments;
FIG. 16 is a schematic illustrating contactless, three-dimensional gestures, according to exemplary embodiments;
FIG. 17-19 are schematics illustrating output sampling, according to exemplary embodiments;
FIGS. 20A and 20B are schematics illustrating a protective case, according to exemplary embodiments; and
FIGS. 21-22 are schematics illustrating other operating environments for additional aspects of the exemplary embodiments.
DETAILED DESCRIPTION
The exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings. The exemplary embodiments may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the exemplary embodiments to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).
Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the like represent conceptual views or processes illustrating the exemplary embodiments. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named manufacturer.
As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes,” “comprises,” “including,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, “connected” or “coupled” as used herein may include wirelessly connected or coupled. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will also be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first device could be termed a second device, and, similarly, a second device could be termed a first device without departing from the teachings of the disclosure.
FIGS. 1 and 2 are simplified schematics illustrating an environment in which exemplary embodiments may be implemented. FIGS. 1 and 2 illustrate an electronic device 20 that accepts touches, swipes, and other physical gestures as inputs. The electronic device 20 , for simplicity, is illustrated as a mobile smartphone 22 , but the electronic device 20 may be any processor-controlled device (as later paragraphs will explain). Regardless, FIG. 1 illustrates a front side 24 of the electronic device 20 , with body 26 housing the components within the electronic device 20 . A display device 28 , for example, displays icons, messages, and other content to a user of the electronic device 20 . The display device 28 interfaces with a processor 30 . The processor 30 executes instructions that are stored in a memory 32 . The electronic device 20 may also include a touch sensor 34 . The touch sensor 34 is conventionally installed on or above a front face of the display device 28 . The touch sensor 34 detects the user's physical inputs above the display device 28 . The display device 28 generates visual output in response to instructions from the processor 30 , and the touch sensor 34 generates an output in response to the user's physical inputs, as is known.
FIG. 2 illustrates a backside 40 of the electronic device 20 . Here the body 26 includes a gesture detector 42 . The gesture detector 42 detects physical gestures that are made on an outer surface 44 of the body 26 . The user may make gestures on the outer surface 44 of the body 26 , and the processor 30 interprets those gestures to control the electronic device 20 . The user's fingers, for example, may contact the body 26 and make a swiping motion on the outer surface 44 . The processor 30 interprets the swiping motion to execute some command, such as transitioning to a different display screen, answering a call, capturing a photo, or any other action. The user may also tap the outer surface 44 of the body 26 to select icons, web pages, or other options displayed on the display device (illustrated as reference numeral 28 in FIG. 1 ). Indeed, the user may associate any gesture to any action, as later paragraphs will explain.
Exemplary embodiments thus greatly increase input area. Conventional electronic devices limit gesture detection to the display device 28 (i.e., the touch sensor 34 above the display device 28 , as FIG. 1 illustrated). Exemplary embodiments, instead, recognize inputs over any portion of the body 26 . The user's fingers may draw shapes across the body 26 of the electronic device 20 , and those shapes may be recognized and executed. Exemplary embodiments thus permit inputs without having to visually observe the display device 28 . The user may make gesture inputs without observing the display device 28 and, indeed, without holding the electronic device 20 in the hand. For example, when the smartphone 22 is carried in a pocket, the user may still make gesture inputs, without removing the smartphone 22 . The gesture detector 42 recognizes simple taps and swipes, more complex geometric shapes, and even alphanumeric characters. Because the electronic device 20 need not be held, exemplary embodiments permit socially acceptable interactions in situations without overtly holding and manipulating the display device 28 . Exemplary embodiments thus permit inconspicuous interaction in a variety of environments, using the entire body 26 as an input surface.
FIG. 3 is a more detailed block diagram illustrating the operating environment, according to exemplary embodiments. FIG. 3 illustrates the electronic device 20 , the processor 30 , and the memory 32 . The processor 30 may be a microprocessor (“μP”), application specific integrated circuit (ASIC), or other component that executes a gesture algorithm 50 stored in the memory 32 . The gesture algorithm 50 includes instructions, code, and/or programs that cause the processor 30 to interpret any gesture input sensed by the gesture detector 42 . When the user draws and/or taps a gesture on the outer surface of the body (illustrated, respectively, as reference numerals 44 and 26 in FIGS. 1-2 ), the gesture detector 42 generates an output signal 52 . The processor 30 receives the output signal 52 and queries a database 54 of gestures. FIG. 3 illustrates the database 54 of gestures as a table 56 that is locally stored in the memory 32 of the electronic device 20 . The database 54 of gestures, however, may be remotely stored and queried from any location in a communications network. Regardless, the database 54 of gestures maps, associates, or relates different output signals 52 to their corresponding commands 58 . The processor 30 compares the output signal 52 to the entries stored in the database 54 of gestures. Should a match be found, the processor 30 retrieves the corresponding command 58 . The processor 30 then executes the command 58 in response to the output signal 52 , which is generated by the gesture detector 42 in response to the user's gesture input.
FIG. 4 is another schematic illustrating the gesture detector 42 , according to exemplary embodiments. While the gesture detector 42 may be any device, the gesture detector 42 is preferably a piezoelectric transducer 70 . The gesture detector 42 may thus utilize the piezoelectric effect to respond to vibration 72 sensed in, on, or around the body 26 . As the user draws and/or taps the gesture 74 on the outer surface 44 of the body 26 , vibration waves travel through or along the outer surface 44 of the body 26 . The piezoelectric transducer 70 senses the vibration 72 . The piezoelectric effect causes piezoelectric transducer 70 to generate the output signal (illustrated as reference numeral 52 in FIG. 3 ), in response to the vibration 72 . Exemplary embodiments then execute the corresponding command (illustrated as reference numeral 58 in FIG. 3 ), as earlier paragraphs explained.
The gesture detector 42 may even respond to sound waves. As the gesture detector 42 may utilize the piezoelectric effect, the gesture detector 42 may sense the vibration 72 due to both mechanical waves and acoustic waves. As those of ordinary skill in the art understand, the vibration 72 may be generated by sound waves propagating along the body 26 and/or incident on the piezoelectric transducer 70 . Sound waves may thus also excite the piezoelectric transducer 70 . So, whether the user taps, draws, or even speaks, the gesture detector 42 may respond by generating the output signal 52 . Indeed, the piezoelectric transducer 70 may respond to the vibration 72 caused by the user's physical and audible inputs. The gesture detector 42 may thus generate the output signal 52 in response to any mechanical and/or acoustic wave.
FIG. 5 is another schematic illustrating the gesture detector 42 , according to exemplary embodiments. Here the gesture detector 42 may respond to electrical charges 80 on or in the body 26 of the electronic device 20 . As the user draws the gesture 74 on surface 44 of the body 26 , electrical charges 80 may build on or within the body 26 . FIG. 5 grossly enlarges the electrical charges 80 for clarity of illustration. Regardless, the electrical charges 80 may cause an electric field 82 , which may also excite the piezoelectric transducer 70 . So, the gesture detector 42 may also generate the output signal (illustrated as reference numeral 52 in FIG. 3 ) in response to the electric field 82 . The gesture detector 42 may thus also respond to the electric charges 80 induced on the body 26 .
FIGS. 6-7 are modeling circuit schematics illustrating the piezoelectric transducer 70 , according to exemplary embodiments. Because the gesture detector 42 may utilize the piezoelectric effect, the gesture detector 42 may sense mechanical waves, acoustic waves, and the electrical charge (illustrated as reference numeral 80 in FIG. 5 ). The piezoelectric transducer 70 responds by generating the output signal 52 . The output signal 52 may be voltage or charge, depending on construction of the piezoelectric transducer 70 . FIG. 6 , for example, is a circuit schematic illustrating the piezoelectric transducer 70 modeled as a charge source with a shunt capacitor and resistor. FIG. 7 illustrates the piezoelectric transducer 70 modeled as a voltage source with a series capacitor and resistor. The output voltage may vary from microvolts to hundreds of Volts, so some signal conditioning (e.g., analog-to-digital conversion and amplification) may be needed.
FIGS. 8-11 are more schematics illustrating the gesture detector 42 , according to exemplary embodiments. Because the gesture detector 42 responds to physical gestures, the gesture detector 42 may be installed at any position or location on or in the body 26 . FIG. 8 , for example, illustrates the gesture detector 42 mounted to a central region 90 on the backside 40 of the electronic device 20 . As the backside 40 may present a large, supplemental gesture surface area 92 for inputting gestures, the gesture detector 42 may be disposed in or near the central region 90 to detect the vibration 72 . FIG. 9 , though, illustrates the gesture detector 42 disposed in or near an end region 94 on the backside 40 of the electronic device 20 . The end region 94 may be preferred in some situations, such as when the body 26 includes an access door 96 to a battery compartment. A discontinuous gap 98 around the access door 96 may attenuate transmission of waves or conduction of charge, thus reducing or nullifying the output signal 52 produced by the gesture detector 42 . A designer may thus prefer to locate the gesture detector 42 in some region of the body 26 that adequately propagates waves or conducts charge.
FIGS. 10 and 11 illustrate frontal orientations. FIG. 10 illustrates the gesture detector 42 disposed on or proximate the front side 24 of the electronic device 20 . Even though the electronic device 20 may have the conventional touch sensor 34 detecting inputs above the display device 28 , any portion of the front side 24 of the body 26 may also be used for gesture inputs. FIG. 11 , likewise, illustrates the gesture detector 42 located in a corner region of the body 26 . The gesture detector 42 may thus be installed at any location of the body 26 to detect the vibration 72 caused by gesture inputs.
FIGS. 12-14 are schematics illustrating a learning mode 100 of operation, according to exemplary embodiments. Wherever the gesture detector 42 is located, here the user trains the electronic device 20 to recognize particular gestures drawn on the body 26 . When the user wishes to store a gesture for later recognition, the user may first put the electronic device 20 into the learning mode 100 of operation. FIG. 12 , for example, illustrates a graphical user interface or screen that is displayed during the learning mode 100 of operation. The user may be prompted 102 to draw a gesture somewhere on the body 26 , such as the supplemental gesture surface area (illustrated as reference numeral 92 in FIG. 8 ). After the user inputs the desired gesture, the user may confirm completion 104 of the gesture.
FIG. 13 again illustrates the backside 40 of the electronic device 20 . Here the outer surface 44 of the backside 40 of the electronic device 20 is the supplemental gesture surface area 92 . The user performs any two-dimensional or even three-dimensional movement. As the gesture is drawn, the vibration 72 propagates through the body 26 as mechanical and/or acoustical waves. The gesture detector 42 senses the vibration 72 and generates the output signal 52 . The gesture detector 42 may also sense and respond to the electrical charges (as explained with reference to FIGS. 5-7 ). The gesture algorithm 50 causes the electronic device 20 to read and store the output signal 52 in the memory 32 . Once the gesture is complete, the user selects the completion icon 104 , as FIG. 12 illustrates.
FIG. 14 illustrates a menu 110 of the commands 58 . The menu 110 is stored and retrieved from the memory (illustrated as reference numeral 32 in FIG. 13 ). The menu 110 is processed for display by the display device 28 . Once the user confirms completion of the gesture, the user may then associate one of the commands 58 to the gesture. The menu 110 thus contains a selection of different commands 58 from which the user may choose. FIG. 14 only illustrates a few popular commands 58 , but the menu 110 may be a much fuller listing. The user touches or selects the command 58 that she wishes to associate to the gesture (e.g., the output signal 52 ). Once the user makes her selection, the processor (illustrated as reference numeral 30 in FIG. 13 ) adds a new entry to the database 54 of gestures. The database 54 of gestures is thus updated to associate the output signal 52 to the command 58 selected from the menu 110 . The user may thus continue drawing different gestures, and associating different commands, to populate the database 54 of gestures.
The database 54 of gestures may also be prepopulated. When the user purchases the electronic device 20 , a manufacturer or retailer may preload the database 54 of gestures. Gestures may be predefined to invoke or call commands, functions, or any other action. The user may then learn the predefined gestures, such as by viewing training tutorials. The user may also download entries or updates to the database 54 of gestures. A server, accessible from the Internet, may store predefined associations that are downloaded and stored to the memory 32 .
FIG. 15 is an exploded component view of the electronic device 20 , according to exemplary embodiments. The electronic device 20 is illustrated as the popular IPHONE® manufactured by Apple, Inc. The body 26 may have multiple parts or components, such as a bottom portion 120 mating with a central portion 122 . The display device 28 and the touch sensor 34 are illustrated as an assembled module that covers the central portion 122 . The body 26 houses a circuit board 124 having the processor 30 , the memory 32 , and many other components. A battery 126 provides electrical power. FIG. 15 illustrates the gesture detector 42 integrated into the assembly, proximate the bottom portion 120 of the body 26 . This location may be advantageous for sensing vibration caused by gestures drawn on the outer surface 44 . The gesture detector 42 may have an interface to the circuit board 124 , such as a metallic strip or contact pad that conducts signals to/from the circuit board 124 . The interface may also be a physical cable that plugs into a socket in the circuit board 124 . Whatever the interface, the gesture detector 42 senses the vibration and/or the electrical charge (referred to above, and illustrated, as reference numerals 72 and 80 ) caused by gesture inputs on the body 26 . The gesture detector 42 produces the output signal (referred to above, and illustrated, as reference numeral 52 ) in response to the vibration 72 . The processor 30 analyzes the output signal 52 and executes the corresponding command 58 , as earlier paragraphs explained.
The body 26 may have any design and construction. The body 26 , for example, may have a two-piece clamshell design with mating upper and lower halves. The body 26 , however, may have any number of mating components that protect the internal circuit board 124 . The body 26 may have a rectangular access opening through which the display device 28 and the touch sensor 34 insert or protrude. The body 26 , in other words, may have an inner rectangular edge or wall that frames the display device 28 and/or the touch sensor 34 . The body 26 may be made of any material, such as metal, plastic, or wood.
Exemplary embodiments thus transform the backside 40 . Conventional smartphones fail to utilize the backside 40 for gesture inputs. Exemplary embodiments, in contradistinction, transform the outer surface 44 of the backside 40 into the supplemental surface area for gesture detection. Whatever the shape or size of the outer surface 44 of the body 26 , gestures may be input to execute the corresponding command 58 , as earlier paragraphs explained. While the gesture detector 42 may be disposed anywhere within the electronic device 20 , the gesture detector 42 is preferable proximate the supplemental gesture surface area. While the gesture detector 42 may be adhered to the outer surface 44 of the body 26 , the gesture detector 42 may be preferably adhered to an inner surface of the bottom portion 120 of the body 26 for added protection from physical damage. A glue or adhesive may simply and quickly adhere the gesture detector 42 to the body 26 . While any adhesive compound may be used, the adhesive may be chosen to minimize attenuation as the vibration 72 travels through the adhesive. However, the gesture detector 42 may alternatively be mechanically adhered, such as by fastener or weld. The gesture detector 42 may be soldered or welded to the body 26 , especially when the body 26 is constructed of aluminum, magnesium, stainless steel, or any other metal. The gesture detector 42 may be soldered, TIG welded, or MIG welded to the body 26 . Indeed, the body 26 , and the supplemental gesture surface area 92 , may be constructed of plastic, metal, wood, and/or any other material.
FIG. 16 is a schematic illustrating contactless, three-dimensional gestures, according to exemplary embodiments. FIG. 16 again illustrates the user's fingers performing some gesture 74 . Here, though, the user's fingers need not contact the body 26 . That is, the user may make the three-dimensional gesture 74 in the vicinity of the gesture detector 42 . The three-dimensional gesture 74 may have motions or movements that do not come into contact with the body 26 of the electrical device 20 . When the user's fingers perform the gesture 74 , the gesture movements may cause air molecules to vibrate. The gesture detector 42 senses the vibrating air molecules and generates its output signal 52 . Moreover, the user's contactless gesture movements may also induce the electrical charges 80 in the air to build on the body 26 , thus also causing the gesture detector 42 to produce the output signal 52 (as explained with reference to FIGS. 5-7 ). Exemplary embodiments may thus respond to both two-dimensional gestures drawn on the body 26 and to three-dimensional gestures having contactless movements.
FIG. 17-19 are schematics illustrating output sampling, according to exemplary embodiments. Whatever gesture the user performs, the gesture detector (illustrated as reference numeral 42 in FIG. 16 ) generates the output signal 52 . The output signal 52 may be voltage or charge (current), depending on the circuit design (as explained with reference to FIGS. 4-7 ). Regardless, the output signal 52 may have too much data for fast processing. For example, FIG. 17 illustrates a graph of the output signal 52 for an exemplary gesture having a one second (1 sec.) duration. The output signal 52 is illustrated as being biased about a biasing voltage V B (illustrated as reference numeral 130 ). Even though the gesture is only one second in duration, the output signal 52 may still contain too much data for quick processing. The processor 30 , in other words, may require more time that desired to process the output signal 52 .
FIG. 18 illustrates sampling of the output signal 52 . Exemplary embodiments may sample the output signal 52 to produce discrete data points 132 according to some sampling rate 134 . For mathematical simplicity, the sampling rate 134 is assumed to be 0.2 seconds, which may be adequate for human gestures. So, when the user performs the gesture having the one second duration, the output signal 52 may be sampled every 0.2 seconds to yield five (5) data points 132 .
FIG. 19 again illustrates the database 54 of gestures. Because the output signal 52 may be sampled, the database 54 of gestures need only store the discrete data points 132 sampled from the output signal 52 . FIG. 19 thus illustrates each sampled output signal 52 as a collection or set of the discrete data points 132 for each output signal 52 . When the database 54 of gestures is queried, exemplary embodiments need only match the sampled values and not an entire, continuous voltage, charge, or current signal. The burden on the processor 30 is thus reduced, yielding a quicker response to the user's gesture input.
FIGS. 20A and 20B are schematics illustrating a protective case 200 , according to exemplary embodiments. As many readers understand, many users of smartphones, tablet computers, and other mobile devices purchase the protective case 200 . The protective case 200 protects the electronic device 20 (such as the smartphone 22 ) from damage. However, the protective case 200 may also deaden or insulate the backside 40 from the user's gesture inputs.
FIG. 20A thus illustrates the gesture detector 42 . Because the protective case 200 may limit access to the backside 40 of the electronic device 20 , the gesture detector 42 may be added to the protective case 200 . FIG. 20A , for example, illustrates the gesture detector 42 adhered to an inner surface 202 of the protective case 200 . The user may thus make gestures on or near the protective case 200 , and the gesture detector 42 may still sense vibration and electrical charge (as explained above). The gesture detector 42 may still have the interface to the circuit board of the electronic device 20 , again such as a metallic contact or socket.
Exemplary embodiments may be applied to the automotive environment. An interior of a car or truck, for example, has many surfaces for mounting the gesture detector 42 . A center console, for example, may have a dedicated gesture surface for sensing the driver's gesture inputs. One or more of the piezoelectric transducers 70 may be affixed, mounted, or integrated into the gesture surface for sensing touch and other gesture-based inputs. An armrest and/or a steering wheel may also have an integrated gesture surface for sensing gesture inputs. As the driver (or passenger) gestures on or near the gesture surface, the piezoelectric transducer 70 senses the vibration 72 or the electric charge 80 , as earlier paragraphs explained. Because the piezoelectric transducer 70 senses vibration and electrical charge, the gesture detector 42 may be integrated into any surface of any material.
Exemplary embodiments may also be applied to jewelry and other adornment. As wearable devices become common, jewelry will evolve as a computing platform. An article of jewelry, for example, may be instrumented with the piezoelectric transducer 70 , thus enabling inputs across a surface of the jewelry. Moreover, as the piezoelectric transducer 70 may be small and adhesively adhered, exemplary embodiments may be applied or retrofitted to heirloom pieces and other existing jewelry, thus transforming older adornment to modern, digital usage.
FIG. 21 is a schematic illustrating still more exemplary embodiments. FIG. 21 is a generic block diagram illustrating the gesture algorithm 50 operating within a processor-controlled device 300 . As the above paragraphs explained, the gesture algorithm 50 may operate in any processor-controlled device 300 . FIG. 21 , then, illustrates the gesture algorithm 50 stored in a memory subsystem of the processor-controlled device 300 . One or more processors communicate with the memory subsystem and execute the gesture algorithm 50 . Because the processor-controlled device 300 illustrated in FIG. 21 is well-known to those of ordinary skill in the art, no detailed explanation is needed.
FIG. 22 depicts other possible operating environments for additional aspects of the exemplary embodiments. FIG. 22 illustrates the gesture algorithm 50 operating within various other devices 400 . FIG. 22 , for example, illustrates that the gesture algorithm 50 may entirely or partially operate within a set-top box (“STB”) ( 402 ), a personal/digital video recorder (PVR/DVR) 404 , a Global Positioning System (GPS) device 408 , an interactive television 410 , a tablet computer 412 , or any computer system, communications device, or processor-controlled device utilizing the processor 50 and/or a digital signal processor (DP/DSP) 414 . The device 400 may also include watches, radios, vehicle electronics, clocks, printers, gateways, mobile/implantable medical devices, and other apparatuses and systems. Because the architecture and operating principles of the various devices 400 are well known, the hardware and software componentry of the various devices 400 are not further shown and described.
Exemplary embodiments may be physically embodied on or in a computer-readable storage medium. This computer-readable medium may include CD-ROM, DVD, tape, cassette, floppy disk, memory card, and large-capacity disks. This computer-readable medium, or media, could be distributed to end-subscribers, licensees, and assignees. These types of computer-readable media, and other types not mention here but considered within the scope of the exemplary embodiments. A computer program product comprises processor-executable instructions for detecting gestures, as explained above.
While the exemplary embodiments have been described with respect to various features, aspects, and embodiments, those skilled and unskilled in the art will recognize the exemplary embodiments are not so limited. Other variations, modifications, and alternative embodiments may be made without departing from the spirit and scope of the exemplary embodiments. | A supplemental surface area allows gesture recognition on outer surfaces of mobile devices. Inputs may be made without visual observance of display devices. Gesture control on outer surfaces permits socially acceptable, inconspicuous interactions without overt manipulation. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a clock generating scheme, and more particularly, to an apparatus and related method for generating an output clock.
[0003] 2. Description of the Prior Art
[0004] As is well known by those skilled in this art, High-Definition Multimedia Interface (HDMI) is an interface for transmitting video/audio data. Data transmitted to the receiving end of the HDMI only includes data for the frequency of a video clock signal. Recovering the frequency of an audio clock signal can be obtained by the following equation:
[0000] N×f v =CTS× 128× f a , Equation (1)
[0005] wherein f v is the frequency of the video clock signal and f a is the frequency of the audio clock signal; N and CTS are parameters included in information frames respectively. In general, a prior art scheme performs a frequency-division operation upon the frequency of the video clock signal (i.e. f v ) to derive a signal having a frequency f v /CTS, and then performs the operation of a phase-locked loop (i.e. a frequency divider, placed on the loop path, performs a frequency-division operation with a division factor N) upon the signal having the frequency f v /CTS to derive a signal having another frequency N*f v /CTS. Finally, the prior art scheme also performs another frequency-division operation upon the signal having the frequency N*f v /CTS with a division factor 128 to derive a signal having a frequency N*f v /(CTS*128). In the HDMI specification, however, parameters N and CTS are defined with 20 bits since they need to have sufficient accuracy. Moreover, to achieve much higher accuracy, the parameter N is almost equal to 11648, and the parameter CTS is a value between tens of thousands and hundreds of thousands. Therefore, in circuit design, it is very difficult for the prior art scheme to perform the above-mentioned operations. The prior art scheme also easily suffers from noise interference.
SUMMARY OF THE INVENTION
[0006] One of the objectives of the present invention is therefore to provide an apparatus and related method for generating an audio output clock with higher accuracy according to video data of a multimedia signal from the multimedia interface, to solve the above-mentioned problems.
[0007] One of the objectives of the present invention is to provide an apparatus for generating an audio output clock. The apparatus utilizes a plurality of frequency dividers to achieve dispersive frequency-division operations such that the anti-noise ability of the apparatus can be improved.
[0008] Another objective of the present invention is to provide an apparatus for generating an audio output clock. The apparatus utilizes dynamic phase adjustment to increase accuracy of the frequency of the audio output clock.
[0009] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a diagram of an apparatus according to an embodiment of the present invention.
[0011] FIG. 2 is a flowchart illustrating operation of the fine tuning circuit for determining fine adjustment according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0012] Please refer to FIG. 1 . FIG. 1 is a diagram of an apparatus 100 for generating an audio output clock S out ′ according to an embodiment of the present invention. As shown in FIG. 1 , the apparatus 100 comprises a first frequency divider 105 , a frequency synthesizer (ex: phase-locked loop or delayed-locked loop) 110 , a third frequency divider 115 , and an audio data buffer 145 . The frequency synthesizer 110 comprises a phase detector 120 , a controlled oscillator 125 , a phase adjusting circuit 130 , a second frequency divider 135 , and an adjusting control circuit 137 . The adjusting control circuit 137 comprises an adder 138 and a fine tuning circuit 140 . The first frequency divider 105 receives a video clock signal S v of a multimedia signal from a multimedia interface and divides the video clock signal S v by a frequency-division factor K to output a clock signal S v ′ having a frequency f v /K. The phase detector 120 detects a phase difference between the clock signal S v ′ and a feedback signal S fb and generates a detection result COMP according to the phase difference. The controlled oscillator 125 (e.g. a voltage-controlled-oscillator (VCO), or a voltage-controlled-delay-line (VCDL)) generates a clock signal S out having a frequency f out according to the detection result COMP. The third frequency divider 115 divides the clock signal S out by a frequency-division factor SF to output the audio output clock S out ′ having a frequency f out /SF, where the audio output clock S out ′ corresponds to an audio clock signal of the multimedia signal. The phase adjusting circuit 130 adjusts a phase of the received clock signal S out to output an adjusted clock signal S c ′ according to a phase adjustment. The second frequency divider 135 divides the adjusted clock signal S c ′ by a frequency-division factor M to generate the feedback signal S fb . The frequency-division factors K, M, and SF mentioned above are frequency-division factors in different frequency dividers respectively and satisfy the following equation:
[0000]
M
K
×
SF
=
N
CTS
Equation
(
2
)
[0013] Based on Equation (2), the frequency-division operations are accomplished by three frequency dividers instead of only two original frequency dividers (N and CTS are parameters contained in an information frame of the multimedia signal and also corresponding frequency-division factors of the two frequency dividers respectively). However, the frequency-division operations accomplished based on Equation (2) can prevent the apparatus 100 from noise interference resulting from the fact that original frequency dividers require higher accuracy for frequency-division factors N and CTS. It should be noted that the audio output clock S out ′ having the frequency f out /SF is still required to be processed by a frequency-division operation (based on the current specification, the corresponding frequency-division factor is 128) to derive the audio clock signal having the frequency f a . The above frequency-division operation with the frequency-division factor 128 , however, can also be integrated into the third frequency divider 115 directly. Certainly, this is not a limitation of the present invention.
[0014] The apparatus 100 , accomplished by the frequency-division operations with frequency-division factors M, K, and SF having limited bit numbers, may not be able to derive the required audio clock signal accurately. Hence, in a preferred embodiment of the present invention, the apparatus 100 further utilizes the phase adjusting circuit 130 and the adjusting control circuit 137 to adjust the generated audio output clock S out ′ accurately by different phase adjustments. In this embodiment, the phase adjusting circuit 130 adjusts the phase of the received clock signal S out according to a phase adjustment D′. The adjusting control circuit 137 controls a predetermined phase adjustment D to output the above-mentioned phase adjustment D′. The fine tuning circuit 140 is utilized for detecting a phase difference between the clock signals S v ′, S out or is utilized for generating a fine adjustment d according to a data amount of the audio data buffer 145 . In another embodiment, a possible way of adjusting the phase of the clock signal S out can also be the following: the controlled oscillator 125 outputs a plurality of candidate oscillating signals and the phase adjusting circuit 130 selects one of the candidate oscillating signals to output the adjusted clock signal S c ′ according to the phase adjustment D′. For example, phase differences between P candidate oscillating signals can be defined as a fixed value T out /P, wherein T out is a period of the clock signal S out . A non-fixed phase difference, however, is also suitable for the present invention. In the above-mentioned example, the phase adjustments D′, D, and the fine adjustment d are all selection parameters utilized for determining a sum of the phase differences. In an embodiment, the phase adjustment D can be ignored (D=zero). The phase adjustment D′, being a sum of the fine adjustment d and the phase adjustment D, can also be a non-integer value. In addition, in other embodiments, the phase adjustment D is a phase adjusting density. For example, two phase unit values are shifted in each period when the phase adjustment D is equal to 2, or one phase unit value is shifted in every two periods when the phase adjustment D is equal to ½. The value of the phase adjusting density D is related to the video clock signal S v , the parameter CTS, the output clock S out ′, and the parameter N. Certainly, the predetermined phase adjusting density D is also used to reduce the tracking time of the frequency synthesizer 110 .
[0015] In the above-mentioned embodiments, the phase adjustment (or the selection parameter) D′ and the audio output clock S out ′ can be represented by the following equation:
[0000]
S
out
′
=
S
v
M
K
×
SF
×
(
1
+
D
′
P
)
Equation
(
3
)
[0016] In order to avoid an over large phase difference between the output signal corresponding to the audio output clock S out ′ generated from the apparatus 100 and the original input signal, and in order to prevent audio data from buffer overflow or buffer underflow, in a preferred embodiment, determining the fine adjustment d requires referencing at least the above-mentioned phase difference and the data amount of the audio data buffer 145 . Please refer to FIG. 2 . FIG. 2 is a flowchart illustrating operation of the fine tuning circuit 140 for determining the fine adjustment according to an embodiment of the present invention. Some possible ways of determining the fine adjustment d are illustrated in FIG. 2 .
[0017] For referencing the above-mentioned phase difference to determine the fine adjustment, in Step 200 , the fine tuning circuit 140 compares the clock signals S v ′ and S out to generate a phase error value and utilizes the phase error value to output a fine adjustment d′. For example, if the phase error value becomes larger, the fine adjustment d′ will be increased by the fine tuning circuit 140 ; otherwise, if the phase error value becomes smaller, the fine adjustment d′ will be decreased by the fine tuning circuit 140 . Please note that the above-mentioned operation will not be executed until the apparatus 100 has been operated in a period. That is to say, after the frequency of the video clock signal S v and the frequency of the generated audio output clock S out ′ are stabilized in that period, the fine tuning circuit 140 starts to compare the clock signals S v ′, S out . The reason is that the frequency of the video clock signal S v and the frequency of the generated audio output clock S out ′ are not stable when the apparatus 100 is just started.
[0018] For referencing the data amount of the audio data buffer 145 to determine the fine adjustment, it is required to consider a current change of the audio data amount, a trend of an extreme value (i.e. a maximum value or a minimum value) of the audio data amount, and the relation between the audio data amount and threshold values of the audio data buffer. More specifically, the adjusting control circuit 137 monitors a data amount of the audio data buffer 145 which temporarily stores an audio data amount of the multimedia signal and generates the phase adjustment according to the data amount of the audio data buffer 145 . In Step 205 , the fine tuning circuit 140 in the adjusting control circuit 137 outputs a fine adjustment d 1 to decrease the phase adjustment (or the selection parameter) D′ inputted into the phase adjusting circuit 130 finally when the data amount of the audio data buffer 145 decreases continuously a plurality of times (e.g. two times). Otherwise, the fine tuning circuit 140 outputs the fine adjustment d 1 to increase the phase adjustment (or the selection parameter) D′ inputted into the phase adjusting circuit 130 finally when the data amount of the audio data buffer 145 increases continuously a plurality of times (e.g. two times). Additionally, in Step 210 , the fine tuning circuit 140 outputs a fine adjustment d 2 to decrease the phase adjustment (or the selection parameter) D′ inputted into the phase adjusting circuit 130 finally when the extreme value of the audio data amount gradually approximates to a specific value below the extreme value (i.e. the data amount of the audio data buffer 145 reaches a threshold). Otherwise, the fine tuning circuit 140 outputs the fine adjustment d 2 to increase the phase adjustment (or the selection parameter) D′ inputted into the phase adjusting circuit 130 finally when the extreme value of the audio data amount gradually approximates to another specific value above the extreme value (i.e. the data amount of the audio data buffer 145 reaches another threshold). It should be noted that, in order to decide the change in the trend of the extreme value of the audio data amount again and again, the fine tuning circuit 140 has to set a recent record value of the extreme value to become zero after outputting the fine adjustment d 2 corresponding to the recent record value. In Step 215 , the fine tuning circuit 140 outputs a fine adjustment d 3 to decrease the phase adjustment (also called the selection factor) D′ when the data amount of the audio data buffer 145 is less than a first threshold value, and the fine tuning circuit 140 outputs the fine adjustment d 3 to increase the phase adjustment (also called the selection factor) D′ when the data amount of the audio data buffer 145 is more than a second threshold value. In this embodiment, for referencing the data amount of the audio data buffer 145 to determine the fine adjustment, a sum of fine adjustments d 1 , d 2 , and d 3 mentioned above is directly adopted as the fine adjustment. In another embodiment, it is also suitable for fine adjustments d 1 , d 2 , and d 3 having different weightings respectively. In addition, the fine adjustments d 1 , d 2 , and d 3 are not all adopted simultaneously, and designers can adopt required fine adjustments according to different requirements. In Step 220 , the fine tuning circuit 140 sums the fine adjustments d′, d 1 , d 2 , and d 3 to determine the fine adjustment d.
[0019] Please note that, in the present invention, the problem caused by the prior art can also be solved by the above-mentioned phase adjustment determined by only using the phase adjusting circuit 130 without the fine tuning circuit 140 . Furthermore, in other embodiments, only three frequency dividers having different frequency-division factors K, M, and SF are also able to generate an audio output clock S out ′. Utilizing only three frequency dividers is helpful in circuit design for avoiding difficulty introduced by directly utilizing extreme values of the frequency-division factors N and CTS to derive the frequency of the audio output clock S out ′. Of course, the spirit of the present invention can also apply to recover any output clock not limited to the above-mentioned audio output clock.
[0020] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | An apparatus for generating an audio output clock is disclosed. The apparatus at least includes a plurality of dividers and a frequency synthesizer. The apparatus utilizes the dividers to achieve dispersive frequency-division operations such that the anti-noise ability of the apparatus can be improved. In addition, the apparatus also utilizes dynamic phase adjustment to increase accuracy of the frequency of the audio output clock. | 7 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. Provisional application No. 60/682,736 filed 19 May 2005, of German patent application 10 2005 023 117.9 filed 19 May 2005, and of German patent application 10 2005 028 688.7 filed 21 Jun. 2005, the disclosure of which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a device and a method for adapting aerodynamic characteristics of an aerodynamically effective construction element or a wing element, to a means of locomotion and to the use of a device for adapting aerodynamic characteristics of a wing element in an aircraft or in a means of locomotion.
TECHNOLOGICAL BACKGROUND
[0003] In modern commercial aircraft, more and more frequently winglets are used, whose purpose it is to reduce the induced resistance of the wing and to increase the Ca/Cw ratio and thus to reduce the resistance and the fuel consumption.
[0004] Generally speaking, winglets are rigid constructions at the end of the wings, comprising an aerodynamic profile that is positioned at three specified angles to the direction of airflow. The alignment of the winglets is designed for the longest flight phase, namely for cruising. Moreover, the maximum effect of the winglets is achieved during cruising. This means that winglets are designed for high Mach numbers Ma=0.8 and approx. 10,000 m cruising altitude with corresponding air pressure, density and temperature. The flight phases of climbing flight, approach to landing, takeoff and landing are not taken into account in the above.
[0005] U.S. Pat. No. 5,988,563 and US 2004/0000619 A1 each disclose a foldable winglet that can rotate in relation to the wing on an attachment axis and that during flight can be moved between a folded-in and a folded-out position.
[0006] Since the aerodynamic load on the winglets is above all extremely high at a large angle of yaw and during lateral gusts, the winglets must be designed so as to be enormously robust for these load cases. Due to the load introduction from the winglet to the wing element, the wing element must then also be designed so as to be correspondingly robust.
[0007] WO 03/00547 discloses that loads resulting from vertical manoeuvres can be reduced by local control surfaces on the winglet, in that by opening these control surfaces the aerodynamic load is reduced.
SUMMARY OF THE INVENTION
[0008] It may be desirable to have a winglet that can be adapted to the operating states of an aircraft.
[0009] According to an exemplary embodiment of the invention an adaption device for adapting aerodynamic characteristics of a wing element is created, wherein the adaption device comprises a winglet, wherein the winglet is movably attachable to the wing element, and wherein the winglet is rotatable in relation to the wing element such that an angle between an associated rotary axis and a main direction of extension of the wing element differs from 90°.
[0010] According to another exemplary embodiment of the invention a method for adapting aerodynamic characteristics of a wing element is provided, wherein a winglet attached to the wing element is rotated in relation to the wing element such that an angle between an associated rotary axis and a main direction of extension of the wing element differs from 90°.
[0011] According to yet another exemplary embodiment of the invention a means of locomotion with a device with the above-described characteristics is provided.
[0012] According to yet another exemplary embodiment of the invention a device with the above-described characteristics is used in an aircraft.
[0013] The spatial position and the movements or rotations of the winglet according to an exemplary embodiment of the invention can be defined by three angles of the aircraft's body coordinate system. The β F -angle denotes the position of the winglet relative to the x F -axis of the aircraft, which axis generally speaking extends along the longitudinal axis of the fuselage; the β F -angle denotes the position of the winglet relative to the y F -axis of the aircraft, which axis generally speaking extends in the direction of the wing tip and perpendicular to the x F -axis; while the γ F -angle denotes the position of the winglet relative to the z F -axis, which generally speaking extends in a vertical plane perpendicular to the x F -axis and the y F -axis. For reasons of mathematical unambiguity a rotary sequence has to be determined, e.g. α F , β F , γ F .
[0014] y F thus extends from the left wing tip to the right wing tip and can therefore be designated the main axis of extension of the wing element.
[0015] The spatial position or the rotations of the winglet can also be described by a body coordinate system or by the Euler rotary angles (compare Brockhaus: Flugregelung, Springer-Verlag, Berlin, 1995).
[0016] In this arrangement with the angle Φ, rotation is first on the body's x-axis, as a result of which the y- and z-axes are moved to new spatial axes positions y 1 and z 1 . For the purpose of consistent designation the axis x is renamed x 1 . Subsequently, rotation at the angle θ on the new y 1 -axis moves the axes x 1 and z 1 to new positions x 2 and z 2 . The y 1 -axis is renamed y 2 . Finally, rotation by the angle ψ takes place on the new z 2 -axis. z, z 1 , z 2 can concretely also be designated the upward axis, while ψ can be designated the toe angle.
[0017] The definition of the body coordinate system is based on a rigid winglet that is attached to the wing element along an axis that extends on the end of the wing element that is located away from the fuselage or that extends within the wing element. This attachment axis may be selected as the body's x-axis. It describes the fold-in or fold-out movement of the winglet relative to the wing element or to the main axis of extension of the wing element. The z-axis then leads through the geometric centre of gravity of the winglet and extends so as to be perpendicular to the x-axis. The y-axis then extends perpendicular to the x-axis and z-axis so that a right-hand system is created. In the case of a plane rectangular wing with a plane rectangular winglet that is attached at a right angle, the x-axis and the z-axis are in the winglet plane while the y-axis is perpendicular to the winglet plane. In this special case the two coordinate systems x, y, z and x F , y F , z F are identical.
[0018] With the device according to the invention, as a result of the flexible construction, above all as a result of the rotatability of the winglets additionally on the upward axis, the load cases to be dimensioned for the winglets and outer wings may be significantly reduced, in particular in the case of large angles of yaw, in the case of lateral gusts and manoeuvres (for example drastic yaw movements and rolling motion), and thus the winglet may be designed in an aerodynamically advantageous way. Depending on the angle of yaw the winglets may rotatably align themselves in relation to the fuselage axis, for example in the direction of the airflow or in the direction of flight, in a way that is similar to sails that are aligned to the direction of the wind. In this way the winglets may be designed so as to be significantly larger and at the same time, due to the reduced loads, both the winglet and the wing element may be designed so as to be lighter. The advantageous aerodynamic design in conjunction with the reduction in weight results in a particularly significant reduction in the fuel consumption and overall in great economy of the aircraft.
[0019] Furthermore, the flexible setting options of the winglet may make possible direct control of wing torsion. In addition to the option of influencing the bending of the wing by fold-in and fold-out winglets, there is now an option available, which option is in many cases much more important, of directly influencing wing torsion. In this way in every flight phase resistance may be minimised and as a result of this still further fuel consumption can be achieved, which represents one of the significant optimisation potentials in aircraft engineering.
[0020] As a result of the great flexibility and free movement option of the winglet, furthermore, optimal lift distribution may be achieved in each flight state. By folding-out or folding-in the winglet, by ideally setting the toe angle, and/or by rotating the winglet on the y 1 -axis, in the approach to landing the coefficient of lift can be increased, and by folding the winglets in during cruising low aerodynamic resistance may be set. For cruising, the winglet may be set relative to the coordinate system of the aircraft, for example for α F =5°, for β F =15° and for γ F =4°.
[0021] According to another exemplary embodiment of the invention the winglet is rotatably attachable to an attachment axis with the wing element. In addition to controlling wing torsion this provides the option of additionally controlling bending of the wing and of adapting it to various aerodynamic load cases.
[0022] The winglet according to the invention may be rotatable in relation to the wing element on one, two or three rotary axes. This high degree of flexibility makes possible high-quality adaptation of the aerodynamic characteristics of the wing element or of the aircraft to the many various operating states such as the takeoff state, landing state, cruising state.
[0023] According to yet another exemplary embodiment of the invention the winglet can be rotatably attachable on the y 1 -axis of the body coordinate system of the winglet. In particular in the case of two-sided winglets, which comprise identical or different surfaces above and below the wing, over 180°-rotation the bending moment that is introduced in the wing may be significantly reduced.
[0024] A winglet may thus be movably attachable to a wing element in a rotary manner such that said winglet can move by two or three degrees of freedom. Not only can it fold inward in the direction of the fuselage, but it can also assume an angle to the main direction of extension of the wing element, which angle essentially differs from 90°, and/or it can rotate on the y 1 -axis of the body coordinate system of the winglet. In this way the winglet can better adapt to various operating states of an aircraft. By means of such adjustment of the winglets to reflect various load cases it is possible to create ideal aerodynamic conditions and at the same time to significantly reduce the aerodynamic loads on the winglets.
[0025] Furthermore, the various rotary options of the winglet are used to influence the wake turbulence characteristics of the aircraft.
[0026] In a further exemplary embodiment the device further comprises a wing element. The winglet according to the invention can for example be used on the end of the wing of an aircraft, on a wind power engine, on a windmill and on any desired component of a means of locomotion, which component is exposed to airflow. Other applications are of course also possible.
[0027] According to a further exemplary embodiment the device comprises an aerodynamic fairing element between the wing element and the winglet in order to cover any gap between the wing element and the winglet, which gap may be aerodynamically unfavourable. In this way aerodynamic losses can be avoided.
[0028] According to a further exemplary embodiment the device comprises at least one suspension element by means of which the winglet is attached to the wing element.
[0029] According to a further exemplary embodiment at least one suspension element is controllably provided so that the winglet can rotate within various degrees of freedom. In order to provide the suspension element so that it is controllably movable, according to another exemplary embodiment at least one suspension element is moved by a driven spindle, for example with the use of an electric motor.
[0030] According to another exemplary embodiment the device further comprises a drive device for moving the winglet and/or the suspension element. In this arrangement the drive device can comprise electric, hydraulic and/or piezoelectric drives. Furthermore, active materials, in particular piezoceramics, can be used.
[0031] According to another exemplary embodiment of the device the winglet is divided into an upper and a lower part, with the upper and/or the lower part of the winglet being movable. In this arrangement the upper or the lower part can be designed so as to slightly, or significantly, project outward. The same applies to the inclination in the direction of the fuselage axis. For example, in a winglet that extends above and below the wing element, only the top surface or only the bottom surface may be movable.
[0032] According to another exemplary embodiment the winglet is in three parts, with an upper, a lower and an outer part, wherein at least one part is movable. According to a further exemplary embodiment each of these parts in turn can be divided into several sub-parts, and each sub-part itself can be movable. According to a further exemplary embodiment furthermore, in addition to the winglet, also a part of the wing element or an entire wing element including the winglet can be rotatable.
[0033] According to another exemplary embodiment of the method rotation of the winglet is controlled by an onboard computer unit. In this arrangement the onboard computer unit can control the winglet on the basis of measured aircraft data such as for example flight altitude, direction of airflow, angle of incidence, air pressure, temperature, etc.
[0034] According to another exemplary embodiment of the method the onboard computer unit can regulate the movement of a winglet by way of a regulating unit. The onboard computer unit or the regulating unit for example reacts to any change in various parameters and automatically sets the winglets accordingly. Regulation can be uniform or adaptive in relation to individual aircraft data. In addition, a particular operating state (such as for example takeoff state, landing state, cruising state) can be used as a criterion for adjusting the position of the winglet.
[0035] According to a further exemplary embodiment of the method, the winglet controls any wing torsion and/or wing bending is controlled so that the wing profile can be aerodynamically optimised.
[0036] According to yet another exemplary embodiment of the invention a wind power engine or a windmill with a device featuring the above-described characteristics is created.
[0037] The embodiments relating to the device also apply to the method and to the means of locomotion as well as to the use, and vice versa.
[0038] With the device and the method according to the invention an effective setting option of the winglets that reflect any operating states of an aircraft may thus be achievable, as a result of which the aerodynamic resistance and the weight-determining loads on the winglets and the wing elements may be reduced. Consequently the winglets, the wings and the transition from the wing to the fuselage may be designed so as to save more weight and so that the fuel consumption may be greatly reduced. In this way the aircraft's economy may be significantly improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] Below, for further explanation and for an improved understanding of the present invention, exemplary embodiments are described with reference to the enclosed drawings. The following are shown:
[0040] FIG. 1 a diagrammatic view of a wing element with a movably attached winglet according to one exemplary embodiment of the invention;
[0041] FIG. 2 a further diagrammatic view of a wing element with a movably attached winglet and its rotary axes according to an exemplary embodiment of the invention;
[0042] FIG. 3 a further diagrammatic view of a wing element with a movably attached winglet in various positions according to one exemplary embodiment of the invention;
[0043] FIG. 4 a diagrammatic view of a suspension element according to one exemplary embodiment of the invention;
[0044] FIG. 5 a diagrammatic view of a controllable suspension element according to one exemplary embodiment of the invention;
[0045] FIG. 6 a diagram showing the achieved reduction in the gradient of the bending moments along the winglet with a change in the toe angle of 4 degrees;
[0046] FIG. 7 a diagram of the achieved reduction in the gradient of the bending moments along the wing, resulting from the change in the toe angle of the winglet;
[0047] FIG. 8 a a diagrammatic view of a rotatable winglet comprising two parts;
[0048] FIG. 8 b a further diagrammatic view of a rotatable winglet comprising three parts;
[0049] FIG. 8 c a further diagrammatic view of a rotatable winglet comprising three parts, one part of which is rotatable.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0050] Identical or similar components in different figures have the same reference characters.
[0051] The illustrations in the figures are diagrammatic and not to scale.
[0052] FIG. 1 shows a diagrammatic top view of a winglet 2 and of a wing element 1 as well as the aircraft's body coordinate system 7 a and the winglet's body coordinate system 7 b . Furthermore, the main axis of extension 6 of the wing element 1 and a rotary axis 7 of the winglet with the rotary angle Φ is shown. This is the first rotary axis 7 according to the convention of the Euler angles. By rotation on the x-axis the winglet 2 can be folded out or folded in. The arrow 8 indicates the direction of the local airflow during flight with a local angle of yaw at the winglet. For example, if the winglet is not to be rotated by the Euler angles Φ and θ, then the axes x, x 1 and x 2 are identical; likewise y, y 1 and y 2 and z, z 1 and z 2 . Rotation on the z-axis in the direction of the local airflow then directly results in a reduction in the aerodynamic load and thus in a reduction in the overall load on the winglet.
[0053] FIG. 2 shows a device for adapting a winglet to an operating state of an aircraft, according to one exemplary embodiment of the invention. Furthermore, a body coordinate system of the winglet is introduced in order to define the rotary axes. By rotation on the x-axis at a rotary angle Φ the winglet has been brought from the perpendicular position to the new flap position. In this way the body coordinate system moves to the new axes x 1 , y 1 , z 1 .
[0054] Rotation on the z 2 -axis or on the y 1 -axis makes it possible to freely select settings required by various flight states or various aerodynamic load cases.
[0055] For the sake of clarity and obviousness the drawing does not show rotation on the y 1 -axis so that x 1 =x 2 , y 1 =y 2 , z 1 =z 2 . Only rotation on the z 2 -axis on the toe angle ψ is illustrated. Illustration of the rotation on the y 1 - and the z 2 -axis is also obvious on the basis of FIGS. 1 and 2 .
[0056] The device comprises a wing element 1 , a winglet 2 and at least one suspension element 3 (see FIG. 4 ). The winglet 2 is attached to the wing element 1 by way of a suspension element 3 . The device according to FIG. 1 shows the way the winglet can rotate on three (spatial) axes. In this way the winglet 2 can be adapted to the local angle of yaw of the flight state. Adaptation of the toe angle (rotation on the Z 2 -axis of the body coordinate system) and rotation on the y 1 -axis makes it possible to change (in particular to reduce) the effective surface of the winglet 2 (in the angle-of-yaw flight, during drastic roll and yaw and also during combined roll and yaw), which effective surface is impinged upon by the lateral component of the airflow so that in particular the resulting transverse forces and bending moments on the winglet 2 and thus also on the outer wing 1 are reduced. By changing the toe angle, the rotation on the y 1 -axis, and by folding-in or folding-out the winglet on the x-axis, the surface of the winglet 2 , which surface is aerodynamically effective in the direction of flight, changes.
[0057] FIG. 3 shows the movement of the winglet on the x-axis or on the attachment axis. It becomes possible, together with the settability of the toe angle, to optimally set the lift characteristics to any given flight phase. During cruising, i.e. at high altitude and at high speed, the winglet 2 ′ can be folded-in in order to reduce the resistance in this way. Depending on aerodynamic conditions and flight phases, i.e. during side slipping, during climbing, descent or in strong side winds, the winglet 2 ″ can assume corresponding intermediate positions. At low speed, in particular during the approach to landing, where a large coefficient of lift may be desired, the winglet 2 ′″ can be folded out so as to increase the wing surface.
[0058] FIG. 4 shows one option of attaching the winglet 2 to a wing element 1 . The suspension element 3 shown, of which there is at least one, connects the wing element 1 to the winglet 2 . By way of a rotary axis 5 , for example the toe angle can be set in a targeted way to the respective load cases. At the same time the suspension element 3 can be attached so as to be articulated so that the winglet 2 can additionally rotate on an attachment axis (x-axis of the body coordinate system of the winglet) and on the y 1 -axis. Rotation on the attachment axis makes it possible for the winglet to fold in and out in relation to the aircraft fuselage, as is shown in the front view of the wing-winglet combination in FIG. 2 .
[0059] FIG. 5 shows one option of controlling the winglet 2 . In this arrangement, rotating the winglet 2 on the upward axis 5 , on the y-axis and on the x-axis, can be achieved by a drive motor that retracts and extends a spindle 4 in a targeted manner. Thus, for example, the winglet 2 rotates on its upward axis 5 . Rotation of the winglet 2 on its attachment axis and on the y 1 -axis can be made possible by a driven articulated suspension element 3 .
[0060] FIG. 6 shows the gradient 10 a , 11 a of the bending moments in the main direction of extension of a rectangular winglet with a change 10 a and without a change 11 a in the toe angle of 4°. The abscissa shows the position z p on the winglet in relation to the winglet length l w from the transition of the winglet to the wing right up to the winglet tip in %, while the ordinate shows the amount of the bending moment in % in relation to the respective position z p /l w . For an angle of yaw manoeuvre according to the European airworthiness requirement JAR25, a change in the toe angle of 4° results in a significant reduction in the gradient of the bending moments. This results in a correspondingly significant reduction in the structural weight of the winglet.
[0061] FIG. 7 in respect of the JAR25 angle of yaw manoeuvre shows the gradient of the bending moments in the main direction of extension in the outer region of a wing element with which a winglet with 10 b and without 11 b toe angle change of 4° is connected. The abscissa shows the position y F,P on the wing in relation to the length l F of the wing in the outer region right up to the transition to the winglet in %, while the ordinate shows the amount of the bending moment in %. It becomes clear that the change in the toe angle may also significantly reduce the wing load.
[0062] FIG. 8 a shows a further embodiment in which the winglet comprises an upward-oriented part ( 2 a ) and an outward-oriented part ( 2 b ). For the sake of clarity only rotation on the y 1 -axis is shown. Consequently the body coordinate system x 1 , y 1 , z 1 is moved to the new coordinate system x 2 , y 2 , z 2 . In the case of significant angles of incidence of the wing element 1 corresponding to the local direction 8 , rotation on the y 1 -axis results in a significant reduction of the bending moments on the winglet and on the wing. The upper part may ensure that no gap is formed towards the front during rotation on the y 1 -axis.
[0063] FIGS. 8 b and 8 c shows 3-part winglet designs. When compared to FIG. 8 a the upper part 2 a continues downward 2 c . In this way during rotation on the y 1 -axis, both on the front and on the rear wing-to-winglet transition, the formation of a gap can be prevented. In FIG. 8 b the upper part 2 a and the lower part 2 c rotate together with the outer part 2 b . In FIG. 8 c only the outer winglet part 2 b rotates.
[0064] The winglet-to-wing transition, the angle between the upper and the outer winglet part, as well as the geometric design of the winglet parts (curvature, profile thickness, sweep, etc. . . . ) can be selected such that, taking into account all the flight phases, optimal aerodynamic characteristics and load characteristics and thus minimal fuel consumption and optimal economy can be achieved.
[0065] To this effect the winglet may be provided with additional rotary options. Furthermore, the winglet may be supplemented by further rotatable parts.
[0066] In practical application the rotary movements may at all times be carried out simultaneously rather than in sequence.
[0067] In this arrangement the toe angle, the flap position of the winglet 2 relative to the fuselage, and/or rotation on the y 1 -axis can be controlled by an onboard computer on the basis of the measured flight state data such as, for example, flight altitude, yaw angle, angle of incidence, roll angle, flight speed, angle of yaw, etc. For example, it may thus be possible to automatically react to any critical aerodynamic load, and the effective aerodynamic surface of the winglet may be reduced.
[0068] In addition it should be pointed out that “comprising” does not exclude other elements or steps, and “a” or “one” does not exclude a plural number. Furthermore, it should be pointed out that characteristics or steps which have been described with reference to one of the above embodiments can also be used in combination with other characteristics or steps of other embodiments described above. Reference characters in the claims are not to be interpreted as limitations. | The present invention relates to a device for adapting aerodynamic characteristics of a wing element ( 1 ), wherein the device comprises a winglet ( 2 ), wherein the winglet ( 2 ) is movably attachable to the wing element ( 1 ), and wherein the winglet ( 2 ) or parts of the winglet is or are rotatable in relation to the wing element ( 1 ) such that an associated rotary axis ( 7 ) with a main direction of extension ( 6 ) of the wing element ( 1 ) encompasses an angle that differs from 90°. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to methods for generating a radio-frequency (RF) signal, and, more particularly, to a method for generating a modulated RF signal with high dynamic range.
BACKGROUND OF THE INVENTION
[0002] Advanced cellular mobile communication standards, such as CDMA2000, WCDMA and the like, use dynamic power control to improve spectral efficiency. Through dynamic power control, when a cellular phone is close to a base station, the output power of the radio-frequency (RF) transmitter of the cellular phone is reduced, whereas when the cellular phone is far from the base station, the output power of its RF transmitter is increased. In communication standards, such as CDMA2000 and WCDMA, the dynamic range of the output power is approximately 80 dB in an attempt to reduce interference between users and prolong the time in which the phone is operable.
[0003] Traditionally, an RF transmitter is implemented with a linear power amplifier. By adjusting the input power of this power amplifier, the RF transmitter can obtain a power output with a dynamic range of 80 dB. However, this linear power amplifier is not efficient such that the efficiency will drop rapidly when backed off from the maximum output power level and severely reduce the operational time of the phone.
[0004] Prior art has disclosed a power-level tracking technique, which essentially adds a DC-DC converter between the power supply of the RF transmitter and the linear power amplifier, so that the power supply voltage of the linear power amplifier can be adjusted by the DC-DC converter. By dynamically adjusting the power supply voltage, the efficiency of the linear power amplifier can be improved significantly, when compared to a conventional RF transmitter. However, since a linear power amplifier is employed, its efficiency is still relatively low.
[0005] The envelope elimination and restoration (EER) transmission technique described in “L-band transmitter using Kahn EER technique” (IEEE Trans. Microwave Theory Tech., vol. 46, no. 12, pp. 2220-2225, December 1998, E H. Raab, B. E. Sigmon, R. G. Myers, and R. M. Jackson) can significantly increase the efficiency of the RF transmitter when operated close to the maximum power level. However, a transmitter adopting the EER technique only has a single control mechanism, wherein both the fast-varying instantaneous output power level and the slow-varying average output power level are controlled concurrently by the information detected by the envelope detector. The single control mechanism is limited by the difference of the maximum and the minimum power supply voltages, which limits the dynamic range of the transmitted RF signals to less than 20 dB. As a result, the dynamic range does not comply with the regulations on the dynamic range of output power specified in the aforementioned communication standards.
[0006] In summary, a dynamic range of 80 dB for the power output can be obtained with the use of a linear power amplifier, but efficiency of the power output is poor; and, although said EER method mitigates poor efficiency, the dynamic range of the power output is inevitably reduced to below 20 dB.
[0007] Thus, there is a need for a method for generating a modulated RF signal that solves the prior art shortcomings, specifically, by not compromising either the average output efficiency or the dynamic range of output power.
SUMMARY OF THE INVENTION
[0008] In the light of forgoing drawbacks, an objective of the present invention is to provide a method for generating a modulated RF signal with high dynamic range and to provide high average output efficiency while maintaining the output power in a range that complies with that specified by current communication standards such as CDMA2000, WCDMA and the like.
[0009] In accordance with the above and other objectives, the present invention provides a method for generating a modulated radio-frequency (RF) signal, comprising the steps of: generating a pulse modulation control signal, a gain control signal, and an average power control signal; receiving a constant-envelope modulated RF signal and the gain control signal by a variable gain module, and the variable gain module adjusting an amplifying gain of the constant-envelope modulated RF signal according to the gain control signal that sets the amplitude of the constant-envelope modulated RF signal to generate an constant-envelope modulated RF signal with an adjusted amplitude, and adjusting the DC supply voltage of a DC power supply to be output to a power amplification module according to the average power control signal to generate a power amplifier with adjusted average power, and receiving and modulating the constant-envelope modulated RF signal with an adjusted amplitude by an instantaneous power adjusting module according to the pulse modulation control signal to generate a pulse modulated RF signal carrying phase information; and receiving the pulse modulated RF signal carrying phase information and the power amplifier with adjusted average power by the power amplification module, and adjusting the output power of the received pulse modulated RF signal carrying phase information in its envelope by the power amplification module according to the power amplifier with adjusted average power, so as to output/generate a pulse modulated RF signal with adjusted power and carrying phase information.
[0010] In another implementation aspect of the method for generating an RF signal with high dynamic range of the present invention, the method includes: generating an instantaneous power control signal, a gain control signal, and an average power control signal; receiving an constant-envelope modulated RF signal and the gain control signal by a variable gain module, having the variable gain module adjust the amplifying gain of the constant-envelope modulated RF signal according to the gain control signal to adjust the amplitude of the constant-envelope modulated RF signal to generate an constant-envelope modulated RF signal with an adjusted amplitude, and then adjust the average power the DC supply voltage of a DC power supply to be output to a plurality of power amplification modules according to the average power control signal to generate a power amplifier with adjusted average power, and receiving and modulating the constant-envelope modulated RF signal with adjusted amplitude by each of a plurality of instantaneous power adjusting modules according to the instantaneous power control signal to simultaneously generate a plurality of modulated RF signals carrying phase information; receiving the plurality of modulated RF signals carrying phase information and the power amplifier with adjusted average power by the plurality of power amplification modules, and then simultaneously adjusting the output powers of the received modulated RF signals carrying phase information by the power amplification modules according to the power amplifier with adjusted average power, so as to output/generate a plurality of modulated RF signals with adjusted power and carrying phase information; and combining the plurality of modulated RF signals with adjusted power and carrying phase information in their envelopes to output/generate an RF signal with high dynamic range.
[0011] Compared to the prior art, the method for generating an RF signal with high dynamic range of the present invention adopts two power adjustment mechanisms to increase the dynamic range of output power. That is, on the one hand, adjustment of average output power can be achieved through the controlling of the DC power supply input of the RF amplifying module; on the other hand, fast adjustment of average output power can also be achieved through the adjustment of the amplitude of the constant-envelope modulated RF signal and pulse modulation (pulse width or duty cycle) of the constant-envelope modulated RF signal. Compared to the single control mechanism of the prior art, the method for generating an RF signal with high dynamic range of the present invention achieves a higher average power output efficiency while allowing the dynamic range of output power to comply with those required by current communication standards such as CDMA2000 and WCDMA.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention can be more fully understood by reading the following detailed description of the preferred embodiments, with reference made to the accompanying drawings, wherein:
[0013] FIG. 1 is a schematic diagram depicting a circuit for carrying out a method for generating a modulated RF signal with high dynamic range of the present invention;
[0014] FIG. 2 is a schematic diagram depicting another circuit for carrying out the method for generating a modulated RF signal with high dynamic range of the present invention;
[0015] FIGS. 3A and 3B are diagrams depicting signal waveforms of an input constant-envelope modulated RF signal and an output pulse modulated RF signal with adjusted power and carrying phase information using the circuitry shown in FIG. 1 ;
[0016] FIGS. 4A and 4B are diagrams depicting signal waveforms of an input constant-envelope modulated RF signal and an output RF signal with high dynamic range using the circuitry shown in FIG. 2 ;
[0017] FIG. 5 is a chart depicting a curve of power added efficiency obtained with an RF transmitter using the method for generating a modulated RF signal with high dynamic range of the present invention;
[0018] FIG. 6 is a chart depicting relationships between input and output powers obtained with an RF transmitter using the method for generating a modulated RF signal with high dynamic range of the present invention;
[0019] FIG. 7 is a chart depicting ACPR 1 and ACPR 2 (Adjacent Channel Power Ratio) curves obtained with an RF transmitter using the method for generating a modulated RF signal with high dynamic range of the present invention;
[0020] FIG. 8 is a chart illustrating a comparison between the efficiencies of a polar coordinated transmitter using the method for generating a modulated RF signal with high dynamic range of the present invention and a commercial linear power amplifier within 40 dB dynamic range;
[0021] FIG. 9 is a flowchart illustrating a method for generating a modulated RF signal with high dynamic range according to an embodiment of the present invention; and
[0022] FIG. 10 is a flowchart illustrating a method for generating a modulated RF signal with high dynamic range according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0023] The present invention is described by the following specific embodiments. Those with ordinary skills in the art can readily understand other advantages and functions of the present invention after reading the disclosure of this specification. The present invention can also be implemented with different embodiments. Various details described in this specification can be modified based on different viewpoints and applications without departing from the scope of the present invention.
[0024] Referring to FIG. 1 , a schematic diagram depicting a circuit for carrying out a method for generating a modulated RF signal with high dynamic range of the present invention is shown. The present invention is capable of producing higher dynamic range for the transmitted power of RF signals. This dynamic range complies with the 80 dB requirement specified by current communication standards (e.g. CDMA2000 and WCDMA).
[0025] As shown in FIG. 1 , a variable gain module 103 receives a constant-envelope modulated RF signal 102 and a gain control signal 104 . The variable gain module 103 adjusts the amplifying gain of the constant-envelope modulated RF signal 102 according to the gain control signal 104 . Specifically, the variable gain module 103 adjusts the amplitude of the constant-envelope modulated RF signal 102 to generate a constant-envelope modulated RF signal with an adjusted amplitude 112 .
[0026] Then, an average power adjusting circuit 101 adjusts the average power of the supply voltage of a DC power supply to be output to a power amplification module 107 according to an average power control signal 108 to generate a DC supply voltage with the adjusted average power 110 . Thereafter, an instantaneous power adjusting module 105 receives the constant-envelope modulated RF signal with the adjusted amplitude 112 , and modulates the constant-envelope modulated RF signal with the adjusted amplitude 112 according to a pulse modulation control signal 106 to generate a pulse modulated RF signal carrying phase information 122 .
[0027] After the pulse modulated RF signal carrying phase information 122 is generated, the power amplification module 107 may receive the pulse modulated RF signal carrying phase information 122 and the DC supply voltage with the adjusted average power 110 , and then the power amplification module 107 may adjust the power of the received pulse modulated RF signal carrying phase information 122 correspondingly according to the DC supply voltage with the adjusted average power 110 , so as to output/generate a pulse modulated RF signal with the adjusted power and carrying phase information 132 .
[0028] It should be noted here that the frequency (or duty cycle) of the constant-envelope modulated RF signal with the adjusted amplitude 112 may be modulated by the instantaneous power adjusting module 105 .
[0029] Moreover, in another aspect of the present invention, the power amplification module 107 is an RF power amplifier.
[0030] Further, in another aspect of the present invention, the variable gain module 103 is a variable gain amplifier.
[0031] Referring to FIG. 2 , a diagram depicting another circuit for carrying out the method for generating a modulated RF signal with high dynamic range of the present invention is shown. As shown in FIG. 2 , a variable gain module 203 receives a constant-envelope modulated RF signal 202 and a gain control signal 204 . The variable gain module 203 adjusts the amplifying gain of the constant-envelope modulated RF signal 202 according to the gain control signal 204 . Specifically, the variable gain module 203 adjusts the amplitude of the constant-envelope modulated RF signal 202 to generate a constant-envelope modulated RF signal with adjusted amplitude 212 .
[0032] Then, an average power adjusting circuit 201 adjusts the average power of the DC supply voltage of a DC power supply to be output to a plurality of power amplification modules 207 according to an average power control signal 208 to generate a DC supply voltage with the adjusted average power 210 .
[0033] Thereafter, each of a plurality of instantaneous power adjusting modules 205 receive an constant-envelope modulated RF signal with the adjusted amplitude 212 , and modulates the constant-envelope modulated RF signal with the adjusted amplitude 212 according to an instantaneous power control signal 206 to simultaneously generate a plurality of modulated RF signals carrying phase information 222 . In other words, the instantaneous power adjusting modules 205 achieve adjustment of the instantaneous power by controlling the frequency or duty cycle of the signals.
[0034] After the plurality of modulated RF signals carrying phase information 222 are generated, the plurality of power amplification modules 207 may each receive a corresponding modulated RF signal carrying phase information 222 and the DC supply voltage with the adjusted average power 210 , and then the plurality of power amplification modules 207 may simultaneously adjust the power of each received modulated RF signal carrying phase information 222 according to the DC supply voltage with the adjusted average power 210 , so as to output/generate a plurality of modulated RF signals with adjusted power and carrying phase information.
[0035] Finally, the plurality of modulated RF signals with the adjusted power and carrying phase information can be combined to output/generate an RF signal with high dynamic range 232 .
[0036] It should be noted that the functions of the instantaneous power adjusting modules 205 and the power amplification modules 207 can be realized by a power digital-to-analog converter (DAC).
[0037] As shown in FIGS. 3A and 3B , diagrams depicting signal waveforms of a received input signal (e.g. constant-envelope modulated RF signal 102 ) and an output RF signal (e.g. pulse modulated RF signal with adjusted power and carrying phase information 132 ) are provided in conjunction with the circuitry shown in FIG. 1 , wherein the waveforms depict an exemplary input signal 102 and output RF signal 132 , respectively.
[0038] In addition, as shown in FIGS. 4A and 4B , diagrams depicting signal waveforms of the received input signal (e.g. constant-envelope modulated RF signal 202 ) and an output RF signal (e.g. an RF signal with high dynamic range 232 ) are provided in conjunction with the circuitry shown in FIG. 2 , wherein the waveforms depict an exemplary input signal 202 and output RF signal 232 , respectively.
[0039] Compared to the single control mechanism of the EER method in the prior art, the present invention adopts two power adjustment mechanisms to increase the dynamic range of the output power. On the one hand, slow adjustment of the average power in the millisecond timeframe can be achieved, while, on the other hand, fast adjustment of the average power in the microsecond timeframe can also be achieved, allowing the dynamic range of output power to comply with those required by current communication standards, such as CDMA2000 and WCDMA.
[0040] When the method for generating a modulated RF signal with high dynamic range of the present invention is applied to a polar coordinated transmitter, the output power efficiency of the polar coordinated transmitter is increased while exhibiting high dynamic range. In order to more clearly understand this, please refer to FIG. 5 , which is a plot depicting a curve of power added efficiency.
[0041] Moreover, as shown in FIG. 6 , by using the method for generating a modulated RF signal with high dynamic range of the present invention, the dynamic range of the output power can be further improved to meet the 80 dB requirement specified by the current communication standards.
[0042] In addition, it is known from the CDMA2000 communication standard that the Adjacent Channel Power Ratio (ACPR 1 ) should be lower than −42 dBc under a measuring bandwidth of 30 KHz or that the power should be lower than −54 dBm under a measuring bandwidth of 1.23 MHz, and that the Alternate Channel Power Ratio (ACPR 2 ) should be lower than −54 dBc under a measuring bandwidth of 30 KHz or the power should be lower than −54 dBm under a measuring bandwidth of 1.23 MHz.
[0043] FIG. 7 is a plot depicting the RF output signal obtained using the method for generating a modulated RF signal with high dynamic range of the present invention by a spectrum analyzer. It can be seen from FIG. 7 , when the output power varies within the 80 dB dynamic range, the ACPR 1 and the ACPR 2 both comply with the CDMA2000 communication standard. In FIG. 7 , the curve consisting of small squares indicates the performance of ACPR 1 , and the curve consisting of small circles indicates the performance of ACPR 2 .
[0044] Referring now to FIG. 8 , a comparison between the efficiencies of a polar coordinated transmitter using the method for generating a modulated RF signal with high dynamic range of the present invention and a commercial linear power amplifier within a 40 dB dynamic range is shown. As can be seen in FIG. 8 , compared to curve 802 (using the commercial linear power amplifier), curve 801 , which indicates the efficiency of the polar coordinated transmitter using the method for generating a modulated RF signal with high dynamic range of the present invention, has an improved power output efficiency when the output power is close to the maximum output power.
[0045] It can be seen from above FIGS. 3 to 6 that the method for generating a modulated RF signal with high dynamic range of the present invention provides an RF signal with high efficiency and high dynamic range (80 dB) for output power through two simultaneous power adjusting mechanisms, namely, pulse width/amplitude modulation and dynamic voltage regulation of the drain of the power amplifier.
[0046] The processes of the method for generating a modulated RF signal with high dynamic range according to an embodiment of the present invention are now further described in conjunction with the system architecture shown in FIG. 1 . FIG. 9 is a flowchart illustrating a method for generating a modulated RF signal with high dynamic range 900 of the present invention. In step S 902 , a pulse modulation control signal, a gain control signal, and an average power control signal are generated. Then, proceed to step S 904 .
[0047] In step S 904 , a constant-envelope modulated RF signal and the gain control signal are received by a variable gain module, which adjusts the amplifying gain of the constant-envelope modulated RF signal according to the gain control signal; specifically, the amplitude of the constant-envelope modulated RF signal is adjusted to generate an constant-envelope modulated RF signal with an adjusted amplitude; and then, an average power of the DC supply voltage of a DC power supply to be output to a power amplification module is adjusted according to the average power control signal to generate a DC supply voltage with the adjusted average power; thereafter, the constant-envelope modulated RF signal with the adjusted amplitude is received and modulated by an instantaneous power adjusting module according to the pulse modulation control signal to generate a pulse modulated RF signal carrying phase information. Then, proceed to step S 906 .
[0048] In step S 906 , the pulse modulated RF signal carrying phase information and the DC supply voltage with the adjusted average power are received by the power amplification module, and then the power of the received pulse modulated RF signal carrying phase information is adjusted by the power amplification module according to the DC amplifier with the adjusted average power, so as to output/generate a pulse modulated RF signal with adjusted power and carrying phase information, and the processes of the method for generating a modulated RF signal with high dynamic range of the present invention are complete.
[0049] The steps of the method for generating a modulated RF signal with high dynamic range according to another embodiment of the present invention are further described in conjunction with the system architecture shown in FIG. 2 . FIG. 10 is a flowchart illustrating a method for generating a modulated RF signal with high dynamic range 1000 according to the present invention. In step S 1002 , an instantaneous power control signal, a gain control signal, and an average power control signal are generated. Then, proceed to step S 1004 .
[0050] In step S 1004 , an constant-envelope modulated RF signal and the gain control signal are received by a variable gain module, which adjusts the amplifying gain of the constant-envelope modulated RF signal according to the gain control signal; specifically, the amplitude of the constant-envelope modulated RF signal is adjusted to generate an constant-envelope modulated RF signal with an adjusted amplitude; and then, the average power of the supply voltage from a DC power supply to be output to a plurality of power amplification modules is adjusted according to the average power control signal to generate a DC supply voltage with the adjusted average power; thereafter, the constant-envelope modulated RF signal with the adjusted amplitude is received and modulated by each of a plurality of instantaneous power adjusting modules according to the instantaneous power control signal to simultaneously generate a plurality of modulated RF signals carrying phase information. Then, proceed to step S 1006 .
[0051] In step S 1006 , the plurality of modulated RF signals carrying phase information and the DC supply voltage with the adjusted average power are received by the plurality of power amplification modules, and then the powers of the received modulated RF signals carrying phase information are simultaneously adjusted by the power amplification modules according to the DC supply voltage with the adjusted average power, so as to output/generate a plurality of modulated RF signals with adjusted power and carrying phase information. Then, proceed to step S 1008 .
[0052] In step S 1008 , the plurality of modulated RF signals with adjusted power and carrying phase information are combined to output/generate an RF signal with high dynamic range, and the steps of the method for generating a modulated RF signal with high dynamic range of the present invention are complete.
[0053] The above embodiments are provided to illustrate the principles of the present invention, and they should not be construed as to limit the present invention in any way. The above embodiments can be modified by those with ordinary skills in the arts without departing from the scope of the present invention as defined in the following appended claims. | A method for generating a modulated RF signal with high dynamic range is disclosed, which electrically combines average output power adjustment and instantaneous output power adjustment to improve the dynamic range of output power of an RF signal. Compared to the single control mechanism in the traditional method for generating a modulated RF signal, the method for generating a modulated RF signal proposed by the present invention can be applied to produce a variety of highly efficient RF transmitters with high dynamic range. | 7 |
BACKGROUND OF THE INVENTION
[0001] Clothes washing machines typically have a detergent dispenser to receive either a powder or a liquid detergent which is added to the tub during a wash cycle of the machine. Some washing machines include compartments for laundry conditioners, such as fabric softener or bleach, as well as a compartment for detergent to be used in a prewash cycle. The prewash cycle is typically followed by a main wash cycle which includes a second dose of detergent from the dispenser. The dispenser configuration for a powder detergent is different than the configuration for a liquid detergent. For example, powder detergents typically do not require walls in the dispenser, which are required to contain liquid detergents. Also, liquid detergents generally work well with a siphon system, whereas powder detergents do not work well with a siphon system. Thus, the specific dispenser or compartment configuration provided in the washing machine normally dictates the type of detergent that can be used.
[0002] Accordingly, a primary objective of the present invention is the provision of an improved detergent dispenser for a clothes washing machine which can handle either powder or liquid detergent for both the prewash and main wash cycles.
[0003] Another objective of the present invention is the provision of an improved detergent dispenser for a washing machine which allows the user to select the configuration, and thus the type of detergent, that can be used for the wash cycle of the machine.
[0004] Still another objective of the present invention is the provision an improved detergent dispenser for a washing machine that can be changed by the user in order to function as either a powder detergent dispenser or a liquid detergent dispenser.
[0005] Yet another objective of the present invention is the provision of a detergent dispenser having dual cups for powder and liquid detergent, with one cup being removably mounted in the other cup.
[0006] Another objective of the present invention is the provision of a washing machine detergent dispenser having a single drain opening for prewash detergent, main wash detergent, and fabric conditioner.
[0007] These and other objectives will become apparent from the following description of the invention.
BRIEF SUMMARY OF THE INVENTION
[0008] An improved detergent dispenser is provided for a clothes washing machine. The machine has a tub for holding clothes to be washed, and may be a front loading or top loading machine. The detergent dispenser includes a base mounted in the washing machine. A first powder detergent cup is mounted in the base to hold and dispense a powder detergent into the tub during the main wash cycle. A second liquid detergent cup is removably mounted in the first cup to hold and dispense a liquid detergent into the tub during the main wash cycle. The dispenser is provided with an area to receive either liquid or powder detergent for a prewash cycle. A third cup is provided for holding and dispensing fabric softener into the tub. The dispenser includes a single drain opening through which the prewash detergent, main wash detergent, and fabric softener pass at the appropriate time of the wash cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is an exploded perspective view of the detergent dispenser of the present invention.
[0010] [0010]FIG. 2 is a top plan view of the detergent dispenser of the present invention.
[0011] [0011]FIG. 3 is a perspective view showing the improved detergent dispenser of the present invention mounted in a front loading washing machine.
[0012] [0012]FIG. 4 is a perspective view of the siphon cap for the liquid detergent cup according to the present invention.
[0013] [0013]FIG. 5 is a sectional view taken along lines 5 - 5 of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The improved detergent dispenser 10 of the present invention is shown mounted in a washing machine 12 in FIG. 3. A lid 14 normally covers the dispenser 10 , and is movable between a closed and open position. The washing machine 12 is shown to be a front-loading machine, but it is understood that the dispenser can also be used on a top-loading machine (not shown). The components and operation of the washing machine 12 are conventional, and thus will not be described in detail.
[0015] The detergent dispenser 10 of the present invention includes a base 16 , with a front wall 18 , back wall 20 , opposite end walls 22 , 24 and a bottom wall 26 . An outlet opening or drain 28 is provided in end wall 24 . The bottom wall 26 slopes downwardly from the end wall 22 towards the drain 28 , such that liquids will flow by gravity toward the drain 28 . A grate 30 is removably mounted within guide tracks 32 adjacent the drain 28 . The grate 30 catches foreign objects or other large particles and precludes the passage of such material into the drain 28 . The base 16 includes bosses 33 for mounting the base 16 to the top panel 13 of the washing machine, as shown in FIG. 3.
[0016] An enlarged tray 34 is adapted to set into the base 16 . The tray 34 includes a back wall 36 , a front wall 38 , opposite end walls 40 , 42 , and a bottom wall or floor 44 . An upright dividing wall 46 divides the tray 34 into a powder detergent cup 48 and a conditioner or fabric softener cup 50 . The tray 34 rests upon shoulders 52 on the bottom wall 26 of the base 16 , such that the bottom wall 44 of the tray 34 is spaced above the bottom wall 26 of the base 16 .
[0017] While the powder cup 48 and softener cup 50 are shown to be integrally formed, it is understood that the cups 48 , 50 could be separate from one another and separately set or positioned within the base 16 .
[0018] The powder detergent cup 48 includes an outlet opening 54 in the end wall 42 adjacent the back wall 36 . The bottom wall 44 slopes downwardly from front to back and end to end toward the outlet opening 54 , such that powder detergent contained within the cup 48 can be flushed out the opening 54 .
[0019] A liquid detergent cup 56 mounts on the powder detergent cup 48 . The liquid cup 56 includes a back wall 58 , a front wall 60 , opposite end walls 62 , 64 , and a bottom wall or floor 66 . A lip 68 is provided on the back wall 58 , front wall 60 , and end wall 64 . The lip 68 engages the walls 36 , 38 , 42 of the tray 34 to support the liquid detergent cup 56 within the powder detergent cup 48 . The liquid cup 56 is shallower than the powder cup 48 , such that the bottom wall 66 of the liquid cup 56 is spaced above the bottom wall 44 of the powder cup 48 .
[0020] A hollow siphon tube 70 extends upwardly from the rear corner of the liquid cup 56 adjacent the back wall 58 and end wall 64 . The bottom wall 66 slopes downwardly from end to end and front to back towards the siphon tube 70 . A siphon cap 72 fits over the siphon tube 70 . The siphon cap 72 has an inside diameter which is greater than the outside diameter of the siphon tube 70 . The lower end of the siphon cap 72 includes a leg 74 which spaces the lower end of the cap 72 above the bottom wall 66 of the liquid cup 56 . An arm 76 extends upwardly from the cap 72 and then downwardly over the upper edge of the back wall 58 and into a slot 78 (FIGS. 1 and 2) formed on the back wall 36 of the powder cup 48 , so as to retain the siphon cap 72 in position over the siphon tube 70 . The siphon tube 70 and cap 72 function in a conventional manner so as to siphon liquid detergent upwardly in the space between the cap 72 and the tube 70 and then downwardly through the tube. The tube 70 discharges into the powder cup 48 , wherein the liquid detergent flows by gravity out the opening 54 , and then into the bottom 26 of the base 16 for drainage out the drain opening 28 .
[0021] It is further understood that powder detergent cup 48 can be molded integrally with dispenser base 16 while still maintaining the prewash compartment 98 . The liquid detergent cup 56 would then be selectively mounted within the integral powder detergent area when it is desired to use liquid detergent.
[0022] The fabric softener cup 50 of tray 34 includes a siphon tube 80 , similar to tube 70 , though shorter in height. A siphon cap 82 is positioned over the siphon tube 80 , and has a similar structure to cap 72 . The cap 82 includes a leg 84 to space the bottom of the cap 82 above the bottom wall 44 of the softener cup 50 , and an arm 86 extending over the back wall 36 and into a slot 88 (FIGS. 1 and 2) on the softener cup 50 so as to retain the cap 82 in position. The bottom wall 44 flows from front to back and end to end toward the siphon tube 80 of the fabric softener cup 50 . The siphon tube 80 and siphon cap 82 function conventionally to siphon a liquid fabric softener upwardly in the space between the cap 82 and the tube 80 , and downwardly through the center of the tube 80 for discharge into the base 16 , then flowing by gravity along the bottom wall 26 and out the drain 28 of the base 16 .
[0023] The front wall 18 of the base 16 includes a plurality of slots or recesses 90 adapted to receive a water diverter 92 . The water diverter 92 has a plurality of water inlet tubes 94 A, B, C, D, E, each of which are adapted to be connected to a water hose or line (not shown). Each tube 94 includes a radially extending pair of flanges 96 having a space therebetween slightly greater than the thickness of the front wall 18 of the base 16 . Thus, the water diverter 92 is adapted to slide onto the front wall 18 of the base 16 , with the tubes 94 received in the recesses 90 , and with the portion of the front wall 18 defining the edges of the recesses 90 extending between the respective flanges 96 of the water diverter 92 . The end of each water inlet tube 94 extending into the base 16 includes an opening through which water is ejected into the dispenser 10 to flush out the detergent or fabric softener.
[0024] More particularly, the water inlet tube 94 A directs water into the softener cup 50 . The water inlet tubes 94 B and C direct water into the powder detergent cup 48 , or the liquid detergent cup 56 . The water inlet tubes 94 D and E introduce water into the base 16 of the dispenser 10 for flushing the prewash powder or liquid detergent out the drain 28 . Dual inlet tubes 94 B, C and 94 D, E are provided for the detergent cup 48 and the prewash compartment 98 to assure sufficient volume of water to flush the detergent out of the cup or compartment. Also, the dual inlet tubes 94 B, C and 94 D, E are preferably hooked to separate hot and cold water lines. Tubes 94 B and D have a larger diameter than tubes 94 C and E to simplify assembly and avoid confusion as to which water line connects to which tube.
[0025] From the foregoing, it can be seen that the dispenser 10 of the present invention allows a user to selectively choose powder or liquid detergent for the prewash cycle, as well as for the main wash cycle of the washing machine 12 . Either liquid or powder detergent can be loaded into the open area or prewash compartment 98 adjacent the end wall 24 of the base 16 . If the liquid detergent cup 56 is mounted in the powder detergent cup 48 , then the user loads liquid detergent into the cup 56 . With the cup 56 removed, the user loads powder detergent into the powder cup 48 . Fabric softener is loadable into the softener cup 50 . At the appropriate time in a cycle of the washing machine 12 , water is introduced through the appropriate inlet tubes 94 A-E to flush out the detergent or fabric softener for drainage through the drain 28 and into the tub of the washing machine 12 .
[0026] From the foregoing, it can be seen that the present invention accomplishes at least all of the stated objectives.
[0027] The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. | A clothes washing machine is provided with an improved detergent dispenser which can use either liquid or powder detergent for both the prewash and wash cycles of the machine. The dispenser includes a base for receiving the prewash detergent. A tray having a powder detergent cup and a fabric softener cup is positioned within the base. A liquid detergent cup is removably nested within the powder detergent cup. The liquid detergent cup includes a siphon which drains into the powder detergent cup, which in turn drains into the base of the dispenser. The softener cup includes a siphon which drains into the base of the dispenser. The base includes an outlet drain through which the detergent and fabric softener drain for introduction into the tub of the washing machine. | 3 |
This is a continuation of application Ser. No. 08/388,371, filed on Feb. 14, 1995, now U.S. Pat. No. 5,595,246.
FIELD OF THE INVENTION
The field of the invention is installing and cementing well liners and providing a circulation system for formation treatment, conditioning, or gravel packing.
BACKGROUND OF THE INVENTION
Oil and gas operators often drill wells in formations that require treatment of the producing formation or gravel packing to ensure optimum production. In past installations, such treatment or gravel packing was not attempted until after a well liner was positioned and cemented in place. The liner and its cement seal served to isolate the producing formation, or pay zone, from other zones above the pay zone so that there was no cross-contamination or fluid and material loss during treatment or gravel packing.
Presently, the liner cementing and formation treatment or gravel packing are accomplished as separate steps, requiring multiple equipment runs into the well bore. First, the well bore is drilled to the point where the liner will be seated. The liner is lowered into position and cemented into place. After the cement has set, a second, smaller diameter drill string is used to drill beyond the cemented liner into the pay zone. The drill string is removed and a circulation system is lowered into the pay zone for treatment or gravel packing of the pay zone. This system is expensive and time-consuming because it requires multiple trips in and out of the hole and multiple drilling runs.
In some cases, a single hole can be drilled into the pay zone, and the liner and production strings lowered in a single trip. However, these situations only occur when there is no need to treat the formation or gravel pack the production string, and the production string can utilize large-opening slotted or perforated production casing. The liner can be cemented into position and the well brought on line without multiple trips in and out of the hole because there is little or no danger of formation contamination or debris plugging the production casing. When formation treatment or gravel packing is required, large-opening production casing cannot be used and this simpler, one-pass approach is unavailable due to the danger of formation damage or plugging the small openings in the production screens.
It is an object of this invention to allow a single drilling operation to complete the well bore into the pay zone when formation treatment or gravel packing is required.
It is a further object of this invention to allow simultaneous insertion of cementing apparatus and formation treatment or gravel packing apparatus into the well bore.
It is a further object of this invention to allow cementing operations without danger of contaminating or clogging either the formation or production equipment installed below the cementing apparatus.
SUMMARY OF THE INVENTION
An apparatus and method is provided that allows an operator to drill a well into a formation requiring treatment or gravel packing in a single pass, then to lower, position, and set the drill-in liner and production strings simultaneously. The invention allows cementing of the drill-in liner prior to any treatment or gravel packing, and provides an integral circulation system to allow formation treatment or gravel packing of the production string. Once treatment or gravel packing is completed, the invention provides mechanical fluid loss control as the circulation system is pulled out of the hole.
The invention comprises a liner assembly, a cementing assembly, and a circulation and production assembly. After the well bore has been drilled into the pay zone, the three assemblies are assembled at the surface and lowered into the well bore. The circulation and production assembly includes the shoe and production screens, with a wash pipe inserted into the interior of this string to provide circulation control during formation treatment or gravel packing.
The cementing assembly includes a cementing valve and means of isolating the annulus of the cementing assembly from the annulus of the circulation and production assembly. During cementing operations, the isolation means is used to prevent cement flow down into the pay zone. The bottom of the liner assembly connects to the top of the cementing assembly, so that cement pumped through the cementing assembly is forced upward to encase and seal the liner in position. "Cement" as used herein includes using cement or other means of achieving a seal between liner and the well bore.
Once the cementing operation is completed, the cementing wash pipe is withdrawn and a new wash pipe is lowered into position to connect to the circulation and production assembly wash pipe. Formation treatment or gravel packing is carried out to prepare the well to be brought on line. When the treatment or gravel packing is completed, the entire wash string is withdrawn. Mechanical means, such as a knock out isolation valve, provides mechanical fluid loss control to prevent fluid backwash in the production assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-E is a partially cut away drawing of the outer equipment string for one embodiment of the one trip cement and gravel pack system.
FIGS. 2A-F is a partially cut away drawing of the inner equipment string for one embodiment of the one trip cement and gravel pack system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1A-E, one embodiment of the outer equipment string 10 of the one pass cement and gravel pack system is shown. The outer equipment string 10 comprises an outer liner assembly 12, an outer cementing assembly 14, and an outer circulation assembly 16.
The outer liner assembly 12 comprises a liner packer 18, such as Baker Product No. 296-14, a liner hanger 20, such as Baker Product No. 292-50, and a liner 22. The liner packer 18, the liner hanger 20, and the liner 22 are normally used in lining and cementing operations, and those skilled in the art will recognize that the particular specifications for these will vary depending on the conditions of the installation.
The outer cementing assembly 14 is in fluid communication with the outer liner assembly 12 and comprises a first seal bore extension 28, such as Baker Product No. 449-40, a cementing valve 30, such as Baker Product No. 810-80, a second seal bore extension 32, such as Baker Product No. 449-40, an external casing packer 34, such as Baker Product No. 301-13, and a third seal bore extension 36, such as Baker Product No. 449-40. Slip-on fluted centralizers 38 may be used to position the outer cementing assembly 14 and to protect the external casing packer 34 from premature setting during insertion into the well bore 40.
The outer circulating and production assembly 16 is in fluid communication with the outer cementing assembly 14 and comprises casing joints 42, a seal bore 44, a perforated extension 46, a lower seal bore 48, a knock-out isolation valve 50, pre-pack screens 52, flapper valves 54, a first O-ring seal subassembly 56, a slotted liner 58, a second O-ring seal subassembly 60, and a set shoe 62, such as a double "V" set shoe.
Referring to FIGS. 2A-F, one embodiment of the inner equipment string 110 of the one pass cement and gravel pack system is shown. The inner equipment string comprises an inner liner assembly 112, an inner cementing assembly 114, and an inner circulation assembly 116.
The inner liner assembly 112 comprises a lift nipple 118, such as Baker Product No. 265-20, a packer setting dog subassembly 120, such as Baker Product No. 270-09, a liner setting tool 122 such as Baker Product No. 265-88, a first wash pipe 124, and a ported landing subassembly 126, such as Baker Product No. 276-04. Seals 128 and 130 isolate a port 132 on the ported landing subassembly 126.
The inner cementing assembly 114 is in fluid communication with the inner liner assembly 112 and comprises a second wash pipe 136, a first seal assembly 138, a slurry placement indicator 140, such as a Baker Model "E," Baker Product No. 445-56, a circulating valve 142, such as a Baker Model "S2P," Baker Product No. 445-66, a closing tool 144, such as a Baker Model "HB," a second seal assembly 146, an indicating collet assembly 148, such as Baker Model "A," Baker Product No. 445-34, and an opening tool 150, such as Baker Model "HB."
The inner circulation assembly 116 is installed coaxially with the outer circulation and production assembly 16. The inner circulation assembly 116 comprises a crossover tool 152, such as Baker Product No. 445-72, a low bottom hole pressure flapper valve 154, an anchor seal assembly 156, and a third wash pipe 160.
Referring to FIGS. 1A-E and 2A-F, the well bore 40 is initially drilled to the depth at which the liner 22 is to be begun. The outer casing 64 is lowered into the well bore 40 and cemented into position. The well bore is then completed, drilling to the final position desired in the pay zone. The one trip cementing and gravel pack system is initially assembled at the surface with the inner equipment string 110 coaxial with and inside the outer equipment string 10 and lowered into position so that the set shoe 62 is in the pay zone at the bottom of the well bore 40. A ball 164 is dropped into the well bore 40 so that it will be caught by the ported landing subassembly 126. Once caught, the ball 164 blocks the fluid flow, allowing internal pressure to be built up from the surface. Seals 128 and 130 prevent the fluid from flowing in the annulus between the inner equipment string 110 and the outer equipment string 10. The increased fluid pressure is forced against the liner hanger 20 to set it. After the liner hanger 20 is set, the port 132 in the ported landing subassembly 126 is closed and the ball 164 is released. If the ported landing subassembly 126 is a type such as Baker Product No. 276-04, these actions are accomplished by further increasing the pressure in the inner equipment string 110, forcing the port 132 to close and breaking a shear pin to release the ball 164. The ball 164 is pumped to the circulating valve 142.
The circulating valve 142 must trap the ball and seal off fluid flow from the region below the circulating valve 142. If the circulating valve 142 is a valve such as a Baker "S2P," the ball 164 is caught on a teflon seat. The teflon seat flexes to form a tight seal between the teflon seat and the ball 164, preventing fluid flow into the region below the teflon seat. Several smaller balls are embedded in the teflon seat and act to hold the ball 164 in position. Once the ball 164 is in position against the teflon seat, fluid flow from above the ball is diverted through a circulating valve port 143.
The first seal assembly 138 is initially positioned inside of the third seal bore extension 36. When the ball 164 lands on the teflon seat, the fluid overpressure is prevented from releasing upwards in the inner equipment string 110 by the first seal assembly 138, and is instead forced downward into the inner circulation assembly 116. This positioning protects the external casing packer 34 from damage due to the fluid overpressure.
After the ball 164 is captured, the inner equipment string 110 is raised to position the first seal assembly 138 inside of the second seal bore extension 32, and the second seal assembly 146 inside the third seal bore extension 36. As the inner equipment string 110 is raised, the indicating collet assembly 148 locates onto the third seal bore extension 36, providing a weight indication on the inner equipment string 110 to indicate position. In this position, the circulating valve port 143 is aligned with the external casing packer 34. The external casing packer 34 is pressure set in accordance with the procedure for the specific model used.
When the external casing packer 34 is set, the internal equipment string 110 is again raised, positioning the first seal assembly 138 in the first seal bore extension 28, and the second seal assembly 146 in the second seal bore extension 32. As the inner equipment string 110 is raised, the indicating collet assembly 148 locates onto the second seal bore extension 32, providing a weight indication on the inner equipment string 110 to indicate position. In this position, the circulating valve port 143 is aligned with the cementing valve 30. Cement is pumped through the cementing valve 30 to fill the annulus between the liner 22 and the well bore 40. If the inner equipment string 110 is raised too far, the cementing valve 30 may be accidentally closed. If the cementing valve 30 is accidentally closed, the inner equipment string 110 may be raised further to use the opening tool 150 to reopen the cementing valve 30.
The slurry placement indicator 140, such as Baker Model "E," comprises a seat and a bypass. When the last of the cement is pumped into the well bore 40 at the surface, a wiper plug 166, such as Baker Product No. 445-56 is pumped on top of the cement and followed with completion fluid to force the cement through the circulating valve port 143. When it reaches the slurry placement indicator 140, the wiper plug 166 seats in the seat of the slurry placement indicator 140, causing a temporary rise in pressure at the surface to notify the surface crew of the location of the wiper plug 166. The increase in pressure forces the bypass in the slurry placement indicator 140 to open, relieving the pressure increase and allowing completion of the cementing operation.
When the cementing operation is completed, the inner equipment string 110 is again raised to use the closing tool 144 to close the cementing valve 30. After pressure testing to insure proper closure of the cementing valve 30, the inner equipment string 110 is lowered until the packer setting dog subassembly 120 engages the liner packer 18. Weight is applied to the inner equipment string 110 to set the liner packer 18.
After the completion of the cementing operation and setting the liner packer 18, the inner liner assembly 112 and the inner cementing assembly 114 of the inner equipment string 110 are raised sufficiently to allow reverse circulation to clean out any excess cement. The inner liner assembly 112 and the inner cementing assembly 114 are then pulled out of the well bore 40. The removed inner liner assembly 112 and the inner cementing assembly 114 may be replaced with a wash pipe which can be connected to the inner circulation assembly 116 for formation treatment or gravel packing operations.
To treat the formation or gravel pack in preparation for production, a wash pipe is run back into the well and engaged onto the inner circulation assembly 116 using conventional fishing equipment. A second ball 168 is dropped into the well bore 40 and is caught by the crossover tool 152. Once caught, the second ball 168 blocks fluid flow in the interior of the inner circulation assembly 116, causing an increase in liquid pressure. The increased pressure exposes the gravel pack port 170.
If the crossover tool 152 is a valve such as Baker "S2P," the second ball 168 is caught on a teflon seat. The teflon seat flexes to form a tight seal between the teflon seat and the second ball 168, preventing fluid flow into the region below the teflon seat. Several smaller balls are embedded in the teflon seat and act to hold the second ball 168 in position. Once the second ball 168 is in position against the teflon seat, fluid flow from above the ball is diverted through the gravel pack port 170.
The crossover tool 152 is initially positioned between the seal bore 44 and the lower seal bore 48, so that fluid flowing out of the crossover tool 152 flows out of the perforated extension 46 and downward into the pay zone, across the knockout isolation valve 50, pre-pack screens 52, flapper valves 54, first O-ring seal subassembly 56 and into the slotted liner 58. The fluid returns up the third wash pipe 160, through the by-pass in the crossover tool 152, and returns to the surface. This circulating position allows fluids to be pumped across the pay zone to treat or gravel pack as required.
Once sufficient circulation is achieved, the inner circulation assembly 116 is raised, pulling the anchor seal assembly 156 into the seal bore 44 and the lower seal bore 48, thereby isolating the perforated extension 46. In this position, the gravel pack port 170 is above the seal bore 44, allowing excess fluids to be reversed or circulated out of the well bore 40.
After the completion of treatment or gravel packing, inner circulation assembly 116 is separated from the anchor seal assembly 156. The inner circulation assembly 116, without the anchor seal assembly 156, is withdrawn from the well bore 40, leaving the anchor seal assembly 156 in position so that it permanently isolates the perforated extension 46.
As the inner circulation assembly 116 is removed, the knock-out isolation valve drops 50 into position to prevent the fluid in the inner circulation assembly 116 from flooding into the outer circulation and production assembly 16. | An apparatus and method is provided that allows an operator to drill a well into a formation requiring treatment or gravel packing in a single pass, then to lower and position the liner and production strings simultaneously. The invention allows cementing of the liner prior to any treatment or gravel packing, and provides an integral circulation system to allow formation treatment or gravel packing of the production string. Once treatment or gravel packing is completed, the invention provides mechanical fluid loss control as the circulation system is pulled out of the hole. | 4 |
BACKGROUND AND SUMMARY OF THE INVENTION
This application claims the priority of German patent document 100 218 14.8, filed May 4, 2001,
The invention relates to a steering system for a motor vehicle.
A steering system of this kind is known from DE 196 07 028 C1 and is designed in such a way that it allows steer-by-wire operation, with a vehicle steering wheel being effectively connected to steerable vehicle wheels by a control system without a positive mechanical connection between the steering wheel and steerable vehicle wheels. A steering system of this kind is provided with a hand-torque actuator, which is connected to the steering wheel in steer-by-wire mode to simulate a steering resistance and/or a restoring torque. The hand-torque actuator can be used to provide haptic feedback at the steering wheel even in steer-by-wire mode—as in a conventional vehicle steering system with a continuous mechanical driving link between the steering wheel and steerable vehicle wheels—this feedback representing a restoring force and a steering resistance. A hand-torque actuator of this kind can likewise be used to simulate steering and disturbing forces actually acting at the steerable vehicle wheels.
Simulation of a steering resistance is of considerable importance for steering feel in steer-by-wire mode.
If the hand-torque actuator fails on a curve during a journey in steer-by-wire mode, the steering resistance simulated by the hand-torque actuator suddenly disappears. Since this steering resistance artificially produced by the hand-torque actuator is in equilibrium with the hand force introduced into the steering wheel by the driver, at least during a constant cornering movement, failure of the hand-torque actuator leads to a sudden disappearance of the steering resistance, with the result that only the hand force of the driver is acting. This can lead to an uncontrolled steering movement.
In order to avoid uncontrolled steering movement in the event of the hand-torque actuator failing, the actuator can have a redundant construction, i.e. the significant components of the hand-torque actuator are duplicated. Apart from the associated complexity and costs, there is also no room to install a redundant hand-torque actuator in certain types of vehicles.
The present invention is concerned with the problem of specifying an embodiment of a steering system of the above discuss type stated at the outset which can ensure adequate vehicle safety even if the hand-torque actuator fails in steer-by-wire mode. Additionally, the steering system should be relatively inexpensive and should require only a relatively small amount of installation space.
The invention is based on the general idea of damping adjusting movements of the steering handle initiated by the driver, at least if the hand-torque actuator fails.
The provision of damping means eliminates the need to fit a redundant hand-torque actuator, thereby making it possible to save on costs, on the effort involved in assembly and on installation space. The invention exploits the realization that it is sufficient to guarantee vehicle safety in the event of the hand-torque actuator failing if the adjusting movements of the steering handle by the driver are dampened in steer-by-wire operation.
It is clear that “failure” of the hand-torque actuator is understood to mean only a malfunction of the kind where the steering handle is not locked by the hand-torque actuator.
In the present invention, the term “damping” is based on the following convention: while a spring action produces displacement-dependent counterforces and countertorques, damping produces speed-dependent counterforces and countertorques. In the present case, this means that relatively rapid adjusting movements of the steering handle by the driver are counteracted by relatively large damping torques while, correspondingly, relatively slow adjusting movements by the driver are counteracted by relatively small damping torques. Since the speed of the adjusting movements by the driver is correlated with the magnitude of the hand torque introduced into the steering handle by the driver, the damping torque counteracting the adjusting movement by the driver depends on the magnitude of the hand torque introduced by the driver.
According to a preferred embodiment of the present invention, the hand-torque actuator can include an electric motor, which is connected to the steering handle in such a way that adjusting movements of the steering handle are associated with relative rotation between a rotor and a stator of the electric motor. The damping means can then have a circuit arrangement that switches windings of the electric motor in such a way that voltages induced by relative rotation between the rotor and the stator produce damping torques that counteract the relative rotation. Here, the effect of the circuit arrangement is that the electric motor operates as a generator if the hand-torque actuator fails. By virtue of this measure, the damping function, in effect, integrated into the hand-torque actuator or electric motor. Such a circuit arrangement requires only a small amount of installation space and is generally inexpensive. Moreover, the circuit arrangement can be mounted directly on the hand-torque actuator or electric motor and can therefore be installed in the electric motor at the manufacturers. It is thus possible to provide a hand-torque actuator with an integral damping function which can be activated for emergency operation of the hand-torque actuator in the event of relevant malfunctions. The integral construction furthermore simplifies assembly without giving rise to high additional costs for emergency operation, requirements of the hand-torque actuator.
In a development of the invention, it is also possible for the circuit arrangement to be designed in such a way that the damping depends on additional parameters, e.g. vehicle speed. At higher vehicle speeds, for example, the damping should be greater than at low vehicle speeds. In particular, the damping can also have a value of zero while the vehicle is being manoeuvred.
According to another embodiment, the damping means can have at least one mechanically operating damper member, which is coupled to the steering handle. A damper member of this kind can, for example, be coupled permanently to the steering handle with its damping action being compensated for in normal operation of the hand-torque actuator by appropriate control of the hand-torque actuator. Another possibility is a damper member that can be connected when required and is therefore coupled to the steering handle only if the hand-torque actuator fails. A damper member of this kind can produce the required damping by mechanical friction, for example. As an alternative, a damper member of this kind can also be designed in such a way that the adjusting movements of the steering handle by the driver drive or displace a fluid in the damper member, the damper member producing the desired damping by restricting the flow of this fluid.
In a preferred development of the steering system according to the invention, a spring device preload the steering handle into a central position. This spring device can be used to apply a restoring torque to the steering handle.
It is self-evident that the features mentioned above and those that will be mentioned below can be employed not only in the respectively indicated combination but also in different combinations or in isolation without departing from the scope of the present invention.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred exemplary embodiment of the invention is illustrated in the drawing and is explained in greater detail in the following description.
The single FIG. 1 shows a schematic basic representation of a steering system according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Steering systems for motor vehicles that allow steer-by-wire operation are well known from the prior art and therefore do not need to be described in greater detail. The following description of the figure therefore relates primarily to those components of a steering system according to the invention in a specific embodiment which are relevant to the invention.
According to FIG. 1, a steering system 1 has a steering handle 2 , which is here designed as a steering wheel. The steering handle 2 is used by the driver of the vehicle to input his steering requirements in the form of a rotary actuation of the steering handle 2 . In terms of drive, the steering handle 2 is connected by a steering shaft 3 to a hand-torque actuator 4 , which is here indicated purely symbolically by a frame illustrated by broken lines.
In the preferred embodiment, the hand-torque actuator 4 has an electric motor 5 , which has a rotor and a stator. The rotor is connected to the steering shaft 3 , for example, while the stator is firmly connected to the vehicle's body. Another possible embodiment has the stator coupled to the steering shaft 3 while the rotor is fixed to the vehicle. In addition, the hand-torque actuator 4 has a hand-torque control unit that actuates the electric motor 5 as a function of parameters. For the sake of clarity, however, this control unit is not shown here.
The electric motor 5 can be designed as a brushless or brush-type motor, for example, which can be either permanently excited or externally excited. The embodiment illustrated here is, for example, a three-phase brushless d.c. motor, which accordingly has three motor windings. The electric motor 5 therefore has three electrical connections 6 a , 6 b , 6 c , which are each connected within the electric motor 5 to one of the windings of the electric motor 5 . The connections 6 a , 6 b , 6 c are connected by corresponding connecting lines 7 a , 7 b , 7 c to inputs 8 a , 8 b , 8 c of a three-pole changeover switch 9 . This changeover switch 9 has first outputs 10 a , 10 b , 10 c , which are connected by connection lines 11 a , 11 b , 11 c to a power supply 12 , e.g. power electronics, of the electric motor 5 . Second outputs 13 a , 13 b , 13 c of the changeover element 9 are each connected via electrical resistors 14 a , 14 b , 14 c to a star point 15 and thereby form a star circuit.
The changeover element 9 contains switching means 16 that can be actuated synchronously and, in a first position illustrated in FIG. 1, connect the inputs 8 a , 8 b , 8 c to the first outputs 10 a , 10 b , 10 c . In a second position, the switching means 16 connect the inputs 8 a , 8 b , 8 c to the second outputs 13 a , 13 b , 13 c.
During steer-by-wire operation of the steering system 1 , the switching means 16 of the changeover switch 9 occupy their first position when the hand-torque actuator 4 is operating correctly. If the hand-torque actuator 4 fails, the switching means 16 of the changeover switch 9 are switched to their second position. The steering system 1 according to the invention operates as follows:
In the steer-by-wire mode of the steering system 1 , correct operation of the hand-torque actuator 4 is continuously monitored. As long as a corresponding control system (not shown here) for the steering system or the hand-torque actuator 4 detects that the hand-torque actuator 4 is operating correctly, the switching means 16 of the changeover switch 9 are switched to their first position. The connections 6 a , 6 b , 6 c of the electric motor 5 are accordingly connected to the power supply 12 by means of which the actuation of the electric motor 5 is performed in order to simulate steering resistance and/or restoring torques and/or disturbing forces at the steering handle 2 .
As soon as a sufficiently serious malfunction is detected in the hand-torque actuator 4 as part of the process of monitoring its operation, this is interpreted as failure of the hand-torque actuator 4 , causing the switching means 16 of the changeover switch 9 to switch to their second position. A corresponding control unit that actuates the changeover switch 9 in a corresponding manner is not shown here. The changeover switch 9 can have a solenoid, for example, which, when energized, switches the switching means 16 to a first position. In this arrangement, spring means can be provided to switch the switching means 16 into a second position when the solenoid is deenergized.
If the hand-torque actuator 4 fails, the connections 6 a , 6 b , 6 c of the electric motor 5 are accordingly connected to one another in a star pattern via the electrical resistors 14 a , 14 b , 14 c . Since the electric motor 5 is then separated from the power supply 12 , it can operate as a generator. When the driver then introduces a hand torque into the steering handle 2 , this results in an adjusting movement of the steering handle 2 and thus a rotation of the steering shaft 3 . By virtue of the coupling of the electric motor 5 to the steering shaft 3 , an adjusting movement of the steering handle by the driver is then inevitably associated with a relative adjustment between the rotor and the stator of the electric motor 5 . Such a relative adjustment between the rotor and the stator induces an electrical voltage in the windings of the electric motor 5 . Since the connections 6 a , 6 b , 6 c are connected to one another via the resistors 14 a , 14 b , 14 c , electric currents can form, with the result that damping torques are produced in the electric motor 5 , counteracting a relative adjustment between the rotor and the stator. These damping torques accordingly also act on the steering handle 2 via the steering shaft 3 . The extent of these damping torques can be set to a desired value by appropriate choice of the resistors 14 a , 14 b , 14 c.
It is also possible to use variable or adjustable resistors instead of constant resistors 14 a , 14 b , 14 c . It is furthermore possible to combine the resistors 14 a , 14 b , 14 c with other electrical components to form an electrical network. Such a network can have active and/or passive, linear and/or non-linear components, thereby allowing the damping of the steering handle 2 to be given a corresponding linear or non-linear, e.g. progressive, configuration. This furthermore makes it possible to take into account additional parameters for the configuration of a desired damping characteristic. The damping effect can, for example, be varied as a function of the vehicle speed and/or as a function of the steering angle.
The damping means described above, namely changeover switch 9 and star circuit 14 , 15 , can be integrated in a particularly simple manner into the hand-torque actuator 4 , giving a hand-torque actuator 4 of compact construction with an integral emergency operating function. In addition or as an alternative, the damping means can also have a mechanically operating damper member 17 coupled to the steering handle 2 . In FIG. 1, the damper member 17 is arranged in such a way that it acts on the steering shaft 3 , the damper member 17 being illustrated only symbolically and in broken lines. The damper member 17 can, for example, give rise to mechanical friction on the steering shaft 3 , thereby enabling a certain damping effect to be achieved. Such a damper member 17 can also be designed in such a way that a steering actuation of the steering handle 2 drives a fluid in the damper member 17 and, for example, displaces it from a first chamber to a second chamber. A restrictor is arranged in the flow path of the fluid, thereby producing the desired damping effect on the adjusting motion of the steering handle 2 .
The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof. | A steering system for a motor vehicle, which allows steer-by-wire operation, a hand-torque actuator being connected in the steer-by-wire mode to a steering handle, e.g. a steering wheel, to simulate a steering resistance or a restoring torque. In order to be able to ensure adequate operating safety for the vehicle if the hand-torque actuator fails, even if the steering system is operated on a steer-by-wire basis, damping means are provided, which damp adjusting movements of the steering handle by the driver in the steer-by-wire mode if the hand-torque actuator fails. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority, under 35 U.S.C. § 119, of German patent application DE 10 2006 034 611.4, filed Jul. 21, 2006; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates to a configuration for exchanging inkjet printing modules or inkjet printing cartridges, in particular in a franking and/or addressing machine.
[0003] It has proven expedient also to utilize the advantages of inkjet printing in the field of machine franking and/or addressing. Here, printing takes place without contact by means of an inkjet print head. See, for example, commonly assigned German patent DE 44 24 771 C1 and its counterpart U.S. Pat. No. 6,367,911 B1, as well as European patent EP 0 696 509 B1 and its counterpart U.S. Pat. No. 6,390,577 B1.
[0004] When commercially available inkjet print heads for office printers are used, the latter are as a rule a constituent part of an inkjet printing module. That is to say, the inkjet print head and cartridge form one unit.
[0005] In the office printer, the inkjet printing module is arranged in a shaft-shaped receptacle apparatus in a lockable and positively guided manner. When the ink has been used up, the inkjet printing module has to be exchanged. This takes place by manual pulling. To this end, first of all a locking lever is released, the inkjet printing module is gripped with two fingers at one gripping corner and pulled obliquely past the locking lever, see, for example, the user manual for HP DeskJet 1220C of 10/1999.
[0006] In contrast to the space conditions in office printers, the accessibility to the inkjet printing modules in franking machines is substantially more restricted, with the result that exchanging is problematic.
[0007] A franking machine having a printing system with two inkjet printing modules and an associated cleaning and sealing apparatus is described in the commonly assigned, copending patent application Ser. No. 11/589,268, filed Oct. 26, 2006, and its German counterpart DE 10 2005 052 150.
[0008] The printing system comprises a frame, two inkjet printing modules and an assigned double-compartment shaft-shaped receptacle for the two.
[0009] Each inkjet printing module comprises an inkjet print head in addition to an ink supply, a chip and a contact field. The mating contacts are attached in the receptacle in an adapted manner.
[0010] The inkjet printing modules are arranged in parallel but offset with respect to one another, in order to achieve the required printing gap length.
[0011] The receptacle is mounted such that it can be pivoted about a pin which is fastened in the frame. In order to prime and to seal the inkjet print head, the receptacle is pivoted out of the printing position into a position to such an extent that the nozzle surface of the latter is directed downward. This is at the same time the position, in which exchanging of the inkjet printing module is possible.
[0012] The printing position and the sealing position are accordingly determined by clearly defined positions of the inkjet print head and the cleaning and sealing apparatus.
[0013] In addition, various cleaning regions are provided. In one cleaning region in front of the sealing position, the inkjet print head is pivoted out of the printing position to such an extent that the nozzle surface is arranged in the engagement region of the wiping lips of the cleaning and sealing apparatus. During the wiping process, the wiping lips wipe both over the nozzle surface and along two side edges, as a result of which residual ink deposits are produced on the latter. When the inkjet printing module is pulled, these deposits can contaminate the mating contacts and accordingly endanger the functional reliability of the printing device.
[0014] This effect is reinforced further if the printing device is provided with an additional ink supply system, as substantially more wiping operations and therefore greater deposits occur in this case.
[0015] A further problem consists in that, during pulling out or plugging in of the inkjet printing module, the abovementioned edge slides along the mating contacts and the latter are damaged as a result. The greater the clearance during exchanging, the greater also the risk of faulty guiding and accordingly of wear.
[0016] The purpose of the invention is an improvement in the functional reliability and an extension of the service life of the printing device.
SUMMARY OF THE INVENTION
[0017] It is accordingly an object of the invention to provide a configuration for exchanging ink jet printing modules which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which allows exchanging an inkjet printing module simply and reliably in a franking and/or addressing machine. In particular, easy pulling out is to be made possible and contamination and mechanical impairment of the meeting contacts for the inkjet printing module is to be prevented.
[0018] With the foregoing and other objects in view there is provided, in accordance with the invention, a configuration for exchanging inkjet printing modules in a franking and/or addressing machine, comprising:
[0019] a shaft-shaped receptacle with a locking lug for the inkjet printing module, the inkjet printing module including an inkjet print head with a nozzle surface, a rear edge of the nozzle surface, and a chip and a contact field disposed on a narrow side adjacent the nozzle surface;
[0020] the receptacle being disposed behind a guide plate formed with a printing window, wherein printing media are guided along the guide plate for printing with the inject printing module (the printing media are guided such that they are in contact and stand on edge);
[0021] devices, in the receptacle, for pulling and decontacting the inkjet printing module, the devices being mechanically coupled to one another such that, when pulling is initiated, decontacting is effected at the same time; and
[0022] a wiping apparatus disposed in a pivoting region of the rear edge of the nozzle surface of the inkjet print head.
[0023] In accordance with an added feature of the invention, the receptacle has side walls and substantially vertical recesses formed in the side walls, and further:
[0024] a draw hook for pulling the inkjet printing module disposed in an elastically adjustable manner in one of the vertical recesses of the side walls, the draws hook protruding out of the receptacle with a gripping opening and bearing by way of a rear end-side contour against an end of a shorter upper lever arm of a rotatably mounted two-armed guide lever, protruding with an end of a longer lower lever arm thereof into an adapted contour of a carrier rear wall of a carrier of the receptacle;
[0025] the draw hook is formed with a recess at the other end of the rear end-side contour adapted to a contour of an end of the shorter lever arm of the guide lever, into which recess the guide lever is latched in a case of a pressed draw hook; and
[0026] a spring pin mounted in a carrier rear wall orthogonally with respect thereto, the spring pin, when the ink jet printing module is pushed in completely, bearing against a locking lug with a force-transmitting connection.
[0027] In accordance with an additional feature of the invention, there is provided a chip holder on the inkjet printing module formed with vertically extending guide webs, wherein the guide webs have beveled ends serving, during an exchange, to space the inkjet printing module away from a carrier rear wall.
[0028] In accordance with another feature of the invention, a vertically extending spring piece is let into a carrier rear wall within a counterpart to the contact field of the inkjet printing module. The spring piece, during unlocking, additionally serves to space the contact field from the counterpart.
[0029] In accordance with a further feature of the invention, the wiping apparatus comprises a pin let into a center wall of the carrier and a tubular covering pushed onto the pin.
[0030] In accordance with again an added feature of the invention, the draw hook is provided, at an end facing away from the gripping part, with a pin guided in an oblong slot of the side wall of the receptacle, and wherein a tension spring fastened at the other end to a journal is attached at a free end of the pin.
[0031] In accordance with a concomitant feature of the invention, a plurality of leaf-shaped guide springs for laterally guiding the inkjet printing modules are disposed in a lower region of the side walls and a center wall of the carrier.
[0032] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0033] Although the invention is illustrated and described herein as embodied in configuration for exchanging inkjet printing modules, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0034] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 shows a perspective view of the printing system in a franking machine with an open service flap, as viewed from the front left;
[0036] FIG. 2 shows a perspective view of the receptacle having printing modules which are pushed in, as viewed from the front left;
[0037] FIG. 3 shows the receptacle according to FIG. 2 , partially in an exploded illustration, with a detail of the carrier rear wall;
[0038] FIG. 4 shows a perspective view of a printing module, as viewed from the rear left;
[0039] FIG. 5 shows a side view of the receptacle having printing modules which are pushed in completely, with a side wall removed, as viewed from the left with a detail of the locking mechanism;
[0040] FIG. 6 shows a side view of the receptacle having printing modules which are pushed in completely, one of them being unlocked and the other being locked, with a side wall removed, as viewed from the left with a further detail of the locking mechanism;
[0041] FIG. 7 shows the receptacle according to FIG. 6 , having a tilted printing module,
[0042] FIG. 8 shows the receptacle according to FIG. 7 , having a completely pulled draw hook and a printing module which is ready for gripping; and
[0043] FIG. 9 shows the receptacle according to FIG. 8 , having a draw hook which has been guided back into the initial position and a printing module which is ready for gripping.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] The illustration is shown partially diagrammatically for simplification and easier understanding.
[0045] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, a service flap 10 which extends as far as the region of the guide plate 101 for the printing media is provided in the covering wall of a franking machine housing 1 . The service flap 10 is shown in the open state, with the result that the receptacle 12 having the two printing modules 11 can be seen. The inner cover 102 serves to prevent unauthorized access of the franking machine. The space below this can be used for additional ink tanks.
[0046] FIG. 2 shows a receptacle 12 for/having two printing modules 11 . The printing modules 11 are pushed in completely and fixed in each case by means of an associated bolt 121 . The receptacle 12 comprises two side walls 122 , 123 and a common double-angled carrier 126 , the fixed constituent part of which is a center wall which is not shown in further detail. In this way, two chambers are formed for receiving the printing modules 11 . The side walls 122 , 123 are of substantially mirror-symmetrical design (the left-hand side wall 122 is somewhat longer), with the result that the further description can be restricted to the left-hand side wall 122 .
[0047] A draw hook 120 which serves to make removal of the printing module 11 easier is guided on the inside in a recess of the side wall 122 . The draw hook 120 protrudes at one end upward out of the receptacle 12 and is provided at this end with a suitable gripping opening (hole). At the opposite end, a pin 1201 is fastened which protrudes through a slot 1225 in the side wall 122 . A tension spring 127 is attached to the free end of the pin 1201 , the other end of said tension spring 127 being fastened to a journal 1222 which is let into the side wall 122 . In this way, the tension spring 127 acts as a restoring spring for the pulled draw hook 120 .
[0048] A pin 1261 with a covering 12611 which is pushed onto it is let into the center wall below the lower edge of the side wall 122 . The covering 12611 serves as a wiping element for the lower rear edge of the printing module 11 , see also FIGS. 3 and 5 which follow.
[0049] A guide lever 125 for the right-hand draw hook 120 is fastened pivotably in the right-hand side wall 123 ; for more details likewise see FIGS. 3 and 5 which follow.
[0050] In FIG. 3 , the left-hand side wall 122 and the right-hand side wall 123 are removed, and the bolt 121 for the left-hand printing module 11 is folded back and the latter is removed. The bolt 121 for the right-hand printing module 11 is closed.
[0051] It can be seen clearly how the draw hook 120 is guided in the right-hand side wall 123 and the guide lever 125 engages into a correspondingly adapted recess (not denoted in further detail) of the draw hook 120 . The guide lever 125 is mounted pivotably on a pin 1231 which is let on one side into the side wall 123 and on the other side into a lug of the rear wall of the carrier 126 . The same is true analogously for the left-hand pin 1221 . The pin 1231 serves at the same time as an upper connection between the right-hand side wall 123 and the carrier 126 . The lower connection and spacing takes place by means of a journal 1232 which, moreover, also serves for attaching the tension spring 127 for the draw hook 120 . Two guide springs 1233 , 1234 which are designed as leaf springs and serve to fix the printing module 11 elastically are fastened on both sides of the guide for the draw hook 120 in the lower region of the right-hand side wall 123 . In a corresponding manner, two further guide springs 1263 , 1264 (not visible) are attached to the center wall of the carrier 126 . In this regard, see also the guide springs 1223 , 1224 , 1264 , 1263 at the front and the rear for the printing module 11 in the left-hand chamber of the receptacle 12 .
[0052] The covering 12611 is pushed onto the pin 1261 as an exchangeable roll made from an absorbent material.
[0053] A counterpart 12651 to the contact field 112 of the printing module 11 is let resiliently into the rear wall of the carrier 126 in the lower region, and a counterpart 12652 for the contact means of the module chip 114 of the printing module 11 is also let resiliently into the rear wall of the carrier 126 , see also FIG. 4 .
[0054] As can be seen readily in detail A, a vertically extending spring piece 12654 is used in the free region of the counterpart contact field 12651 , in the form of a flat web which is beveled at the ends. This counterpart 12654 serves as a diverter for protecting the contacts. The function of a spring pin 12653 is similar, which is used above the counterpart 12652 and is released when the bolt 121 is open, in order to interrupt the electrical contact reliably.
[0055] According to FIG. 4 , a commercially available printing module 11 comprises, in the lower part, an inkjet print head 110 having a nozzle surface 111 which is situated on the base and has a rounded rear edge 1111 . In the region of the inkjet print head 110 , the contact field 112 is situated on the rear side of the printing module 11 in the form of two angles which are arranged at a spacing from one another in a mirror-symmetrical manner. The chip holder 113 having the module chip 114 is arranged above the contact field 112 . The chip holder 113 has guide webs 1131 which extend vertically on the sides, and is beveled at the top and the bottom.
[0056] A locking lug 115 which is adapted to the contour of the bolt 121 is formed integrally on the rounded upper rear edge of the printing module 11 . A gripping part (not designated in greater detail) is provided in the front upper part.
[0057] FIG. 5 shows the positional relationships in printing modules 11 which have been pushed in completely and locked, with the left-hand side wall 122 removed. The bolts 121 rest on the upper side of the printing modules 11 with a force-transmitting connection. The rear side of the printing modules 11 bears against the carrier rear wall 1265 in parallel. The nozzle surfaces 111 of the inkjet print heads 110 protrude parallel to one another and to the underside of the carrier 126 out of said carrier 126 . The roll 12611 bears against the rear side of the associated inkjet print head 110 . The draw hook 120 is pushed in completely and the tension spring 127 is shortened to a minimum. The two-armed guide lever 124 is formed with its shorter upper lever arm end integrally in the associated recess of the draw hook 120 , and bears against a round groove of the carrier rear wall 1265 with its longer lower lever arm end. A lug which lies in the engagement region of the guide web 1131 is formed integrally and transversely on the lever arm end.
[0058] Detail B shows the positional relationships in the region of the module chip 114 and above. The printing module 11 bears against the end face of the spring pin 12653 by way of its locking lug 115 with a force-transmitting connection, with the result that said spring pin 12653 dips completely into the carrier rear wall 1265 . The module chip 114 and its counterpart 12652 are in contact with one another.
[0059] In FIG. 6 , the bolt 121 is folded back completely and the left-hand inkjet printing module 11 is therefore unlocked but still pressed completely into the receptacle 12 ; the same is true of the draw hook 120 .
[0060] As can be seen in detail C, the spring pin 12653 is therefore released and presses the inkjet printing module forward to such an extent that the contact between the module chip 114 and the counterpart 12652 , and between the contact field 112 and the counterpart 12651 , is canceled. This effect is assisted further by the spring piece 12654 .
[0061] In FIG. 7 , the draw hook 120 is pulled up to such an extent that the guide lever 124 with its shorter upper lever arm end leaves the associated recess of the draw hook 120 and bears against its linear part. Here, the guide lever 124 slides along the guide web 1131 of the chip holder 113 by way of the lug of the longer lower lever arm end. The inkjet printing module 11 is pressed forward by the action of the guide lever 124 to such an extent that its front side bears against a front wall (not shown in greater detail) of the receptacle 12 , which front wall is inclined forward. The spring piece 12654 becomes completely free and the contact between the contact field 112 and the counterpart 12651 is canceled. The lower rear edge 1111 of the nozzle surface 111 of the inkjet printing module 11 slides past the covering 12621 and is freed from abovementioned ink residues in the process.
[0062] In FIG. 8 , the draw hook 120 is pulled up as far as the upper stop within the slot 1225 , see also FIG. 3 . Here, the lower rear edge 1111 of the nozzle surface 111 of the inkjet printing module 11 bears against the spring piece 12654 which prevents contact of the counterpart 12651 with respect to the contact field 112 . The inkjet printing module 11 now protrudes out of the receptacle 12 to such an extent that it can be gripped comfortably by hand. The draw hook 120 is returned to its initial position by the tension spring 127 , the inkjet printing module 11 remaining in its final position, see FIG. 9 .
[0063] As a result of the measures which are described in the above text, readily accessible pulling of the inkjet printing module 11 by means of drawing hooks 120 is possible firstly. Secondly, wear on the contact surfaces is prevented as a result of the combination of the draw hook 120 with the guide lever 124 , 125 , the spring pin 12653 and the spring piece 12654 , and guide webs 1131 on the chip holder 113 . Finally, additional protection of the contact surfaces against ink residues is also achieved by a wiping apparatus (pin 1262 with covering 12621 ) for the rear edge 1111 of the nozzle surface 111 of the inkjet print head 110 . | A configuration for exchanging inkjet printing modules in a franking and/or addressing machine having a shaft-shaped receptacle with a locking device for the inkjet printing modules. The functional reliability and an extension of the service life of the printing device are improved by achieving simple and reliable exchanging of the inkjet printing module. In particular, easy drawing of the inkjet printing module is made possible and mechanical impairment of the mating contacts for the inkjet printing module is prevented. Devices are provided for pulling and releasing the contact of the inkjet printing module in the receptacle. These devices are coupled mechanically to one another in such a way that, when the pulling process is initiated, contact is released at the same time. A wiping apparatus is arranged in the pivoting region of the rear edge of the nozzle surface of the inkjet print head. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention is directed to bicycle brake devices and, more particularly, to a bicycle brake cable retainer, a bicycle brake lever assembly, a bicycle brake cable connector, and a bicycle brake system.
[0002] A bicycle brake system commonly comprises front and rear braking devices for applying braking forces to the front and rear wheels, front and rear brake levers mounted on the handlebar and designed to operate the front and rear braking devices, and brake cables secured to the front and rear braking devices and to the front and rear brake levers. Each brake cable comprises an inner wire that slides within an outer casing, wherein the inner wire is connected at one end to the brake lever and at the other end to the braking device. The outer casing ordinarily has one end mounted to a bracket for the brake lever and another end mounted to a bracket for the braking device.
[0003] The braking device comprises a braked member that rotates with the wheel and a braking member capable of coming into contact with the braked member. The braked member usually is the rim or hub of the wheel. The braking device for applying the braking force to a wheel rim may be a caliper brake or a cantilever brake, whereas the braking device for applying the braking force to a wheel hub may be an internal expanding brake in the form of a band brake, disk brake, roller brake, or the like. The braking device usually includes a play adjusting mechanism for adjusting the gap between the braked member and the braking member (that is, the play of the braking device) when the brake lever is not being operated. In a typical mechanism, an outer retainer for securing the outer casing is screwed into the braking device, the retention position of the outer casing is shifted in the axial direction of the cable by the rotation of the outer retainer, and the play is thus adjusted. This operation also sets the brake timing of the braking device.
[0004] A cable connector that allows the front and rear braking devices to be operated simultaneously with a single brake lever is disclosed in JP (Kokai) 4-2588, for example. In that device, the cable connector is disposed in the middle of the front and rear brake cables. The cable connector has a connection member for connecting exposed portions of the inner wires of the front and rear brake cables together and a bracket that allows the connection member to move. Outer retainers for securing the portions of the outer casings extending toward the braking devices and the portions of the outer casings extending toward the brake levers are disposed at opposite ends of the bracket. In a brake system having such a cable connector, both inner cables are pulled when a single brake lever is actuated, thus making it possible to obtain enhanced frame stability and stabilized braking characteristics. In addition, braking can be accomplished by operating either the left or right brake lever, thus making it possible to operate the brake levers with ease and to increase the service life of the braking devices by dispersing the braking force.
[0005] Since both inner cables are pulled when a single brake lever is actuated in such a system, the inner cable secured to the unactuated brake lever extends further from the outer casing, sags, and causes the brake lever to become loose. Furthermore, since the front and rear inner cables move simultaneously, the front and rear brake timing may vary considerably if the play is markedly different for each braking device. Since the inner cable connected to the rear braking device is longer than the one connected to the front braking device, it tends to stretch more during use. As a result, the rear brake timing gradually shifts away from the initial timing during use, thus making it necessary to readjust the amounts of play for the front and rear braking devices.
[0006] Optimally, the play of the front and rear braking devices should be kept the same or be limited to a specific difference. In a conventional braking device in which braking force is applied to the rim, the play can be kept constant by equalizing the gap between the brake shoe and the rim for the front and back wheels. In practice, however, this is difficult to do. In systems in which braking force is applied to the wheel hub, the braking member brought into contact with the drum is disposed inside the braking device, thus making it impossible to see the gap formed between the braking member and the hub. This makes it even more difficult to provide the front and back braking devices with the desired amounts of play.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to an apparatus that can be used to simplify the adjustment of brake play and/or minimize looseness of the brake cable. In one embodiment of an invention directed to a cable connecting apparatus for a control cable having an inner wire that slides within an outer casing, the cable connecting apparatus includes a cable sleeve adapted to receive the outer casing of the control cable; a guide having a first end portion and a second end portion, wherein the guide supports the cable sleeve so that the cable sleeve moves toward the first end portion and the second end portion; and a biasing device for biasing the cable sleeve toward the second end portion of the guide. This allows slack to be taken up in a brake cable attached, for example, to a brake lever in a system wherein the front and rear cables are connected together for simultaneous operation.
[0008] In an embodiment of an invention directed to an indicating apparatus for a control cable having an inner wire that slides within an outer casing, the indicating apparatus includes a guide adapted to receive the outer casing of the control cable, an indicator adapted to be retained to the outer casing of the control cable, and a window for viewing the indicator. In another embodiment of an invention directed to an indicating apparatus for a control cable having an inner wire that slides within an outer casing, the indicating apparatus includes a guide adapted to receive the outer casing of the control cable, an indicator adapted to be retained to the outer casing of the control cable, and indicia supported by the guide for cooperating with the indicator to indicate a position of the outer casing of the control cable.
[0009] In an embodiment of an invention directed to a connecting apparatus for a first control cable having a first inner wire that slides within a first outer casing and a second outer casing and a second control cable having a second inner wire that slides within a third outer casing and a fourth outer casing, the apparatus includes a bracket including a first support for supporting the first outer casing, a second support for supporting the second outer casing, a third support for supporting the third outer casing, and a fourth support for supporting the fourth outer casing. A connecting member is provided for connecting a portion of the first inner wire located between the first outer casing and the second outer casing to a portion of the second inner wire disposed between the third outer casing and the fourth outer casing, wherein the connector moves together with the first inner wire and the second inner wire. A position confirmation means is provided that allows the position of at least one of the first outer casing, the second outer casing, the third outer casing and the fourth outer casing to be visually confirmed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a side view of a bicycle that incorporates a particular embodiment of a braking apparatus according to the present invention;
[0011] [0011]FIG. 2 is a detailed view of the braking apparatus;
[0012] FIGS. 3 ( a ) and 3 ( b ) are views illustrating the operation of a braking device shown in FIG. 2;
[0013] [0013]FIG. 4 shows partial cross sectional views of the outer retainers and cable connector shown in FIG. 2;
[0014] [0014]FIG. 5 is an exploded view of the cable connector shown in FIG. 2;
[0015] [0015]FIG. 6 is a detailed cross sectional view of the cable connector shown in FIG. 2;
[0016] FIGS. 7 ( a ) and 7 ( b ) are a schematic views illustrating how play in the braking devices is confirmed;
[0017] [0017]FIG. 8 is a partial cross sectional view of another embodiment of a cable connector according to the present invention;
[0018] [0018]FIG. 9 is a partial cross sectional view of another embodiment of a cable connector according to the present invention; and
[0019] [0019]FIG. 10 is a cross sectional view of a braking device that includes a particular embodiment of a braking force modulator.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0020] [0020]FIG. 1 is a side view of a bicycle that incorporates a particular embodiment of a braking apparatus according to the present invention. In this embodiment, the bicycle is a touring bicycle comprising a frame 1 with a double-loop frame body 2 and a front fork 3 , a handle assembly 4 for steering, a drive unit 5 for transmitting the rotation of pedals 5 a to a rear wheel 7 , a front wheel 6 , and a brake system 8 for braking the front and rear wheels 6 and 7 . The handle assembly 4 comprises a handle stem 10 fixedly mounted in the upper portion of the front fork 3 and a handlebar 11 fixedly mounted on the handle stem 10 . The handle assembly 4 , drive unit 5 , front wheel 6 , rear wheel 7 , and brake system 8 are mounted together with a saddle 9 and other components on the frame 1 .
[0021] As shown in FIG. 2, the brake system 8 comprises front and rear brake levers 12 f and 12 r , braking devices 13 f and 13 r actuated by the front and rear brake levers 12 f and 12 r , front and rear brake cables 14 f and 14 r connected between the front and rear brake levers 12 f and 12 r and the front and rear braking devices 13 f and 13 r , and a cable connector 15 for connecting the front and rear brake cables 14 f and 14 r in a manner described below. The brake cables 14 f and 14 r comprise inner cables 16 f and 16 r connected at both ends to the brake levers 12 f and 12 r and to the braking devices 13 f and 13 r , and outer casings 17 f and 17 r for covering the inner cables 16 f and 16 r . The outer casings 17 f and 17 r are divided by the cable connector 15 into the outer casings 17 fa and 17 ra extending from cable connector 15 toward the brake levers 12 f and 12 r , and the outer casings 17 fb and 17 rb extending from cable connector 15 toward the braking devices 13 f and 13 r.
[0022] The front brake lever 12 f is mounted inwardly from a grip 18 a attached to the left end of the handlebar 11 , and the rear brake lever 12 r is mounted inwardly from a grip 18 b attached to the right end of the handlebar 11 . The brake levers 12 f and 12 r are mirror images of each other. The brake levers 12 f and 12 r each comprise a lever bracket 20 mounted on the handlebar 11 , a lever member 21 pivotably supported by the lever bracket 20 , and an outer retainer 22 fixedly screwed into the lever bracket 20 .
[0023] Each lever bracket 20 comprises a rocking shaft 20 a for pivotably supporting the lever member 21 , a mounting component 20 b detachably mountable on the handlebar 11 , and an internally threaded component 20 c capable of threadably accepting the outer retainer 22 and receiving the inner cables 16 f and 16 r therethrough. Each lever member 21 is biased by a biasing member (not shown) in the direction of brake release, and each lever member 21 has an inner retainer 21 a for securing the inner cables 16 f and 16 r of the brake cables 14 f and 14 r.
[0024] As shown in FIG. 4, each outer retainer 22 comprises a cable sleeve 23 , a guide 24 , a coil spring 25 , and a cable cover 26 . The guide 24 is a cylindrical member whose tip is provided with an externally threaded portion 24 a for detachable threaded engagement with the internally threaded component 20 c of a conventional lever bracket 20 . Such a structure makes it easy to remove and/or repair outer retainer 22 . The cable sleeve 23 is a perforated cup-shaped member capable of securing the tips of the outer casings 17 fa or 17 ra , and it has on the external periphery thereof a spring sleeve 23 a that is folded near the opening. Guide 24 is designed to support the cable sleeve 23 on the internal peripheral surface thereof while allowing cable sleeve 23 to move a predetermined distance along the axis of the brake cables 14 f and 14 r . The coil spring 25 , disposed in compressed form between the tip of guide 24 and the spring sleeve 23 a of cable sleeve 23 , biases the cable sleeve 23 toward the base end (cable insertion side) of guide 24 . The base end of guide 24 opens to allow the passage of the cable sleeve 23 , and an annular lid member 27 made of metal and capable of accommodating the outer casings 17 fa and 17 ra therein is fixedly mounted in the opening by press fitting. The cable sleeve 23 is thus retained inside guide 24 against the biasing force of the coil spring 25 . Cable sleeve 23 is moved toward the tip of guide 24 (toward the brake lever) against the biasing force of the coil spring 25 when the inner cables 16 f and 16 r of the brake cables 14 f and 14 r are pulled, and the cable sleeve 23 is moved toward the base end of guide 24 (toward the lid member 27 ) by the coil spring 25 when the inner cables 16 f and 16 r are released from tension, as shown by the chain line in FIG. 4. The cable cover 26 , which is a contractible bellows member made of an elastic material, sealingly covers the external peripheral surfaces of the guide 24 and the outer casings 17 fa and 17 ra to prevent the entry of water or other contaminants to prevent freezing or corrosion of the components.
[0025] As shown in FIGS. 2 , 3 ( a ) and 3 ( b ), the front and rear braking devices 13 f and 13 r are roller-type internal expanding brakes. The braking devices 13 f and 13 r comprise fixed brackets 30 f and 30 r fixedly mounted to the back portions of the bicycle front fork 3 and frame body 2 , play adjusting components 31 f and 31 r for securing the outer casings 17 fb and 17 rb and adjusting the play of the braking devices 13 f and 13 r , brake bodies 32 f and 32 r , and brake operating arms 33 f and 33 r that can pivot relative to the brake bodies 32 f and 32 r . The play adjusting components 31 f and 31 r are provided with outer retainers screwed into the fixed brackets 30 f and 30 r , thus allowing the play of the braking devices 13 f and 13 r to be adjusted by moving the end positions of the outer casings 17 fb and 17 rb back and forth in the axial direction.
[0026] The brake bodies 32 f and 32 r have substantially the same structure, so the rear brake body 32 r alone will be described herein. As shown in FIGS. 3 ( a ) and 3 ( b ), the rear brake body 32 r comprises a rotary component 40 that rotates integrally with the hub shell of the rear wheel 7 , a brake drum (braked member) 41 fixedly mounted on the internal peripheral surface of the rotary component 40 , and brake shoes (braking members) 42 capable of coming into contact with and disengaging from the brake drum 41 . The brake shoes 42 are brought into contact with the brake drum 41 for applying a braking force to the rear wheel 7 when a plurality of rollers 44 supported by a roller case 43 are moved radially outward by the rotation of a rotary cam 45 . The rotary cam 45 rotates in conjunction with the brake operating arm 33 r , wherein the inner cable 16 r is secured to the brake operating arm 33 r . Thus, pulling the inner cable 16 r by gripping the brake lever 12 r will cause the brake operating arm 33 r to rotate clockwise from the brake release position shown in FIG. 3( a ) to the braking position shown in FIG. 3( b ). This, in turn, causes the brake shoes 42 to come into contact with the brake drum 41 and apply a braking force to the rear wheel 7 . The gap formed between the brake shoes 42 and the brake drum 41 during brake release constitutes the play of the braking device 13 r.
[0027] The cable connector 15 is a device for connecting the front and rear brake cables 14 f and 14 r together so that both the front and rear braking devices 13 f and 13 r may be actuated by operating either one of the front and rear brake levers 12 f and 12 r . As shown in FIGS. 4 - 6 , the cable connector 15 comprises a connection member 45 for connecting the inner cables 16 f and 16 r of the front and rear brake cables 14 f and 14 r together, a bracket 46 for housing the connection member 45 , a play confirmation component 47 that allows the play of the front and rear braking devices 13 f and 13 r to be confirmed visually, and a casing 48 for covering the bracket 46 .
[0028] The connection member 45 is movably mounted inside the bracket 46 and comprises a first connector 45 a connected by screws 45 c to a second connector 45 b . The front and rear inner cables 16 f and 16 r are connected together by the insertion of the two cables 16 f and 16 r between the two connectors 45 a and 45 b . The connection member 45 is biased by two coil springs 49 in the direction of the braking devices 13 f and 13 r . Such biasing aids the initial setting of connection member 45 .
[0029] The bracket 46 comprises a bracket body 46 a formed of metal and press-molded into a substantial U shape, and a bottom plate component 46 b mounted over the open portion of the bracket body 46 a . The central portion of the bracket body 46 a is provided with outer retainers 46 c for securing the outer casings 17 fa and 17 ra on the side of the brake levers 12 f and 12 r . The bottom plate component 46 b , which is disposed opposite the central portion, is provided with outer retainers 46 d designed to secure the outer casings 17 fb and 17 rb on the side of the braking devices 13 f and 13 r . A guide 50 is disposed in contact with the lower surface of the bottom plate component 46 b . Guide 50 allows confirmation knobs 51 f and 51 r to be supported while allowing movement of confirmation knobs 51 f and 51 r in the axial direction. A casing 48 is mounted to cover the bracket 46 and the guide 50 , and a transparent indicator window 52 with the graduation marks 52 f and 52 r is provided to the casing 48 . The upper end of the casing 48 is closed while the lower end is blocked by the guide 50 . The upper end of the casing 48 is provided with through holes 48 f and 48 r for accommodating the outer casings 17 fa and 17 ra . The outer casings 17 fa and 17 ra are sealed with an O-ring 55 (FIG. 6) around the through holes 48 f and 48 r to prevent liquids from penetrating inside.
[0030] The confirmation knobs 51 f and 51 r comprise cup-shaped indicators 53 f and 53 r and knob components 54 f and 54 r . The inner cables 16 f and 16 r are sealed with a seal ring 56 mounted inside the indicators 53 f and 53 r . Indicators 53 f and 53 r are made readily visible by being colored, for example, red or yellow, and they are fixed by crimping to the tips of the outer casings 17 fb and 17 rb . Guide 50 movably guides the indicators 53 f and 53 r . Thus, the play of the braking devices 13 f and 13 r can be visually confirmed by determining the position occupied by the end portions 57 f and 57 r of the indicators 53 f and 53 r in relation to the graduation marks 52 f and 52 r when the outer casings 17 fb and 17 rb are pulled toward the braking devices 13 f and 13 r.
[0031] When the brake cables 14 f and 14 r are set, the inner cables 16 f and 16 r are in a retracted state, so the cable sleeves 23 are moved by the outer casings 17 fa and 17 ra toward the brake lever against the biasing force of the corresponding coil springs 25 . When one of the front and rear brake levers 12 f and 12 r (for example, the rear brake lever 12 r ) is operated, the inner cable 16 r is pulled, and the rear braking device 13 r experiences a braking force. The inner cable 16 f , which is connected to the inner cable 16 r by connection member 45 , also is pulled, thus causing the braking device 13 f to experience a braking force as well. However, at this time no tension is applied to the portion of inner cable 16 f between the connection member 45 and the brake lever 12 f , thus causing slack in the inner wire 16 f . When this happens, the cable sleeve 23 is biased and moved by the coil spring 25 toward the base end (cable insertion side) of outer retainer 22 as shown by the chain line in FIG. 4. Consequently, the lever member 21 remains taut.
[0032] To adjust the play of braking devices 13 f and 13 r during manufacture or during routine brake adjustment, the knob components 54 f and 54 r of the confirmation knobs 51 f and 51 r are grasped, and the outer casings 17 fb and 17 rb are pulled toward the braking devices 13 f and 13 r . At that time, the play of the braking devices 13 f and 13 r can be visually confirmed by determining the position occupied by the bottom portions 57 f and 57 r of the indicators 53 f and 53 r on the graduation marks 52 f and 52 r . The play of the rear braking device 13 r should be slightly reduced if the goal is to provide the front braking device 13 f with a slower response than the one possessed by the rear braking device 13 r . In this case, the play should be adjusted using play adjusting components 31 f and 31 r so that the bottom portion 57 f of the indicator 53 f for the front braking device 13 f is aligned with the graduation mark 52 fb shown by the broken line in FIG. 7, and so that the bottom portion 57 r of the indicator for the rear braking device 13 r is aligned with the graduation mark 52 ra shown by the solid line in FIG. 7.
[0033] While the above is a description of various embodiments of the present invention, further modifications may be employed without departing from the spirit and scope of the present invention. For example, the size, shape, location or orientation of the various components may be changed as desired. Components that are shown directly connected or contacting each other may have intermediate structures disposed between them. The functions of one element may be performed by two, and vice versa. It is not necessary for all advantages to be present in a particular embodiment at the same time. Although the original embodiment was described with reference to a case in which roller-type internal expanding brakes for exerting a braking force on wheel hubs were used as the braking devices, such brakes may include band or disk brakes for exerting a braking force on hubs, or caliper or cantilever brakes for exerting a braking force on rims.
[0034] Although the original embodiment was described with reference to a case in which coil springs 49 and 25 were mounted on the cable connector 15 and outer retainer 22 , respectively, it is also possible to adopt an arrangement in which a coil spring is provided to either of the components, and the inner cable or the outer casing is biased in the direction in which the inner cable is exposed. FIG. 8 is a partial cross sectional view of another embodiment of a cable connector according to the present invention. The cable connector 65 shown in FIG. 8 is devoid of a coil spring for biasing a connection member 75 . The rest of the structure is the same as in the above embodiment. In this structure, the gap between the brake cables 14 f and 14 r can be reduced in proportion to the absence of springs. A more compact cable connector 65 can therefore be designed.
[0035] Although the original embodiment was described with reference to a case in which separate brackets and casings were used, it is also possible to integrate the casings and brackets together. FIG. 9 is a partial cross sectional view of such an embodiment. In the cable connector 80 shown in FIG. 9, the cylindrical bracket 84 doubles as a casing, and the connection member 85 is mounted while allowed to move in the axial direction. In this case, the entire connection member 85 is biased by a single coil spring 86 . In this embodiment, the outer casings 17 fb and 17 rb are provided with annular markings 87 . Play should be adjusted such that the markings 87 reach a position beyond the bottom portion 84 a of the bracket 84 when the outer casings 17 fb and 17 rb are pulled toward the braking device during play adjustment.
[0036] It is also possible to mount a modulator (brake force adjusting mechanism) capable of varying the braking force of one of the two front and rear braking devices 13 f and 13 r during braking. In FIG. 10, a modulator 95 is mounted inside a hub 94 connected to a front braking device 93 f . The modulator 95 comprises washers 96 with retaining holes nonrotatably secured in the hub 94 , and lugged washers 97 disposed between the washers 96 with retaining holes. The lugged washers 97 are secured in an annular cup 99 that rotates in conjunction with the rotary component 98 of the braking device 93 f , and are caused to rotate in conjunction with the rotary component 98 . The modulator 95 allows the rate at which the braking force increases with the operating force during braking to be reduced in accordance with the contact pressure of the two types of washers 96 and 97 .
[0037] Although the original embodiment was described with reference to an arrangement in which the casing 48 was not fixedly mounted on the frame 1 , it is also possible immovably mount the casing on the frame 1 . Furthermore, although the above embodiment was described with reference to an arrangement in which the play confirmation mechanism was provided to the cable connector 15 , it is also possible to provide the gauge to the front and rear braking devices 13 f and 13 r.
[0038] Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such feature(s). Thus, the scope of the invention should not be limited by the specific structures disclosed or the apparent initial focus on a particular structure or feature. | A cable connecting apparatus for a control cable having an inner wire that slides within an outer casing includes a cable sleeve adapted to receive the outer casing of the control cable; a guide having a first end portion and a second end portion, wherein the guide supports the cable sleeve so that the cable sleeve moves toward the first end portion and the second end portion; and a biasing device for biasing the cable sleeve toward the second end portion of the guide. A connecting apparatus for a first control cable having a first inner wire that slides within a first outer casing and a second outer casing and a second control cable having a second inner wire that slides within a third outer casing and a fourth outer casing includes a bracket including a first support for supporting the first outer casing; a second support for supporting the second outer casing spaced apart from the first outer casing; a third support for supporting the third outer casing; and a fourth support for supporting the fourth outer casing spaced apart from the third outer casing. A connecting member is provided for connecting a portion of the first inner wire located between the first outer casing and the second outer casing to a portion of the second inner wire disposed between the third outer casing and the fourth outer casing, wherein the connector moves together with the first inner wire and the second inner wire. A position confirmation means is provided that allows the position of at least one of the first outer casing, the second outer casing, the third outer casing and the fourth outer casing to be visually confirmed. | 5 |
[0001] This application claims the benefit of provisional application No. 61/489,540 filed May 24, 2011 and which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention provides an external adapter to shorten and dampen the stroke of a commercially available reciprocating saw as may be desirable to facilitate using such a saw for cutting through the urethane adhesive used to attach windshields to the pinchweld of an automobile.
SUMMARY OF THE INVENTION
[0003] The main purpose of this invention is to shorten the length of the stroke of a standard reciprocating saw such as manufactured by companies such as Dewalt Tools and Milwaukee Tool Company. While such reciprocating saws are intended primarily for use with a toothed saw blade having its cutting edge along one side, they may also be fitted with a broad, flat-bladed cutting tool similar to a putty knife or spatula having a sharpened leading cutting edge to remove damaged automotive windshields by cutting though the adhesive polyurethane bead which retains the windshields.
[0004] While a typical “off-the-shelf ” reciprocating saw has a stroke of 0.75 to 1.5 inches in length, and is a fixed unattenuated mechanical movement. This stroke is typically longer than desirable for windshield removal since it creates a “kickback” from the impact of the wide cutting blade as it comes into contact with the hardened urethane adhesive. This can making it difficult to use and reduce its effectiveness in cutting through the urethane.
[0005] A shorter stroke produces a smoother stroke for the tool operator. The longer stroke creates bounce as the blade makes and loses contact with the urethane adhesive. A shorter stroke provides faster cutting because the cutting blade can remain in contact with the urethane being cut, rather than bouncing off because of the heavy vibration of the reciprocating or oscillating movement.
[0006] Therefore, the stroke of the reciprocating saw is preferably modified and shortened to improve the functionality of the saw tool for this purpose. The present invention shortens the stroke without requiring modification of any the machine's internal mechanical parts such as gears, cams or shafts. This invention is attached to the shaft of the reciprocating saw in place of and in the same manner as a normal saw blade and provides for further attachment of an appropriate cutting tool. The invention is suitable for use with any powered reciprocating tool including those which are electrically or pneumatically powered.
[0007] In addition to shortening the length of the stroke the present invention incorporates an internal compression spring which further facilitates use of a leading edge cutting tool by absorbing some of the impact shock of the resulting back and forth motion of the reciprocating saw shaft as the cutting blade makes contact with the urethane adhesive being cut. In essence, the tool provides improved control of the cutting tool by allowing application of an attenuated cutting force without unnecessary reciprocating movement. During the compression stroke this spring absorbs the impact of the blade as it comes into contact with the adhesive bead until a point where the compressive force is greater than the necessary cutting force. Upon the extension portion of the stroke extension of the spring allows the cutting edge of the blade to remain essentially in contact with the bead.
[0008] The present invention further provides a simplified and secure method of attachment of the cutting blade by providing a clamp assembly with one or more blade securing pins but only a single removable securement screw in order to facilitate easily changing the blade. This assembly further stiffens the cutting blade without other external sheath jacket or similar stiffening reinforcement.
[0009] It is an object of the present invention to provide an external adapter which can be retrofitted to a standard reciprocating saw to reduce its stroke.
[0010] It is an object of the present invention to provide a means of reducing the stroke of a standard reciprocating without mechanical modification of the saw.
[0011] It is an object of the present invention to provide a means of dampening the impact of the stroke of a standard reciprocating saw.
[0012] It is an object of the present invention to provide a means of dampening the impact of the stroke of a standard reciprocating saw without mechanical modification of the saw.
[0013] It is an object of the present invention to provide a means of keeping a forward edge cutting tool in constant contact with the material being cut while using an reciprocating tool.
[0014] It is an object of the present invention to adapt a reciprocating saw to be suitable for cutting through the adhesive bead securing an automotive windshield.
[0015] It is an object of the present invention to provide an inexpensive tool suitable for cutting through the adhesive bead securing an automotive windshield.
[0016] It is an object of the present invention to provide a secure and easily changeable method of securing a cutting tool to a reciprocating shaft.
[0017] It is another object of the present invention to provide a secure and easily changeable method of securing a cutting tool to a reciprocating shaft.
[0018] It is an object of the present invention to provide an adapter to allow securement of a cutting tool to a reciprocating power tool without any external sheath, jacket or similar stiffening reinforcement.
DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a perspective view of the device of the preferred embodiment in place between a cutting blade and a reciprocating power tool.
[0020] FIG. 2 is an exploded top view of the device.
[0021] FIG. 3 is an exploded partially cutaway view corresponding to FIG. 2 .
[0022] FIG. 4 is a top view showing the device in an extended configuration.
[0023] FIG. 5 is a top view showing the device in a compressed configuration.
[0024] FIG. 6 is a partially cutaway top view showing the device in an extended configuration.
[0025] FIG. 7 is a partially cutaway top view showing the device in a compressed configuration.
[0026] FIG. 8 is a side view of the device of the preferred embodiment as it would be used.
[0027] FIG. 9 is an exploded side view of the device of the preferred embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The device of the present invention is comprised of three primary components, two coaxial, nested shaft or body portions 2 and 3 , which are slidable between an axially extended and an axially compressed configuration as shown in FIGS. 4 and 5 respectively. The respective body portions are nested to provide a telescoping axial movement, with body portion 2 being received into and axially slidable within correspondingly sized chamber 3 a in body portion 3 . Chamber 3 a may be appropriately lined with a bronze or “oilite” bearing sleeve 11 for various purposes including reduction of sliding friction, improving wear resistance, and/or reducing the potential for galling of the sliding surfaces. Cylindrical chamber portions 13 a and 13 b combine to form a central axial chamber 13 to hold a compression spring 7 which biases body portion 2 and 3 to an extended axial position. The body portions are preferably constructed from a suitably tough and durable material such as 4130 or 4140 steel alloys but could be constructed from materials such as various aluminum alloys, synthetic or composite materials in order to achieve benefits such as light weight.
[0029] A typical cutting tool 1 is attached to shaft portion 2 . Tool 1 , as would be used for the specific purposes described herein, comprises a broad “spatula” type cutting blade with a leading cutting edge. Blade 1 is attached to blade connecting shaft portion 2 , using a removable semi-cylindrical blade anchor cover 4 affixed and aligned with dowel pins 5 and anchoring screw 9 . Use of the single anchoring screw 9 facilitates removal and installation the cutting blade. Dowel pins 5 are received into blind holes 5 ′ and pass through correspondingly sized holes in the blade to secure it. Blade locating pins 5 are permanently pressed into blade connecting shaft 2 , blade locating cover 4 is placed so as the two locking pins 5 align in blind holes 5 ′ in blade locking cover 4 . A single countersunk screw 9 is placed through blade locking cover 4 and threaded into blade connecting shaft 2 to secure the cutting blade 1 and prevent it from moving while tool is operational. It is to be understood that the term “cutting tool” as used herein includes any tool or device which may be attached to and driven by a reciprocating power tool.
[0030] Changing of blade 1 is facilitated by locking cover 4 being a separate removable piece, in contrast to using a slot in blade connecting shaft 2 to secure cutting blade 1 . A flat surface 2 a is machined in blade connecting shaft 2 to provide a seat for cutting blade 1 , which is fastened in place to using blade locking cover 4 and blade locating pins 5 .
[0031] At an end opposite from its attachment to a power tool shaft B, connecting shaft 3 slips over blade connecting shaft 2 to create a coaxial nested configuration. The device is assembled with compression dampening spring 7 located within a central coaxial chamber 13 inside the saw connecting shafts 2 and 3 , then pressing two connecting shafts 2 and 3 together axially and securing them with anchor and guide pin 6 through travel guide slots 8 and pressed into hole 12 where it is held by its own tension. Elongated guide slots 8 have a minor dimension corresponding to the diameter of guide pin 6 . Guide pin 6 can be a standard spring or tension pin which, in conjunction with elongated slots 8 , allows relative axial movement while keeping the two connecting shafts 2 and 3 from separating or rotating relative to one another while the device is in operation and, further provides a limit to the extension of the device as shown in FIG. 4 . The lack of relative rotational movement between the body portion insures that the orientation of a flat cutting blade can be manually controlled by an operator.
[0032] Set screw 10 is used to secure invention to the operating shaft B of a reciprocating tool. Set screw 10 is threaded down against the shaft of the tool.
[0033] In use with the device fully assembled, cutting blade 1 is placed against the urethane at the metal pinchweld area where the urethane and the glass windshield meet. As the reciprocating motion of the tool transfers into the shaft of the invention and the compression dampening spring 7 , absorbs some of the stroke of the reciprocating tool. While spring 7 is preferably a suitably sized metallic coil spring any appropriate resilient and compressible material or method could similarly be used. A rubber or similar elastomeric synthetic material could be used instead of a metal compression spring 7 , to absorb shock and then recoil back to its original shape and size. Similarly a body of air or gas could be contained in a cylindrical compartment between the two shafts 2 and 3 , could be used to absorb some of the stroke and shock of the reciprocating tool by compression of the gas.
[0034] At the beginning of a stroke, the force against the cutting blade 1 is limited by the rate of spring 7 , and increases as the spring is further compressed through the stroke. The stroke of the reciprocating tool is absorbed and or shortened until the applied force is greater than the force needed to cut the urethane adhesive.
[0035] Upon full compression of the device as shown in FIGS. 5 and 7 , the end 14 of shaft 2 comes into full contact with an internal shoulder 15 of body portion 3 . This effectively creates a “stop” such that all further axial motion and force of the reciprocating stroke is transferred directly to shaft 2 and the cutting tool A. In order to provide the smoothest operation of the tool it may be desirable to choose a spring having a spring rate such that when this stop is reached the force on the compressed spring is close to or equal to the force required for blade 1 to cut an adhesive bead. Shaft end 14 is appropriately provided with a circumferential chamfered edge 14 a to help prevent any “mushrooming” of the shaft end from impact and limit or prevent any binding of the sliding movement of the shaft 2 within body 3 .
[0036] Upon full compression the two shafts 2 and 3 act as one. At the end of the compression stroke the reciprocating tool pulls the blade back towards the tool itself. The compression spring 7 , then uncompresses and pushes the two shafts 2 and 3 apart. The entire cycle starts over with every stroke of the reciprocating tool this cycle is repeats at a typical rate of 1000 to 3000 cycles per minute. This rapid cycling motion of the cutting tool cuts the adhesive material quickly. The operator keeps the blade in contact with the urethane adhesive material and adjusting the angle of the tool to facilitate a smooth cutting action.
[0037] Other variations within the scope of this invention will be apparent from the described embodiment and it is intended that the present descriptions be illustrative of the inventive features encompassed by the appended claims. | A stroke shortening adapter for use with a reciprocating power tool which holds a cutting tool at one and is affixed to the shaft of the power tool at the opposite end. The adapter provides two coaxial body portions which are nested and axially slidable with respect to one another. A compression spring is retained in a central chamber between said portions to bias the portions to an axially extended position. The axial stroke of the power tool is partially absorbed by axial movement between said portions and compression of the spring. | 8 |
This application is a national stage application of international application number PCT/CN2010/075495, filed on Jul. 27, 2010, claiming priority to Chinese application number CN 200910055459.0, filed on Jul. 28, 2009.
FIELD OF THE INVENTION
The invention relates to the field of wheel processing technique, and particularly relates to a rolling forming method of wheel disc.
BACKGROUND OF THE INVENTION
In prior art, the CNC (Computerized Numerical Control) spinning forming method is widely used to form the truck wheel discs at home and abroad, The method spins an equal-thickness blank into an equal-strength section with gradually reduced thickness. The technological process of spinning forming method is as shown in FIG. 1 :
a. Baiting a circular blank and punching a positioning hole for spinning.
b. Spinning the blank into a wheel disc by the CNC spinning forming method on a tapered circular cylinder exploratory so as to meet the requirements of forming an equal-strength section which gradually becomes thinner.
c. Processing the excircle and the end surface of the spinning formed wheel disc in a dedicated vertical lathe in order to meet the requirement on the tolerance of the outer diameter and the requirement that the height of the wheel disc should be uniform. (This step aims at to attain the dimensional precision requirement of products, which the spin-forming technology can not achieve).
d. Punching a center hole and screw holes.
e. Punching hand holes (air holes) and then extruding the hand holes (air holes).
f. Reaming the spherical surfaces of the screw holes (or extruding the spherical surfaces of the screw holes).
g. Turning the center hole (or extruding the center hole).
h. Reshaping the flat surface and unifying the geometrical shape (for avoiding the out-of-roundness of the single air hole caused by irregular deformation during punching).
As shown in FIG. 2 and FIG. 3 , the existing spinning technology performs spinning on a work piece (circular blank) R with a spinning wheel P. The larger the spinning angle (α 1 +α 2 ) of the spinning technology, the larger the spinning gripping angle (α 3 +α 4 ) of the spinning wheel. Furthermore, the smaller the gripping angle, the stronger the extrusion force, therefore the extrusion force of the existing spinning technology is smaller. In addition, because the spinning explorator Q is cylindrical, and the forming method on the spinning explorator Q is an open type forming way without deformation size limitations, the well extrusion effect can not be achieved. Besides, fewer limitations on the spinning forming method and nonuniformity of the materials will result in instability of the spinning wheel P along with the changes in resistance during the movements of spinning wheel P, which cause small deformation on hard portion of the material whereas large deformation on soft portion, so micro-uneven conditions in the axial direction and the circumferential direction of the wheel disc will be brought about, and consequently the unbalance of the wheel disc. On the other hand, turning of the excircle will generate turning eccentricity, which can also further increase the unbalance of the wheel disc, as a result the precision of the excircle of the formed product can not meet the matching dimensional precision, and the spinning ring is retained on the formed product, which makes excircle processing in the vertical lathe indispensable. Furthermore, because of the unevenness of the height of formed product due to the material nonuniformity, turning of the end surface is necessary. Thus it can be seen, the only way to improve the spinning efficiency is to increase the number of the vertical lathes and the number of staffs. However, the production cost is also increased.
SUMMARY OF THE INVENTION
The invention aims at providing a rolling forming method of wheel disc for improving the precision, strength and the speed of the disc forming.
The technical principle of the invention is as follows: The inventor invents a rolling forming method of the wheel disc against the defects in the existing spinning forming method of the wheel disc. During the rolling forming process, the compression area of the rolled blank is large and the rolling force is stronger than the existing spinning force. In addition, during the rolling forming process, a rolling explorator plays a role in limiting the outer diameter of the formed disc and the deformation resistance is further generated in order to enable the blank to be extruded and make precise deformation of the blank.
The purpose of the invention is achieved in this way: A rolling forming method of wheel disc comprises the following steps:
(1) Baiting a circular blank;
(2) Placing the circular blank in a cavity of a circular rolling explorator; and adopting at least two rolling wheels symmetrically arranged along the circumferential direction of the rolling explorator to perform planar synchronous staggered rolling on the circular blank in the cavity of the rolling explorator, in order to roll the circular blank into a wheel disc blank which gradually becomes thinner from the center to the rim; (The planar rolling refers to the situation that the rolling trajectories of the rolling wheels are always in a plane. The synchronous rolling refers to the situation that the rolling motions of the at least two rolling wheels are synchronous in order to ensure the uniform quality of the rolled surface of the circular blank. The staggered rolling refers to the situation that the rolling wheels are disposed mutually staggered in their initial positions in order to prevent the rolling trajectories of the rolling wheels on the surface of the circular blank from coinciding to ensure the surface of the circular blank compact. In other words, the more the rolling wheels is disposed, the more compact the rolling traces on the surface of the circular blank become, the better the quality of the surface is achieved. However, the factors of economic cost and stress state should be taken into account while determining the amount of the rolling wheels.)
(3) Performing trimming and sizing on the wheel disc blank;
(4) Stretching the wheel disc blank to form a wheel disc to meet the shape requirements of the section of the wheel disc and the dimensional requirements of the outer diameter and the height of the wheel disc.
Preferably, the rolling motions of the at least two rolling wheels in the step (2) comprise feed motions of the at least two rolling wheels in a horizontal direction and a rotation of each rolling wheel.
Preferably, the feed motion of each rolling wheel in the step (2) is controlled by a rolling wheel feeding mechanism connected with an electric control system, wherein the electric control system controls the feed rate and the feed amount of each rolling wheel feeding mechanism respectively thereby to further control the feed rate and the feed amount of each rolling wheel.
Preferably, the rotation of each rolling wheel in the step (2) is driven by a rolling wheel driving element connected with each rolling wheel respectively. Each rolling wheel driving element is connected with and controlled by an electric control system. The rolling wheel driving element drives each rolling wheel to generate an initial rotational speed respectively so as to prevent the rolling wheel from damage caused by excessive friction force generated between the rolling wheel and the circular blank at the very beginning of rolling. Once the rolling wheel starts to roll the circular blank, the driving force of the rolling wheel will not be supplied by rolling wheel driving element any more, but supplied by the friction force, which causes the servo of rolling wheel generated by rolling contact between the rolling wheel and the circular blank.
Preferably, the rolling forming method of the wheel disc further comprises the step (5): processing a center hole, screw holes, hand holes and the spherical surfaces of the screw holes on the formed wheel disc.
Preferably, the section of the cavity of the rolling explorator adopted in the step (2) is an equal-strength section, and the shape of the cavity of the rolling explorator corresponds to the shape of the wheel disc.
Preferably, in the step (1), the center hole is punched on the circular blank to position the circular blank in the cavity of the rolling explorator after cutting the circular blank.
Preferably, in the step (3), performing trimming and sizing on the wheel disc blank in a blanking method.
Preferably, in the step (4), stretching the wheel disc blank in dwell method in order to make the outer diameter dimension of the formed wheel disc precise.
The step (2) is implemented by a rolling forming machine. The rolling forming machine used for rolling the circular blank comprises:
A frame configured as a support structure of the whole rolling forming machine;
A lower rotating head assembly fixed on the frame; An actuating mechanism of the lower rotating head assembly connected with the lower rotating head assembly;
An electric control system connected with the actuating mechanism of the lower rotating head assembly;
A disc-like rolling explorator, the bottom of which is fixed to the lower rotating head assembly, having a cavity which could be formed into various shapes depending on the shapes of workpieces to be machined;
At least two rolling wheel units symmetrically arranged along the circumferential direction of the rolling explorator, wherein each rolling wheel unit comprises a rolling wheel which performs rolling motions in the cavity; the number of the rolling wheel unit can also be three, four or even more. The symmetrical arrangement of the rolling wheels aims at balancing the unbalanced radial force generated during the rolling deformation process of the workpieces. The symmetrical arrangement can greatly offset the unbalanced deformation force and prolong the service life of the rolling forming machine.
An upper rotating head assembly connected with a feed mechanism of the upper rotating head assembly to compress the rolling explorator under the drive of the feed mechanism of the upper rotating head assembly connected with the electric control system;
At least two rolling wheel feeding mechanisms correspondingly connected with the rolling wheel units and vertically connected with the feed mechanism of the upper rotating head assembly to drive the horizontal synchronous motions of the rolling wheels under the control of the electric control system.
Preferably, each rolling wheel unit is further correspondingly connected with a rolling wheel driving element connected with the electric control system. The purpose of arranging the rolling wheel driving element is to impart an initial rotational speed to the rolling wheel at the beginning of rolling forming in order to avoid damage of the rolling wheel caused by the excessive friction force between the rolling wheel and the workpiece when the rolling wheel enters into the rolling working position.
Preferably, a center hole is arranged at the center of the rolling exploratory and is coupled to the upper rotating head assembly. The center hole is used together with the upper rotating head assembly for positioning role so as to prevent workpiece from slipping in the cavity.
Preferably, the electric control system comprises: A plurality of displacement sensors correspondingly arranged on the feed mechanism of the upper rotating head assembly and each rolling wheel feeding mechanism respectively; A control PLC (programmable logic controller) connected with each displacement sensors respectively for performing data exchange with all of the displacement sensors; A plurality of proportional valves connected with the control PLC and correspondingly connected with the feed mechanism of the upper rotating head assembly and each rolling wheel feeding mechanism respectively for correspondingly controlling the feed rate of the feed mechanism of the upper rotating head assembly and each rolling wheel feeding mechanism respectively.
The electric control system can adjust the feed amount and the feed rate of the upper rotating head assembly depending on the factors such as the thickness of the circular blank in order to ensure the compaction of the circular blank. And the electric control system can further precisely control the horizontal feed rate and the horizontal feed amount of each rolling wheel during the rolling process, in order to control the circular blank to deform steady according to the precision requirements of the product and enable the shape of the formed variable section to meet the requirements of dimensional precision.
Preferably, each rolling wheel unit further comprises: A hollow sliding block correspondingly fixed to each rolling wheel feeding mechanism; A rotating shaft arranged in the hollow sliding block, wherein one end of the rotating shaft is correspondingly connected with each rolling wheel respectively and the other end of the rotating shaft is correspondingly coupled to a rolling wheel motor.
Preferably, a cross beam with at least two horizontally arranged sliding slots is further arranged between the upper rotating head assembly and the feed mechanism of the upper rotating head assembly. The rolling wheel feeding mechanisms are arranged over the cross beam. And the sliding blocks correspondingly slide along the sliding slots. The sliding slots and the corresponding sliding blocks on the cross beam play a well guiding role of the rolling wheels in the horizontal direction in order to enable the horizontal feed trajectories of the rolling wheels to be more precise and more stable.
Preferably, the frame comprises:
A base, on which the lower rotating head assembly is fixedly mounted;
At least four columns symmetrically vertically arranged on the base;
An upper box fixed on the upper ends of all the columns and coupled to the feed mechanism of the upper rotating head assembly.
Preferably, each rolling wheel feeding mechanism comprises:
A hydraulic cylinder fixed to the feed mechanism of the upper rotating head assembly vertically;
A connector with a horizontally arranged threaded hole coupled to a positioning bolt, wherein one end of the connector is fixed to the piston rod of the hydraulic cylinder, the other end of the connector is fixed to each sliding block correspondingly, the threaded hole and the corresponding positioning bolt are used for positioning the horizontal position of the rolling wheel unit.
Preferably, the feed mechanism of the upper rotating head assembly is a hydraulic cylinder assembly, and the actuating mechanism of the lower rotating head assembly is a hydraulic motor.
Preferably, each rolling wheel unit further comprises a spray cooling device which is connected with the electric control system. The spray cooling devices sprays cooling lubricating liquid towards the circular blank and each rolling wheel during the rolling process to avoid heating-up and abrasion of the surfaces of the circular blank and the rolling wheels.
The working process of the rolling forming machine is as follows:
1) Loading: Positioning the circular blank with a punched center hole into the cavity of the rolling explorator.
2) The feed mechanism of the upper rotating head assembly is driving the upper rotating head assembly towards the circular blank in order to compress it and driving the rolling wheel units to descend synchronously under the control of the electric control system.
3) The actuating mechanism of the lower rotating head assembly drives the lower rotating head assembly to rotate and simultaneously drives the rolling explorator and the circular blank to rotate together under the control of the electric control system, thus the upper rotating head assembly rotates together with the circular blank.
4) The rolling wheel driving element imparts an initial rotational speed to each rolling wheel under the control of the electric control system, and the rolling wheel feeding mechanism simultaneously drive each rolling wheel unit to feed horizontally under the control of the electric control system, so as to enable the rolling wheel unit to slowly enter into the space above the circular blank for rolling, wherein the initial feed amounts of the rolling wheels in the horizontal direction are staggered arranged, that is, the initial rolling trajectories of the at least two rolling wheels on the surface of the circular blank are not coincident. However, the feed increments are synchronous and constant during the whole rolling process. Such process will produce a high-quality rolled wheel disc with a fine grained surface.
5) The feed mechanism of the upper rotating head assembly drives the upper rotating head assembly to depart from the wheel disc blank and drive the rolling wheel units to ascend simultaneously under the control of the electric control system. The electric control system further controls the lower rotating head assembly to stop rotating.
The invention of rolling forming method is a planar rolling forming process which refers to the process with little cutting amount or without cutting amount. The circular blank is formed in the cavity of the rolling explorator in the way of rolling and extruding. The shape of the cavity could be various surfaces, for example, a circular plane, a circular inclined plane, a circular corrugated surfaces or a circular wave surface. The workpiece produced by the method is more compact in structure, higher in strength, lighter in weight, lower in material consumption, and lower in energy consumption (energy consumption can be saved by above 80% in comparison with hot die forging). Besides, the production efficiency will be multiplied several times.
Comparing with the prior art, the rolling forming method of wheel disc has advantages and positive effects as follows:
(1) The force acting on the workpiece is stronger and the deformation precision of the workpiece blank is better because the rolling explorator will limit the deformation of the workpiece (different from the open type forming way in a spinning explorator) in the rolling forming process, and then generate a deformation resistance which will extrude the workpiece blank.
(2) The bending fatigue life of the workpiece produced with the same material can be greatly prolonged. The bending fatigue test of the wheel disc has proved that the service life of the workpiece can be prolonged by 30%, and the bending fatigue life of the product rolling formed with the 380 material (380 is the tensile strength of the material) can achieve the bending fatigue life of the product spinning formed with the 420 material (420 is the tensile strength of the material).
(3) The rolling forming method is a kind of coercive forming method, which limits the deformation of the workpiece in large scale. The invention can precisely form various geometric sections with the gradual deformation depending on the shape of the cavity of the rolling explorator. The formed product has a uniform mass in the axial direction and the circumferential direction, and has a high dynamic balance precision.
(4) The invention can produce a workpiece with high forming precision, therefore after the rolling step, just stamping, trimming and forming steps need to be performed to meet the 5 precision requirements of outer circle and the height of the end surface of the workpiece. And because the stamping rate and the stamping efficiency are much higher than the existing turning rate and turning efficiency, the invention will greatly improve the production efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
The following figures is used for explain the invention in detail with corresponding embodiment.
FIG. 1 is a schematic diagram of the spinning process of the wheel disc;
FIG. 2 is a schematic diagram of spinning motion state;
FIG. 3 is a view of FIG. 2 from the A-direction.
FIG. 4 is a schematic diagram of the structure of rolling forming machine adopted in an embodiment of the invention;
FIG. 5 shows the structure of the cross beam of the rolling forming machine adopted in an embodiment of the invention;
FIG. 6 is a schematic diagram of the rolling forming process of the invention;
FIG. 7 is a schematic diagram of rolling motion state;
FIG. 8 is a view of FIG. 7 from the A-direction;
FIG. 9 shows a top view of the cavity of rolling explorator in one shape in the invention;
FIG. 10 is a top view of the cavity of rolling explorator in another shape in the invention;
FIG. 11 is a top view of the cavity of rolling explorator in further another shape in the invention.
NUMERAL REFERENCES
P spinning wheel
Q spinning explorator
R circular blank
1 frame
11 base
12 column
13 upper box
2 lower rotating head assembly
3 actuating mechanism of lower rotating head assembly (hydraulic motor)
4 rolling explorator
41 cavity
42 center hole
5 rolling wheel unit
51 rolling wheel
52 sliding block
53 rotating shaft
6 upper rotating head assembly
7 feed mechanism of upper rotating head assembly (hydraulic cylinder assembly)
8 rolling wheel feeding mechanism
81 hydraulic cylinder
82 connector
821 threaded hole
83 positioning bolt
9 hydraulic motor of rolling wheel
10 cross beam
101 sliding slot
102 column hole
103 center hole of cross beam
104 side hole
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will become more fully understood from the following detail description and the accompanying figures.
A rolling forming machine shown in FIG. 4 and FIG. 5 is adopted for rolling forming in this embodiment. The rolling forming machine comprises a frame 1 which is configured as a support structure of the whole rolling forming machine. The frame 1 comprises a base 11 , four columns 12 symmetrically vertically mounted on the base 11 and an upper box 13 fixed on the upper ends of four columns. The rolling forming machine further comprises a lower rotating head assembly 2 fixed on the base 11 of the frame 1 ; an actuating mechanism of lower rotating head assembly 3 (hydraulic motor) coupled to the lower rotating head assembly 2 ; a disc-like rolling explorator 4 with a cavity 41 having a center hole 42 at its center area, wherein the bottom of rolling explorator 4 is fixedly connected with the lower rotating head assembly 2 ; an upper rotating head assembly 6 connected with a feed mechanism of the upper rotating head assembly 7 (In this embodiment, the feed mechanism of the upper rotating head assembly 7 is a pair of hydraulic cylinders); two rolling wheel units 5 symmetrically arranged along the circumferential direction of the rolling explorator 4 , wherein each rolling wheel unit 5 comprises a rolling wheel 51 , a rotating shaft 53 coupled to the rolling wheel 51 and arranged in a hollow sliding block 52 thereby coupled to a rolling wheel feeding mechanism 8 through the sliding block 52 ; a spray cooling device; and a hydraulic motor 9 of the rolling wheel correspondingly connected with the rotating shaft 53 (the hydraulic motor 9 of the rolling wheel is arranged as the rolling wheel driving element); Two rolling wheel feeding mechanisms 8 correspondingly connected with two rolling wheel units 5 so as to drive two rolling wheel 51 to move horizontally and synchronously, and vertically connected with the feed mechanism of the upper rotating head assembly 7 , wherein each rolling wheel feeding mechanism 8 comprises a hydraulic cylinder 81 vertically fixed to the feed mechanism of the upper rotating head assembly 7 , a connector 82 with a horizontally arranged threaded hole 821 coupled to a positioning bolt 83 for positioning the horizontal position of the rolling wheel unit 5 , wherein one end of the connector 82 is fixedly connected with the piston rod of the hydraulic cylinder 81 and the other end of the connector 82 is fixedly connected with each sliding block 52 through screws respectively in order to connect the sliding block 52 to the hydraulic cylinder 81 .
A cross beam 10 is arranged between the upper rotating head assembly and the feed mechanism of the upper rotating head assembly. All the rolling wheel feeding mechanisms are arranged above it. The cross beam 10 has two horizontally arranged sliding slots 101 , and the sliding blocks of the rolling wheel units slide along the sliding slots 101 respectively. The sliding slots 101 and the corresponding sliding blocks can well guide the motion of the rolling wheels in the horizontal direction so as to make the horizontal feed trajectories of the rolling wheels more precise and more stable. The cross beam 10 has four column holes 102 used for arranging the cross beam 10 onto the columns. A center hole 103 on the cross beam 10 is used for arranging the upper rotating head assembly. A side holes 104 on the cross beam 10 is used for arranging one pair of the hydraulic cylinders acting as the feed mechanism of the upper rotating head assembly.
The feed mechanism of the upper rotating head assembly 7 , the actuating mechanism of lower rotating head assembly 3 , each rolling wheel feeding mechanism 8 , the spray cooling device and the hydraulic motor 9 of rolling wheel are connected with and controlled by an electric control system respectively. The electric control system comprises a plurality of displacement sensors correspondingly arranged on the feed mechanism of the upper rotating head assembly and each rolling wheel feeding mechanism respectively; a control PLC (programmable logic controller) connected with each displacement sensors respectively for performing data exchange with all of the displacement sensors; a plurality of proportional valves connecting the control PLC and correspondingly connected with the feed mechanism of the upper rotating head assembly and each rolling wheel feeding mechanism respectively for correspondingly controlling the feed rate of the feed mechanism of the upper rotating head assembly and each rolling wheel feeding mechanism respectively.
The electric control system can adjust the feed amount and the feed rate of the upper rotating head assembly depending on the factors such as the thickness of the circular blank, in order to ensure the compaction of the circular blank. And the electric control system can further precisely control the horizontal feed rate and the horizontal feed amount of each rolling wheel during the rolling process in order to further control the circular blank to deform steady according to the precision requirements of the product and enable the shape of the formed variable section to meet the requirements of dimensional precision.
The working process of the rolling forming machine is as follows:
1) Loading: Positioning the circular blank into the cavity of the rolling explorator.
2) The feed mechanism of the upper rotating head assembly is driving the upper rotating head assembly to feed towards the circular blank in order to compress it and is driving the rolling wheel units to descend synchronously under the control of the electric control system.
3) The actuating mechanism of the lower rotating head assembly drives the lower rotating head assembly to rotate and simultaneously drives the rolling explorator and the circular blank to rotate together under the control of the electric control system, thus the upper rotating head assembly rotates together with the circular blank.
4) The rolling wheel driving element imparts an initial rotational speed to each rolling wheel under the control of the electric control system, and the rolling wheel feeding mechanism simultaneously drive each rolling wheel unit to feed horizontally under the control of the electric control system, so as to enable the rolling wheel unit to slowly enter into the space above the circular blank for rolling, wherein the initial feed amounts of the rolling wheels in the horizontal direction are staggered arranged, that is the initial rolling trajectories of the at least two rolling wheels on the surface of the circular blank are not coincident. However, the feed increments are synchronous and constant during the whole rolling process. Such process will produce a high-quality rolled workpiece with a fine grained surface.
5) The feed mechanism of the upper rotating head assembly drives the upper rotating head assembly to depart from the wheel disc blank and drive the rolling wheel units to ascend simultaneously under the control of the electric control system. The electric control system further controls the lower rotating head assembly to stop rotating.
It should be understood that the rolling forming machine described above is merely an equipment for performance the rolling actions of the rolling wheels in the step (2), and it should not be considered as the limitations on the rolling forming method of the invention.
The steps of the rolling forming method of wheel disc in this embodiment are shown in FIG. 6 :
(1) Baiting a circular blank and punching a center hole at the center of the circular blank.
(2) Positioning the circular blank with the centre hole, and the rolling wheels starting rolling on the plane of the circular blank. The rolling angle α 5 shown in FIG. 7 and the rolling griping angle α 6 shown in FIG. 8 are constant during the rolling process. Two rolling wheels 51 are symmetrically arranged above the processing plane of the circular blank R along the circumferential direction of the rolling explorator 4 . Rolling the circular blank R into a wheel disc blank with the rolling wheels 51 in the cavity of the rolling explorator in order to make the wheel disc blank gradually become thinner from the centre to the rim. The rolling process is described as above.
The cavity of the rolling explorator can be formed into various shapes depending on the shapes of workpieces in order to meet various demanding requirements.
FIG. 9 shows a top view of the cavity of rolling explorator 4 in one shape. The salient circles shown in the figure are for the circular holes on the wheel disc. Placing the circular blank into the cavity shown in the figure and rolling the upper surface of the circular blank with the rolling wheels. The salient parts of the rolled circular blank are very thin, hence the holes on the wheel disc can be formed by lightly knocking off or punching the salient parts merely, which is quite simple and convenient.
FIG. 10 shows a top view of the cavity of rolling explorator 4 in another shape.
FIG. 11 shows a top view of the cavity of rolling explorator 4 in further another shape. It can be seen that the shape of the cavity of the rolling explorator 4 can be changed depending on the desired shape of the workpiece from FIG. 9 to FIG. 11 . It should be understood that the shapes of the cavity of the rolling explorator in the invention could be various, and the shapes shown in FIG. 9 to FIG. 11 are merely three embodiments which can not be considered as the limitations on the invention.
After rolling forming process described above, the wheel disc blank has a uniform mass along the circumferential direction and has a high dynamic balance precision, so the outer circle of the wheel disc blank does not need to be further processed on a vertical lathe. The precision of the end surface of the outer circle can be ensured by moulds, as long as following steps will be performed:
(3) Performing trimming and sizing on the wheel disc blank in a blanking method.
(4) Stretching the wheel disc blank in dwell method with a blank holder.
(5) Blanking the center hole and screw holes.
(6) Blanking hand holes and then extruding them.
(7) Reaming the spherical surface of the screw holes.
(8) Turning the center hole.
As shown in FIG. 2 , FIG. 3 , FIG. 7 and FIG. 8 , the forming forces, the deformation ways of the blanks and the results are different between the rolling forming method of the invention and the spinning forming method. The spinning deformation force, which makes the blank stretch in the forming process of the wheel disc, is smaller than the rolling deformation force. During the rolling forming process, the stress area of the blank is larger, the force is stronger and the blank is extruded in the explorator, which generates a yield deformation of the blank. The reason for that the deformation forces are different between the rolling forming method and the spinning forming method is that the angles in these two forming ways are different. The rolling angle α 5 is smaller than the spinning angle (α 1 +α 2 ) (the smaller the angle, the stronger the force), and the rolling gripping angle α 6 (i.e. the gripping angle of the rolling wheel 51 ) of the rolling wheel 51 is smaller than the spinning gripping angle (α 3 +α 4 ) of the spinning wheel (the smaller the rolling gripping angle, the stronger the extruding force), therefore the rolling force in the invention is much stronger than the spinning force.
The inventor adopts the rolling forming method of the invention to form wheel disc products with 380 material, and then performs bending fatigue tests on the wheel disc products. The results of the bending fatigue tests show that cracks occur in the wheel disc products (i.e. the wheel disc products are damaged) after above 1.5 million tests, and the wheel disc products are still intact after 1.2 million tests.
In order to contrast with the effect of rolling forming method of the invention, the inventor also adopts the spinning forming method to form wheel disc products with 380 material, and then also performs bending fatigue tests on the wheel disc products. The results of the bending fatigue tests show that the wheel disc products are generally damaged after about 1 million tests.
It can be seen that the rolling forming method of the invention is shorter in processing time, higher in production efficiency, higher in product precision and larger in bending fatigue strength comparing with the existing spinning forming method.
The above description is merely embodiments in nature and is in no way intended to limit the invention, its application, or use. | The invention provides a rolling forming method of wheel disc, which comprises the following steps: (1) Baiting a circular blank; (2) placing the circular blank in a cavity of a rolling explorator and adopting at least two rolling wheels symmetrically arranged along the circumferential direction of the rolling explorator to perform planar synchronous staggered rolling on the circular blank in the cavity of the rolling explorator; (3) performing trimming and sizing; and (4) stretch forming. The rolling forming method of wheel disc of this invention can precisely form various geometric sections with gradual deformation. The formed product has a uniform mass in the axial direction and the circumferential direction, and has a high dynamic balance precision. The invention can make the blank deform precisely, enhance the production efficiency, and reduce the cost, therefore the invention has good application and popularization prospect. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a Continuation Application of International Application No. PCT/JP2007/000387, filed Apr. 11, 2007, designating the U.S., in which the International Application claims a priority date of Apr. 26, 2006, based on prior filed Japanese Patent Application No. 2006-122409, the entire contents of which are incorporated herein by reference.
BACKGROUND
1. Field
The present invention relates to a head mountable image displaying apparatus (a wearable display).
2. Description of the Related Art
In recent years, a wearable display in which a displaying device such as a liquid crystal display element (LCD) is mounted on a head portion of a user is proposed. This wearable display is generally called as a head mount display (HMD) and so on (refer to Patent Document 1, and so on).
The user couples the HMD to a mobile media player (terminal) and so on, carries it, and thereby, it is possible to enjoy desired video contents at a place where the user has gone and so on (Patent Document 1: Japanese Unexamined Patent Application Publication No. 2002-232810).
In future, a requirement in which plural HMD users want to enjoy the same contents simultaneously may occur when the HMD users increase. However, an equipment branching a video signal output from the terminal, an equipment converting the video signal into a radio signal, and so on are necessary to realize the above-stated requirement by the conventional HMD.
SUMMARY
A proposition of the present invention is to provide a wearable display suitable for plural users to enjoy contents including images simultaneously.
To realize the above-stated proposition, a wearable display according to the present invention includes an apparatus body including a device making information of contents including images into a state capable of being sensed by a user and mounting fixtures mounting the device on a head portion of the user, and an external output unit outputting a signal having same contents as a signal input to the device to an external device, at an exterior part of the apparatus body.
Incidentally, a signal processing part performing a process for the signal output to the external device is included inside the apparatus body, and the signal processing part limits operations of the process during a period when the external device is not coupled to the external output unit.
Besides, the mounting fixtures are able to invert a direction of the device relative to the user, and an inverting processing part inverting only the signal input to the device between the signal input to the device and the signal output to the external device, in accordance with an inverting direction thereof when the direction is inverted, may be included inside the apparatus main body.
Besides, it is desirable that at least an image displaying device making the images included in the contents into a state capable of being sensed by one eye of the user, is included in the device.
Besides, it is desirable that the image displaying device making the images included in the contents into a state capable of being sensed by one eye of the user and an audio output device making audio included in the contents into a state capable of being sensed by left and right ears of the user are included in the device.
Besides, a memory part capable of storing files of the contents, and a signal reproducing part reproducing the files of the contents and generating the signal may be included inside the apparatus body.
Besides, an external input unit inputting the signal from the external device may be provided at the exterior part of the apparatus body.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an embodiment of an HMD system of a first embodiment.
FIG. 2 is a block diagram showing an internal configuration of an HMD main body 100 of the first embodiment.
FIG. 3 is an operation flowchart of a CPU 520 of a second embodiment.
FIG. 4A and FIG. 4B are exterior views (schematic views) of the HMD main body 100 of a third embodiment.
FIG. 5 is a block diagram showing an internal configuration of the HMD main body 100 of the third embodiment.
FIG. 6 is an operation flowchart of the CPU 520 of the third embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
First Embodiment
A first embodiment of the present invention is described. The present embodiment is an embodiment of an HMD system.
First, an overall configuration of the present system is described.
FIG. 1 is an overall configuration chart of the present system. As shown in FIG. 1 , two HMD main bodies 100 , 100 ′ having the same configuration with each other, and a terminal 500 are included in the present system.
The HMD main body 100 includes left and right headphones 102 L, 102 R, a headband 103 supporting these headphones 102 L, 102 R, a side arm 104 coupled to the headband 103 , a displaying unit 101 fixed at a tip portion of the side arm 104 , and so on. The headband 103 presses the left and right headphones 102 L, 102 R to left and right ears of a user when this HMD main body 100 is mounted on a head portion of the user. The side arm 104 disposes the displaying unit 101 in front of one eye of the user in this state. Here, this eye is set to be a left eye, and it is called as a “viewing eye”.
An operating button CB is provided on a case of the right headphone 102 R, and an external input terminal 202 in and an external output terminal 202 out are provided on a case of the left headphone 102 L, in this HMD main body 100 . Among them, the external input terminal 202 in is coupled to an external output terminal 500 out of the terminal 500 via a cable 200 , and the external output terminal 202 out is coupled to an external input terminal 202 in of the HMD main body 100 ′ via a cable 200 ′.
Incidentally, each of the external input terminals 202 in , the external output terminal 202 out , and the external output terminal 500 out has at least three kinds of electric contacts to transmit/receive later-described video signal and left/right audio signals, and connectors complying with these terminals are provided at both ends of the cables 200 , 200 ′.
Files such as video/audio contents, audio contents, video contents, still image contents are stored inside the terminal 500 , and various kinds of operating buttons are provided at a surface of the terminal 500 . It is possible for the user to specify any of the contents to give a reproduction indication thereof to the terminal 500 by operating these operating buttons. When certain contents are specified and the reproduction indication is given, the terminal 500 reproduces the file of the contents, generates a contents signal, and outputs the contents signal to the HMD main body 100 in a generation sequence.
Here, when a subject of reproduction is the video/audio contents, the contents signals become a video signal and left/right audio signals (all of them are analog signals) generated in parallel. Besides, when the subject of reproduction is the audio contents, the contents signals become the left/right audio signals (both of them are analog signals) generated in parallel. Besides, when the subject of reproduction is the video contents, the contents signal becomes the video signal (analog signal). Besides, when the subject of reproduction is the still image contents, the contents signal becomes the video signal for still images (analog signal).
Hereinafter, it is described that the subject of reproduction is the video/audio contents, and the contents signals are the video signal and the left/right audio signals generated in parallel.
Next, an internal configuration and operations of the HMD main body 100 are described.
FIG. 2 is a block diagram showing an internal configuration of the HMD main body 100 . In FIG. 2 , elements which are the same as those in FIG. 1 are shown by the same reference numerals.
A lens 101 L, a mirror 101 M, an LCD (liquid crystal display element) 101 D, a backlight 101 B, and so on are disposed sequentially from the viewing eye side, inside a case of the displaying unit 101 . The LCD 101 D is to make the video signal into video information capable of being sensed by the viewing eye. The lens 101 L has a function to form a magnified virtual image of the LCD 101 D behind the displaying unit 101 .
A left speaker 570 L, a CPU 520 , a RAM 530 used for a work of the CPU 520 , a ROM 510 storing operation programs of the CPU 520 , an encoder 540 en and a decoder 540 de complying with a standard such as an NTSC, an LCD driver 101 D′, a backlight driver 101 B′, an amplifier 550 , and so on are disposed inside the case of the left headphone 102 L. Besides, the external input terminal 202 in and the external output terminal 202 out are provided on the case of the left headphone 102 L, as stated above.
A right speaker 570 R, a power supply circuit 501 , and so on are disposed inside the case of the right headphone 102 R. The power supply circuit 501 supplies necessary power to respective parts of the HMD main body 100 under an indication of the CPU 520 . Besides, the operating button CB is provided on the case of the right headphone 102 R as stated above. The user operates this operating button CB to give an indication to the HMD main body 100 .
Incidentally, disposition destinations of elements other than the lens 101 L, the mirror 101 M, the LCD 101 D, the backlight 101 B, the speakers 570 L, 570 R may be changed in the above-stated HMD main body 100 .
The video signal and the left/right audio signals are input in parallel from an external device (terminal 500 ) coupled thereto to the external input terminal 202 in . These video signal and the left/right audio signals are digitally processed in parallel at the decoder 540 de , and thereafter, downloaded to the CPU 520 . The CPU 520 transmits the video signal to the LCD driver 101 D′, and transmits the left/right audio signals to the amplifier 550 .
The LCD driver 101 D′ converts the given video signal into an appropriate modulating signal, gives it to the LCD 101 D, and performs a time modulation of a transmissivity distribution of the LCD 101 D. At this time, the backlight 101 B is lighted by the backlight driver 101 B′ with appropriate intensity. Accordingly, video is displayed on a front surface of the LCD 101 D, and the video capable of being sensed by the viewing eye of the user is supplied from the HMD main body 100 .
The amplifier 550 performs an amplifying process of the given left/right audio signals in parallel, and thereafter, transmits the left audio signal to the speaker 570 L, and transmits the right audio signal to the speaker 570 R. Accordingly, audio is output from the speakers 570 L, 570 R, and the audio capable of being sensed by the left and right ears of the user is supplied from the HMD main body 100 .
Besides, the CPU 520 transmits the video signal which is the same as the one transmitted to the LCD driver 101 D′ and the left/right audio signals which are the same as the ones transmitted to the amplifier 550 , to the encoder 540 en in parallel. These video signal and the left/right audio signals are analog processed in parallel at the encoder 540 en , then given to the external output terminal 202 out , and output to an external device (HMD main body 100 ′) which is coupled thereto in parallel.
Further, the above-stated operations of the HMD main body 100 are similarly applicable for another HMD main body 100 ′ (refer to FIG. 1 ). Accordingly, the HMD main body 100 ′ supplies the video and audio to the user in accordance with the video signal and the left/right audio signals transmitted from the coupled external device (HMD main body 100 ) in parallel. The video and audio supplied to the user of the HMD main body 100 ′ at a certain timing are the same as the ones supplied to the user of the HMD main body 100 at approximately the same timing.
Accordingly, it is possible to let the user of the HMD main body 100 and the user of the HMD main body 100 ′ enjoy the same video/audio contents simultaneously only by coupling the HMD main body 100 and the HMD main body 100 ′ properly in the present system.
Modified Example of First Embodiment
Incidentally, two HMD main bodies having the same constitution are coupled with each other in the present system, but three or more HMD main bodies having the same constitution as the above may be coupled with each other. Accordingly, it is possible to let three or more users enjoy the same video/audio contents simultaneously.
Besides, the HMD main body 100 of the present system transmits the contents signals (here, the video signal and the left/right audio signals) input from outside to outside via the CPU 520 , but the contents signals may be transmitted to outside as they are not via the CPU 520 .
Besides, the ROM 510 is to store the operation programs of the CPU 520 in the HMD main body 100 of the present system, but the files of the contents may be stored in the ROM 510 while using a large-capacity, rewritable memory (flash memory and so on) as the ROM 510 . In this case, a function reproducing the file to generate the contents signal is given to the CPU 520 of the HMD main body 100 . Besides, in this case, the HMD main body 100 may output the contents signal generated internally to outside instead of outputting the contents signal input from outside to outside.
Besides, a coupling terminal to couple to an information terminal such as a computer and so on, and to transmit/receive the files of the contents between the information terminal is provided at the HMD main body 100 , when the files of the contents are stored in the ROM 510 .
Besides, the HMD main body 100 of the present system includes the speakers 570 L, 570 R, but they may not be given if it is not necessary to supply audio to the user. In this case, the circuit relating only to the audio (amplifier 550 ) may not be given within the HMD main body 100 .
Second Embodiment
A second embodiment of the present invention is described. The present embodiment is a modified example of the HMD main body 100 of the first embodiment. Here, only different points from the HMD main body 100 of the first embodiment are described. The different points exist in the operations of the CPU 520 .
FIG. 3 is an operation flowchart of the CPU 520 of the present embodiment. As shown in FIG. 3 , the CPU 520 begins to monitor whether the external input terminal 202 in is coupled to an external device or not based on a coupling state of the external input terminal 202 in (step S 11 ), when power of the HMD main body 100 is turned on, and the power supply to the respective parts of the HMD main body 100 is started.
The CPU 520 continues the power supply for the decoder 540 de (step S 12 ) during a period when the external input terminal 202 in is coupled to the external device (terminal 500 ) (YES in step S 11 ). At this time, the supply of the video and audio (supply of contents) from the HMD main body 100 to the user becomes possible. Incidentally, a supply method of the contents for the user is as same as it is described in the first embodiment.
On the other hand, the CPU 520 stops the power supply for the decoder 540 de (step S 13 ) during the period when the external device (terminal 500 ) is not coupled to the external input terminal 202 in (NO in step S 11 ). At this time, the supply of the contents from the HMD main body 100 to the user becomes impossible.
Besides, the CPU 520 controls the encoder 540 en as same as the control relating to the decoder 540 de as stated above (The flow thereof is the same as in FIG. 3 , and the drawing is not given). Namely, the CPU 520 monitors whether the external output terminal 202 out is coupled to the external device or not based on a coupling state of the external output terminal 202 out .
The CPU 520 continues the power supply for the encoder 540 en during the period when the external output terminal 202 out is coupled to the external device (HMD main body 100 ′). At this time, an output of a video signal and audio signals (output of contents signals) from the HMD main body 100 to the external device becomes possible. Incidentally, an output method of the contents signals for the external device is as same as it is described in the first embodiment.
On the other hand, the CPU 520 stops the power supply for the encoder 540 en during the period when the external device is not coupled to the external output terminal 202 out . At this time, the output of the contents signals from the HMD main body 100 to the external device becomes impossible.
As stated above, the HMD main body 100 of the present embodiment limits the operations of the encoder 540 en and the decoder 540 de to the minimum, and therefore, a power consumption thereof can be reduced.
Incidentally, subjects of limitation of the power supply are set to be both the encoder 540 en and the decoder 540 de in the HMD main body 100 of the present embodiment, but it may be either one of them.
Third Embodiment
A third embodiment of the present invention is described. The present embodiment is a modified example of the HMD main body 100 of the first embodiment. Here, only different point from the HMD main body 100 of the first embodiment is described. The different point exists in a point that it is configured such that a switching of the viewing eye is possible.
FIG. 4A is an exterior view (schematic view) of the HMD main body 100 of the present embodiment, and an appearance in which a user U wearing the HMD main body 100 is viewed from a lateral direction is shown.
As shown in FIG. 4A , the HMD main body 100 of the present embodiment has a turning mechanism 580 between the side arm 104 and the left headphone 102 L, and the side arm 104 can turn within an angle range of approximately 180° while using a line coupling between the left and right headphones (a line in a front-rear direction of a page space) as a turning axis resulting from a motion of the turning mechanism 580 , as shown by a dotted arrow in FIG. 4A . An appearance of the HMD main body 100 after it is turned 180° is shown in FIG. 4B .
Hereinafter, a state of the HMD main body 100 shown in FIG. 4A (=a turning angle of the side arm 104 is in a vicinity of 0°) is set as a “standard state”, and a state of the HMD main body 100 shown in FIG. 4B (=the turning angle of the side arm 104 is in a vicinity of 180°) is set as an “inverted state”.
Besides, whether the HMD main body 100 is in the standard state or in the inverted state is detected by a sensor 580 s provided in a vicinity of the turning mechanism 580 . This sensor 580 s is, for example, a mechanical switch which is turned on (or turned off) only when the turning angle of the side arm 104 is 90° or more.
The user U of the HMD main body 100 sets the HMD main body 100 in the standard state ( FIG. 4A ), and wears the HMD main body 100 on a head portion so that the left headphone 102 L is in contact with the left ear and the right headphone is in contact with the right ear, when the user U views the video with a left eye EL.
On the other hand, the user U of the HMD main body 100 sets the HMD main body 100 in the inverted state ( FIG. 4B ), and wears the HMD main body 100 on the head portion so that the left headphone 102 L is in contact with the right ear and the right headphone is in contact with the left ear, when the user U views the video with a right eye ER.
Accordingly, when it is viewed from the user U side, up, down, left and right of the displaying unit 101 are inverted and left and right of the headphone are inverted when the user U views the video with the right eye ( FIG. 4B ).
FIG. 5 is a block diagram showing an internal configuration of the HMD main body 100 of the present embodiment. In FIG. 5 , elements which are the same as those in FIG. 2 are shown by the same reference numerals. As shown in FIG. 5 , a selector 550 s is inserted at an output side of the amplifier 550 , and an output of the sensor 580 s is coupled to the CPU 520 , in the HMD main body 100 of the present embodiment.
It is possible for the CPU 520 to monitor the output of the sensor 580 s , and to recognize whether the HMD main body 100 is in the standard state or not.
Besides, it is possible for the CPU 520 to switch a transmission destination of the right audio signal and a transmission destination of the left audio signal between the right speaker 570 R and the left speaker 570 L by giving an indication to the selector 550 s . The audio supplied from the speakers 570 R, 570 L to the user is inverted between left and right, resulting from this switching.
Besides, it is possible for the CPU 520 to indicate the LCD driver 101 D′ to invert an output destination of the modulating signal among up, down, left and right. The video supplied from the LCD 101 D to the user inverts among up, down, left and right resulting from this inversion.
Consequently, the CPU 520 may perform the inversion of the contents as stated above when the HMD main body 100 shifts from the standard state ( FIG. 4A ) to the inverted state ( FIG. 4B ). Accordingly, it is possible for the HMD main body 100 to provide the information of the contents to the user in a proper direction in either case when the viewing eye is left or right.
FIG. 6 is an operation flowchart of the CPU 520 of the present embodiment. As shown in FIG. 6 , the CPU 520 of the present embodiment monitors whether the HMD main body 100 is in the standard state or not based on the output of the sensor 580 s (step S 21 ).
The CPU 520 supplies the contents to the user (step S 22 ) and outputs the contents signal of the same contents to outside (step S 23 ) as same as in the first embodiment, during the period when the HMD main body 100 is in the standard state (YES in step S 21 ).
On the other hand, the CPU 520 inverts the contents supplied to the user as stated above (step S 24 ) and outputs the contents signal of the same contents before the inversion to outside (step S 25 ) during the period when the HMD main body 100 is in the inverted state (NO in step S 21 ).
As stated above, the HMD main body 100 of the present embodiment can switch the viewing eyes, and has the function to invert the contents in accordance with the switching of the viewing eyes. However, the switching is not reflected on the contents signal transmitted to outside.
Consequently, it is possible for the HMD main body 100 of the present embodiment to provide the contents to the user in the proper direction, and it is also possible to prevent a possibility of malfunction of the coupled HMD main body 100 ′ (refer to FIG. 1 ).
Incidentally, in the HMD main body 100 of the present embodiment, the switching method of the viewing eye is not limited to the above-stated method (the method in which the side arm is turned 180°), but, for example, any of the methods described in Japanese Unexamined Patent Application Publication No. 2004-233780 can be adopted.
Besides, the present embodiment is the modified example of the HMD main body 100 of the first embodiment, but the HMD main body 100 of the second embodiment may be modified similarly.
The many features and advantages of the embodiments are apparent from the detailed specification and, thus, it is intended by the appended claims to cover all such features and advantages of the embodiments that fall within the true spirit and scope thereof. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the inventive embodiments to the exact construction and operation illustrated and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope thereof. | A proposition is to provide a wearable display suitable for enjoying contents including images by plural users simultaneously. To realize the proposition, the wearable display provides an external output unit outputting a signal having the same contents as a signal input to a device to an external device, at an exterior part of an apparatus body including the device making information of contents including images into a state capable of being sensed by a user, and mounting fixtures mounting the device on a head portion of the user. | 6 |
[0001] This application is a continuation-in-part of, and claims the benefit of, pending U.S. patent application Ser. No. 09/654,024 filed on Sep. 1, 2000, and which is a continuation of U.S. Pat. No. 6,170,220, filed Jan. 16, 1998, and issued Jan. 9, 2001, both of which are incorporated herein in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention encompasses a building component used to make insulated concrete forms and, more particularly, a system that can be used to make cast-in-place walls using two opposed side panels or tilt-up walls using a single side panel. The present invention further encompasses components to improve the walls formed and to simplify the construction process.
[0004] 2. Background Art
[0005] Concrete walls in building construction are most often produced by first setting up two parallel form walls and pouring concrete into the space between the forms. After the concrete hardens, the builder then removes the forms, leaving the cured concrete wall.
[0006] This prior art technique has drawbacks. Formation of the concrete walls is inefficient because of the time required to erect the forms, wait until the concrete cures, and take down the forms. This prior art technique, therefore, is an expensive, labor-intensive process.
[0007] Accordingly, techniques have developed for forming modular concrete walls that use a foam insulating material. The modular form walls are set up parallel to each other and connecting components hold the two form walls in place relative to each other while concrete is poured therebetween. The form walls, however, remain in place after the concrete cures. That is, the form walls, which are constructed of foam insulating material, are a permanent part of the building after the concrete cures. The concrete walls made using this technique can be stacked on top of each other many stories high to form all of a building's walls. In addition to the efficiency gained by retaining the form walls as part of the permanent structure, the materials of the form walls often provide adequate insulation for the building.
[0008] One embodiment of form walls is disclosed in U.S. Pat. No. 5,390,459, which issued to Mensen on Feb. 21, 1995, and which is incorporated herein by reference. This patent discloses “bridging members” that comprise end plates connected by a plurality of web members. The bridging members also use reinforcing ribs, reinforcing webs, reinforcing members extending from the upper edge of the web member to the top side of the end plates, and reinforcing members extending from the lower edge of the web member to the bottom side of the end plates. As one skilled in the art will appreciate, this support system is expensive to construct, which increases the cost of the formed wall. Also, these walls cannot feasibly be used to make floors or roof panels.
SUMMARY OF THE INVENTION
[0009] The present invention provides an insulated concrete form comprising at least one longitudinally-extending side panel and at least one web member partially disposed within the side panel. The web member extends from adjacent the external surface of the side panel through and out of the interior surface of the side panel. Three embodiments of the present invention that may be used to construct a concrete form are described herein. The first embodiment uses opposed side panels that form a cavity therebetween into which concrete is poured and substantially cured. The second embodiment uses a single side panel as a form, onto which concrete is either poured or below which concrete is poured and the form inserted into. Once the concrete cures and bonds to the side panel in the second embodiment, it is used as a tilt-up wall, floor, or roof panel. The third embodiment operates similar to the first embodiment but, instead of having two opposed side panels to form the cavity, the present invention uses one side panel and an opposed sheet or other form on the opposed side to form the cavity. After the concrete substantially cures in the third embodiment, the sheet can be removed and reused again or, alternatively, remain as part of the formed structure. If the sheet is removed, the resulting structure is similar to a tilt-up wall formed using the second embodiment of the present invention.
[0010] In the first embodiment, the web member is preferably partially disposed in the side panel so that a portion of the web member projects beyond the interior surface of the side panel and faces but does not touch an opposing side panel. The first embodiment also uses a connector that attaches to the two web members in opposing side panels, thereby bridging the gap between the two side panels to position the side panels relative to each other. The connectors preferably have apertures to hold horizontally disposed re-bar. The connectors also have different lengths, creating cavities of different widths for forming concrete walls having different thicknesses. The connectors are interchangeable so that the desired width of the wall can be set at the construction site.
[0011] For the second embodiment, a portion of the web member preferably projects beyond the interior surface of the side panel. In one design, the side panel is first horizontally disposed so that the interior surface and portion of the web member extending therethrough are positioned upwardly. Forms are placed around the periphery of the side panel and concrete is then poured onto the interior surface. In a second design, the concrete is poured into a volume defined by perimeter forms and then the side panel is placed upon the fluid concrete so that at least a portion of the web member in the side panel is disposed in the concrete. Alternatively, a third design is formed as a hybrid of the first and second designs, namely, one side panel is horizontally disposed, concrete is poured onto the interior surface and contained by forms, and then another panel is place upon the poured concrete so that side panels are on both sides of the concrete. For all three designs, once the concrete substantially cures and bonds with the interior surface of the side panel and the portion of the web member extending therethrough, the side panels and connected concrete slab can be used as a tilt-up wall, flooring member, or roof panel.
[0012] The third embodiment of the present invention encompasses a process generally similar to the first embodiment, except that a sheet of plywood or the like is used instead of a second side panel. The sheet can either be removed after the concrete cures and used again or remain part of the formed structure.
[0013] The present invention further comprises components to improve the walls formed using side panels and to simplify the construction process.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
[0014] [0014]FIG. 1 is a perspective view of a first embodiment of the present invention.
[0015] [0015]FIG. 2 is a perspective side view of a FIG. 1 taken along line 2 - 2 .
[0016] [0016]FIG. 2A is an alternative view of FIG. 2 showing concrete disposed between the two opposed side panels. FIG. 2A also shows the tilt-up wall formed with side panels on the two opposed sides of the concrete that has been erected.
[0017] [0017]FIG. 3 is a perspective view of one side panel shown in FIG. 1, in which three web members show four attachment points extending through the interior surface of the side panel. Two of the web members show two connectors attached to attachment points and one web member shows two connectors and a stand-alone web member attached to those two connectors.
[0018] [0018]FIG. 4 is a perspective view of the connector shown in FIG. 3.
[0019] [0019]FIG. 4A is a perspective view of an alternative of the connector shown in FIG. 4.
[0020] [0020]FIG. 5 is a perspective view of one design of the side panel of the present invention, in which a portion of the side panel is cut away to show the body portion of the web member partially disposed and integrally formed therein.
[0021] [0021]FIG. 6 is an exploded perspective view of an alternative design of the web member shown in FIGS. 3 and 5 and having five attachment points instead of four. FIG. 6 also shows an anchor and an extender used in conjunction with the different embodiments of the present invention.
[0022] [0022]FIG. 7 is a perspective view of a second embodiment of the present invention showing generally the concrete formed below the side panel.
[0023] [0023]FIG. 8 is another perspective view of the second embodiment of the present invention showing generally the concrete formed above the side panel.
[0024] [0024]FIG. 9 is a perspective view of a third embodiment of the present invention showing a cavity defined by a side panel and a sheet.
[0025] [0025]FIG. 9A is an alternative view of FIG. 9 showing concrete disposed between the side panel and the sheet.
[0026] [0026]FIG. 10 is a perspective view of a stand-alone web member and a connector, both of which include a spacer.
[0027] [0027]FIG. 11 is a perspective view of an upstanding concrete structure formed by two of the second embodiments or the third embodiment of the present invention, which are shown in FIGS. 7, 8, 9 , and 9 A.
[0028] [0028]FIG. 12 is a cross-sectional side view showing two opposed side panels and the web members partially disposed therein, in which the side panels are interconnected in various combinations by flexible linking members joining extenders or slots formed into the web members.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The present invention is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. As used in the specification and in the claims, “a,” “an,” and “the” can mean one or more, depending upon the context in which it is used. The preferred embodiment is now described with reference to the figures, in which like numbers indicate like parts throughout the figures.
[0030] As shown in FIGS. 1 - 12 , the present invention comprises a concrete form system 10 used for constructing buildings. A first embodiment of the present invention, shown best in FIGS. 1 - 2 A, comprises at least two opposed longitudinally-extending side panels 20 , at least one web member 40 partially disposed within each of the side panels 20 , and a connector 50 disposed between the side panels 20 for connecting the web members 40 to each other. As shown in FIG. 2A, concrete C is poured between the side panels 20 so that it bonds with the side panels 20 and the web members 40 . Two designs of a second embodiment of the present invention, which is discussed in more detail below and shown in FIGS. 7 and 8, involves using a single side panel 20 that bonds with the concrete C, instead of using opposed side panels 20 on both sides of the concrete C. The second embodiment also includes a design in which the wall has side panels 20 on both sides of the concrete to appear as the wall in FIG. 2A, but is formed differently from the first embodiment. A third embodiment of the present invention is shown in FIGS. 9 and 9A and is similar to the first embodiment, but uses one side panel 20 and a sheet 80 instead of two opposed side panels 20 .
[0031] Each side panel 20 has a top end 24 , a bottom end 26 , a first end 28 , a second end 30 , an exterior surface 32 , and an interior surface 34 . The presently preferred side panel 20 has a thickness (separation between the interior surface 34 and exterior surface 32 ) of approximately two and a half (2½) inches, a height (separation between the bottom end 26 and the top end 24 ) of sixteen (16) inches, and a length (separation between the first end 28 and second end 30 ) of forty-eight (48) inches. The dimensions may be altered, if desired, for different building projects, such as increasing the thickness of the side panel 20 for more insulation. Half sections of the side panels 20 can be used for footings.
[0032] Referring now to FIGS. 1 and 2 showing the first embodiment of the present invention, the interior surface 34 of one side panel 20 faces the interior surface 34 of another side panel 20 and the opposed interior surfaces 34 are laterally spaced apart from each other a desired separation distance so that a cavity 38 is formed therebetween. Concrete—in its fluid state—is poured into the cavity 38 and allowed to substantially cure (i.e., harden) therein to form the wall 10 , as shown in FIG. 2A. Preferably, for the first embodiment, the opposed interior surfaces 34 are parallel to each other. The volume of concrete received within the cavity 38 is defined by the separation distance between the interior surfaces 34 , the height of the side panels 20 , and the length of the side panels 20 .
[0033] The side panels 20 are preferably constructed of polystyrene, specifically expanded polystyrene (“EPS”), which provides thermal insulation and sufficient strength to hold the poured concrete C until it substantially cures. The formed concrete wall 10 using polystyrene with the poured concrete C has a high insulating value so that no additional insulation is usually required. In addition, the formed walls have a high impedance to sound transmission.
[0034] As best shown in FIGS. 3 and 5, the interior surface 34 preferably includes a series of indentations 36 therein that increase the surface area between the side panels 20 and concrete C to enhance the bond therebetween. To improve further the bond between the side panels 20 and the concrete C poured in the cavity 38 , a portion of each of the web members 40 formed in or passing through the side panels 20 extends through the interior surface 34 of the side panels 20 into the cavity 38 . A portion of each web member 40 is preferably integrally formed within one side panel 20 and is also cured within the concrete C so that the web member 40 strengthens the connection between the side panel 20 and the concrete C. That is, since the web member 40 is preferably an integral part of the side panel 20 , it bonds the side panel 20 to the concrete C once the concrete is poured and substantially cures within the cavity 38 . However, other designs are contemplated, such as designs in which the web member is not integrally formed into the side panel and, for example, the web member is slid into slots precut into the side panel at the construction site.
[0035] As shown in FIGS. 1 - 3 and 5 , each side panel 20 has at least one web member 40 formed into it. Preferably, the each web member 40 formed within one side panel 20 is separated a predetermined longitudinal distance from other web members 40 , which is typically eight (8) inches. Based on the preferred length of the side panel 20 of forty-eight (48) inches, six web members 40 are formed within each side panel 20 , as shown in FIGS. 3 and 5.
[0036] Portions of each web member 40 that extend through the interior surface 34 of the side panel 20 forms one or more attachment points 44 . The attachment points 44 are disposed within the cavity 38 and are preferably spaced apart from the interior surface 34 of the side panels 20 in the first embodiment. However, as one skilled in the art will appreciate, the attachment points 44 may take any of a number of alternate designs formed by or independently of the web members 40 , including as examples: slots, channels, grooves, projections or recesses formed in the side panels; hooks or eyelets projecting from or formed into the side panels; twist, compression or snap couplings; or other coupling means for engaging cooperating ends of the connectors.
[0037] Preferably, as addressed in more detail below and as shown best in FIGS. 3, 5, and 6 , each attachment point 44 is substantially rectangular and flat in plan view to be complementarily and slidably received within one respective end 52 of the connector 50 . Thus, in the first embodiment, the connectors 50 shown in FIGS. 4 and 4A engage two attachment points 44 on opposed web members 40 , which position the interior surfaces 34 of the side panels 20 at a desired separation distance and support the side panels 20 when the fluid concrete is poured into the cavity 38 . In the preferred embodiment, the connector 50 makes a two-point connection with opposed web members 40 because each connector has two ends 52 that each couple to one attachment point 44 , although it is contemplated making a four-point connection (i.e., each connector 50 engages four attachment points 44 instead of two as illustrated in the figures).
[0038] Referring now to FIGS. 3, 6, and 10 , each web member 40 also preferably has an end plate 42 that is disposed adjacent the exterior surface 32 of the side panel 20 in the preferred embodiment. The end plates 42 are preferably substantially rectangular in plan view. Except when used as a stand-alone web member 40 ′ for the third embodiment as discussed below, each end plate 42 of the web members 40 is preferably completely disposed within a portion of one respective side panel 20 , as shown best in FIGS. 2 and 5. That is, the end plates 42 are located slightly below the exterior surface 32 of, or recessed within, the side panel 20 , preferably at a distance of one-quarter (¼) of an inch from the exterior surface 32 . This position allows for easily smoothing the surface of the side panels 20 without cutting the end plate 42 should the concrete, when poured, create a slight bulge in the exterior surface 32 of the side panels 20 . However, when embedded within the side panel 20 , it is desired that some visual indicia be included on the external surface 32 to enable the construction worker to locate quickly and accurately the end plate 42 . Alternatively, the end plates 42 can abut the exterior surface 32 of panels 20 so that a portion of the end plate 42 is exposed over the exterior surface 32 . It is also preferred in the first and third embodiments that each end plate 42 is oriented substantially upright and disposed substantially parallel to the exterior surface 32 of the side panel 20 when forming a concrete form 10 .
[0039] Similar to the end plate 42 , the attachment points 44 are also preferably oriented substantially upright in the first and third embodiments so that one attachment point 44 is disposed above another attachment point 44 . As best shown in FIGS. 2, 3, and 9 , in one design each of the web members 40 has four spaced-apart attachment points 44 , in which the attachment points 44 for each web member 40 are vertically disposed within the cavity 38 in a substantially linear relationship. The attachment points 44 are placed in two groups—a top group of two attachment points 44 and a bottom group of two attachment points 44 . Adjacent attachment points 44 in the two groups are spaced apart a first distance from each other, preferably approximately two and an eighth (2⅛) inches apart between center points. In addition, the closest attachment points 44 of the two groups, i.e., the lowermost attachment point 44 of the top group and the uppermost attachment point 44 of the bottom group, are spaced apart a second distance from each other. The second distance, which is approximately six (6) inches in the preferred embodiment for a twelve (12) inch connector, is more than double and almost triple the first distance.
[0040] In an alternative design, the web member 40 includes five attachment points 44 , which is illustrated best in FIG. 6. This design also has the two groups of two attachment points 44 as discussed above, but also includes a fifth attachment point 44 at approximately the center of the two groups. This design having five attachment points 44 is presently preferred over the web member 40 having four attachment points because it provides even greater flexibility for the architect and/or construction worker. As one skilled in the art will appreciate, the number of attachment points 44 used for each web member 40 can be further varied in number and spacing based on relevant factors such as the dimensions of the side panels 20 and the wall strength or reinforcement desired.
[0041] The designs of the multiple attachment points 44 of the present invention is an improvement over prior art systems, which lack multiple mounting points for attaching an interconnecting device. The side panels 20 and web members 40 in the present invention can be cut horizontally over a wide range of heights to satisfy architectural requirements, such as leaving an area for windows, forming odd wall heights, and the like, yet still have at least two or three attachment points 44 to maintain structural integrity of the wall. Prior art systems, in contrast, lose structural integrity if cut horizontally, thus requiring extensive bracing to resist collapsing when concrete is poured into the cavity between the panels. One skilled in the art, however, will appreciate that the web member of the present invention is not limited to these exemplary designs and can include other shapes in which a portion is disposed adjacent both the interior and exterior surfaces in which the web member is disposed.
[0042] Referring again to FIGS. 1 and 2 showing the first embodiment of the present invention, the attachment points 44 of the web members 40 extend into the cavity 38 and the attachment points 44 of each web member 40 formed within one side panel 20 are spaced apart from the attachment points 44 of the web members 40 formed within the opposed side panel 20 . Thus, the web members 40 preferably do not directly contact each other; instead, each attachment point 44 independently engages the connector 50 that interconnects the web members 40 and, accordingly, the side panels 20 .
[0043] Referring now to FIGS. 4 and 4A, the illustrated connectors 50 have opposed ends 52 and a length extending therebetween. The ends 52 of the connectors 50 are each of a shape to engage one attachment point 44 of two respective web members 40 within opposed panels. As mentioned above and as best shown in FIGS. 5, 6, and 12 , the attachment points 44 are preferably substantially rectangular and flat and a stem 48 extends the attachment point 44 through the side panel 20 from the remaining portions of the web member 40 . As such, the stem 48 and the attachment point 44 are “T” shaped in cross-sectional view, in which the attachment point forms the top of the “T.”
[0044] In conjunction, as best shown in FIGS. 4 and 4A, each end 52 of the connector 50 has a track 54 into which the preferably rectangular attachment point 44 is complementarily and slidably received. The connector 50 , accordingly, is movable between a separated position and an attached position. In the separated position (as illustrated, for example, in FIGS. 4 and 4A), the end 52 of the connector 50 is spaced apart from the respective attachment point 44 to which it will be connected. In the attached position, the end 52 of the connector 50 is engaged to the attachment point 44 , which is shown, for example, in FIGS. 2 and 3.
[0045] In the preferred embodiment, the ends 52 of the connector 50 are detachably locked to the respective attachment points 44 when in the attached position. By being detachably locked, it will be appreciated that, while only contacting the connector 50 , an applying force needed to remove the connector 50 from the attachment point 44 is greater than a force needed to attach that connector to that attachment point 44 . Stated differently, an applying force needed to move the connector 50 from the separated to the attached position is less than a removing force needed to move the connector 50 from the attached to the separated position. The differences in the applying and removing forces may be slight or significant and still be within the scope of the present invention.
[0046] The present invention thus comprises a means for detachably locking the end 52 of the connector 50 into the attached position. The preferred embodiment of the locking means is illustrated in FIGS. 4A and 6. Referring first to FIG. 6, latching members 46 are disposed either above and below the attachment points 44 , although it is acceptable if only one latching member 46 is disposed either above or below the attachment point 44 . The latching members 46 are preferably integrally formed as part of the web member 40 , but can alternatively either be affixed to the web member 40 after it is formed or be connected to the side panel 20 . As shown in FIG. 6, the tip 47 of the latching member 46 is spaced apart from the attachment point 44 and, preferably, flexibly movable but predisposed or biased to be in an extended position, again as shown in FIG. 6. Since it is preferred that the tip 47 of the latching member 46 be flexible, the latching member 46 may be formed as a relatively thin component, which should not prevent the latching member 46 from performing its intended function.
[0047] In conjunction, referring again to FIG. 4A, the connector 50 has a detent 58 disposed above its track 54 . Specifically, the illustrated detent 58 is an indentation formed at the center of the closed end of the track 54 (which is shown as the top end in FIG. 4A). It is further preferred that the detent 58 include a raised back 59 that is located at the back end of the detent 58 . As one skilled in the art will appreciate, however, the detent 58 can be aligned differently such that, for example, the detent 58 is in the center of the closed end of the track 54 instead of at its top or the detent 58 is off-center instead of in the middle of the closed end.
[0048] To move the connector 50 shown in FIG. 4A to the attached position onto the web member 40 shown in FIG. 6, the bottom of the track 54 of the connector 50 is aligned with the top edge of a one attachment point 44 and slid vertically downwardly while the web member 40 is oriented in an upstanding position. Although not preferred or discussed further, the connector could alternatively be aligned with the bottom edge of the selected attachment point and slid upwardly. As the closed portion of track 54 of the connector 50 slides closer to the attachment point 44 while moving downwardly, the closed portion contacts the flexible tip 47 of the latching member 46 . That contact moves the tip 47 of the latching member 46 inwardly toward the end plate 42 of the web member 40 until the detent 58 is aligned with the tip 47 of the latching member 46 , at which time the latching member 46 extends outwardly away from the end plate 42 to its normal extended position to be complementarily received within the detent 58 . Thus, at that point (which preferably is reached when the attachment point 44 is fully received within the track 54 of the connector 50 ), the connector 50 is detachably locked into place by the tip 47 of the latching member 46 being positioned within the detent 58 so that the connector 50 cannot be freely removed from the attachment point 44 . In conjunction, the raised back 59 behind the detent 58 prevents the tip 47 from over extending beyond the detent 58 .
[0049] As one skilled in the art will appreciate, the locking means shown in FIGS. 4A and 6 allows the connector 50 to be easily slid down onto the attachment point 44 using very light downward force (i.e., with just two fingers) to latch the connector 50 to the attachment point 44 . That is, the preferred embodiment of the connector 50 shown in FIGS. 4A and 6 allows a construction worker to slide relatively “loosely” the end 52 of the connector 50 onto the attachment point 44 without significant frictional resistance. Such a design is advantageous because even mild frictional resistance may be burdensome given the number of connectors 50 involved in some construction projects, which may literally involve thousands of connectors 50 each attaching to two web members 40 in opposed side panels 20 . The scope of the connections made may be appreciated by considering FIG. 2, which shows the connections for one pair of opposed side panels 20 . As such, this less burdensome process may translate into a reduction in the amount of time necessary to attach the connectors 50 to the attachment points 44 .
[0050] To remove the connector 50 from the attachment point 44 back to the separated position (which is unusual to occur during a construction project), the flexible tip 47 of the latching member 46 must be pressed inwardly away from the detent 58 and toward the end plate 42 and, concurrently, the connector 50 must be slid upwardly toward the latching member 46 a sufficient distance so that the tip 47 of the latching member 46 is no longer aligned or in registry with the detent 58 . After this initial movement, the connector 50 can be removed from the attachment point 44 , either while still holding the tip 47 of the latching member 46 in the compressed position or releasing the latching member 46 so that its tip 47 contacts the closed portion of the track 54 .
[0051] Thus, although there is low frictional resistance moving the connector 50 to the attached position, the detachably locked connector 50 cannot easily be removed—even with strong upward force—unless the flexible tip 47 of the latching member 46 is compressed, which often requires a two-handed operation to separate the connector 50 from the web member 40 . This latching design further allows a construction worker or foreman to verify that a connector 50 is properly attached to the web members 40 by tapping on the bottom of the connector 50 and having the connector 50 remain in place, whereas other designs might result in the connector 50 “popping off” the attachment points 44 in response to such an upward tapping force. Further, the detachably locking design also more effectively resists the upward forces exerted by concrete to the connectors 50 as the fluid concrete is first placed, or pumped, into the cavity 38 of the concrete form. In so resisting the forces applied by the fluid concrete, the connectors 50 keep the side panels 20 in place and maintain the integrity of the structure when subjected to various forces or pressures.
[0052] Another embodiment of the locking means is shown referring to FIG. 4. As will be noted, the track 54 of the connector 50 forms a gap 56 into which a portion of the stem 48 is complementarily received when the connector 50 is moved to the attached position. The locking means in this embodiment comprises at least one barb 55 on the track 54 of the connector 50 that is oriented into the gap 56 and a corresponding indentation 49 on the stem 48 of the web member 40 (as shown in FIG. 6). As such, when the connector 50 is in the attached position, the barb 55 is complementarily received into the indentation 49 . FIG. 4 shows two spaced-apart barbs 55 extending toward each other in the gap and there would be two corresponding indentations 49 formed into the stem 48 . These barbs 55 provide a frictional fit between the connector 50 and the attachment point 44 of the web member 40 to hold the connector 50 at the attached position. However, the frictional resistance also exists when moving the connectors 50 to the attached position, which makes this embodiment of the locking means less desired.
[0053] One skilled in the art will appreciate that the locking means for the connectors 50 can also be used for the stanchions (some embodiments of which are discussed below and shown in FIG. 6). One skilled in the art will further appreciate that other locking means are possible, such as having the latching member 46 formed on the connector 50 and the detent 58 formed on the web member 40 .
[0054] Referring again to FIGS. 2, 4, and 4 A, the connectors 50 also preferably define an aperture 56 of a size to complementary receive a re-bar (not shown) therein. The re-bar provides reinforcing strength to the formed wall. The diameter of the re-bar can be one quarter (¼) inch or other dimension as required for the necessary reinforcement, which depends on the thickness of the concrete wall and the design engineering requirements. The connectors 50 preferably have two or more apertures 56 and re-bar can be positioned in any of the apertures 56 before the concrete is poured into the cavity 38 . The apertures 56 can be designed so that the re-bar is securably snapped into place for ease of assembly.
[0055] To vary the width of the cavity 38 (i.e., the separation between the interior surfaces 34 of the opposed side panels 20 ), different connectors 50 can have varying lengths. The width of the cavity 38 can be two (2), four (4), six (6), eight (8) inches or greater separation. Different connectors 50 are sized accordingly to obtain the desired width of the cavity 38 . Also, as one skilled in the art will appreciate, the fire rating, sound insulation, and thermal insulation increase as the width of the cavity 38 , which is filled with concrete, increases. One skilled in the art will appreciate that the cavity 38 may only be partially filled with concrete, but such an embodiment is not preferred or desired.
[0056] The web members 40 and connectors 50 are preferably constructed of plastic, more preferably high-density plastic such as high-density polyethylene or high-density polypropylene, although other suitable polymers may be used. Other contemplated high-density plastics include acrylonitrile butadiene styrene (“ABS”) and glass-filled polyethylene or polypropylene, particularly for connectors and stanchions since they are more expensive materials. Factors used in choosing the material include the desired strength of the web member 40 and connector 50 and the compatibility with the material used to form side panels 20 and with the concrete. Another consideration is that the end plates 42 should be adapted to receive and frictionally hold a metal fastener, such as a nail or screw, therein, thus providing the “strapping” for a wall system that provides an attachment point for gypsum board (not shown), interior or exterior wall cladding (not shown), or other interior or exterior siding (not shown). Thus, the web members 40 function to align the side panels 20 , hold the side panels 20 in place during a concrete pour, and provide strapping to connect siding and the like to the formed concrete wall 10 .
[0057] Referring again to FIG. 1, one skilled in the art will appreciate that a plurality of side panels 20 can be longitudinally aligned to form a predetermined length and be vertically stacked to form a predetermined height. For example, as shown in FIG. 1, the first end 28 of one side panel 20 abuts the second end 30 of another side panel 20 and the bottom end 26 of one side panel 20 is disposed on the top end 24 of another side panel 20 . Thus, a series of side panels 20 can be aligned and stacked to form the concrete system 10 into which concrete C is poured to complete the construction of the wall 10 . One consideration, however, is that the side panels 20 are not vertically stacked too high and filled at once so that the pressure on the bottom side panel 20 is greater than the yield strength of the web members 40 or EPS side panels 20 . Instead, the stacked wall of panels 20 can be filled and cured in stages so that the static and dynamic pressures are not excessive on the lower side panels 20 .
[0058] To facilitate the stacking of the components, the side panels 20 are optionally provided with a series of projections 35 and indentations 37 that complementarily receive offset projections 35 and indentations 37 from another side panel 20 (i.e., a tongue-and-groove-type system). The projections 35 and indentations 37 in the adjacent side panels 20 mate with each other to form a tight seal that prevents leakage of concrete C during wall formation and prevents loss of energy through the formed wall.
[0059] Referring still to FIG. 1 for the first embodiment of the present invention, the present invention also uses comer sections 39 . Preferably, each corner section 39 forms a substantially right angle and concrete C is also poured into the corner section similar to the other sections of the concrete form system 10 . Forty-five degree angle comer sections can also be used. Thus, the formed concrete wall is contiguous for maximum strength, as opposed to being separately connected blocks. Still another embodiment of the present invention, which is not shown, uses non-linear side panels so that the formed wall has curvature instead of being straight.
[0060] The first embodiment of the present invention is an improvement over the prior art. Although other systems may use connector elements, the prior art lacks a web member 40 having an end plate 42 , which provides a nailing/screwing strip adjacent the exterior surface 32 of the side panel 20 , and has an attachment point 44 or similar connection projecting into the cavity 38 adjacent the interior surface 34 . Moreover, the present invention uses less plastic and is, therefore, less expensive to manufacture.
[0061] Furthermore, in prior art systems, the panels are made so that large, thick, plastic connector elements slide down in a “T” slot formed within the inside surface of the panel itself. These prior art designs are structurally weaker and the construction workers in the field have substantial difficulty avoiding breaking the panels while sliding the connector element into place. Additionally, the prior art panels can break off from the cured concrete if any “pulling” occurs while mounting sheetrock or other materials onto the outer side of the panel. The preferred embodiment of the present invention having the web member 40 integrally formed into the side panel 20 provides a stronger “interlocking” system among the side panels 20 , the web member 40 , and the connectors 50 , which are imbedded within concrete in the cavity 38 . Nonetheless, as mentioned above, it is contemplated within the scope of the present invention using web members 40 that are not integrally formed into the side panels 20 .
[0062] Now moving to the second embodiment of the present invention, as noted above, there are three methods of constructing the tilt-up walls 10 of the present invention: (1) pouring the concrete and then inserting the panel 20 into the poured concrete, which is also known as “wet-setting” and is shown in FIG. 7; (2) pouring the concrete onto a substantially horizontally-disposed side panel 20 , which is shown in FIG. 8; or (3) pouring the concrete onto a substantially horizontally-disposed side panel 20 and then inserting the panel 20 into the top surface of the poured concrete so that the concrete is “sandwiched” between two opposed side panels 20 and, when erected, appears the same as the wall 10 formed by the first embodiment shown in FIG. 2A. All of the walls 10 formed by these three methods or designs are known as tilt-up walls.
[0063] As noted, the first two designs of the second embodiment use a side panel 20 on only one side of the formed concrete structure 10 , unlike the third design that uses opposed side panels covering both faces of the concrete C. Thus, the walls 10 formed by the first two designs of this embodiment are insulated on one side, which may be either the interior or exterior of the wall. Leaving the external surface as a concrete surface without a side panel is advantageous for insect control, such as preventing termite infestation since termites cannot burrow through concrete C, but may attack and bore through EPS—the preferred material to form the side panels 20 . Alternatively, leaving the interior surface as a concrete surface is advantageous for warehouses in which fork lifts, for example, could potentially damage any interior finishes by forcefully contacting them, whereas a concrete surface subjected to the same contact will remain substantially unimpaired. The side panels 20 may extend the full or a partial height of the tilt-up wall and, as discussed above, provide both sound impedance and thermal insulation.
[0064] For the wet-setting method shown in FIG. 7, it is preferred that a concrete floor slab (not shown), which will serve as a casting base for the tilt-up walls, is formed on a prepared, well-compacted subbase. It has been found that a five-inch (5″) or thicker slab is desired. Also, instead of forming the entire floor during the initial pouring, the slab is typically held back several feet from its ultimate perimeter dimension (i.e., the interior boundaries of the building) to allow space for raising and setting the tilt-up walls after being formed on the floor slab. As discussed below, the gap that exists is subsequently filled in after the tilt-up walls are later erected.
[0065] After the floor slab cures, the perimeter foundations or forms (not shown) within which the concrete is poured for forming the tilt-up walls are next positioned and braced to form a substantially contained volume. The perimeter forms are often dimension lumber of sufficient width to allow the walls to be made the desired thickness. Once the periphery forms are in place, door and window openings are blocked out and set. One skilled in the art will also appreciate that reinforcement, typically re-bar, is also positioned within the perimeter forms to be contained within the interior of the tilt-up wall after the concrete is poured. Likewise, items to be embedded within the tilt-up wall, such as for attachments for the lifting cables (discussed below), are also positioned within the perimeter forms.
[0066] Concurrently, the side panels 20 are sized and interconnected to match (or, if desired, be smaller than) the length and width dimensions of the tilt-up sections to be cast. Specifically, the side panels 20 are joined together using the projections 35 and indentations 37 (i.e., tongue-and-groove-type connectors) so that a top end 24 of one panel 20 abuts a bottom end 26 of another panel 20 and/or a first end 28 of one panel 20 abuts a second end 30 of another. The side panels 20 are usually joined in a side-by-side configuration while they are horizontally oriented.
[0067] The assembled side panels 20 forming an array of panels are preferably fastened together using strongbacks (not shown), which are often a metal “C”-shaped channel or similar device that provides stiffness to the array. Screws are typically used to interconnect the end plates 42 of the web members 40 to the strongbacks, which run the entire height or length of the assembled array of panels 20 .
[0068] Either before or after fastening the array of panels together, the side panels 20 are cut not only for height and width dimensions, but also for any penetrations to be included within the tilt-up wall (i.e., windows and doorways), embedded items, and welding plates. The assembled panels with strongbacks are then staged to be “wet set” after consolidation and screeding of the concrete.
[0069] With the preliminary steps completed, a release agent is sprayed or poured onto the concrete floor slab or other surface used, if not completed earlier. The fluid concrete is then poured into the perimeter foundations (or other substantially contained volume) and leveled or screeded. The side panels 20 are then “wet set,” in which the interior surface 34 of the side panels 20 are oriented downwardly and pressed firmly into the wet concrete so that a portion of the interior surface 34 of the side panel 20 contacts or is adjacent to the upper surface of the poured concrete.
[0070] Two men can easily lift each array of panels, which may measure, in an example construction, four feet by twenty feet. In such an example, each array may be formed of panels abutting end to end 28 , 30 and five arrays of side panels 20 may be coupled together top end 24 to bottom end 26 to form a surface that is twenty feet by twenty feet. If necessary, small “fill-in” pieces of the side panels 20 are easily installed by hand after the arrays of panels are positioned. Compared to insulation mounted onto a tilt-up wall after the concrete slab C has cured, these contiguous, interlocked side panels 20 of the present invention provide superior insulation over systems that have breaks (i.e., at the location of a ferring member) and are significantly less expensive to install.
[0071] In the preferred embodiment, each side panel 20 in the array of panels measures sixteen inches by forty-eight inches (16″×48″) and has thirty (30) attachment points 44 that penetrate into the concrete C forming the tilt-up wall. Thus, there are 5.6 penetrations per square foot of wall surface area. If it is believed that the attachment points 44 will not provide a sufficient bond to the concrete C, then stanchions can be used, which are discussed below and some of which are shown in FIG. 6.
[0072] When the side panels 20 are firmly pressed into the wet cement, the attachment points 44 penetrate into the wet concrete. A stinger vibrator (not shown) or the like may also be used on the strongbacks or side panels 20 to aid in the consolidation of the concrete around the attachment points 44 . After setting the side panels 20 , the strongbacks are removed so that the tilt-up system 10 is complete and ready for curing. Once the poured concrete substantially cures and forms a concrete slab C, that slab maintains its relative position against the interior surface 34 of the side panel 20 by the attachment points 44 . That is, by projecting beyond the interior surface 34 of the side panel 20 , the web members 40 anchor the side panel 20 to the concrete slab C so that the concrete slab C and side panel 20 form the tilt-up concrete structure 10 of the present invention. After the concrete slab C is substantially cured, the formed concrete structure 10 is tilted up, as discussed below and shown generally in FIG. 11.
[0073] Referring again to FIG. 7 generally illustrating the wet-setting construction method of the tilt-up walls, one skilled in the art will appreciate that this process has specific benefits. First, the side panels 20 that are disposed over the concrete—which may be performed within ten minutes of pouring—can act as a barrier to the ambient environment. The less temperate the ambient conditions, the more beneficial the wet-setting method using the side panels 20 positioned over the wet concrete. For example, in hot conditions, the side panels 20 retard evaporation so that a slower “wet cure” of the concrete occurs and the formed tilt-up wall is stronger based on the curing process. Without using the side panels 20 of the present invention, either the moisture evaporates too quickly resulting in a structurally weaker concrete or, more typically, a sealing membrane or “retardant” is sprayed over the top of the fluid concrete after screeding and leveling-an expense that is not incurred using the wet-setting process of the present invention. Alternatively, if the ambient environment is cold (i.e., close to or below freezing conditions), the side panels 20 also facilitate curing by including an insulating layer. Without using the wet-setting process of the present invention, the prior art techniques have involved using tents with propane blowers, blanketing the top surface of the concrete, or heating the area around the poured tilt-up wall using other means known in the art. The present invention is advantageous because it avoids or reduces the labor, fuel, and equipment costs associated with heating the concrete as it cures. Another advantage of the wet-setting method is that irregularities in the upper surface of the concrete after pouring are acceptable. That is, the poured concrete should be leveled within plus or minus one quarter inch (±¼″) before placing the side panels 20 into the concrete. Accordingly, the process of using a power trowel, which is labor intensive and can be expensive, is most likely avoided. Therefore, the wet-setting method circumvents the need for curing compounds, power trowels or other surface finishing, and curing thermal blankets or other heating processes.
[0074] For the second method of forming the tilt-up walls shown generally in FIG. 8, the side panel 20 is horizontally-disposed so that the attachment points 44 extend upwardly (i.e., opposite to the orientation of the wet-setting embodiment). The interior surface 34 of the side panel 20 becomes the surface onto which concrete is poured. Perimeter forms (not shown) are placed around the of the periphery, namely, the top end 24 , bottom end 26 , first end 28 , and second end 30 of one side panel 20 or an array of side panels 20 , to prevent the fluid concrete from leaking off of the interior surface 34 . Furthermore, as discussed below if a connector 50 is used as a stanchion instead of other exemplary embodiments shown in FIG. 6, re-bar can be positioned within the apertures 56 to strengthen the tilt-up wall prior to pouring the concrete. Once the concrete is poured, leveled, and substantially cured, the forms are removed and the side panel 20 and substantially cured concrete slab C creates the tilt-up wall 10 . The second method of forming a tilt-up wall advantageously avoids use of a release agent. Also, one skilled in the art will appreciate that the term “a side panel” as used for the second and third designs may encompass multiple panels, including an array of panels discussed above for the first design.
[0075] The third method or design of forming the tilt-up wall repeats first steps used in the second design, namely, the side panel 20 is horizontally-disposed so that the attachment points 44 extend upwardly; perimeter forms are placed around the of the periphery of the side panel 20 ; and the concrete is poured. However, before the concrete cures to any substantial degree, another, second side panel 20 is wet set into the poured concrete, as occurs in the first design. Thus, the third method is a hybrid of the first two methods to create a wall 10 that, when substantially cured and tilted up, has the design shown in FIG. 2A. As will be appreciated, the interior surfaces 34 of the opposed side panels 20 and the web members 40 disposed therein are spaced apart in a non-contacting relationship with each other so that the first and second side panels are stationarily positioned relative to each other by only the concrete slab C disposed within the cavity 38 . That is, unlike the first embodiment shown in FIG. 2, there are no connectors 50 or other components interconnecting the opposed side panels 20 .
[0076] This third method of making a tilt-up wall 10 has many advantages. When considered to prior art tilt-up walls, it encompasses the same advantages of both the first and second methods of forming a tilt-up wall, such as avoiding the need for (1) curing thermal blankets or other heating processes, (2) curing compounds, (3) power trowels or other surface finishing, and (4) a release agent. This third design also has greater insulating value and sound impedance than either of the first two designs since there are side panels 20 on each side of the concrete slab C, instead on only on one side.
[0077] The third embodiment also has potential advantages over the first embodiment of the present invention, which is shown in FIGS. 1 and 2, particularly if the wall being formed is greater than one story high. Most obviously, this dual-panel tilt-up wall form using the third design does not use connectors so there is a cost savings both by avoiding the purchase of these components and by not requiring the labor to install the connectors to interconnect the side panels. In addition, for a wall greater than one story high, the cost of external bracing and scaffolding during the wall assembly and pouring of concrete is not required. Since the panels 20 are laid flat during pouring of the concrete, there are minimal hydrostatic pressures compared to the panels being erected before pouring. As one skilled in the art will further appreciate, the practice of forming a wall as shown in the first embodiment typically involves filling in the cavities in four foot vertical increments, called lifts. The process of forming each lift is more labor intensive than filling the cavity continuously at a single horizontal location. Furthermore, it is imprudent—and prohibited by some building codes—to drop concrete more than ten feet because the constituents of the concrete tend to separate from each other, resulting in a weak final product. Thus, the usual practice in vertical-wall formation is to cut holes into the side panels at different elevational positions and then patch the holes after they are used as a filling port between the source of concrete and the cavity. This process of using the holes in the side panels, obviously, increases the labor costs and time required to fill the cavity for a wall greater than one story in height. The third design of the tilt-up wall, in comparison, avoids these problems and, accordingly, is quicker and less expensive to construct than the first embodiment of the dual-panel wall for wall structures greater than one story in height.
[0078] Regardless of the method used to form the tilt-up walls of the present invention, the side panels 20 —either with or without the stanchions connected—forge a bond with the concrete as it cures. Once the concrete C obtains sufficient strength for lifting (usually 2,500-3,000 psi) that is typically reached in five to ten days (depending on ambient conditions), a crane (not shown) or other means connects to cables (not shown) attached to embedded inserts cast into the tilt-up wall. The crane sequentially lifts each tilt-up wall and sets it on a prepared foundation around the building perimeter. FIG. 11 shows a single concrete structure 10 having been tilted up. Before any of the tilt-up walls are released by the crane, temporary braces (not shown) are installed—at least two per tilt-up wall—to brace up the respective tilt-up walls until the roof structure is attached.
[0079] Next, connections between individual tilt-up walls are made, which usually entail welding splices of steel ledger angles (not shown), and then the joints between the tilt-up walls (typically three-quarter inch (¾″)) are caulked. Also, any necessary patching is made to repair blemishes. Approximately the same time, the closure strip between the tilt-up walls and the floor slab (usually a two-foot-wide strip) is filled with concrete and the bracing is removed when the roof has been permanently connected to the tilt-up walls.
[0080] One of the advantages of using tilt-up walls 10 of the present invention is the shortened construction time. All of the steps discussed above in forming a building frame, from pouring the floor slab to erecting the tilt-up walls that are ready to receive the roof structure, often require only four weeks. Tilt-up walls are also generally less labor intensive to construct, which results in a financial savings. Moreover, tilt-up walls 10 of the present invention may be used to form multi-story buildings.
[0081] When considering the benefits of using the side panels 20 with tilt-up walls, one skilled will appreciate the improved insulation and sound impedance that exists using the side panels 20 , which would be difficult and expensive to install on a conventional tilt-up wall once erected. Also, the web members 40 , when set into the concrete and substantially cured, insure a substantially permanent, worry-free connection for the side panels 20 and provide a solid attachment point that may be used to connect wallboard such as sheet rock, brick, or stone finishes. Moreover, electrical and plumbing runs are easily installed within the side panels 20 . That is, installing electrical and plumbing is accomplished by cutting the “run's” using a hot knife, router, or electric chain saw into the side panel 20 of preferred embodiment, which is made of EPS. Also, using the preferred side panels 20 removes any potential metal contact problems and makes it much easier to connect pipes and wires compared to achieving the same with conventional tilt-up walls.
[0082] The tilt-up wall concrete structure 10 using a side panel 20 on only one side of the concrete slab C can also be used as an insulated concrete floor, in which the panels are formed and raised upwardly to form a floor of the building. Likewise, the structure 10 can also be used to create roof panels. Thus, the present invention can be used to construct the majority of an entire building, namely, the walls, floors/ceilings, and roof panels. Also of note, the side panels 20 do not affect the engineered structural design of the formed tilt-up wall as compared to not using the panels.
[0083] If the concrete or “slump” is dry or if ambient conditions are cold, the attachment points 44 —being rectangular and substantially flat and extending eleven-sixteenths ({fraction (11/16)}) of an inch from the interior surface 34 of the side panel 20 in the preferred embodiment—may have difficulty penetrating into the fluid concrete. The present invention, as mentioned above, includes stanchions or extending devices that assist in bonding the side panels 20 to the wet concrete. The primary function of the stanchions is to form better bonds between the concrete C and the side panel 20 . As such, the side panels 20 are less likely to separate from the concrete slab C of the tilt-up wall or other wall of the present invention throughout its life. A secondary function of the stanchions is to give greater structural integrity to the side panels 20 and associated wallboard, brick, or stone finishes attached to the end plates 42 of the web members 40 . That is, by being more firmly anchored, the concrete slab C provides a better connection to the side panels 20 and a stronger foundation for any materials hung from the side panels 20 . The stanchions are discussed in the specific context of a tilt-up wall but, as one skilled in the art will appreciate, the stanchions, for example, may also be useful in a dual-panel wall discussed above to buttress the connection between the side panel 20 and the concrete poured into the cavity 38 .
[0084] One specific embodiment of the stanchion comprises a connector 50 , for example, coupled to one attachment point 44 to increase the surface area to which the concrete C bonds. If the connectors 50 are the incorrect length, then they can easily be cut to the proper dimension at the construction site. The connectors 50 , as discussed above, are best shown in FIGS. 4 and 4A.
[0085] Two additional such stanchions are shown in FIG. 6, namely, an extender 60 and a tilt-up anchor 70 . First addressing the extender 60 , it includes a tip end 62 , an opposed base end 64 , and a body 66 extending therebetween. Preferably, the tip end 62 is of a size to complementarily engage one end 52 of a connector 50 and the base end 64 is of a size to complementarily engage one attachment point 44 . Similar to the preferred designs discussed above, the tip end 62 is preferably rectangular in plan view—as is the attachment point 44 —and the base end 64 preferably defines a track of a size to slidably receive a selected one of the tip end 62 or the attachment point 44 therein—as does one end 52 of the connector 50 . The locking means is preferably also part of the extender 60 and other stanchions.
[0086] The body 66 of the extender 60 is preferably non-smooth, which assists in bonding to concrete C. In the preferred embodiment, the body 66 defines a passage 68 therethrough. As will be noted by FIGS. 6 and 12, the passage 68 has a substantially rectangular cross-section. In the preferred embodiment, the width of the sides of the passage 68 is between one-quarter (¼) and one (1) inch to have a cross-sectional area between approximately 0.125 and 1 square inches, and more preferably between one-half (½) inch and three-quarter (¾) inch to have a cross-sectional area between approximately 0.25 and 0.57 square inches. This range of widths allows a portion of a flexible linking member 90 (shown in FIG. 12) to be received therethrough (as discussed below) as well as being of a dimension to allow fluid concrete to at least partially flow into the passage 68 for better bonding. Of course, other dimensions are contemplated to achieve these same functions and, in fact, the minimal dimension to allow fluid concrete to flow partially therein may be a function of the viscosity of the fluid concrete and size of the aggregate stone used. Likewise, other cross-sectional shapes for the passage 68 are also contemplated, such as circular, elliptical, triangular, or other polygonal shapes. As one skilled in the art will also appreciate, the body 66 of the extender 60 can be manufactured in different lengths, depending on the use of the extender 60 ; however, the preferred length between the tip end 62 and the base end 64 is approximately one inch.
[0087] Three functions of the extender 60 of the present invention are addressed herein: (1) as a stanchion; (2) as an extension for the connectors 50 ; and (3) as part of a connection between side panels 20 or to buttress the connection between panels 20 . The first listed function of extender 60 is the same as the other stanchions, which is to provide an additional surface to which the concrete can bond while curing to form a stronger connection with the side panel 20 . The extender 60 connects to one respective attachment point 44 of the web member 40 and extends into the concrete C a greater distance than the attachment point 44 . This longer extension, in and of itself, strengthens the bond between the concrete C and the side panel 20 to which the extender 60 is connected since there is more surface area to which the concrete C may bond during curing. Moreover, this bond is further strengthened by the extender 60 in the preferred embodiment having a non-smooth surface and, in the preferred embodiment, the non-smooth surface resulting in part from the passage 68 extending therethrough. As mentioned above, the passage 68 is preferably of a dimension to allow fluid concrete to at least partially flow therein, which enhances the bond with concrete C.
[0088] The second listed function of the extender 60 is to extend the reach of the connectors 50 . As discussed above, it is preferred to make the connectors 50 having lengths so that the width of the cavity 38 is two (2), four (4), six (6), eight (8) inches or greater. If, however, it is desired to have the width of the cavity 38 be three (3), five (5), or seven (7) inches, then the preferred embodiment of the extender 60 could be used to obtain that extra inch of separation.
[0089] Assume, for example, that the connector 50 shown in FIGS. 4 and 4A connects to the two attachment points 44 of opposed side panels 20 in the dual-panel embodiment (which is discussed above and shown in FIGS. 1 and 2) to form a cavity 38 that is two inches wide. To increase the width of the cavity 38 to be three inches wide, the preferred extender 60 is used in conjunction with the connector 50 shown in FIG. 4 or FIG. 4A. That is, the tip end 62 of the extender 60 is preferably formed to be the same dimensions as an attachment point 44 of the web member 40 so that the tip end 62 can be slidably received into the track 54 at one end 52 of the connector 50 , similar to the attachment point 44 being slidably received into the end 52 of the connector 50 . The base end 64 of the extender 60 , in conjunction, preferably forms a track into which one attachment point 44 of a web member 40 is slidably received (i.e., the same dimension as the track 54 of the connector 50 shown in FIG. 4 or FIG. 4A). Accordingly, the connector 50 is coupled to the attachment point 44 of one side panel 20 , the base end 64 of the extender 60 is coupled to the attachment point 44 of the opposed side panel 20 , and the connector 50 is attached to the tip end 62 of the extender 60 so that a three-inch wide cavity 38 is formed between two opposed side panels 20 , instead of a two-inch cavity if the connector 50 shown in FIG. 4 or FIG. 4A was used alone. Thus, in the preferred embodiment, for each extender 60 added between the connector 50 and the attachment point 44 , the extender 60 advantageously allows the cavity 38 to be extended one inch in width. As such, the extender 60 can be used to meet this need to have an irregularly sized cavity without requiring the manufacturer to mold special new connectors, which would be an expensive endeavor. As one skilled in the art will appreciate, the extender 60 can have a length other than one inch, if desired.
[0090] The third potential function of the extender 60 is to establish or to buttress the connection between side panels 20 . One example in which the extender 60 is beneficial when one wall or panel is at a non-parallel angle to another wall or panel, often being disposed at right angles to form a T-wall in top plan view. Since concrete has to be poured into the cavity 38 defined by the side panels 20 that are not oriented parallel to each other (as exists in FIG. 2), the normally linear connectors 50 shown in FIGS. 4 and 4A cannot feasiblely be used. As one skilled in the art will appreciate, although within the scope of the present invention, manufacturing non-linear connectors would be expensive and often not be viable for a large percentage of construction projects.
[0091] In conjunction, one problem with constructing such a T-wall is that when the concrete is poured into the cavity 38 , pressures against the abutting side panel 20 (i.e., at the top of the “T”) forces the side panel outwardly. The prior art solution is to brace the wall on the exterior surface 32 of the side panel 20 using, for example, lumber braces. The braces, however, are difficult and labor intensive to construct, particularly when used on multistory building above the first or ground floor.
[0092] Referring now to FIG. 12, the extender 60 , used with a flexible linking member 90 , such as a zip-tie, plastic tie strap, tie wire, or other similar component, provides an easy and effective solution to buttress a connection between side panels 20 , particularly for situations in which the respective interior surfaces 34 are not parallel to each other. Although not required, it is preferred that the flexible linking member 90 be contiguous and connect to itself in by forming a closed loop, in which the looped linking member 90 interconnects the opposed side panels 20 .
[0093] For one design shown at the top of FIG. 12, respective extenders 60 are connected to attachment points 44 formed on different side panels 20 . That is, in this design there are two extenders: a first extender 60 connected to the attachment point 44 of one web member 40 partially disposed within a first panel 20 and a second extender 60 connected to the attachment point 44 of one web member 40 partially disposed within the opposed second panel 20 . A portion of the flexible linking member 90 , in conjunction, traverses through the passage of the first extender 60 and a portion of the flexible linking member 90 also traverses through the passage of the second extender 60 . The flexible linking member 90 is connected through the respective passages of two extenders 60 and tightened, thereby securely interconnecting the spaced-apart panels 20 .
[0094] In another embodiment, it is also contemplated that at least one of the two web members 40 defines a slot 41 extending therethrough. The slot 41 is preferably located adjacent the interior surface 34 of the first panel in which the web member 40 is disposed and preferably integrally formed with the web member 40 . The slot 41 is also preferably of a size to receive a portion of the flexible linking member 90 therein. Thus, as shown at the bottom of FIG. 12, a portion of the flexible linking member 90 traverses through the slot 41 of one web member 40 and also traverses through the extender 60 connected to the attachment point 44 of the other web member 40 to interconnect the spaced-apart panels 20 . In still another embodiment shown at the middle of FIG. 12, a portion of the flexible linking member 90 traverses through the slot 41 of one web member 40 and the slot 41 of the other web member 40 to interconnect the spaced-apart panels 20 . The three illustrated embodiments shown in FIG. 12, of course, may be used independently of each other.
[0095] Similarly, the extender 60 with the flexible linking members 90 can be used anywhere on the side panels 20 where there may be weakness in the structure. As an example, weakness may exist where a cut-up design is used or the wall zig-zags. As another example, weakness may also occur wherever quick turns are used in the layout of the side panel 20 . In these situations, the extenders 60 and interconnecting flexible linking members 90 may be used in lieu of external bracing. Although not preferred, it is also contemplated that the flexible linking member 90 —in concert with the passages 68 of extenders 60 or the slots 41 formed into the web members 40 —may interconnect opposed side panels 20 in the first embodiment (shown, for example, in FIGS. 1 and 2), instead of using connectors 50 to interconnect the side panels 20 .
[0096] In comparison to the extender 60 , another design of the stanchion, the anchor 70 , is also shown in FIG. 6 and is less broad in its potential functional uses. The primary purpose of the anchor 70 is to strengthen the bond between the side panel 20 and the adjacent concrete once that concrete has substantially cured. The preferred anchor 70 has a forward end 72 , an opposed back end 74 , and a body 76 extending therebetween. The back end 74 is preferably of a size to complementarily engage one attachment point 44 .
[0097] Also, it is preferred that the body 76 has at least one prong 78 extending from it and, more preferably, two prongs 78 oriented co-linearly to each other. However, as one skilled in the art will appreciate, other permutations also fall within the scope of the present invention, such as three or more prongs 78 or two prongs 78 not oriented colinearly. The presently preferred prongs 78 have a length of a half (½) inch to one (1) inch and a generally round cross-sectional shape that has a diameter of one quarter (¼) inch. One skilled in the art, however, will appreciate that wider range of values are possible for the prongs 78 —the important consideration being that the prongs 78 not break when fluid concrete flows past the anchor 70 during the construction process or after substantial curing. Also, the prongs 78 can be integrally formed to the anchor 70 or coupled thereto using any means known in the art.
[0098] Returning to the presently preferred embodiment of two co-linear prongs 78 , it is preferred that when the anchor 70 is connected to the attachment point 44 , the two prongs 78 form an angle that is not perpendicular or normal to a plane formed by the interior surface 34 of the side panel 20 (and also the plane formed by the exterior surface of the concrete C on the tilt-up wall). In fact, it is most preferred that the two prongs 78 extend parallel to the plane formed by the interior surface 34 of the side panel 20 to which the anchor 70 is attached, an angle which is generally perpendicular to the direction that the anchor 70 extends between its forward and back ends 72 , 74 when connected to the attachment point 44 . This angular orientation of the prongs 78 provides increased bonding strength with the concrete C.
[0099] Although it is presently preferred that there is at least one prong 78 , the present invention contemplates that no prongs be included; instead, the body 76 of the anchor 70 can be of a non-smooth or non-linear shape to bond with the fluid concrete that flows around the body 76 . One contemplated design includes a generally mushroom shape that is narrow at the back end 74 and flares outwardly moving toward the forward end 72 . Other contemplated designs include the forward and back ends 72 , 74 being wider in side view than the intervening portion of the body 76 so that the body appears similar to a chef's hat or an hourglass in side view. Of course, symmetry is not required in any of these alternative embodiments. As one skilled in the art will appreciate, one important consideration is that the fluid concrete be able to flow around the anchor 70 to improve bonding after the concrete substantially cures.
[0100] Although the length of the connector 50 , extender 60 , or anchor 70 used as a stanchion between the interior surface 34 of the side panel 20 and the tip of the stanchion may be any dimension shorter than the thickness of the concrete portion of the tilt-up wall, the preferred embodiment uses a length of one inch (1″) or less. The reason for using a length shorter than the possible maximum length is that a longer stanchion would potentially interface with the re-bar or other structural support within the tilt-up wall. That is, either by convention or as required by applicable building code requirements, the re-bar is usually placed one inch or more away from either surface of the tilt-up wall so that the ends of the respective stanchions, extending the maximum of one inch, will not interface with or contact the re-bar, which could impede the proper setting of the side panels 20 into the fluid concrete.
[0101] As with the connectors 50 , the other embodiments of the stanchions are preferably formed of a high-density plastic, such as high-density polyethylene or polypropylene, although other polymers can be used as noted above. Advantages of the high-density plastics for the stanchions include cost of manufacturing, strength, rigidity when the component is sufficiently thick, and the like.
[0102] As one skilled in the art will also appreciate, the stanchions are not necessary for the present invention to function and, in fact, may not even be desired if the concrete is very “wet” or a plasticizer has been added to the concrete in the context of constructing tilt-up walls. If stanchions are used, it is contemplated using one stanchion per web member 40 connected to the center attachment point 44 (i.e., the middle attachment point 44 shown in FIG. 6); however, it is also contemplated using up to and including one stanchion on each attachment point 44 (i.e., five stanchions used on every web member in the embodiment shown in FIG. 6).
[0103] Referring now to FIGS. 9 and 9A, the third embodiment of the present invention is analogous to the first embodiment because a cavity is formed into which concrete is poured. However, instead of the formed concrete structure having opposed side panels 20 each connected to the concrete portion as in the first embodiment shown in FIGS. 2 and 2 A, this embodiment preferably uses a side panel 20 on only one side of the formed concrete structure 10 . That is, the formed concrete structure 10 is similar to the tilt-up wall discussed above (i.e., a concrete slab C with side panels 20 positioned only on one side), but is made using a different construction process.
[0104] More specifically and as best shown in FIG. 9, the third embodiment uses a side panel 20 and an opposed sheet 80 to form the cavity 38 into which the concrete is poured. That is, in forming the wall 10 , the process involves positioning the side panel 20 and the sheet 80 substantially upright so that a portion of the interior surface 34 of the side panel 20 faces a portion of an inside surface 82 of the sheet 80 . The interior surface 34 and the inside surface 82 are laterally spaced apart from each other so that a cavity 38 is formed therebetween, just as occurs in the first embodiment using spaced-apart side panels 20 .
[0105] The sheet 80 is preferably plywood, but can be any solid material that can be coupled to either a web member 40 or a connector 50 and can withstand the forces exerted by the fluid concrete when poured into the cavity 38 without substantial bowing, warping, breaking, or other type of failure. Other contemplated materials include combined steel frame and plywood center, commonly known as a steel-ply panel. Accordingly, the sheet 80 functions as a form or barrier while the concrete is curing.
[0106] The process next involves attaching one end 52 (“the first end”) of the connector 50 to the attachment point 44 of the side panel 20 and connecting a portion of the inside surface 82 of the sheet 80 to the other end 52 (“the second end”) of the connector 50 . However, it may be a matter of preference for the order of construction so the first end of the connector 50 may be attached to the attachment point 44 before positioning the sheet 80 or the sheet may be positioned before the first end of the connector 50 is attached to the attachment point 44 .
[0107] The sheet 80 can be either directly or indirectly coupled to the connector 50 . That is, referring back to FIG. 3, there are two options for the second or “free end” of the connector 50 , which is the end not attached to the web member 40 located within the side panel 20 . First, for the indirect connection and as shown in FIG. 9, the free end can be connected to, for example, a stand-alone web member 40 ′, which is a web member that is not formed within a side panel 20 and is illustrated in FIGS. 3, 6, 9 , and 10 . The sheet 80 is then connected to the end plate 42 of the stand-alone web member 40 ′, instead of being directly connected to the second end of the connector. This indirect connection forms the preferred embodiment.
[0108] [0108]FIG. 3 shows only one stand-alone web member 40 ′ that is attached to the connectors 50 . As one skilled in the art will appreciate, however, multiple web members 40 are preferably used when preparing the wall structure 10 (i.e., between two and six stand-alone web members 40 ′ used for the side panel 20 shown in FIG. 3 based on there being six web members 40 located within the side panel 20 ). It is, of course, preferred to use a sufficient number of web members to withstand the dynamic and static forces that exist when the fluid concrete is poured into the cavity (i.e., preferably six for the side panel 20 shown in FIGS. 3 and 9).
[0109] Alternatively and less preferred, the sheet 80 may be connected directly to the second or free end of the connector 50 . Still referring to FIG. 3, four connectors 50 are shown in this configuration (i.e., connected to the web member 40 located within the side panel 20 but not connected to a stand-alone web member 40 ′). Thus, unlike the indirect connection having an intervening stand-alone web member 40 ′ or other component, the sheet 80 in this design is directly coupled to the second ends of the connectors 50 . The potential drawback with this design is that it is more difficult to attach or couple the sheet 80 to the connectors 50 at the construction site. However, if the free end of the connectors 50 is formed with more surface area than included in the illustrated embodiments, this potential drawback may be reduced.
[0110] It is also contemplated using connectors 50 that are integrally attached to or formed with the web members 40 located in the side panels 20 for the third embodiment (as well as other embodiments). Stated differently, the connectors 50 and web members 40 may be a unitary structure and, as such, the attachment points 44 in this contemplated design extend a distance from the interior surface 34 of the side panel 20 to the attachment points 44 that is substantially equivalent to the desired thickness of the cavity 38 for the direct connection process. Thus, the step of attaching the connectors 50 to the attachment points 44 of the web members 40 disposed within the side panels 20 is avoided because the inside surface 82 of the sheet 80 is attached directly to the attachment point 44 to form the cavity 38 . Alternatively, the extended attachment points 44 may be designed to connect to the stand-alone web member 40 ′ or similar structure is using the indirect connection method. However, this design of integrally forming the connectors 50 to the attachment points 44 has a potential drawback of the increased space needed to transport a given quantity of side panels 20 to the construction site if the web members 40 are integrally formed into the side panels 20 , as opposed to being inserted through precut slots at the construction site.
[0111] Regardless of the component to which the sheet 80 is connected, it is preferred that the sheet be detachably connected, or removably attached, to the second end of the connector 50 or stand-alone web member 40 ′. By being detachably connected, the present invention entails that the sheet 80 can be removed from the end plate 42 or connector 50 substantially intact, preferably so that the sheet can be reused to form another concrete structure. Many means are contemplated for detachably coupling the sheet 80 to the end plate 42 or connector 50 , such as using a nail or screw. One skilled in the art will appreciate that this list is not exhaustive and can include other coupling means such as chemical adhesives, rivets, tacks, nuts and bolts, and the like.
[0112] Once the sheet 80 and side panel 20 are interconnected and stationarily positioned relative to each other, the process of forming the structure 10 involves pouring fluid concrete into the cavity 38 and allowing the concrete to substantially cure to form a concrete slab C. The formed concrete structure 10 is shown in FIG. 9A. In the preferred embodiment, after the concrete substantially cures (which may take about three days depending on ambient conditions and the thickness of the cavity 38 ) the process involves removing the sheet 80 from the concrete slab C to expose a portion of the concrete slab C to atmosphere, which is shown in FIG. 11. That is, after substantially curing, the sheet 80 is preferably removed leaving a concrete structure 10 that has a side panel 20 disposed on one side and concrete C exposed to ambient or atmosphere on the other, opposed side. The sheet 80 is also preferably reusable for forming another wall. However, although not preferred, it is contemplated having the sheet 80 remain a permanent part of the tilt-up structure 10 as shown in FIG. 9A.
[0113] A potential aesthetic drawback with the above process is that when the sheet 80 is removed, the exposed surface will be predominately concrete C with the end plates 42 or the ends 52 of the connectors 50 recurrently showing on the exposed concrete surface. To avoid this non-contiguous appearance and as shown in FIG. 10, the present invention also contemplates using a spacer 84 attached or permanently affixed to the end plate 42 of the stand-alone web member 40 ′ or to one end 52 —the free or second end—of the connectors 50 . The spacer 84 is to be disposed in a contacting relationship with the inside surface 82 of the sheet 80 .
[0114] Referring now to FIG. 10, one embodiment of the spacer 84 is cone-shaped in side view, in which the narrow end is attached or coupled to the end plate 42 of the stand-alone web member 40 ′ or the end 52 of the connector 50 and preferably extends between a quarter and three-quarter (¼-¾) inches, more preferably one-half (½) inch. The cone-shaped spacers may also be inverted so that the wide end is attached to the end plate 42 . It is also contemplated that the cone-shaped spacer 84 has openings or slots extending between the narrow end and the wide end. Other shapes are contemplated for the spacer 84 , such as circular, elliptical, or rectangular shapes in plan view. It is also contemplated having the spacer 84 use a constant cross-sectional area along its length, instead of being cone shaped.
[0115] The sheet 80 is mounted to abut the wide end of the spacer 84 and the screw—if used as the coupling means—traverses through the sheet 80 , spacer 84 , and then into and through a portion of either the end plate 42 of the stand-alone web member 40 ′ or end 52 of the connector 50 . If the wide end of the spacer 84 is attached to the end plate 42 , then the coupling means need not traverse through the interior of the spacer, which may be easier at the construction site because less precise aligning is required. If the spacer 84 has openings, at least some concrete may enter into its internal volume when the cavity 38 is filled with concrete.
[0116] Using the spacers 84 , after the concrete substantially cures and the sheet 80 is removed, the interior volume of the spacer 84 is exposed so that there are only small portions of the concrete surface in which the concrete C is not contiguous on the face of the structure 10 . However, since the preferred spacer 84 is cone-shaped, a finish coat of cementitious material, including concrete, a parging coat, or stucco, can quickly be spread into the interior volume of the spacers so that when it cures, the exposed face of the concrete structure 10 appears as a uniform concrete surface, as opposed to having the ends 52 of the connectors 50 or the end plates 42 exposed.
[0117] One skilled in the art will appreciate that a uniform concrete appearance obtained using the spacers 84 is more aesthetically appealing if the exposed surface of the concrete structure remains exposed when the building is completed. However, if it is desired to mount materials such as drywall or masonry tiles directly onto the surface originally covered by the sheet 80 , not using the spacers 84 may be preferred. That is, the exposed end plates 42 of the stand-alone web members 40 ′ or the ends 52 of the connectors 50 facilitate attaching materials to the concrete surface because it is easier to connect materials to these members, compared to attaching the materials to the cured concrete C. Also, if the entire exposed concrete surface will be coated with stucco or the like, then depending on the bonding properties of the coating, it may be irrelevant whether the spacers 84 are used.
[0118] Although the present invention has been described with reference to specific details of certain embodiments thereof, it is not intended that such details should be regarded as limitations upon the scope of the invention except as and to the extent that they are included in the accompanying claims. | An insulated concrete structure including a longitudinally-extending side panel and at least one web member connected to the side panel. The web member extends from adjacent the external side of the side panel through and out of the interior surface of the side panel. The side panel is coupled to fluid concrete and cured to be used as a tilt-up wall, floor, or roof panel. Alternatively, the concrete can be bonded to opposed side panels. It is noted that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to ascertain quickly the subject matter of the technical disclosure. The abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims pursuant to 37 C.F.R. 1.72(b). | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to production of methane from subterranean coal beds, and more particularly to a process in which a carbon dioxide-containing gas is continuously injected into one or more injection wells to produce methane from one or more recovery wells spaced from the injection wells. The produced methane includes both free methane displaced by the injection gas and methane that is desorbed from the coal surface by differential adsorption of carbon dioxide on the coal surface.
Much of the early work on recovering coal bed methane was driven by a need to reduce methane levels sufficiently to enable safe mining. More recently, deep unmineable coal beds have been utilized as a source of large volumes of methane for commercial purposes.
The primary mechanism of methane retention in coal beds is by adsorption on the coal surfaces within the matrix pore structure. This is a very different mechanism for gas storage than in conventional sandstone or limestone gas reservoirs, where free gas is compressed within the pore spaces. Within the meso and micropores of a coal bed there exists tremendous surface area on which methane molecules may be adsorbed.
Another important aspect of the coal reservoir is a set of natural fractures called cleats which form during the coalification process. The dominant cleat is referred to as the face cleat with the subordinate cleat, oriented roughly perpendicular to the face cleat, termed the butt cleat. These constitute the macroporosity of the reservoir and store a small amount of compressed gas, but are often filled with water. More importantly, however, they provide a permeability conduit through which methane can flow.
Many coalbed methane wells exhibit an unusual production profile with regard to both gas and water production rates. Initially, in virgin coalbeds, the cleats may be saturated with water. A period of water production is then required prior to gas production.
The movement of gas into the cleat system eventually results in two phase flow of water and gas. Initially the water saturates the fracture system and the gas is adsorbed to the coal matrix. Only water is flowing in the cleats. As the pressure declines and the cleats are partially dewatered, gas desorption occurs. Mostly water moves in the cleats as the gas slowly starts to move in the system. The gas saturation needs to exceed critical saturation before two phase flow happens in the fracture or cleats. Diffusion of gas, after desorption from the matrix, will continue to move the gas in the fracture, and two phase flow happens around the wellbore.
As a result of this mechanism, the gas production will typically lag the water production. As the pressure is reduced, the gas desorption rate will increase causing the gas production to reach a peak, after which it will decline as the gas is depleted in the drainage area of the well.
Many procedures have been proposed over the years for improving the results of conventional methane production techniques. Most of these procedures involve injection of a fluid into one or more injection wells to displace methane and recover the methane from recovery wells spaced from the injection wells.
2. Brief Description of the Prior Art
A process for removing methane from coal beds by injecting a carbon dioxide-containing fluid, ceasing injection and holding the injected fluid in the coal bed to enable desorption of methane, followed by recovery of desorbed methane through a recovery well, is described in U.S. Pat. No. 4,043,395 to Every et al. The Every et al. patent is directed to reducing methane in mineable coal seams to a safe level for mining, and indicates that continuous injection is not as effective as the periodic shut in procedure described therein.
U.S. Pat. No. 4,883,122 to Puri et al describes recovery of methane from coal beds by injection of an inert gas, such as nitrogen, that does not adsorb to the coal.
U.S. Pat. No. 5,133,406 to Puri describes a method of injecting oxygen depleted air from a fuel cell into a coal bed to increase methane production.
U.S. Pat. No. 5,072,990 to Vogt, Jr. et al describes a method of injecting hot water or steam into a coal bed to enhance methane recovery.
An article by Reznick et al entitled "An Analysis of the Effect of CO 2 Injection on the Recovery of In-Situ Methane from Bituminous Coal: An Experimental Simulation", Society of Petroleum Engineers Journal, October 1984, essentially confirms the process described in the Every et al patent discussed above.
While some of the above-described procedures have been successful to a degree, there has been a continuing need for improved procedures for recovery of coal bed methane.
SUMMARY OF THE INVENTION
According to the present invention, methane is recovered from a coal bed by continuously injecting a carbon dioxide-containing exhaust gas from a hydrocarbon-fueled internal combustion engine into the coal bed to sweep both free methane and methane which is preferentially desorbed by any carbon dioxide in the injected gas. The methane is recovered from one or more production wells spaced from the injection point.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In one embodiment, the injection gas is exhaust gas from a diesel engine. This exhaust gas can be injected directly from the engine, as technology is currently available to supply diesel engine exhaust directly from the engine at a pressure of 400 to 600 psig. If necessary, heating and/or compression of the engine exhaust gas can be utilized, as well as treatment of the exhaust gas for reduction of moisture and corrosive compounds.
In a process for recovering methane from a typical deep coal bed, the injection gas might be at a pressure of about 2000 psig and a temperature of from 350° to 600° F. Even higher temperatures are desirable if the gas handling equipment can tolerate such temperatures. Injection gas temperatures in this range can be provided by utilizing a large industrial diesel engine modified to provide a portion of the engine exhaust at about 400 to 600 psig. The gas may be cooled initially to remove moisture and corrosive compounds, and the cooled and dewatered exhaust gas can then be compressed to about 2000 psig, which raises the gas temperature to about 350° F. for injection. Compressing the gas to a higher pressure by additional stages of compression, and/or operating an oxygen converter downstream of the compressor, can produce gas temperatures of 600° F. or higher. The compressor is preferably driven by the engine providing the exhaust gas.
The injection gas pressure obviously has to be at least sufficient to overcome the coal bed pressure, and the higher the injection pressure the more rapidly the process will proceed.
The use of injection gas temperatures at or above 350° F. provides an overall increase in permeability of the coal bed, especially near the injection well, along with increased methane production. Water is a flow impediment when present in the coal bed cleats and matrices. The heat can vaporize the water with the vapor and remaining liquid water being expelled by the flow of injection gas. Dehydration causes the coal to shrink, which leads to enlargement of present cleats and creation of new interstices, resulting in increased permeability. The high temperature also minimizes adsorption of carbon dioxide near the injection well bore, thus preventing coal swelling and permeability reduction that would otherwise result from carbon dioxide adsorption. The high temperatures enhance desorption of methane which is adsorbed on the coal, with resultant shrinkage of the coal.
In situations where the gas handling equipment can tolerate temperatures above about 600° F., a gas turbine engine can be utilized to produce large volumes of very hot exhaust gas, which can be injected directly from the engine or compressed or otherwise conditioned as desired prior to injection.
In some embodiments, the engine providing the injection gas can be partly or wholly fueled by methane recovered in the process.
The permeability of the coal around the injection well can be further increased by cyclically varying the temperature of the injection gas to thermally expand and contract the coal around the injection well, thereby creating new fractures and enlarging existing fractures.
The pressure at the production well can be cyclically adjusted from a higher pressure to a lower pressure which in certain situations can expand the well cavity by breaking off coal from the well bore wall and expelling the broken coal out from the well bore by gas flow. Cyclic pressure replenishment at the production well results primarily from continuous injection of gas at the injection well.
Previous attempts to use a carbon dioxide containing gas in recovering coal bed methane have been discouraged because adsorption of large volumes of carbon dioxide would be expensive, and would also swell the coal and reduce permeability of the coal bed. These objections are largely overcome by the present invention which provides a very inexpensive source of carbon dioxide and which minimizes adsorption of carbon dioxide in the critical area around the injection well because of the use of hot injection gas, such as at 350° F. or above.
The process of this invention is well suited to a situation where a pattern of wells drilled into a coal bed have initially been used to produce connate water and associated gas from the coal bed. After initial water removal, a portion of the water removal wells can be converted to gas injection wells, and the remaining water removal wells can continue as methane producing wells.
EXAMPLE 1
In this example, a modified diesel engine provides an exhaust gas. The exhaust gas is cooled to remove moisture and corrosives. Compression provides a gas temperature of approximately 350° F. Exhaust gas is injected continously and directly into an injection well extending into a coal bed.
EXAMPLE 2
This example is similar to example 1 above, but the exhaust gas is obtained from a gas turbine engine. After startup of the process, the gas turbine is fueled with methane recovered from the production wells.
EXAMPLE 3
This example is similar to Example 1 above, but the diesel engine is fueled with a mixture of diesel fuel and methane recovered from the production wells.
EXAMPLE 4
In this example, a pattern of water removal wells is drilled into a deep unmineable coal bed. Water and associated gas is produced from the wells until most of the water is removed from the coal bed. Part of the wells are converted to gas injection, and a carbon dioxide containing gas at about 600 psig is obtained from a group of industrial diesel engines. The gas is cooled to remove water, compressed to about 2000 psig in compressors driven by the diesel engines, and injected through the injection wells into the coal bed at a temperature of about 350° F. The remaining original water removal wells, spaced about the gas injection wells, are then utilized to recover methane which is displaced and desorbed by the injection gas. | A process for producing methane from a subterranean coal bed by continuously injecting a carbon dioxide-containing gas into the coal bed and recovering displaced and desorbed methane from a recovery well. The injection gas may be exhaust gas from a hydrocarbon fueled engine. | 4 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a process for preparing halogenated benzene derivatives by adsorptive separation.
(2) Description of the Prior Art
Halogenated benzene derivatives typically include dichlorobenzene, chlorotoluene, dichlorotoluene and dichlorocumene, and these are important as intermediates for synthesis of agricultural chemicals and medicines.
A halogenated benzene derivative is generally obtainable as a mixture of isomers through halogenation of benzene, alkyl benzene or halogenated alkyl benzene and is provided by isolating the desired isomer from such mixture of isomers. Separation of the isomer is generally made by distillation, crystallization or adsorption. But, as these isomers are not much different in boiling or freezing point, a conventional distillation or crystallization method is hardly applicable.
On the other hand, there have recently been developed methods of isomerizing a dialkylbenzene such as xylene in the presence of a catalyst (U.S. Pat. No. 4,409,413) and a method of adsorptive separation of a mixture of alkylbenzene isomers with a zeolite adsorbent (Japanese Examined Patent Publication No. 15681/1977 and Japanese Examined Patent Publication No. 38202/1983). According to these methods, the desired isomer is obtainable at a considerable purity. Further, by feeding the remaining components after separation to an isomerization process and thus isomerizing them, and then separating the desired isomer in adsorptive separation once more, it is possible to ultimately produce the desired isomer only.
However, when said method of isomerization and adsorption separation is applied to production of halogenated benzene derivatives, degradation of the zeolite adsorbent occurs gradually, resulting in reduction of productivity.
SUMMARY OF THE INVENTION
The inventors looked into the cause of degradation of the zeolite adsorbent and found that a very small amount of hydrogen halide contained in the material and a very small amount of water cause degradation of the zeolite adsorbent.
Further, the inventors found that zeolite adsorbent of the water absorbing type, such as faujasite type zeolite, are degraded to a considerable extent.
Moreover, the inventors found that the zeolite adsorbent is deteriorated by the co-presence of water and hydrogen halide a high concentration in the material to be adsorbed, and degraded the adsorbing capacity.
Therefore, the inventors found that it is required to suppress the water content in the material to be adsorbed as far as practicable, and that it is possible to prevent degradation of the zeolite adsorbent.
An object of the present invention is to provide, in contacting a mixture of the isomers of halogenated benzene derivatives containing hydrogen halide with a zeolite adsorbent and, thus, selectively separating the desired isomer of the halogenated benzene derivative, a process of preventing degradation of the zeolite adsorbent by selectively separating industrially a desired isomer of the halogenated benzene derivative for a long time without reduction of productivity.
Another object of the present invention is to provide a process of contacting a mixture of isomers of a halogenated benzene derivative containing a hydrogen halide with a zeolite adsorbent and, thus, selectively separating the desired isomer in high purity.
Other and further objects, features and advantages of the invention will appear from the following description.
These objects are attained by process for producing halogenated benzene derivatives comprising distilling or stripping a mixture of the isomers of a halogenated benzene derivative containing a hydrogen halide to remove the hydrogen halide from the isomeric mixture of the halogenated benzene derivative and then contacting with a zeolite adsorbent for selectivity separating the desired isomer of the halogenated benzene derivative.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram illustrating continuous adsorptive separation of a dichlorobenzene isomer using a simulated moving bed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the halogenated benzene derivative used as a starting material according to the method of the invention, for example, there by be cited compounds expressed by the following general formula (I): ##STR1##
wherein X 1 represents a halogen atom, X 2 and X 3 a haolgen or hydrogen atom, and R a lower alkyl group or halogen atom.
Here, R is a lower alkyl group and shows an alkyl group of 1 to 4 carbon atoms. Specifically, there may be listed a methyl group, ethyl group, n-propyl group, iso-propyl group, n-butyl group, sec-butyl group, and tert-butyl group. When X 1 , X 2 , X 3 or R represents a halogen atom, the halogen atom may be the same or different. Specifically, the halogen atom includes chlorine, bromine and iodine atom, preferably chlorine and bromine. Halogenated benzene derivatives include, for example, dichlorobenzene, chlorotoluene, dichlorotoluene, trichlorobenzene, trichlorotoluene, tetrachlorobenzene, dibromobenzene, bromotoluene, dibromotoluene, dichlorobromobenzene, tribromobenzene, dibromochlorobenzene, chlorocumene, dichlorocumene, trichlorocumene, dibromocumene and bromocumene. Of these, chlorobenzene, chlorotoluene, dichlorotoluene and dichlorocumene are preferable. These halogenated benzene derivatives are respectively supplied as a mixture of isomers.
The mixture of isomers of a halogenated benzene derivative used as a material according to the method of the invention is normally provided by halogenation reaction of benzene, alkylbenzene or halogenated alkyl benzene, or isomerization reaction, and contains a very small amount of a hydrogen halide as a by-product. The isomer mixture of halogenated benzene derivative usually contains a small amount of water.
The halogenation reaction or the isomerization reaction may be carried out by a conventional method.
For example, the isomerization reaction is carried out by contacting a starting material, such as a mixture of isomers of a halogenated benzene derivative, with a catalyst. Here, as a catalyst, aluminum trichloride or zeolite is usable. Specific examples of zeolite catalyst, a faujasite type zeolite, pentasil type zeolite and mordenite type zeolite may be listed. When a zeolite catalyst is used for isomerization, the isomerization may be effected according to Unexamined Japanese Patent Publication No. 144330/1983. That is, any system of gas phase reaction, such as liquid phase reaction, fixed bed, moving bed or fluidized bed are usable under the conditions of a reaction temperature of 200° to 550° C., preferably 250° to 500° C., and a weight hourly space velocity (WHSV) of 0.05 to 30 hours -1 , preferably 0.1 to 20 hours -1 .
In the method of the invention, it is important that the mixture of isomers of a halogenated benzene derivative containing a hydrogen halide is subjected to a distillation or stripping treatment for removal of the hydrogen halide.
Absorption with an aqueous alkaline solution that is a conventional method for removal of the hydrogen halide is not preferable in that the isomeric mixture of halogenated benzene derivative unavoidably comes into contact with water and thus has a very small amount of water dissolved, which in turn causes degradation of the zeolite adsorbent used in the subsequent process.
The distillation or stripping treatment enables removal of the hydrogen halide without contact with water.
The isomeric mixture of the halogenated benzene derivative to be subjected to the distillation or stripping treatment is not restricted, and may be the isomerization reaction mixture itself or the extracted or distilled halogenated benzene derivative.
In the method of the invention, the stripping treatment refers to blowing an inert gas suh as N 2 into the reaction liquid containing a hydrogen halide to remove hydrogen halide, water and volatile components from the reaction liquid. The distillation treatment refers to the distillation process carried out according to a conventional method.
The distillation or stripping treatment is practicable either by a plate tower or by a packed tower. The operation may be under atmospheric, vacuum or increased pressure. The distillation or stripping treatment is carried out until the concentration of the hydrogen halide in the reaction liquid is reduced to 10 ppm or less, preferably 1 ppm or less.
In the process of the invention, water present in the material is also simultaneously removed by the distillation or stripping treatment.
The distillation or stripping treatment is carried out until the water content is the reaction liquid is reduced to 10 ppm or less, preferably 1 ppm or less.
If the isomerization of a halogenated benzene derivative involves side reactions such as transalkylation, dehalogenation and/or demethylation, there are produced demethylated and/or dehalogenated low boiling components as by-products. For example, when chlorotoluene is isomerized, toluene and chlorobenzene are incidentally produced, each in a very small amount. Such low boiling components scarcely degrade the zeolite adsorbent. But, when a high purity product is required, the low boiling components should be removed. Here, by the distillation or stripping treatment, the low boiling components can be simultaneously removed. When the low boiling components are of a small relative volatility, a multi-stage distillation or stripping tower should be used.
The isomeric mixture of halogenated benzene derivative subjected to the distillation or stripping treatment is fed to a process-of adsorptive separation, and in the adsorptive separation process, the desired isomer of the halogenated benzene derivative is selectively separated.
For the adsorbent, a zeolite is usable. These is no particular restriction of the zeolite adsorbent, but those zeolite adsorbents which are subject to great degradation by hydrogen halides provide particularly good results. Specifically, the most preferably result can be obtained, when such zeolites as X types, Y type and other faujasite type zeolites, pentasil type zeolites such as ZSM-5, mordenite type zeolites, L types zeolites and beta type zeolites are used.
As a desorbent, toluene, xylene and other aromatic compound are usable. For adsorption and desorption, ordinary methods and conditions may be employed. For example, adsorption and desorption may be made according to the method in Japanese Examined Patent Publication No. 24981/1988.
The mixture of isomers after adsorptive separation of the desired isomer may be subjected to an isomerization reaction to enhance the concentration of the desired isomer to an equilibrium rate. By such recycling, the desired isomer can be industrially advantageously produced.
The invention will be more clearly understood as it is described with reference to the following examples.
EXAMPLE 1
An aqueous mixture comprising 135 g of sodium silicate, 8.6 g of Al 2 (SO 4 ) 18H 2 O, 15 g of n-propylamine, 11.2 g of H 2 SO 4 and 400 g of water was maintained 155° C. for 72 hours for crystallization, and thus there was produced a powder of Zeolite ZSM-5 of SiO 2 /Al 2 O 3 molar ratio of 45.5 mol/mol. This ZSM-5 powder was subjected to ion exchange for five times with a 10% by weight aqueous solution of ammonium chloride used (solid/liquid ratio, 2.0 l/kg at about 90° C.), then thoroughly rinsed, dried at 120° C. for 15 hours and calcined at 600° C. for 2 hours in air, and there was obtained and acid type ZSM-5 catalyst.
Using the acid type ZSM-5 catalyst thus obtained, and employing a fixed bed flow reactor, isomerization of o-dichlorobenzene was carried out in a liquid phase, and there was obtained a mixture of isomers of dichlorobenzene containing hydrogen chloride. o-Dichlorobenzene was dehydrated with a moleculate sieve. The conditions for isomerization are shown below.
WHSV=4.5 hour -1
Reaction temperature=300° C.
Reaction pressure=30 kg/cm 2 G
After the reaction, the composition of the mixture of isomers was o-dichlorobenzene:m-dichlorobenzene:p-dichlorobenzene=58:27:15, and the concentration of hydrogen chloride was 20 ppm, and water was 10 ppm. The concentration of the by-product chlorobenzene was 0.09% by weight.
The obtained reaction mixture was distilled at 200 mmHg for about 30 minutes to remove hydrogen chloride and water from the reaction mixture. After distillation, the hydrogen chloride in the reaction mixture was 1 ppm, water 6 ppm and low boiling components 0.01% by weight. This isomeric mixture was subjected to adsorptive separation by the simulated moving bed system shown in FIG. 1.
The system shown in FIG. 1 will now be briefly described.
To the adsorption chambers 1 through 12, each of an inner capacity of about 13 ml, and X type zeolite adsorbent represented by 0.75 LiO 2 .0.25Na 2 O.Al 2 O 3 .2.5SiO 2 (hereinafter referred to as "Li-X type zeolite") was charged. Through the line 13, the desorbent, toluene, was fed at 300 ml/hr, and though the line 15, said mixture of isomers was fed at 17 ml/hr. Through the line 14, the extract flow was discharged at 74 ml/hr, and through the line 16, the raffinate flow was discharged at 29 ml/hr. The remaining liquid was discharged through the line 17. Flow of the liquid between the adsorption chambers 1 and 12 is closed by a valve 18. Then, the adsorption chamber 1 was shifted to the position of the adsorption chamber 12, the chamber 11 to 10, 8 to 7 and 5 to 4 respectively, at an interval of about 150 seconds (the other chambers being also shifted upward by one chamber simulataneously). The adsorption temperature was 130° C.
At two hours after the start of adsorptive separation, the purity of m-dichlorobenzene in the mixture of isomers of dichlorobenzene contained in the raffinate flow was 99.5%, and the recovery rate of m-dichlorobenzene was 70%. Further, preserving the raffinate flow and extract flow, the composition after 100 hours was examined, and the purity of the product, m-dichlorobenzene in the dichlorobenzene mixture in the raffinate flow, was 99.5%, and the recovery rate was 68%.
EXAMPLE 2
Isomerization and adsorptive separation were carried out as in Example 1, except that instead of distillating the reaction mixture, N 2 gas was bubbled in the reaction mixture at about 1 l/min for about 1 hour under room temperature and atmospheric pressure to strip hydrogen chloride and water and thus remove them. After stripping, the concentrations of hydrogen chloride, water and low boiling components in the reaction mixture were 8 ppm, 7 ppm and 0.08% by weight, respectively.
The purity of the product, m-dichlorobenzene in the raffinate flow at 2 hours after start of the adsorptive separation, was 99.6%, and the recovery rate of the product, m-dichlorobenzene was 68%. After 100 hours, the purity of the product, m-dichlorobenzene in the raffinate flow was 99.6%, and recovery rate was 67%.
COMPARATIVE EXAMPLE 1
Isomerization and adsorptive separations were carried out as in Example 1 except that the reaction mixture was not distilled but was directly fed to the process of adsorptive separation.
In the reaction mixture, the hydrogen chloride was 120 ppm, water 10 ppm and low boiling components were 0.09% by weight. The product, m-dichlorobenzene in the raffinate flow at 2 hours after start of the adsorptive separation, was of 99.5% purity and had a recovery rate 68%. After 48 hours, the purity of the product, m-dichlorobenzene in the raffinate flow was 91.3% and the recovery rate was 60%.
EXAMPLE 3
With 2,5-dichlorotoluene used in place of o-dichlorobenzene, and with an X type zeolite substituted by Ag used in place of Li-X type zeolite in Example 1, isomerization, distillation and adsorptive separations were carried out as in Example 1. The product, 2,6-dichlorotoluene, was obtained. The results are shown in Table 1.
Isomerization and adsorptive separations were carried out as in Example 3 except that the reaction mixture was not distilled but directly fed to the process of adsorptive separation. The results are shown in Table 1 as Comparative Example 2.
EXAMPLE 4
With 2,4-dichlorocumene used in place of o-dichlorobenzene and wity Y type zeolite substituted by K used in place of Li-X type zeolite in Example 1, isomerization, distillation and adsorptive separations were carried out as in Example 1. The product, 3,5-dichlorocumene, was obtained. The results are shown in Table 1.
Isomerization and adsorptive separations were carried out as in Example 4, except that the reaction mixture was not distilled but was directly fed to the process of adsorptive separation. The results are shown in Table 1 as Comparative Example 3.
TABLE 1______________________________________ After Distillation orHalogen- After Reaction stripping ated Hydrogen Hydrogen Benzene Chloride Water Chloride Water Derivatives (ppm) (ppm) (ppm) (ppm)______________________________________Example Dichloro- 120 10 1 61 benzeneExample Dichloro- 120 10 8 72 benzeneCompar- Dichloro- 120 10 -- --ative benzeneExampleExample Dichloro- 2500 20 5 43 tolueneCompar- Dichloro- 2500 20 -- --ative tolueneExample2Example Dichloro- 3500 150 6 104 cumeneCompar- Dichloro- 3500 150 -- --ative cumeneExample3______________________________________ At 2 Hours After At 100 Hours After Separation Separation (*) Purity of Recovery Purity of Recovery Product Rate Product Rate (%) (%) (%) (%)______________________________________Example 99.5 70 99.5 68Example 99.6 68 99.6 672Comparative 99.5 68 91.3 60Example1Example 99.7 95 99.7 943Comparative 99.5 87 98.1 65Example2Example 99.4 90 99.4 904Comparative 97.5 82 96.3 52Example3______________________________________ (*)Concerning Comparative Examples 1, 2, and 3, the purity and recovery rate are the data at 48 hours after separation, not at 100 hours after separation. | By a process for preparing halogenated benzene derivatives comprising distilling or stripping a mixture of the isomers of a halogenated benzene derivative containing a hydrogen halide to remove the hydrogen halide from the isomeric mixture of the halogenated benzene derivative and then contacting with a zeolite adsorbent for selectivity separating the desired isomer of the halogenated benzene derivative, it is possible to prevent from degrading the zeolite adsorbent. And it is possible to separate selectively industrially an desired isomer of the halogenated benzene derivative for a long time without reduction of productivity and to separate selectively the desired isomer in high purity. | 2 |
BACKGROUND OF THE INVENTION
The present invention is directed to a roll-up partition system assembly which has a protective partition for covering a window or door opening that may be rolled up into a housing when not in use. More particularly, the present invention is directed to a modular assembly implementing an improved emergency opening mechanism for roll-up partition systems. The embodiments disclosed herein illustrated the various aspects of the present invention applied to one particular type of roll-up partition system: rolling protective shutters formed from a plurality of interconnected slats. It will be apparent to those of ordinary skill in the art that the present invention has application in other systems wherein a partition member is coupled to and rolls up onto a support member within a housing, such as roll-up doors, roll-up grills, roll-up gates and the like. The application of the present invention to the various types of roll-up partition systems is contemplated by the inventor.
One type of roll-up partition system is a rolling protective shutter. Rolling protective shutters are conventional and are used to provide protection against extreme weather conditions and to deter theft, for example. One such rolling protective shutter is disclosed in U.S. Pat. No. 4,345,635 to Solomon. As shown in FIGS. 1 and 2 of that patent, the Solomon shutter is composed of a plurality of elongate slats, each of which has a pair of circular ribs attached to its sides. The slats are interconnected by a plurality of elongate hinges, each of which has a pair of circular apertures in which the circular ribs of the slats are disposed. When the Solomon shutter is unrolled to its protective position, each of the slats in the shutter is disposed vertically with the ends of the slats disposed within guide channels or side tracks on either side of the opening. When not in use, the Solomon shutter may be rolled up into a housing disposed at the upper end of the protective shutter.
Another type of rolling protective shutter is disclosed in U.S. Pat. No. 5,575,322 to Miller. As shown, the shutter assembly includes a shutter support member mounted for rotation in a shutter housing. A rolling shutter composed of a plurality of individual slats is coupled to the shutter support member so that the shutter can be rolled up onto the shutter support member. A pair of shutter tracks extend downwardly from either end of the shutter housing. When the shutter is in its unrolled position, the ends of the slats are disposed within the tracks.
Roll-up partitions in general, and rolling protective shutters in particular, typically incorporate one or more torsion spring assemblies to assist in rolling and unrolling the shutters manually or by a powered opening device. In one arrangement, the assembly is a self-contained modular unit having a spring shaft surrounded by a coiled torsion spring. One end of the spring shaft includes a spring shaft support that is rotatable about the spring shaft, and a spring plate rigidly fixed to the spring shaft and to the proximate end of the torsion spring to prevent rotation of the end of the torsion spring relative to the spring shaft. The other end of the spring shaft includes a spring drive that is rotatable about the spring shaft and rigidly fixed to the other end of the torsion spring. The assembly is inserted into the shutter support member with one end of the spring rigidly fixed to the shutter housing. The spring shaft support and spring drive engage the interior of and rotate with the shutter support member. When the shutter is unrolled, the torsion spring is wound tighter, thereby providing additional torque to assist in lifting and rolling the shutter onto the shutter support member. During normal operation of the rolling protective shutters, the torsion spring exerts a minimum torque when the shutter is in the rolled position and a maximum torque when the shutter is in the unrolled position.
The torsion spring therefore assists in lifting the shutter to an open position, whether motor driven or manually operated. In many municipalities, it is required that a person could easily pull a lever and have any type of security door or gate open ("pop up") for easy and fast egress in case of an emergency, such as, for example, a fire, inside the building on which the security door or gate is installed. This "pop up" operation must be done mechanically rather than by electrical power, in the event that electrical power is interrupted due to the fire or other emergency in the building.
Accordingly, it is necessary to have a system that enables a torsion spring to raise the door or gate by a manual operation. Typically, motor driven security doors or gates use a braking system of some type to maintain the position of the door or gate when the motor is stopped. This braking system must be disengaged when the door or gate needs to be raised.
A typical type of overhead door uses a large motor mounted outside of a housing that contains the door or gate when it is rolled up. The motor can be hidden in the ceiling of the building in which the door or gate is installed. Through the use of gears and/or chains, it has been fairly easy to provide a mechanism to disengage the braking system and permit the torsion spring to raise the shutter. However, this type of external motor system is extremely costly, very large, difficult to install, and can be unsightly if it cannot be hidden in a ceiling.
One primary alternative to such external motor systems is the use of tubular motors to raise and lower doors and gates. Tubular motors can be encased inside of a roller tube around which the door or gate is wound when the door or gate is opened. As the motor system is always hidden within the roller tube, it is never visible and thereby gives the door or gate a very clean look. The use of a tubular motor also makes installation of the door or gate much simpler.
Present designs for rolling doors or gates having tubular motors do not have satisfactory mechanisms for utilizing a torsion spring to raise the door in an emergency. Typically, a cable mechanism is used to manually release a brake inside the tubular motor. Such cable mechanisms do not work well in practice because the required travel of the cable is so small in order to effectively release the brake that the cable mechanisms either simply do not work or are extremely difficult to install properly. Accordingly, presently there are no known commercial manufacturers of tubular motors that offer a system for rolling up a door or gate in an emergency.
In view of the foregoing problems and disadvantages, there is a need for a system that can be used with a tubular motor that enables the use of a torsion spring to open a door or gate in case of an emergency.
Summary of the Invention
The present invention is directed to a roll-up partition assembly, such as a rolling protective shutter, implementing an improved mechanism for opening the partition assembly in an emergency situation.
In accordance with a preferred embodiment of the present invention, a mechanism is provided for disengaging a motor from a roller tube of a rolling shutter. The mechanism includes a manually operable actuating member that passes through an axial passage in a spring shaft to which a torsion spring is mounted. The manually operable actuating member is connected to a coupling mechanism. When the manually operable actuating member is pulled, the coupling mechanism is separated from the motor drive shaft, thereby disengaging the roller tube from the motor drive shaft.
The features and advantages of the invention will be apparent to those of ordinary skill in the art in view of the detailed description of the preferred embodiment, which is made with reference to the drawings, a brief description of which is provided below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a rolling shutter assembly that can implement the present invention;
FIG. 2 is a fragmentary perspective view of a portion of the shutter of the shutter assembly of FIG. 1;
FIG. 3 is a schematic top view of a portion of the shutter assembly of FIG. 1, in a configuration for normal, motorized operation; and
FIG. 4 is a schematic top view of a portion of the shutter assembly of FIG. 1, in a configuration for emergency, manual operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One type of roll-up partition system, rolling shutter assembly 10, that may implement the present invention is shown in FIGS. 1-3. Referring to FIG. 1, the shutter assembly 10 has a shutter housing which includes a top wall 12, a pair of side walls 14, and a front wall 16. A partition support member 20 is mounted for rotation within the shutter housing. The support member 20 includes a generally cylindrical central roller tube 22 and a plurality of mounting members 24 fixed to the roller tube 22.
The upper end of a rolling shutter 30 is coupled to the mounting members 24. Alternatively, however, the mounting members 24 may be omitted and the rolling shutter 30 mounted directly to the roller tube 22. The shutter 30 is composed of a plurality of individual, elongate slats 32. One example of a configuration of slats 32 is illustrated in FIG. 2. The slats 32, each of which is substantially flat, having two substantially planar side portions, and may be composed of steel, are interconnected by a plurality of hinges 34, each of which joins together a pair of adjacent slats 32.
Each of the slats 32 includes an upward projection 35 extending longitudinally along the upper edge of the slat 32 and having a rearwardly and downwardly extending hook 36 at the top. Each of the slats 32 further includes a downward facing U-shaped recess 37 extending longitudinally along the lower edge of the slat 32 and having a forward horizontal projection 38 formed on the rear edge of the recess 37. The hook 36 of a lower slat 32 and the recess 37 and projection 38 of an upper slat 32 interlock to form each hinge 34.
Instead of being integrally formed with the shutter slats 32, the hooks 36 and U-shaped recesses 37 described above could be separate components connected thereto, such as by bolting or riveting. Instead of hooks and recesses, other locking members having different structures could be used to form the hinges. Other configurations of slats 32 and interconnecting hinges 34, such as the configuration of the Solomon shutters, are well known in the art and are contemplated by the inventor as having use with the present invention.
Referring back to FIG. 1, the ends of the slats 32 are disposed within a pair of shutter tracks 40. When mounted to protect a window or other opening, the shutter tracks 40 of the shutter assembly 10 are positioned on either side of the opening and the shutter housing is positioned over the top of the opening. Alternatively, in some applications, the side tracks 40 and shutter housing are positioned within the opening.
The shutter assembly 10 includes a tubular electric motor 42 (shown schematically in FIGS. 3 and 4) disposed within the roller tube 22. When the shutter 30 is not in use, it is rolled up on the roller tube 22 via the motor 42 so that it is at least partially enclosed by the shutter housing.
Now referring to FIGS. 3 and 4, the motor 42 is directly coupled to the roller tube 22, on which the shutter rolls up, by means of a motor drive coupling 44 driven by a motor shaft 46 extending from the motor 42. The motor drive coupling includes a splined socket portion 48 that mates with a splined end portion 50 of an axially movable drive shaft 52. The splined end portion 50 also mates with a splined drive plate 54 that is fixedly secured to the roller tube 22 for rotation therewith. The axially movable drive shaft 52 passes through a first spacer plate 56 and a second spacer plate 58. A compression spring 60 wrapped around the axially movable drive shaft 52 is disposed between the first spacer plate 56 and a compression spring plate 62 that is fixed to the axially movable drive shaft 52. The compression spring 60 tends to press the axially movable drive shaft 52 toward the left as shown in FIG. 3, and thus tends to press the splined end portion 50 of the movable drive shaft 52 into engagement with the splined socket portion 48 of the motor drive coupling 44.
As previously discussed, roll-up partition assemblies incorporate torsion springs to assist in lifting and rolling the shutters. Referring to the right hand portion of FIGS. 3 and 4, the shutter assembly 10 includes a torsion spring assembly 64 that facilitates ease of movement of the shutter 30 from the unrolled position to the rolled position. The torsion spring assembly 64 includes a hollow spring shaft 66 surrounded by a coiled torsion spring 68 disposed within the roller tube 22. The hollow spring shaft 66 is anchored to the side wall 14 on the right hand side of the rolling shutter assembly 10.
A torsion spring plate 70 is rigidly mounted to the hollow spring shaft 66. The outer diameter of the torsion spring plate 70 is small enough to allow the roller tube 22 to rotate relative to the hollow spring shaft 66 without engaging the outer surface of the torsion spring plate 70. The torsion spring plate 70 is rigidly connected to a first end 72 of the coiled torsion spring 68 to prevent rotation of the first end 72 of the coiled torsion spring 68 relative to the hollow spring shaft 66.
The counterbalancing mechanism further includes a spring drive 74 rotatably mounted to the hollow spring shaft 66 adjacent a second end 76 of the coiled torsion spring 68 opposite the first end 72 thereof. The spring drive 74 is rigidly attached to the roller tube 22 for rotation therewith. The second end 76 of the coiled torsion spring 68 is coupled to the spring drive 74 and rotates with the roller tube 22 relative to the hollow spring shaft 66. When the rolling shutter 30 is unrolled, the coiled torsion spring 68 is wound tighter as the second end 76 connected to the spring drive 74 rotates relative to the first end 72 connected to the torsion spring plate 70, thereby providing additional torque to assist in lifting and rolling the shutter 30 onto the roller tube 22.
A manually operable actuating member 78 passes through the hollow spring shaft 66 and is connected to the axially movable drive shaft 52. A bearing 80 is disposed between the manually operable actuating member 78 and the axially movable drive shaft 52, to prevent twisting of the manually operable actuating member 78 when the roller tube 22 and the axially movable drive shaft 52 are rotated to raise or lower the shutter 30. The manually operable actuating member 78 can be in the form of a flexible steel cable or a rigid metal rod. When the manually operable actuating member 78 is pulled, the compression spring 60 is compressed and the axially movable drive shaft 52 is moved toward the right, as seen in FIG. 4, disengaging the axially movable drive shaft 52 from the splined socket portion 48. Once disengaged from the splined socket portion 48, the axially movable drive shaft 52 is disconnected from the motor 42, permitting the torsion spring assembly 64 to raise the rolling shutter 30 without having to overcome the torque required to turn the motor 42. The manually operable actuating member 78 may then be released after the shutter 30 has been raised using the torsion spring assembly 64.
Once the manually operable actuating member 78 is released, the compression spring 60 presses the axially movable drive shaft 52 toward the left, as seen in FIG. 3, re-engaging the axially movable drive shaft 52 to the splined socket portion 48. The rolling shutter assembly 10, is therefore ready to be operated using the motor 42.
The embodiments disclosed herein illustrate the various aspects of the present invention applied to a rolling protective shutter. It will be apparent to those skilled in the art that the present invention may be applied to other systems wherein a partition member is coupled to a support member and rolled up into a housing. Such partition systems include roll-up doors, roll-up grills, roll-up gates and the like. The application of the present invention to the various types of roll-up partition systems is contemplated by the inventor.
Other modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. This description is to be construed as illustrative only, and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the structure and method may be varied substantially without departing from the spirit of the invention, and the exclusive use of all modifications which come within the scope of the appended claims is reserved. | The present invention is directed to a modular roll-up partition assembly, such as a rolling protective shutter, implementing an improved mechanism for raising the partition in an emergency by disengaging a motor from a rolling shutter. The mechanism includes a cable that passes through an axial passage in a spring shaft to which a torsion spring is mounted. When the cable is pulled, the coupling mechanism is separated from the motor drive shaft, thereby disengaging the spring shaft from the motor drive shaft and permitting the torsion spring to quickly raise the rolling shutter. | 4 |
This invention relates to a regenerative and friction brake blend control method and apparatus.
BACKGROUND OF THE INVENTION
In many electric vehicles, energy that places the vehicle in motion is partially recovered during vehicle braking using what is known as regenerative braking. Regenerative braking is achieved during braking maneuvers by configuring the drive motor as a generator and storing or redistributing the power generated by the motor. The act of generating power creates a braking torque on the motor that is transmitted to the road wheels to slow the vehicle. In many situations, regenerative braking cannot accomplish all of the vehicle braking so regenerative braking is blended with hydraulic braking to achieve the total desired braking.
SUMMARY OF THE PRESENT INVENTION
A regenerative and friction brake blend control method according to this invention is characterized by the features specified in claim 1.
Advantageously, this invention provides a regenerative brake blending method that maximizes recovery of available regenerative energy. Advantageously, this invention enables maximum use of available regenerative energy during regenerative braking by reducing and/or eliminating hydraulic braking during a braking event as the regenerative braking capability increases.
Advantageously, this invention provides a regenerative and friction brake blending control method that blends position control of brake actuators with electric motor regenerative braking. Advantageously, in one example, this invention blends regenerative braking during normal brake events and during anti-lock brake events.
Advantageously, an example regenerative and friction brake blend control method according to this invention, for use in a vehicle with at least one positionable hydraulic brake actuator for achieving friction braking and an electric propulsion motor with regenerative braking capability wherein an amount of regenerative braking achieved is indicated by a signal, comprises the steps of determining a hydraulic actuator position command indicating a desired vehicle braking, determining responsive the hydraulic actuator position command a regenerative braking command, commanding the electric propulsion motor to regeneratively brake the vehicle responsive to the regenerative braking command, receiving the signal indicative of regenerative braking achieved, convening the signal indicative of regenerative braking achieved to an actuator position reduction signal, subtracting the actuator position reduction signal from the hydraulic actuator position command to determine a difference command, and commanding the hydraulic actuator according to the difference command, wherein the hydraulic actuator and the regenerative braking together achieve the desired vehicle braking.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 illustrates a schematic vehicle with hydraulic and regenerative braking systems according to this invention;
FIGS. 2a, 2b and 2c illustrate flow diagrams according to this invention; and
FIG. 3 is a graph illustrating the operation of this invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the example vehicle braking system illustrated includes left and right front wheels 10 and 12 and left and right rear wheels 14 and 16, driven by electric motor drive 61. In a hybrid vehicle example, the front wheels 10 and 12 may be driven by an internal combustion engine. The front and rear wheels 10, 12, 14 and 16 have respective hydraulic actuated brakes 18, 20, 34 and 36 actuated by hydraulic pressure generated via respective electrohydraulic actuators 22, 24 and 62 (for both rear brakes 34 and 36; in another example, each rear brake has a separate electrohydraulic actuator). Each of the hydraulic brakes 18, 20, 34 and 36 are further hydraulically coupled to a conventional master cylinder 26 through respective normally opened electromagnetic valves 28, 30 and 60. Actuators 22, 24, 60 include a working chamber hydraulically coupled to the wheel brakes 18, 20, 34 and 36 and the valves 28, 30 and 60. In the preferred form of the invention, the electrohydraulic actuators 22, 24 and 60 each take the form of a brushless de motor driven actuator wherein a motor is operated to control a piston for regulating the braking pressure (the motor for actuator 60 drives two pistons in parallel, one for each rear brake 34, 36).
Friction brake torque is established at each brake 18, 20, 34, 36 at a value proportional to the position of each actuator piston and is reflected through the torque output of the respective motor. For example, the electrohydraulic brake actuators 22, 24, 62 may each take the general form of the electrohydraulic actuator as described in the U.S. Pat. No. RE 33,557, which issued Mar. 19, 1991, assigned to the assignee of this invention. As discussed below, the actuators 22, 24 and 62 may be operated using techniques described in U.S. patent application, Ser. No. 08/355,468, filed Dec. 14, 1994, assigned to the assignee of this invention, the disclosure of which is incorporated herein by reference.
The master cylinder 26 is operated by a conventional vehicle brake pedal 32 in response to the foot pressure applied by the vehicle operator.
While as illustrated in FIG. 1 the rear wheels are friction braked by electrohydraulic actuator 62, the rear wheels may alternatively be friction braked means of a pair of electrically operated brakes 34 and 36. Such brakes 34 and 36 may each take the form of an electrically operated drum brake in which the braking torque is established by operation of a de torque motor at a value proportional to the torque output of the dc torque motor. One example of such a brake is illustrated in the U.S. Pat. No. 5,000,297, issued Mar. 19, 1991, assigned to the assignee of this invention.
In addition to the brake hydraulic brakes 34 and 36, the rear wheels are also braked regeneratively by the electric motor drive 65.
The front and rear brakes 18, 20, 34 and 36 and the electric motor drive 65 are operated to establish a desired braking condition by means of an electronic brake controller 38 and electronic motor controller 63. The electronic controllers 38, 63 each are microprocessor-based devices including random access and read-only memories and appropriate input/output interface circuitry to receive the input signals and provide the command outputs shown. Construction of suitable controllers is within the level of one skilled in the art.
In general, the electronic brake controller 38 senses a braking command input by the vehicle operator by sensing the state of a conventional brake switch 40, which provides a signal when the vehicle operator applies pressure to the brake pedal 32. When the brake switch input is sensed, the electronic controller 38 operates the electromagnetic valves 28, 30 and 60 to close off the hydraulic communication between the master cylinder and the electrohydraulic actuators 22 and 24. This effectively isolates the wheel brakes 18, 20, 34 and 36 from the master cylinder 26 such that the hydraulic pressures at the wheel brakes are controlled solely by means of the electrohydraulic actuators 22, 24 and 62. The degree of braking effort commanded by the vehicle operator is sensed by means of a pedal position sensor 41 and a pressure sensor 42 monitoring operator depression of pedal 32 and the hydraulic pressure output of master cylinder 26, respectively. As is well known, the hydraulic pressure output of the master cylinder 26 is directly proportional to the applied pressure to the brake pedal 32 controlling the position of the master cylinder 26 and the position output of sensor 41.
Both the pedal position and the pedal pressure may be used to determine the operator requested brake effort command. In response to the brake effort command, the electronic controller 38 provides for establishing a desired brake torque at the front wheels 10 and 12 via the brakes 18 and 20 by commanding the motor current to each actuator 22, 24 to establish the actuator position, and therefore brake pressure, for each front brake 18, 20 at a desired level related to the brake effort command.
Also in response to the brake effort command, the electronic controller 38 receives, from motor controller 63, information concerning available and achieved regenerative braking of electric motor drive 65. Responsive to this information and the brake effort command, electronic controller 38 sends a regenerative braking command to motor controller 63, which commands the electric motor drive 65 to convert rotational motion of the rear wheels 14, 16 to electric energy that is transferred via power bus 66 from the electric motor drive 65 to the dc storage battery 68. In the event that the rear wheels do not achieve the desired brake torque solely through the regenerative braking, controller 38 establishes the remainder of the desired rear brake torque via brakes 34 and 36 by commanding motor current to actuator 62 to establish the actuator position, and therefore brake pressure, for each rear brake 34, 36 at the desired level. More particularly, the rear brakes 34 and 36 are commanded so that the sum of the friction brake torque and the electric motor regenerative brake torque equal the desired rear brake torque.
The actuator position feedback provided by the actuators 22, 24 and 68 is used in a standard commutation control to control the switching of the dc brushless motors and to provide closed-loop brake actuator position control. The position feedback may be used in accordance with the like control described in pending U.S. patent applications, Ser. No. 08/355,468, Ser. No. 08/513,191, and Ser. No. 08/513,192, assigned to the assignee of this invention.
Referring now to FIGS. 2a-c, the brake control routine shown is entered when a vehicle operator depresses the brake pedal 32 (FIG. 1) and that depression is sensed by the brake pedal switch 40 (FIG. 1). The routine first checks, at block 100, whether the brake control is in ABS mode. In general, ABS mode occurs when the brake pedal is depressed and one or more of the vehicle wheels is in an incipient lock-up condition. This is typically determined in a manner well known to those skilled in the art when a rotational velocity of one or more of the vehicle wheels is slower than the vehicle wheel(s) with the fastest rotational velocity by more than a predetermined threshold. The difference in wheel rotational velocities is often referred to as "slip."
If ABS is active, the routine moves to block 160, described in detail further below. If ABS is not active, the routine moves to block 110 where it determines a position command, BLEND, responsive to the signal, RGNRSP, from the motor controller 63 indicating the amount of regenerative brake torque achieved. During the first control loop after the brake pedal has been depressed, RGNRSP is zero. BLEND is determined according to the equation:
BLEND=RGNRSP * KRGNRSP,
where KRGNRSP is a conversion constant.
In general, the value BLEND corresponds to the pedal position at which the pedal must be depressed to require friction braking in addition to regenerative braking. Thus, according to this invention, block 110 converts the regenerative braking achieved to a position value allowing interface between the regenerative braking and the position control of the friction brake actuators.
At block 112, the routine determines if the vehicle speed is greater than the threshold speed KVSPD. If the vehicle speed is not greater than the threshold speed, the routine moves to blocks 114 and 116 where the regenerative braking command, REGENCMD, is reduced to ensure smooth transition of the regenerative command to zero when the vehicle speed equals 0 m.p.h. This may be important in some systems to prevent adverse effects on a vehicle battery or electric motor when recharging is commanded but the vehicle is not moving. Block 114 compares REGENCMD to zero. If REGENCMD equals zero, the routine jumps ahead to block 130. If REGENCMD does not equal zero, REGENCMD is reduced according to the equation:
REGENCMD=REGENCMD-(DECEL*KRGNDECEL),
where KRGNDECEL is a predetermined constant and DECEL is the measured or computed actual vehicle deceleration. Block 116 sets the value BLEND according to:
BLEND=RGNRSP/KHYDR,
where KHYDR is a calibratable constant. KHYDR determines the rate that the hydraulic brake command ramps-up when the regenerative braking command is reduced to zero as the vehicle speed approaches zero. After block 116, the routine jumps ahead to block 130, described in detail further below.
Referring again to block 112, if the vehicle speed is greater than the threshold speed, KVSPD, the routine moves to block 118. At block 118, REGENCMD is determined responsive to the measured pedal position, PEDALPOS, multiplied by a conversion constant KRGNPED. Also at block 118, the regenerative braking reduction term is set equal to zero.
At blocks 120, 122 the routine determines whether the REGENCMD is to be reduced because of possible vehicle yaw. Block 120 compares the steering wheel angle to right and left turn thresholds KSWHI and KSWLO. If the steering wheel angle is between KSWHI and KSWLO, the routine jumps to block 124. If the steering wheel angle is not between KSWHI and KSWLO, the routine moves to block 122 where it determines a value STEERANG according to:
STEERANG=STEERING-((KSWHI+KSWLO)/2),
where STEERING is the measured steering wheel angle. Block 122 then determines a possible vehicle yaw, POSYAW, according to:
POSYAW=VSPD*KSWRGN* STEERANG,
where VSPD is measured vehicle speed and KSWRGN is a conversion constant. The regenerative braking reduction term RGNRED is then set equal to the value POSYAW.
At blocks 124 and 126, the routine determines if the regenerative brake torque reduction term is to be increased due to rear wheel slip. The value HIRSLIP is set equal to the highest measured slip of the two rear wheels. At block 124, the value HIRSLIP is compared to a threshold KSLIP. If HIRSLIP is not greater than KSLIP, the routine jumps to block 128. If, at block 124, the value HIRSLIP is greater than KSLIP, the routine moves to block 126 where the regenerative braking reduction term is increased according to:
RGNRED=RGNRED+(KSLIP*HIRSLIP).
The routine then moves to block 128 where REGENCMD is reduced by the regenerative braking reduction term according to:
REGENCMD=REGENCMD-RGNRED.
At block 130 the routine performs a series of calculations to determine the non-ABS braking motor position commands for the friction brake actuator motors. The ABS motor position commands are described further below. A value DESIREDDECEL, representative of the desired vehicle deceleration, is determined responsive to the measured pedal position multiplied by a predetermined gain constant KD. A value DECELGAIN, representative of the difference between DESIREDDECEL and the actual vehicle deceleration is determined according to:
DECELGAIN=DECEL-DESIREDDECEL.
A hydraulic brake command, HYDCMD, is determined responsive to the pedal position multiplied by DECELGAIN. The rear hydraulic brake command, RHYDCMD, is determined according to:
RHYDCMD=HYDCMD-BLEND.
The routine then looks up motor position commands for the front actuator motors responsive to HYDCMD and for the rear actuator motors responsive to RHYDCMD, vis-a-vis position look-up tables. This may be done in accordance with the teaching set forth in the above-mentioned pending applications Ser. No. 08/355,468, Ser. No. 08/513,191, and Ser. No. 08/513,192.
At block 132 the routine determines if the available regenerative braking is greater than the commanded regenerative braking. The available regenerative braking is determined responsive to motor speed and battery voltage in a manner well known to those skilled in the art. If the available regenerative braking is greater than the commanded regenerative braking at block 132, the routine moves to block 134 where the command REGEN is set equal to the commanded regenerative braking REGENCMD. If, at block 132, the available regenerative braking is not greater than the commanded regenerative braking, then the routine moves to block 136 where the command REGEN is set equal to the available regenerative braking.
From blocks 134 or 136, the routine moves to block 138 where the command REGEN is output to the electric motor controller to command regenerative braking and RGNRSP, indicating the amount of regenerative braking torque achieved, is received from the electric motor controller. A variety of methods are known to those skilled in the art for determining the amount of regenerative braking torque achieved. In one example, the motor controller monitors current generated by the motor or in a phase of the motor during regenerative braking. The measured generated current is then multiplied by a constant to determine regenerative braking torque achieved.
Also at block 138, a motor current command for each actuator is determined responsive to the position error for each actuator, which is the difference between the actual actuator position and the desired position determined at block 130 or at block 150. A proportional derivative control loop controls the actuator position in a manner such as described in the above-mentioned U.S. patent application Ser. No. 08/355,468 or as described in pending applications, Ser. No. 08/513,191, and Ser. No. 08/513,192. The available regenerative braking, RGNAVAIL, is updated according to the equation:
RGNAVAIL=(MAXBATTVOLT-BATTVOLT)*KBATT,
where MAXBATTVOLT is the maximum allowable battery voltage, BATTVOLT is the measured battery voltage and KBATT is a conversion constant. After block 138, the brake control routine is exited for this loop of the control program and the routine is repeated in the next loop of the control program using the updated values of RGNRSP and RGNAVAIL.
In the event that, at block 100, the control routine is in ABS mode, the routine moves to block 160 where a series of calculations are performed. Block 160 determines a value representing the amount of actuator position equivalent to the amount of braking achieved by the regenerative braking, RPOS, by multiplying the total regenerative braking torque achieved, RGNRSP, by a position conversion constant, KRPOS. Also at block 160, the rear actuator position commands LRABSPOS and RRABSPOS are determined by summing the motor position command LRMPOS and RRMPOS, determined as described further below, with the position signal corresponding to regenerative braking achieved, RPOS. The commands LRABSPOS and RRABSPOS are then used to calculate new motor position commands LRABSPOS and RRABSPOS by using an ABS control algorithm of a type known to those skilled in the art and converting the resultant left and right brake commands to position commands and vice versa using conversion constants that can be easily determined for a specific vehicle system by one skilled in the art.
At block 162 the routine determines if either rear wheel is in the release mode. If so, the routine moves to block 164 where the REGEN command is set to zero. If, at block 162, neither of the rear wheels are in release mode, the routine moves to block 166 where it compares the vehicle speed with the vehicle speed threshold, KVSPD. If the vehicle speed is less than KVSPD, block 168 reduces the position corresponding to regenerative braking achieved by an amount equal to vehicle deceleration multiplied by the reduction constant, KRGNDECEL.
The routine then moves to block 170 where the values LRMPOS and RRMPOS are determined. If the value RPOS is greater than LRABSPOS, then block 170 sets RPOS equal to LRABSPOS. Similarly, if RPOS is greater than RRABSPOS, then RPOS is set equal to RRABSPOS. If the value LRABSPOS equals RPOS, then the value LRMPOS is set equal to zero. Otherwise, the value LRMPOS is set equal to the difference between LRABSPOS and RPOS. Similarly, if the value RRABSPOS is equal to RPOS then the value RRMPOS is set equal to zero. Otherwise, the value RRMPOS is set equal to the difference between RRABSPOS and RPOS. The motor position commands LRMPOS and RRMPOS are used at block 138 to control the electrohydraulic actuator motors. Block 170 determines the regenerative braking command, REGENCMD, according to:
REGENCMD=RPOS/KRPOS.
After block 170, the routine returns to block 132 in and continues in the manner described above to apply the regenerative braking and friction braking commands to the vehicle brakes.
The anti-lock braking control shown limits regenerative braking during anti-lock brake control by convening the regenerative torque achieved signal to a regenerative braking position signal (block 160). The regenerative braking position signal is then summed with the motor commands to determine the actual actuator position commands achieved by both the electrohydraulic actuators and the regenerative braking and those sums are used to determine the new actuator position commands (block 160). The control shown assumes that the vehicle includes two rear brake actuators, one for each rear wheel. If the vehicle has only one rear brake actuator, the minimum of the two rear commands may be used.
The regenerative braking position signal is then limited to no greater than the new actuator position commands (block 170) and is convened back to a regenerative braking command, which is used to command regenerative braking (output at block 138) within the constraints of the new actuator position commands. Similarly, the motor commands are determined to provide the difference in braking from that commanded by the new actuator position commands and that commanded by the regenerative braking command (block 170).
Through the above-described control, the amount of friction braking commanded is increased and/or decreased in response to available increases or decreases in regenerative braking to make maximum use of available regenerative braking. An advantage according to this invention is the blending of regenerative braking and the position control of the brake actuators. This advantage is achieved by converting the regenerative braking achieved to a position signal indicative of an amount of actuator position that it would take to achieve regenerative braking achieved. This position signal is then used with the position control according to this invention to modify the actuator position commands to effectively blend the friction and regenerative braking in an efficient manner, achieving efficient regenerative braking while maintaining, for the vehicle operator, a transparent "feel" of operation and consistent overall braking performance.
Referring now to FIG. 3, the graph shown illustrates the operation of this invention during a vehicle braking maneuver. Trace 202 illustrates that the vehicle is traveling at 40 m.p.h. at time t 0 , just before the brakes are applied. The vehicle speed is reduced to zero at time t 5 . At time t 1 , after the brakes are applied, the regenerative braking torque 206 and the total vehicle braking torque 204 begin rising. Between times t 1 and t 2 , the regenerative braking torque 206 and the total vehicle braking torque 204 are equal. After time t 2 , the regenerative braking torque 206 can no longer match the required total vehicle braking torque 204 so the hydraulic brakes are applied, causing a rise in the hydraulic braking torque trace 208. After time t 2 , the total braking torque 204 equals the sum of the regenerative braking torque 206 and the hydraulic braking torque 208.
After time t 3 , the vehicle speed is lower than the threshold speed at which the regenerative braking command is ramped out. The effect of the ramp out of the regenerative braking command is shown by regenerative braking torque trace 206 between times t 3 and t 4 . After time t 3 , trace 208 illustrates the ramp up of the hydraulic braking torque to the point where, after time t 4 , when the regenerative braking torque 206 equals zero, the hydraulic braking torque 208 provides the total vehicle braking torque 204. | A regenerative and friction brake blend control method for use in a vehicle with at least one positionable hydraulic brake actuator for achieving friction braking and an electric propulsion motor with regenerative braking capability wherein an amount of regenerative braking achieved is indicated by a signal, wherein the method comprises the steps of determining a hydraulic actuator position command indicating a desired vehicle braking, determining responsive the hydraulic actuator position command a regenerative braking command, commanding the electric propulsion motor to regeneratively brake the vehicle responsive to the regenerative braking command, receiving the signal indicative of regenerative braking achieved, converting the signal indicative of regenerative braking achieved to an actuator position reduction signal, subtracting the actuator position reduction signal from the hydraulic actuator position command to determine a difference command, and commanding the hydraulic actuator according to the difference command, wherein the hydraulic actuator and the regenerative braking together achieve the desired vehicle braking. | 1 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. provisional patent application Ser. No. 60/773024 filed on Feb. 14, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to drilling fluid telemetry systems, and, more particularly, to a system and method for enhancing data transfer.
[0004] 2. Description of the Related Art
[0005] Drilling fluid telemetry systems, generally referred to as mud pulse telemetry systems, are particularly adapted for telemetry of information between the bottom of a borehole and the surface of the earth during oil well drilling operations. The information telemetered often includes, but is not limited to, operational parameters, such as pressure, temperature, direction and deviation of the wellbore. Other parameters include well logging data such as electrical conductivity of the various formation layers, acoustic and nuclear properties, porosity, and pressure gradients related to the reservoirs surrounding the wellbore. This information is useful during the drilling operation and economic production of the reservoirs.
[0006] A number of different types of pulser devices (pulsers) which have been utilized to generate pressure pulses in the mud are known to those skilled in the art. Such pulsers include: poppet pulsers for generating positive or negative pressure pulses; siren pulsers for generating continuous wave pulse signals; and rotationally oscillating shear-valve pulsers that may generate discrete pulses and/or continuous wave signals. Various encoding techniques are known in the art for transmitting data utilizing the generated pulse signals. In general, such systems generate a pressure pulse by blocking or venting a portion of the drilling fluid flowing in the drill string to the bit. The generated pulse propagates to the surface where it is detected and decoded for further use.
[0007] A number of factors affect the reception and proper decoding of the transmitted information. For example, one source of noise in the detected signal is a result of the large pressure pulses associated with the use of positive displacement, plunger type pumps utilized for pumping the drilling fluid through the system. Such pumps commonly generate pressure pulses one to two orders of magnitude greater than the detected pressure signals at the point of signal detection. In addition, the pump frequency, and/or its harmonics, are commonly within the range of the pulsed signal frequency. Another factor that can affect the reception of the transmitted information at the surface is a change in the drill string wave guide transmission channel during the drilling process. Multiple reflections from the joints in the drill string and from impedance changes along the transmission channel also can cause some frequencies to be substantially attenuated while other frequencies are transmitted with little attenuation. These variations in the transmission path can cause substantial degradation in the received signal, which can cause loss of signal detection, thus resulting in lost time in the drilling operation.
[0008] Thus, there is a need for an improved method that enhances signal detection and information transfer reliability.
SUMMARY OF THE INVENTION
[0009] In one aspect of the present invention, a system for transmitting information in a well comprises a tubular string disposed in the well and having a drilling fluid flowing therethrough. In one aspect, a pulser is disposed in the tubular string and transmits a pulse synchronization marker comprising a chirp signal. A surface controller, acting under programmed instructions, detects the chirp signal and adjusts a signal decoding technique based on the detected chirp signal. The surface controller performs the function of noise cancellation in which noise, including at least a portion of the pump noise, is removed. The controller estimates a channel transfer function characterizing the mud channel between the downhole pulser and the surface. Additional steps performed by the controller include an equalization to remove distortion between the processed signal and transmitted signal. The equalizer may be an adaptive linear equalizer, adaptive decision feedback equalizer, or any other suitable equalizer.
[0010] In another aspect, a method for transmitting information in a well is provided that includes disposing a pulser in a tubular string in the well. The tubular string has a drilling fluid flowing therethrough. The pulser transmits at least one pulse synchronization marker that may be a chirp signal. The chirp signal is detected at the surface. A decoding technique is adjusted based upon the detected chirp signal. Noise cancellation, including cancellation of pump noise is performed. A channel transfer function characterizing the mud channel between the downhole pulser and the surface is estimated. Additional steps performed by the controller include an equalization step to remove distortion between the processed signal and transmitted signal. The equalization may be performed by a feedback equalizer.
[0011] Another embodiment of the invention is a computer readable medium for use with a mud-pulse telemetry apparatus. The apparatus includes a downhole pulser which transmits signals to a surface location through a mud channel. A surface processor receives signals after transmission through the mud channel. The received signal includes noise such as pump noise. The medium includes instructions that enable a processor to cancel the noise, estimate a transfer function of the channel and recover the transmitted signal. The computer readable medium may include ROMs, EPROMs, EAROMs, Flash Memories, hard drives and Optical disks.
[0012] Examples of the more important features of the invention thus have been summarized rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For detailed understanding of the present invention, references should be made to the following detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals, wherein:
[0014] FIG. 1 shows an exemplary drilling system according to one embodiment of the present invention;
[0015] FIG. 2 is a flow chart of a drilling fluid telemetry system according to one embodiment of the present invention;
[0016] FIG. 3 is a sketch of an exemplary Non-Return to Zero (NRZ) encoding timeline;
[0017] FIG. 4 shows an exemplary continuous wave, frequency shift key (FSK) pulse signal and the corresponding NRZ baseband signal;
[0018] FIG. 5 shows an exemplary amplitude shift key (ASK) signal and the corresponding NRZ baseband signal;
[0019] FIG. 6 shows an exemplary continuous phase modulated (CPM) signal and the corresponding digital bits;
[0020] FIG. 7 shows an exemplary dual pressure transducer detection layout;
[0021] FIG. 8 shows an exemplary transmission stream comprising synchronization frames and unequal data frames;
[0022] FIG. 9 shows details of one embodiment of a synchronization frame;
[0023] FIG. 10 shows a representation of a chirp signal as a function of frequency versus time and as a function of amplitude versus time;
[0024] FIG. 11 shows an autocorrelation function of a chirp signal in the time domain;
[0025] FIG. 12 shows an autocorrelation of a chirp signal in the frequency domain; and
[0026] FIG. 13 shows a block diagram of a channel transfer function.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 1 is a schematic diagram showing a drilling rig 1 engaged in drilling operations. Drilling fluid 31 , also called drilling mud, is circulated by pump 12 through the drill string 9 down through the bottom hole assembly (BHA) 10 , through the drill bit 11 and back to the surface through the annulus 15 between the drill string 9 and the borehole wall 16 . The BHA 10 may comprise any of a number of sensor modules 17 , 20 , 22 which may include, for example, formation evaluation (FE) sensors, sensors that provide information about operating conditions of the BHA, and survey sensors that provide survey information about the borehole. A partial list of FE sensors may include nuclear sensors, resistivity sensors, acoustic sensors, NMR sensors, etc. A partial list of the operating conditions may include temperature, pressure, rate of penetration, weight on bit, rotational speed, torque, and whirl measurements. Survey sensors may include a magnetometer, an accelerometer, and/or a gyroscope. These sensors are well known in the art and are not described further. The BHA 10 also contains a pulser assembly 19 which induces pressure fluctuations in the mud flow. The pressure fluctuations, or pulses, propagate to the surface through the mud and are detected at the surface by a sensor 18 and a control unit 24 . The sensor 18 is connected to the flow line 13 and may comprise at least one of a pressure sensor, a flow sensor, and a combination of a pressure sensor and a flow sensor. As one skilled in the art will appreciate, the pressure pulse has an associated fluid velocity pulse that also propagates through the drilling fluid and may be detected and decoded.
[0028] In one embodiment, pulser assembly 19 comprises an oscillating shear valve pulser capable of generating continuous wave pulses. Such a pulser is described in U.S. Pat. No. 6,975,244, issued on Dec. 13, 2005, U.S. Pat. No. 6,626,253, issued on Sep. 30, 2003, and U.S. application Ser. No. 10/422,440, filed on Apr. 24, 2003 and published as US 2004/0012500 on Jan. 22, 2004, each of which is assigned to the assignee of this application, and each of which is incorporated by reference herein. The oscillating shear valve described in these references is capable of generating pulse waveforms of varying frequency, amplitude, phase, and shape, including substantially continuous sinusoidal waves at frequencies of at least 40 Hz. Other types of pursers, such as a poppet type pulser, may also be used.
[0029] The downhole pulser 19 , also called a transmitter, is only one part of the MWD telemetry system. The complete telemetry system consists of the transmission channel, a surface receiver, and additional surface and downhole processing layers. The surface and downhole components of the system are designed to provide a reliable telemetry system delivering the highest possible bit rate for the particular drilling environment.
[0030] FIG. 2 is a functional block diagram of one embodiment of fluid telemetry system 100 . As shown therein, data from sensors 17 , 20 , 22 (see FIG. 1 ) are input to pulser 19 . Pulser 19 contains circuits and a processor, as described in the incorporated reference documents, for processing and transmitting the data to the surface. In the downhole system the data is compressed. The compression scheme 40 may encompass data scaling and/or any data compression technique known in the art of digital information transmission.
[0031] The optionally compressed and error protection encoded binary data is modulated 42 . In one embodiment, a non return to zero (NRZ) modulation scheme for baseband transmission is used. In the NRZ scheme, see FIG. 3 , the time line is divided into intervals of equal time, each of which is a bit-period, T bit . The signal level is held constant at one of two levels for the duration of the bit-period. For example, a binary 1 may be represented by a level of +1 and a binary zero by a level of −1.
[0032] In another embodiment of the present invention the optionally compressed and error protection encoded binary data is modulated 42 using a baseband pulse amplitude modulation (baseband PAM) scheme for transmission. The baseband PAM scheme provides more than two signal levels. Preferably the number of levels M is a power of two so that the number of bits transmitted per symbol can be expressed m=log 2 M. In the PAM scheme the time line is divided into intervals of equal time, each of which is a symbol period where the symbol period equals m bit-periods. The signal level is held constant at one of m levels for the duration of the symbol-period.
[0033] As discussed previously, pulser 19 is capable of generating pulse frequencies up to about 40 Hz. This feature allows the use of modulation schemes commonly called passband modulation. Passband modulation encompasses signals on, or centered on, a carrier frequency. Modulation of the carrier frequency is performed to transmit information. Pulser 19 is well suited to transmit such signals. There are four subsets of passband signaling that are of interest: frequency shift keying (FSK), amplitude shift keying (ASK), phase shift keying (PSK) and continuous phase modulation (CPM).
[0034] Frequency-Shift-Keying (FSK) is the use of a frequency modulated waveform to carry digital information. In case of binary FSK a first frequency represents a 1, and a second frequency represents a 0. The order of the frequencies is not important, so long as it is known at both the transmitter and receiver locations. An example of such a modulated signal 400 is shown in FIG. 4 , where the bitstream pictured in the bottom drawing is modulated. A frequency f 1 represents a 1, and a frequency f 2 represents a 0. Higher level modulation schemes with m different frequencies are possible as well.
[0035] Amplitude-Shift-Keying (ASK) is the use of an amplitude modulated waveform to carry digital information. In ASK a waveform of a single frequency is used to represent a 1 and no signal is sent for a 0. Alternatively, the transform may be inverted so that a 0 is represented with a waveform of known signal, and a 1 with no signal. An example of an ASK signal 500 is shown in FIG. 5 , where the bitstream pictured in the bottom drawing of FIG. 5 is ASK modulated. A constant frequency signals to transmit a 1 and no signal represents a 0. Note that the same data word, “1010011”, is transmitted in both FIG. 4 and FIG. 5 . Higher level modulation schemes with m amplitude levels of the same frequency are possible as well.
[0036] Phase-Shift-Keying (PSK) is the use of a phase modulated waveform to carry digital information. In PSK transmission the frequency is kept constant, and the phase of the signal is changed at bit boundaries. Referring to FIG. 6 , for example, with binary PSK (only two states to be represented, 0 or 1), the phase difference is 180°. Because a pulser typically cannot instantaneously change phase, a transition time slot 602 between the pulses will be inserted. This time slot is exactly one period (of the carrier frequency) long. In order to keep the data rate constant over the time, the time slot will be inserted prior to every bit, even when the phase of the carrier frequency 600 does not change at bit edges (binary sequence 11 or 00). In this case the PSK modulator inserts one period of the carrier frequency. When the bit changes from 1 to 0 or from 0 to 1, the modulator inserts half a period of half the carrier frequency to generate the phase change. The insertion of this ‘transition period’ will be done with respect to the phase of the carrier signal at the end of the preceding bit. The beginning of each modulated bit thus depends on the previous bit. This is an example of continuous phase modulation (CPM). Higher level modulation schemes with m phase levels of the same frequency are possible as well.
[0037] Once the data are baseband modulated 42 , data are passed to transmitter 43 , which in one embodiment, is pulser 19 .
[0038] Referring back to FIG. 2 , the encoded and modulated information is transmitted as pressure signals across fluid transmission path 50 and the signals are detected at receiver 44 at or near the surface. Receiver 44 comprises sensor 18 described previously which may be a pressure sensor, a flow sensor, a combination of pressure and flow sensors. Alternatively, a plurality of pressure sensors, flow sensors, or a combination thereof may be used as a sensor array for detecting the pressure signals, as described below. The surface system is basically the inverse of the downhole system, however employing several additional tasks to compensate the measured signal for distortion during transmission. The received signals are treated to remove noise components and distortion using noise cancellation 45 and channel equalization 46 techniques. The data are then demodulated 47 , and decoded 48 . The data are then decompressed 49 , and output to permanent storage and/or further analysis and interpretation as required drilling operations and/or reservoir interpretation.
Surface Detection Using a Dual Pressure Transducer Technique (DPT)
[0039] This technique uses data from a pair of longitudinally-spaced transducers, see FIG. 7 , at the surface to discriminate between signal components which are traveling upstream (e.g. information from downhole pulser 19 ) and those traveling downstream (e.g. mud pump noise).
[0040] Two input channels correspond to a matched pair of transducers. These may be either pressure transducers, or flow transducers. They should be placed in the same straight pipe section. DPT outputs a single channel containing the component of the signals which is estimated to be traveling upstream.
DPT Description
[0041] Referring to FIG. 7 , the outputs from the two transducers are labeled T 1 and T 2 . T 2 is from the upstream transducer, closer to the pumps. Each transducer's response contains a steady component P, a down going transient component D, and an up going transient component U. The transducer responses can be written as
[0000] T 1( t )= P 1 +D 1( t )+ U ( t ) (1),
[0000] T 2( t )= P 2 +D 2( t )+ U 2( t ) (2).
[0042] If there is a signal component traveling downstream from the pumps, it will reach T 2 before it reaches T 1 , with a time delay δt. So the downward component at transducer T 2 at time (t−δt), written as D 2 (t−δt), is the same as the component D 1 (t) at transducer T 1 .
[0043] Suppose now that we delay the signal from T 2 by δt, and subtract it from the signal at T 1 :
[0000] T 1( t )− T 2( t−δt )= P 1 +D 1( t )+ U 1( t )− P 2 −D 2( t−δt )− U 2( t−δt ) (3)
Substituting D 2 (t−δt)=D 1 (t),
[0044] T 1( t )− T 2( t−δt )= P 1 −P 2 +U 1( t )− U 2( t−δt ). (4)
In addition, the up going component takes time δt to travel from T 1 to T 2 , so
[0045] U 2( t−δt )= U 1( t− 2 δt ) (5)
[0000] and
[0000] T 1( t )− T 2( t−δt )= P 1 −P 2 +U 1( t )− U 1( t −2 δt ). (6)
[0000] The delay and subtract operation is therefore able to eliminate the down going component, while leaving the up going transient component in the form U 1 ( t )−U 1 ( t− 2·δt). By inspection, this is an approximation of the time derivative of the up going component U 1 , and therefore it should be possible to reconstruct the up going component by time integration. For evenly sampled data, time integration can be accomplished by cumulative summing. However, it is not desirable to integrate the steady component (P 2 −P 1 ), since this could cause the output to ramp up or down indefinitely. Therefore the transient component is isolated by high pass filtering, before the integration is performed. The steady component of the original signal (i.e., its DC component) can be found by low pass filtering the original transducer outputs. Final output from the technique is the sum of the steady and transient components.
[0046] The transducers T 1 , T 2 may be placed in a single uniform straight pipe section to minimize attenuation and reflections. Separation between the transducers may be such that the delay is relatively low, for example, no more than 1/20 second, which corresponds to a maximum spacing of about 50 m. Minimum spacing may be equivalent to about 10 data samples; at a sample rate of 1024 per second this corresponds to about 10 m. Details of the use of the dual-pressure transducer are disclosed in U.S. patent application Ser. Nos. 11/018,344 and 11/311,196 having the same assignee as the present invention and the contents of which are incorporated herein by reference.
Surface Processing of Detected Signals
[0047] Additional techniques are applied to the detected signals to reduce the effects of noise and distortion in the detected signal as compared to the transmitted signal. As discussed previously, pump noise is present in the detected signals and the pump signal may be significantly greater than the desired data signal. In addition, the reflections and transmission characteristics of the drill string transmission channel cause distortion in the data signal as it transits the transmission channel. Several techniques are used to try to minimize these effects. It should be noted that more than one processor may be used for processing at the surface.
Pump Noise Cancellation (PNC)
[0048] In one embodiment, the PNC technique utilizes pump strobe signals from each active pump. In concept at least, this technique is relatively easy to describe. The signature for each pump is assembled by marking the time at which successive pump strobes occur, and stacking the pressure records between the strobes. This results in random noise being cancelled out, and the pump signature emerges. This pump signature is then subtracted from the raw pressure data; the result is the measured pressure signal with the signal from the pump cancelled out. In the ideal case, which occurs quite often, this resultant signal contains only the signal from pulser 19 . For additional details, refer to U.S. Pat. No. 4,642,800, which is incorporated herein by reference.
[0049] Alternatively, the pump pressure signal may be analyzed directly to provide an indication of the pump signal frequency signature. This technique eliminates the need for pump strobe sensors. Further details of such a technique are disclosed in application docket number 564-39321-US and 564-42151-US, filed on the same day as this application and assigned to the assignee of this application, and which is incorporated herein by reference.
Channel Equalization
[0050] Channel equalization is directed to removing any distortions of the waveforms that may have occurred during their transit through the telemetry channel. In one embodiment, an inference filter is used to estimate the response of the transmission channel. Basically, a model of the transfer function (also known as the frequency response function) of the telemetry channel is computed, see FIG. 13 . The transfer function is nothing more than a description of the changes in amplitude and phase for each frequency bin that occur to a signal during its travel from downhole to surface. The technique estimates pressure and/or flow at downhole pulser using the measured pressure and flow at surface and the detailed description of the mud line between the pulser and the sensors (pressure sensor and flow meter).
[0051] For the model to simulate data transmission through the mud channel the transfer matrix method is used. Derived from partial differential equations describing the wave propagation with the states of pressure and flow, transfer matrices are calculated for the different system components. Here, the different components are pipes (BHA, drillpipe, Kelly hose, etc)
[0000]
T
pipe
=
[
cosh
(
γ
l
)
-
Z
c
ρ
g
sinh
(
γ
l
)
1
Z
c
ρ
g
sinh
(
γ
l
)
cosh
(
γ
l
)
]
(
7
)
With γ 2 =Cs(Ls+R) where L=1/gA is the inertance, C=gA/a 2 is the capacitance, A=πID 2 the inner cross section area, s=σ+iω, and R the linearized resistance per unit length dependent on the flow in the tube.
[0052] Using these transfer matrices for each drillstring component it is possible to connect the pressure and flow states of an upstream and downstream end (the surface and downhole locations). For drill strings with different sections the matrices have to be multiplied from left coming uphole. That is,
[0000]
[
p
q
]
sensor
=
T
pipe
4
T
pipe
3
T
pipe
2
T
pipe
1
T
[
p
q
]
pulser
.
(
8
)
[0000] Arbitrary combinations of pipe sections are possible and described in a file containing the drill string description. For the reconstruction of the pulser pressure we use the inverse transfer matrices with zeros at the frequencies of possible poles:
[0000]
[
p
q
]
pulser
=
T
-
1
T
inv
[
p
q
]
sensor
(
9
)
[0000] The first row for the calculation reads:
[0000] p pulser =T inv1,1 ·p sensor +T inv1,2 ·q sensor (10)
[0053] This last equation describes the inference filter in the frequency domain as disclosed in U.S. patent application Ser. No. 10/412,915 of Jogi et al. and assigned to the assignee of this application, and which are incorporated herein by reference. In the time domain the output of the inference filter is given by convolving the measured pressure and flow signals with the inverse Fourier transform respectively of T inv1,1 and T inv1,2 . The calculation of the filter coefficients is done in surface controller 24 (see FIG. 1 ) or any other suitable processing device at the surface., and updated with the new coefficients. This calculation is performed at every change in the drill string and/or mud line between pulser and surface sensors (when adding a new joint of pipe, changing BHAs, and so on). Additional details on channel equalization are contained in U.S. applications filed under docket number 564-42779 and 564-43121, filed on the same day as this application and assigned to the assignee of this application, and which are incorporated herein by reference. The determination of the channel transfer function may be done using a reference chirp signal as described in U.S. patent application Ser. No. 11/284,319 of Hentati et al. assigned to the assignee of this application, and which are incorporated herein by reference.
[0054] In addition to channel equalization and pump noise cancellation, other techniques are used to enhance the reliability of the data transfer. These include Channel Estimation described in U.S. application Ser. Nos. 11/311,196 and 11/018,344 and assigned to the assignee of this application, and which are incorporated herein by reference.
Synchronization
[0055] In order to demodulate 47 and decode 48 the received data, it is necessary for the surface system to synchronize on the data stream. As described previously, in one embodiment, the data is transmitted in a known pattern having a bitperiod, Tbit. To decipher the incoming data stream, the surface controller 24 must identify the start of the bit pattern so that the bit value, 1 or 0, in each bit period can be determined. Synchronization on the data stream is achieved through the use of pulse synchronization markers 601 , which typically are embedded in the pulse stream when the pulser starts-up and periodically within the ongoing data stream, and frame identifiers (FIDs) 602 which occur periodically within the bit stream, see FIG. 8 . The FIDs 602 are of a fixed length, and delineate the start of a frame of data. Within a frame the data bits 603 fall within words in a format that is known to both the downhole transmitter and surface receiver. The synchronization markers 601 are inserted in the data stream during the downhole encoding 41 .
[0056] In one embodiment, the synchronization marker comprises one or more chirp signals and a preamble, see FIG. 9 . The chirp signal, see FIG. 10 , is a linear, frequency modulated pulse. At the beginning of the pulse (time=0 sec) the frequency is f 0 and rises to f end >f 0 at pulse end. FIG. 10 shows the chirp pulse in the time domain (lower figure) and its frequency over time (upper figure). The frequency rises over the pulse time width T from 0 Hz to 40 Hz. The exemplary chirp pulse has then a bandwidth of 40 Hz.
[0057] Chirps have the important characteristic of being compressible in the time domain as well as in the frequency domain. Chirp-compression is done by the correlation operation. The autocorrelation of a chirp results in a very sharp and high amplitude pulse. The same operation in the frequency domain gives a high peak at frequency 0 Hz. The autocorrelation function gathers (compresses) most of the energy of the chirp pulse at one point. FIG. 11 shows the autocorrelation of the chirp pulse in time domain and in frequency domain. Chirp-compression means a projection of the linear frequency curve 800 , 801 on to the vertical axis in case of time domain correlation, and on to the horizontal axis in case of frequency domain correlation, see FIGS. 11 and 12 respectively.
[0058] As shown above, chirp-compression generates sharp pulses with high peaks. The peak width is equal to 2/chirp bandwidth. The amplitude of the peak equals T (the chirp length). In FIG.S 11 and 12 the correlation function is normalized to the chirp pulse width T. The chirp can be detected when the amplitude of the correlation function of the signal with the reference chirp exceeds a given threshold. However, this method is very sensitive to noise, especially when the signal average changes over time. To overcome this problem the signal is split into overlapped blocks of length 2*N−1 (N is the length of a chirp) and each signal block is normalized by the mean value of its amplitude.
[0000]
y
(
i
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=
x
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i
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1
2
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i
=
1
2
N
x
(
i
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.
(
11
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[0000] The number of overlapped samples affects the accuracy of detecting the chirps. Test well data have shown that using an overlap of (2*1024−1)−256 samples (shift by 256 samples) is enough.
[0059] The estimated chirp position is found from the maximum amplitude of the normalized signal blocks. The peak value of the L-th signal block is given by:
[0000] p L ( i )=max{| y ( i )|} (12).
If the peak value is higher than a given threshold (T-Threshold), then a chirp will be detected and its position will be output to the next step.
[0060] Due to the fact that the noise levels changes over time, the block wise measured peak values are averaged and the threshold (for detecting chirps) is set to 1.2 times the averaged value. The threshold S T will be updated every time the peak value of a new signal block is calculated:
[0000]
S
T
(
n
)
=
1
n
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i
=
1
n
p
i
.
(
13
)
In order to get reliable chirp detection, the estimated chirp positions will be checked by the following.
Frequency Domain Chirp Compression
[0061] At this stage, the reference chirp is multiplied with a signal block that has the same length as the chirp and which begins at the chirp position estimated by the previous step. The resultant signal is transformed in the frequency domain by an FFT. Only a bandwidth of 40 Hz concentrated at 0 Hz is considered at this stage. This is not to be construed as a limitation to the invention.
Correct for Chirp Position
[0062] When chirp pulse occurs, the frequency domain compression results in a high peak at frequency 0 Hz. Similar to the time domain peak detection, we normalize the FFT output to the mean value of its amplitude. If the amplitude at 0 Hz exceeds a given threshold S F (F-Threshold, frequency domain threshold) then the chirp position estimated in step 1 will be assumed to be the correct position of a chirp; otherwise it will be considered a false alarm.
Chirps Signaling
[0063] To mark the chirp pulse positions in the incoming signal, the chirp detection technique adds to the first sample of the chirp pulse an integer number with very high amplitude. This assures that the resulting peak is much higher than the highest MWD signal amplitude. These peaks will be detected in the decoding 48 step to keep synchronization.
[0064] In addition to the chirps discussed above, other sequences such as stepped frequency sine waves may be transmitted to aid in synchronization.
[0065] In one embodiment, for FSK, CPM and PSK modulated signals, a known multibit preamble, for example sixteen bits, is used to enhance fine synchronization. The use of multiple bits in a known sequence allows the surface system to more accurately determine the bit boundaries for eventual decoding of signals.
[0066] In one embodiment, chirp signals are embedded in the data stream at known points and the surface system locates and identifies these chirps to gain or maintain synchronization.
[0067] Once the surface controller is synchronized with the data stream, the signal is demodulated 47 , decoded 48 , decompressed 49 and output for storage and or further analysis.
[0068] While discussed above in relationship to data traveling from downhole to the surface, one skilled in the art will appreciate that a similar transmission scheme may be used for transmitting data from the surface to a downhole receiver. Such a system is described in U.S. application Ser. No. 10/422,440, filed on Apr. 24, 2003 and published as US 2004/0012500 on Jan. 22, 2004, previously incorporated herein by reference. It will be appreciated that such a downlink enables changes in the downhole system operation, and further enables a substantially automated telemetry system for adjusting transmission schemes to improve the reliability of information transfer.
[0069] The decompressed data may then be stored on a suitable medium for further processing and/or display. Such displays commonly include logs of the formation properties that are measured by the formation evaluation sensor, the operating conditions of the BHA, and borehole so information.
[0070] The operation of the transmitter and receivers may be controlled by the downhole processor and/or the surface processor. Implicit in the control and processing of the data is the use of a computer program on a suitable machine readable medium that enables the processor to perform the control and processing. The machine readable medium may include ROMs, EPROMs, EAROMs, Flash Memories and Optical disks.
[0071] The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible. It is intended that the following claims be interpreted to embrace all such modifications and changes. | A system for transmitting information in a well comprises a tubular string disposed in the well and having a drilling fluid flowing therethrough. A pulser is disposed in the tubular string and transmits a pulse synchronization marker comprising a chirp signal. A surface controller, acting under programmed instructions, detects the chirp signal adjusts a signal decoding technique based on the detected chirp signal. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automatic focusing control technique of a camera, and more particularly to a method for controlling focusing areas of a camera for partitioning a picture picked up by an optical system into a plurality of areas, and an apparatus for executing the same.
2. Description of the Prior Art
A technique for controlling auto focusing of a camera is used for detecting a subject by using a luminance signal of the subject that is picked up via a camera lens, and driving an optical system to be fitted to the detected subject, thereby automatically adjusting its focus. FIG. 1 illustrates a block diagram showing a conventional circuit for controlling auto focusing of a camera.
Referring to FIG. 1, the conventional circuit for controlling the auto focusing of the camera includes an optical system 10 including an objective lens 10a, a zoom lens 10b, an iris 10c and a focusing lens 10d, and a charge-coupled device (hereinafter simply referred to as "CCD") 20 for converting an image of a subject picked up via optical system 10 into an electric signal. Additionally, an automatic gain controller (hereinafter simply referred to as "AGC") circuit 30 carries out automatic gain control of a video signal converted by means of CCD 20. A digital signal processing section 40 digitizes the AGC-processed video signal, and separates it into a luminance signal and a chrominance signal to process the obtained signals, and a high-pass filter 42 filters an output luminance signal of digital signal processing section 40 to provide only high band components thereof. An area setting section 44 sets an area for performing focusing controlling by using the high-pass filtered luminance signal as an input, and an evaluation value detecting section 46 detects an evaluation value of the subject luminance signal within the area which is set in area setting section 44. In addition to these, a controlling section 48 judges whether the subject is detected or not by means of the evaluation value detected in evaluation value detecting section 46 and provides a focusing area control signal and a lens driving control signal in accordance with the result of the determination. A motor driving section 130 receives the lens driving control signal from controlling section 48 and provides a driving signal. A focusing lens motor 140 drives focusing lens 10d in accordance with the driving signal.
The image picked up by optical system 10 is converted into an electric video signal in CCD 20 via objective lens 10a, zoom lens 10b, iris 10c and focusing lens 10d. Then, the resultant video signal is automatically gain-controlled by AGC circuit 30 to be supplied into digital signal processing section 40.
An A/D converter 40a of digital signal processing section 40 converts an analog video signal input into a digital signal, and an Y/C separator 40b separates the digital video signal into luminance signal Y and chrominance signal C.
Separated chrominance signal C is processed via a chrominance signal processor 40c, and luminance signal Y is processed via a luminance signal processor 40d. By doing so, a composite video signal CVS is obtained by adding signals C and Y in adder 40e.
At this time, the luminance signal provided from luminance signal processor 40d is filtered by high-pass filter 42 to provide only the high band components of the luminance signal corresponding to the outline portion of the image, and area setting section 44 receives the high-pass filtered luminance signal to execute the auto focusing controlling upon the subject picked up by optical system 10.
More specifically, in the conventional technique as shown in FIG. 2, a picture area is set by a first area A1 and a second area A2, in which the auto focusing operation is performed depending on whether the subject is detected within first area A1 or not after first area A1 is fixed.
In this case, the picture area is divided into two areas A1 and A2. Unless subject is detected within area A1, the subject is detected in its expanding area A2 to continuously maintain its expanding area A2.
In association with the foregoing detection of the subject and auto focusing operation, a luminance signal level of the subject detected in the corresponding area is detected by evaluation value detecting section 46. Thus, in accordance with the result of comparing the detected value with a predetermined reference value, the auto focusing is performed by driving lens driving motor 140 via motor driving section 130.
That is, the subject picked up by optical system 10 involves a distinct difference (or change) in the luminance signals between the subject and the background image. Due to this fact, by evaluating the luminance signal value, the presence or absence of the subject corresponding to the background image can be detected. Thereafter, the auto focusing is accomplished by driving the lens to the direction and position where the luminance signal having the maximum level is detected, to be matched with the detected subject.
In the above-described conventional technique for dividing the picture area into areas A1 and A2 and variably controlling the areas as shown in FIG. 2, the auto focusing is performed by detecting the subject under the state of changing into area A2 unless the subject is detected in area A1. However, area A2 is continuously maintained even after executing the auto focusing to have a drawback that, if a new subject is joined later, the auto focusing upon multiple subjects caused by the new subject becomes impossible in expanding area A2.
SUMMARY OF THE INVENTION
The objects of the present invention are to overcome problems and disadvantages of the conventional apparatus and method for controlling focusing areas of a camera.
Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
Therefore, it is an object of the present invention to provide a method for controlling focusing areas of a camera capable of enhancing precision of the auto focusing with respect to a main subject in the case of multiple subjects, continuously tracking the auto focusing of a subject that moves to the outer peripheral side of the center of a picture, and improving a tracking property with respect to the center area when varying the picture areas.
It is another object of the present invention to provide an apparatus for controlling focusing areas of a camera capable of enhancing precision of auto focusing with respect to a main subject in case of multiple subjects, continuously tracking the auto focusing of a subject that moves to the outer peripheral side of the center of a picture, and improving the tracking property with respect to the center area when variably changing the picture areas.
To achieve the above objects, the present invention is performed by partitioning a picture area of a subject picked up by an optical system into a supervisory area and a focusing area. Then, in accordance with the result of subject detection in the supervisory area, auto focusing is performed in the supervisory area, or a supervisory mode is entered that carries out constant detection of the subject in the supervisory area after or during auto focusing. The auto focusing is performed by executing the area variation into a variable area to detect the subject.
More specifically, a first aspect of a method for controlling focusing areas of a camera according to the present invention is carried out by partitioning a picture image area representing an image of a subject into a plurality of picture areas and setting a supervisory area among the plurality of picture areas. A focusing area is set among said plurality of picture areas based on whether the subject is present or absent in the supervisory area, and an auto focusing operation is performed in the focusing area.
A second aspect of the method for controlling focusing areas of the camera according to the present invention is carried out by partitioning a picture image area representing an image of a subject into a plurality of picture areas and setting a center area among the plurality of picture areas as a first area and an outer peripheral area as a second area. One of the first and second areas is set as a focusing area, and an auto focusing operation is performed in the focusing area. Another of the first and second areas is set as a supervisory area, and a presence or absence of the subject within the supervisory area is detected while setting the focusing area. Exchanging the focusing area and the supervisory area; performing an auto focusing operation on the focusing area; and detecting the presence or absence of the subject within the supervisory area are repeated, when the presence of the subject within the supervisory area is detected.
Furthermore, an apparatus for controlling focusing areas of a camera includes a first detector for setting a supervisory area among a plurality of picture areas collectively representing an image field, and detecting whether a subject is present or absent within the supervisory area; a second detector for setting a focusing area among the plurality of picture areas, and detecting whether a subject is present or absent within the focusing area; and a controller for exchanging the supervisory area and the focusing area based on a result of the detecting of the first detector, and for performing an auto focusing operation in the focusing area, and continuously detecting whether a subject is present or absent within the supervisory area.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and other advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
FIG. 1 is a block diagram showing a conventional apparatus for controlling focusing areas of a camera;
FIG. 2 is a view for explaining the setting of the focusing areas according to a conventional method;
FIG. 3 is a view for explaining the setting of the focusing areas in a first embodiment of a method for controlling focusing areas according to the present invention;
FIG. 4 is a flowchart of the first embodiment of the method for controlling focusing areas according to the present invention;
FIG. 5 is a view for explaining the setting of the focusing areas in a second embodiment of the method for controlling focusing areas according to the present invention;
FIG. 6 is a flowchart of the second embodiment of the method for controlling focusing areas according to the present invention; and
FIG. 7 is a block diagram showing an apparatus for controlling focusing areas of a camera for performing the method for controlling focusing areas of the camera according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
To begin with, a first embodiment of a method for controlling focusing areas of a camera according to the present invention will be described. The first embodiment of the method for controlling focusing areas of the camera is performed by a first step of partitioning a picture area of a subject image picked up by the optical system into a plurality of picture areas and setting a center area among the plurality of picture areas as a supervisory area. In a second step, an optional picture area among the plurality of picture areas is set as a focusing area in accordance with whether a subject is detected within the supervisory area or not. Successively, after executing the second step, the auto focusing is performed in a third step. Then, a fourth step is carried out in a manner to advance to a supervisory mode for constantly detecting the subject with respect to the supervisory area, after completing the third step.
FIG. 3 illustrates the plurality of partitioned picture areas set in the first embodiment of the method for controlling focusing areas of the camera, and FIG. 4 is a flowchart for embodying the first embodiment of the method for controlling focusing areas of the camera.
As shown in FIG. 3, in the first embodiment of the present method, the picture areas are, preferably, identified by setting supervisory area A1 in the center area, and a first variable area A1+A2 and a second variable area A1+A2+A3 gradually expanding across the areas in the outer periphery.
Referring to FIG. 4, once the camera begins operating in step S1, the image of the subject picked up by the optical system is partitioned into plurality of areas A1, A2 and A3 in step S2. Then, center area A1 among plurality of areas A1, A2 and A3 is set as the supervisory area in step S3 to judge whether the subject is detected or not while constantly observing supervisory area A1 in step S4.
In accordance with the result of the subject detection within supervisory area A1, a proper focusing area is set among plurality of partitioned picture areas A1, A2 and A3.
In other words, when the subject is detected in supervisory area A1, the evaluation value with respect to the luminance signal of the subject is detected in supervisory area A1 to decide the driving direction of the focusing lens for performing the auto focusing in step S6.
In response to the result of the decision with respect to the focusing lens driving direction of step S6, the focusing lens is driven in supervisory area A1 to track the subject in step S7. In step S8, a peak confirmation is carried out before/after a point (a peak of transiting the luminance signal) determined as the subject (i.e., the focusing lens is properly driven forward and backward).
Upon the completion of the auto focusing in S6, S7 and S8 with respect to the subject in supervisory area A1 as described above, the program advances to the supervisory mode that constantly detects the subject with respect to supervisory area A1 in step S9, thereby continuously performing the subject detection within supervisory area A1.
However, if the subject is not detected in supervisory area A1, the area is variably extended to first variable area A1+A2 in step S5 to attempt to detect the subject in first variable area A1+A2 in step S4. If the subject is not detected in this area either, the area is variably extended to second variable area A1+A2+A3 in step S5, thereby detecting the subject in second variable area A1+A2+A3 in step S4.
When the subject is detected in first variable area A1+A2 or second variable area A1+A2+A3, the evaluation value with respect to the luminance signal of the subject is detected in the corresponding area, so that the driving direction of the focusing lens is determined to perform the auto focusing in step S6.
In response to the result of the decision with respect to the focusing lens driving direction of step S6, the focusing lens is driven in the supervisory area to track the subject in step S7. In step S8, a peak confirmation is carried out before/after a point (a peak of transiting the luminance signal) determined as the subject (i.e., the focusing lens is properly driven forward and backward).
Upon the completion of the auto focusing in S6, S7 and S8 with respect to the subject in the supervisory area as described above, the program advances to the supervisory mode that constantly detects the subject with respect to supervisory area A1 in step S9, thereby continuously performing the subject detection within supervisory area A1.
That is, supervisory area A1 is employed only for observing the subject, and the variation (change) of the area is performed with respect to just first variable area A1+A2 and second variable area A1+A2+A3.
Hereinbelow, a second embodiment of the method for controlling focusing areas of the camera according to the present invention will be described. The second embodiment of the method for controlling focusing areas of the camera according to the present invention is performed by the sequence of a first step of partitioning a picture area of a subject image picked up by the optical system into a plurality of areas and setting a center area among the plurality of picture areas into a first area and an outer peripheral area into a second area. Then, in a second step, an optional area either the first area or second area is set as a focusing area to execute the auto focusing. A third step is performed by detecting the presence or absence of the subject, using the other area which is not the focusing area, between the first and second areas as a supervisory area. Successively, if the detection in the third step results in the presence of the subject within the supervisory area, the focusing area of the second step is shifted to be the supervisory area of the third step, thereby repeating the second and third steps in a fourth step.
FIG. 5 illustrates the plurality of partitioned picture areas set in the second embodiment of the method for controlling focusing areas according to the present invention, and FIG. 6 is a flowchart for embodying the second embodiment of the method for controlling focusing areas according to the present invention.
As shown in FIG. 5, in the second embodiment of the present method, a picture area of a subject image picked up by the optical system is partitioned into plurality of areas A11 and A12.
Preferably, center area A11 among the plurality of picture areas A11 and A12 is set as the first area and outer peripheral area A12 is set as the second area.
During performing the auto focusing by setting an optional area either the first area or second area into the focusing area, the other area which is not the focusing area is employed as the supervisory area to detect the presence or absence of the subject.
For example, in case that supervisory area A11 is set and supervisory area A11 and variable area A12 (where areas A11 and A12 are exclusive from each other) are shifted to each other, as shown in FIG. 6, the camera operation begins in step S11. Then, the picture area of the subject image picked up by the optical system is partitioned into plurality of picture areas A11 and A12 in step S12. After this, the auto focusing is carried out with respect to area A12 set as the focusing area in step S13. The subject detection is decided within the area set as supervisory area A11 during executing the auto focusing in step S14. If the subject is detected in supervisory area A11 in step S14, the supervisory area is changed into area A12 from area A11, the focusing area is changed into area A11 from area A12 in step S15. Under this changed state, the program proceeds to step S13 to perform the auto focusing in accordance with the result of the decision in step S14. Whereas, if it is decided that the subject is not detected in supervisory area A11 in step S14, the program proceeds to step S13 to continue the auto focusing in the previous focusing area prior to being changed.
In other words, supervisory area A1 executes only the subject observation while the area shift is performed with respect to first variable area A1+A2 and second variable area A1+A2+A3 in the first embodiment of the method according to the present invention shown in FIG. 3. By contrast, in the second embodiment of the present invention shown in FIG. 6, supervisory area A11 and variable area A12 are shifted to each other in accordance with the detection of the subject in the supervisory area.
Now, referring to FIG. 7, an apparatus for controlling focusing areas for performing the method for controlling focusing areas of the camera according to the present invention will be described.
The apparatus for controlling focusing areas of the camera according to the present invention shown in FIG.7 includes an optical system 10 formed by an objective lens 10a, a zoom lens 10b, an iris 10c and a focusing lens 10d for picking up the image of the subject by a prescribed picture area. Also, a CCD 20 converts the image of the subject picked up by optical system 10 into an electric video signal, and an AGC circuit 30 performs the automatic gain control of the video signal converted by CCD 20. In addition to these, a digital processing section 40 digitizes the AGC-processed video signal and separates the digitized signal into a luminance signal and a chrominance signal to process them, and a high-pass filter 50 filters an output luminance signal of digital signal processing section 40 to provide high band components thereof. A supervisory area setting section 80 sets a first predetermined area among the picture areas of optical system 10 formed of the output signals of high-pass filter 50 as a supervisory area, and a contrast detecting section 90 obtains an integrated value of the filtered high band components with respect to the supervisory area. Also included as part of the apparatus are a reference value supplying section 110 for supplying a reference value of a contrast value, and a comparing section 100 for comparing an output value of contrast detecting section 90 with the reference value supplied from reference value supplying section 110. A focusing area setting section 60 sets a predetermined second area among the picture areas of optical system 10 as a focusing area. An evaluation value detecting section 70 detects an evaluation value with respect to the focusing area set by focusing area setting section 60. A controlling section 120 executes the auto focusing control in the focusing area by performing the area shift from the supervisory area into the focusing area when the subject is not detected in the supervisory area, while constantly observing the presence or absence of the subject in the supervisory area based on the output of comparing section 100. Further to this, controlling section 120 controls to continuously observe the presence or absence of the subject in the supervisory area even after completing the auto focusing or during performing the auto focusing in the focusing area. A motor driving section 130 receives a lens driving control signal from controlling section 48 to drive a focusing lens driving motor 140 which is driven under the control of motor driving section 130 for driving focusing lens 10d.
The image picked up in optical system 10 is converted into the electric video signal in CCD 20 via objective lens 10a, zoom lens 10b, iris 10c and focusing lens 10d. Then, the obtained video signal is automatically gain-controlled by AGC circuit 30 to be supplied into digital signal processing section 40.
An A/D converter 40a of digital signal processing section 40 converts an analog video signal input into a digital signal, and an Y/C separator 40b separates the digital video signal into a luminance signal Y and a chrominance signal C.
Separated chrominance signal C is processed via a chrominance signal processor 40c, and luminance signal Y is processed via a luminance signal processor 40d. By doing so, a composite video signal CVS is obtained by adding signals Y and C in adder 40e.
At this time, the luminance signal provided from luminance signal processor 40d is filtered by high-pass filter 50 to provide only the high band components of the luminance signal corresponding to the outline portion of the image. Under the control of controlling section 120, supervisory area setting section 80 sets the predetermined first area, preferably the center area, among the picture areas of optical system 10 formed of the output signals of high-pass filter 50 as the supervisory area.
With respect to the supervisory area set by supervisory area setting section 80, contrast detecting section 90 obtains the integrated value of the filtered high band components. The detected integrated value is supplied to comparing section 100 together with the reference value of the contrast value with respect to the supervisory area supplied from reference value supplying section 110. Then, comparing section 100 compares the output value of contrast detecting section 90 with the reference value supplied from reference value supplying section 110 to provide the result of the comparison to controlling section 120.
Aforementioned supervisory area setting section 80, contrast detecting section 90, comparing section 100 and reference value supplying section 110 function as a detecting section X which detects the presence or absence of the subject in the supervisory area.
In the meantime, controlling section 120 determines that the subject is detected in the set supervisory area when the integrated value of the outline components is larger than the reference value in the set supervisory area. Or it determines that the subject is not detected in the set supervisory area when the integrated value of the outline components is smaller than the reference value in the set supervisory area.
When it is determined that the subject is detected in the supervisory area, controlling section 120 provides the lens driving control signal to control motor driving section 130. Focusing lens motor 140 drives focusing lens 10d based on the control output of motor driving section 130, thereby carrying out the auto focusing control in the supervisory area.
However, if it is determined that the subject is not detected in the supervisory area, controlling section 120 decides whether the subject is detected or not in the focusing area, which is to be described later.
Here, under the control of controlling section 120, focusing area setting section 60 sets the predetermined second area among the picture areas of optical system 10 formed of the output signals of high-pass filter 50 as the focusing area.
Evaluation value detecting section 70 then detects the evaluation value by a difference value of the integrated values of the filtered high band components with respect to the focusing area set by focusing area setting section 60.
At this time, focusing area setting section 60 and evaluation value detecting section 70 function as a detecting section Y which detects the presence or absence of the subject in areas except the supervisory area.
On the other hand, when the subject detection in the focusing area is determined in accordance with the output of evaluation value detecting section 70, controlling section 120 provides the lens driving control signal to control motor driving section 130. Then, focusing lens motor 140 drives focusing lens 10d based upon the control output of motor driving section 130, thereby executing the auto focusing in the focusing area.
Here, the focusing area may consist of plurality of areas. In this case, if it is decided that the subject is not detected in the supervisory area, preferably, the areas nearer to the supervisory area set in the center area among the plurality of focusing areas are sequentially set as the focusing areas to decide the subject detection in corresponding area. In turn, in accordance with the result of the detection, the auto focusing control is performed in the corresponding area or the area is variably changed to the next area.
As described above, after completing the auto focusing in the focusing area, controlling section 120 advances to the supervisory mode for detecting the subject in the supervisory area. Or it continuously observes the presence or absence of the subject in the supervisory area even during executing the auto focusing in the focusing area to thereby perform the auto focusing in the supervisory area once the subject is detected in the supervisory area.
Furthermore, the focusing area may be set by excluding the supervisory area among the picture areas of optical system 10, as shown in FIG. 5.
In case that detecting section X, consisting of supervisory area setting section 80, contrast detecting section 90, comparing section 100 and reference value supplying section 110, detects the subject within the supervisory area, the supervisory area is changed by the focusing area and, vice versa, the focusing area is changed by the supervisory area to perform the auto focusing in the replaced supervisory area.
By employing the method for controlling focusing areas and apparatus for performing the same according to the present invention, the supervisory area is applied for enhancing precision of the auto focusing with respect to the center subject in case of multiple subjects. Furthermore, overall picture areas are utilized to accurately decide the direction, although there is no subject in the center area, while enabling the correct focusing.
Especially, when using a wide area, it is possible to be sensitive to the change of the main subject.
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. | In automatic focus controlling of a camera, a method for controlling focusing areas of the camera is performed by setting a supervisory area in the center of a subject area picked up by an optical system; setting plural variable areas into an outer periphery of the supervisory area; and detecting the subject to perform the auto focusing while performing area variation to the variable areas, unless the subject is detected while constantly observing the supervisory area. An apparatus for executing the method is also provided, enhancing precision of the auto focusing to the main subject in the case of multiple subjects, continuously tracking the auto focusing of the subject that moves to the outer peripheral side of the center of the picture, and improving the tracking property of the center area when varying the picture areas. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 09/801,264 filed Mar. 7, 2001, which is a continuation of the U.S. national phase designation of International Application PCT/EP99/06621, filed Sep. 7, 1999. This application also claims the benefit of U.S. provisional application No. 60/099,383 filed Sep. 8, 1998.
FIELD OF INVENTION
[0002] The present invention relates to a milk-based powder for pets. Particularly, the present invention is directed to a pet milk composition that may be reconstituted to provide a milk-based nutritional composition for pets, especially for young pets.
BACKGROUND OF RELATED ART
[0003] Many pet owner's, especially owners of young pets, feed cow's milk or cow's milk based compositions to their pets since cow's milk is an excellent source of nutrition. Further, in cases where very young pets are unable to obtain milk from their mothers, cow's milk or compositions based upon cow's milk may be the only source of nutrition for the young animal.
[0004] Unfortunately, the feeding of cow's milk to pet mammals may result in gastrointestinal intolerance. This manifests itself in a variety of intestinal symptoms which include bloating, distension, cramps, flatulence, lower fecal consistency and, in severe cases, diarrhea. Lower fecal consistency and diarrhea are particularly well known symptoms. (Mundt, H. C. and Meyer, H.; 1989, Waltham Symposium 7: Nutrition of the Dog and Cat, Cambridge University Press, pages 267-274). The cause of the gastrointestinal intolerance is attributed to the lactose in cow's milk.
[0005] Removal of lactose from cow's milk for human applications is well known. This is usually done by micro- or ultra-filtration or enzymatic treatment, or both, of liquid milk or whey solutions. Further milk or whey powders which are low in lactose, or lactose-free, are commercially available and may be fed to pets, but these powders are generally too expensive for commercial use in pet products. For pets, a possible solution to the problem is described in EP 0259713, where the lactose in the composition is reduced by reducing the content of milk powder in the composition to below about 60% by weight. In order to make up for the reduction in protein, lactose-reduced or lactose-free milk proteins are then added to the composition. In this way, the lactose content of the composition may be reduced to below about 30% by weight, but this requires the addition of large amounts of lactose-reduced or lactose-free milk proteins which increases the cost.
[0006] Mundt and Meyer, supra, suggest that another solution to this problem is to hydrolyze the lactose using enzymes prior to producing the pet milk powder. This is an acceptable solution when milk is freely and inexpensively available in liquid form, but it is not a feasible solution when the milk ingredient is available in powdered form; which is commonly the case.
[0007] Thus, there remains a need for a cow's milk-based powder which may be reconstituted to provide a milk-based nutritional composition, which is relatively simple to prepare and relatively inexpensive.
SUMMARY OF THE INVENTION
[0008] In one aspect, this invention provides a pet milk powder comprising a cow's milk powder which contains lactose, and a lactase. It has been surprisingly found that the simple addition of lactase to milk powder is able to avoid or significantly reduce the gastrointestinal problems associated with the consumption of lactose. This is despite the fact that the milk composition produced by reconstituting the milk powder may be consumed immediately after reconstitution; that is before the lactose has had the time to degrade the lactose in the milk powder. Preferably, at least a portion of the lactose in pet milk powder will become hydrolyzed upon reconstitution with solvent. Accordingly, upon reconstituting the pet powder product as a drink, and before its ingestion by the pet, the composition will comprise hydrolyzed and unhydrolyzed lactose. Preferably, 5 to 80% of the lactose is hydrolyzed upon reconstitution with a solvent.
[0009] Preferably, the lactase is a β-galactosidase, and more preferably, the β-galactosidase is from micro-organism origin. A β-galactosidase that is active at an acidic pH is particularly preferred.
[0010] The milk powder may further comprise one or more of a lipid source, protein source, vitamins, and minerals.
[0011] In another aspect of the invention, the milk powder is formulated for cats, the powder comprising a cow's milk powder which contains lactose, a lactase, taurine, arginine and choline. In yet another aspect of the invention, the milk powder is formulated for dogs, the powder comprising a cow's milk powder which contains lactose, lactase, and choline.
[0012] In a further aspect, the invention provides a method for reducing the symptoms of gastrointestinal intolerance in a mammalian pet after consumption of a nutritional composition based on cow's milk, the method comprising administering to the pet an effective amount of lactase in combination with the nutritional composition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Preferred embodiments of the invention are now described by way of example only.
[0014] The invention concerns a milk-based powder which may be reconstituted with water or other solvent to provide a nutritional drink for pets comprising hydrolyzed and unhydrolyzed lactose before ingestion.
[0015] The milk-based powder contains cow's milk powder and a lactase. The cow's milk powder may be any suitable milk powder which is based upon cow's milk; for example skimmed milk powder and whole milk powder. Further, milk powders produced from standardized milk-based solutions may be used. If desired, the cow's milk powder may contain additives such as vitamins, minerals, protein, lipids, and the like. The lactose content of the milk powder is not critical to the invention. Of course, if cow's milk powders having low lactose contents are readily and inexpensively available, they may be advantageously used.
[0016] The lactase may be any suitable lactase which is generally recognized as safe. β-galactosidases are preferred; especially β-galactosidases of microbial origin. Since conditions in the gastrointestinal tract are acidic, a lactase which remains active under acidic conditions is preferred. It is also possible to use lactases which are active under neutral or basic conditions. In these cases, however, it may be useful to include an alkali in the milk-based powder which slows the pH drop in the gastrointestinal tract.
[0017] An enzyme which is particularly suitable is a β-galactosidase which may be obtained from Amano Enzyme USA Co Ltd of Lombard, Ill., USA. The enzyme is available under the name “Lactase Amano”. The enzyme is obtained from Aspergillus oryzae and has an optimum pH of about 4.8 when lactose is the substrate. The enzyme has an activity of more than 50000 units/g at optimum pH. The enzyme is generally recognized as safe and is food grade.
[0018] The amount of the lactase to be added will depend upon various factors such as the lactose content of the cow's milk powder and the activity of the enzyme. The useful amount may be readily determined by a skilled person. Ordinarily, the lactase may be added to provide about 25 UI100 g to about 200 UI/100 g powder; for example about 50 UI/100 g to about 125 UI/100 g powder. The unit, UI, indicates the amount of enzyme which produces 1 micromole of o-Nitrophenol per minute at 30. degree. C. when 3.0 ml of a solution which contains 200 mg of -Nitrophenol-.β galactopyranoside per 100 ml of 0.1 M Mcllvaine buffer, pH 4.5; is added to 1.0 ml of diluted enzyme solution. The reaction is stopped after 10 minutes.
[0019] For an enzyme which has an activity of about 50 UI/100 g to about 125 UI/100 g powder, the lactase may comprise about 0.05% to about 0.4% by weight of the milk-based powder; and preferable from about 0.15% to about 0.25% by weight.
[0020] If it is desired to make the milk-based powder more nutritionally complete, other nutritional components may be added to the powder. For example, a lipid source may be added to the milk-based powder. Any suitable lipid source may be used; for example vegetable oils such as soybean oil, sunflower oil, safflower oil, corn oil, peanut oil, and rapeseed oil, or animal fats such as milk fats and tallow. In general, the lipid source used will be selected on the basis of nutritional value, cost and palatability considerations.
[0021] It is also possible to add further protein and amino acids sources. For example, whey protein powders may be added to the milk-based powder. Similarly, the milk-based powder may be supplemented with free amino acids which are required by the mammal for complete nutrition. For example, for milk-based powder intended for kittens, the powder may be supplemented with taurine or arginine, or both.
[0022] The milk-based powder may also contain vitamins and minerals. It is particularly preferred to include a source of calcium; for example dicalcium phosphate.
[0023] The milk-based powder may also include a probiotic micro-organism. A probiotic micro-organism is a micro-organism which beneficially affects a host by improving its intestinal microbial balance (Fuller, R; 1989; J. Applied Bacteriology, 66: 365-378). In general, probiotic micro-organisms produce organic acids such as lactic acid and acetic acid which inhibit the growth of pathogenic bacteria. Examples of suitable probiotic micro-organisms include yeasts such as Saccharomyces, Debaromyces, Candida, Pichia and Torulopsis, molds such as Aspergillus, Rhizopus, Mucor, and Penicillium and Torulopsis and bacteria such as the genera Bifidobacterium, Bacteroides, Clostridium, Fusobacterium, Melissococcus, Propionibacterium, Streptococcus, Enterococcus, Lactococcus, Staphylococcus, Peptostrepococcus, Bacillus, Pediococcus, Micrococcus, Leuconostoc, Weissella, Aerococcus, Oenococcus and Lactobacillus. Specific examples of suitable probiotic micro-organisms are: Saccharomyces cereviseae, Bacillus coagulans, Bacillus licheniformis, Bacillus subtilis, Bifidobacterium bifidum, Bifidobacterium infantis, Bifidobacterium longum, Enterococcus faecium, Enterococcus faecalis, Lactobacillus acidophilus, Lactobacillus alimentarius, Lactobacillus casei subsp. casei, Lactobacillus casei Shirota, Lactobacillus curvatus, Lactobacillus delbruckii subsp. lactis, Lactobacillus farciminus, Lactobacillus gasseri, Lactobacillus helveticus, Lactobacillus johnsonii, Lactobacillus reuteri, Lactobacillus rhamnosus (Lactobacillus GG), Lactobacillus sake, Lactococcus lactis, Micrococcus varians, Pediococcus acidilactici, Pediococcus pentosaceus, Pediococcus acidilactici, Pediococcus halophilus, Streptococcus faecalis, Streptococcus thermophilus, Staphylococcus carnosus, and Staphylococcus xylosus. The probiotic micro-organisms are preferably in powdered, dried form; especially in spore form for micro-organisms which form spores. Further, if desired, the probiotic micro-organism may be encapsulated to further increase the probability of survival; for example in a sugar matrix, fat matrix or polysaccharide matrix.
[0024] Further, the milk-based powder may also include a source of a fermentable soluble fiber, for example, chicory fibers, inulin, fructooligosaccharides, and the like. Preferably the fermentable soluble fibre selected is a substrate for the probiotic micro-organism selected, or such that the fermentable soluble fibre and probiotic micro-organism form a symbiotic relationship for promoting beneficial effects.
[0025] It is of course possible that vitamins, minerals, amino acids and a lipid source may have been used in the preparation of the cow's milk powder. In this case, less or none of these ingredients need be added.
[0026] The milk-based powder may be manufactured by dry mixing the cow's milk powder, the lactase, and any other ingredients. If a lipid source is added, it is preferably mixed in last. Any suitable mixing apparatus may be used. The milk-based powder is then packed into suitable packages.
[0027] The amount of the nutritional composition to be fed to a mammal each day will depend upon factors such as the mammal's age, the type of mammal, and other sources of nutrition. In general, the nutritional composition may be used in much the same way and in the same amounts as milk is used. For example, for medium and large dogs, up to about 250 ml of the nutritional composition per day may be fed to the dog. For smaller dogs, up to about 125 ml of the nutritional composition per day may be fed to the dog. Similar values may be readily determined for cats and other mammals.
EXAMPLES
[0028] By way of illustration, specific examples of the invention are now described.
Example 1
[0029] A milk-based powder for dogs is prepared by dry mixing together whole milk powder, β-galactosidase (“Lactase Amano”), vitamins, minerals and soybean oil. The composition of the powder is as follows:
[0030] 1 Ingredient Percent by Weight Milk powder 96.2 Soybean oil 1.7 Dicalcium phosphate 1.1 Choline 0.4 β-galactosidase 0.2 Vitamins, Minerals 0.4 The milk-based powder has a lactose content of about 33% by weight. The milk powder is added to tap water and is rapidly reconstituted to provide a milk-based nutritional composition. The nutritional composition is highly palatable to puppies and dogs.
Example 2
[0031] A milk-based powder for cats is prepared by dry mixing together whole milk powder, β-galactosidase, arginine, taurine, vitamins, minerals and soybean oil. The composition of the powder is as follows:
[0032] 2 Ingredient Percent by Weight Milk powder 97.1 Dicalcium phosphate 1.5 Choline 0.4 Arginine 0.4 .β.-galactosidase 0.2 Soybean oil 0.05 Vitamins, Minerals 0.35 The milk-based powder has a lactose content of about 33% by weight. The milk powder is added to tap water and is rapidly reconstituted to provide a milk-based nutritional composition. The nutritional composition is highly palatable to kittens and cats.
Example 3
[0033] Seven beagle dogs 5 to 12 years are used in a trial. Each dog is separately housed in a cage. The dogs have access to a dry diet ad libitum.
[0034] In the first part of the trial, the dogs are fed a milk reconstituted from a full fat milk powder for a period of 7 days. The milk contains vitamins and minerals. The milk is reconstituted immediately before serving by adding cold tap water to the fill fat milk powder. Food consumption, liquid consumption and faecal consistency are monitored. In the second part of the trial, the dogs are fed a nutrition composition reconstituted from the milk-based powder of example 1 for a period of 7 days. The nutrition composition is reconstituted immediately before serving by adding cold tap water to the milk-based powder. Food consumption, liquid consumption and faecal consistency are monitored. In both parts of the trial, each dog is fed 900 g per day of the milk or nutritional composition. The milk or nutritional composition is available from 9 a.m. to 3 p.m. and is the only liquid source during this period. In general, the entire amount of liquid is consumed rapidly. From 3 p.m. to 9 a.m., the dogs have free access to water.
[0035] 3 Percentage of stool having Percentage of stools being Food loose stool consistency diarrhoeic Milk 36 19 nutritional 12 7 composition of example 1 The nutritional composition offers a significant improvement even at this high level of consumption.
Example 4
[0036] Seven cats aged 5 to 12 years are used in a trial. Each cat is separately housed in a cage. The cats have access to a fish-based dry diet ad libitum.
[0037] In the first part of the trial, the cats are fed a milk reconstituted from a full fat milk powder for a period of 7 days. The milk contains vitamins and minerals. The milk is reconstituted immediately before serving by adding cold tap water to the full fat milk powder. Food consumption, liquid consumption and faecal consistency are monitored. In the second part of the trial, the cats are fed a nutrition composition reconstituted from the milk-based powder of example 2 for a period of 7 days. The nutrition composition is reconstituted immediately before serving by adding cold tap water to the milk-based powder. Food consumption, liquid consumption and faecal consistency are monitored.
[0038] In both parts of the trial, each cat is presented with 180 g per day of the milk or nutritional composition. The milk or nutritional composition is available from 3:00 p.m. to 9 a.m. and is the only liquid source during this period. From 9 a.m. to 3 p.m., the cats have free access to water.
[0039] 4 Percentage of stool having Percentage of stools being Food loose stool consistency diarrhoeic Milk 42 37 nutritional 20 0 composition of example 2.
[0040] The nutritional composition offers a very significant improvement. No significant change in consumption between the milk and nutritional composition is noticed. Hence palatability is unaffected by the addition of the enzyme.
Example 5
[0041] A milk-based powder is prepared using a .β.-galactosidase enzyme obtained from Novo Nordisk A/S of Bagsvaerd, Denmark and sold under the name Lactozym. The powder is substantially identical to the powder of example 1 except that this different enzyme is used. The enzyme is optimally active under basic conditions. When fed to beagle dogs, the milk-based powder has substantially the same properties as the powder of example 1. | A pet milk powder of a cow's milk powder which contains lactose, and lactase in an amount sufficient to reduce the symptoms of gastrointestinal intolerance in pets when the powder or a solution made from the powder is ingested by the pet. At least a portion of the lactose in the pet milk powder is hydrolyzed upon reconstitution of the powder with a solvent. Also, a pet milk-based drink made by reconstituting the powder with a solvent such as water. | 0 |
This is a division of application No. 08/386,328, now U.S. Pat. No. 6,123,789 filed Feb. 10, 1995 which is an FWC of 07/913,842 now abandoned, filed Jul. 15, 1992.
BACKGROUND
1. The Field of the Invention
The present invention is related to illuminant compositions which emit significant quantities of infrared radiation. More particularly, the present invention is related to castable infrared illuminant compositions which exhibit high initial burn rates, burn cleanly, and emit relatively small quantities of visible light in proportion to the infrared radiation emitted.
2. Technical Background
There is a need in various situations for an ability to see clearly at night, or during periods of substantially reduced sunlight. Such situations may, for example, include search and rescue operations, police surveillance, and military operations. In these types of situations, it is often important that key personnel have the ability to see clearly, even though there is limited sunlight.
In order to solve the problem of visibility at night, or during periods of substantially reduced sunlight, devices have been developed which allow one to see based upon available infrared illumination, rather than visible light. While the infrared vision devices take on various configurations, perhaps the most common type of infrared vision devices are night vision goggles. These devices provide individual users with the ability to see much more clearly at night, while not significantly limiting the mobility of the individual user.
In order to facilitate the use of infrared vision devices, it has been found advantageous to enhance the available infrared radiation in the area of interest. In that regard, infrared emitting flare mechanisms have been developed. Such mechanisms have taken on a variety of configurations; however, the most widely used mechanisms comprise flares which emit relatively large quantities of infrared radiation in addition to any visible light that may be produced.
Infrared emitting flares are generally configured in much the same manner as visible light emitting flares. Such flares may provide infrared radiation at a single position on the ground, or they may provide such radiation above the ground. In the case of above-ground operation, the flare system includes an internal or external means of propulsion which allows the user to fire the flare in a desired direction. In addition, the flare itself includes a material which, when burned, produces significant quantities of infrared radiation. In general operation the flare is propelled over the area of interest and ignited. The emitted infrared radiation then greatly enhances the usefulness of infrared viewing devices, such as night vision goggles.
A number of problems have been encountered in the development of suitable infrared emitting compositions for use in such flares. For example, it will be appreciated that it is often desirable to provide an infrared emitting flare which does not emit excessive quantities of visible light. In situations where it is desirable to conduct operations under cover of night with a degree of secrecy, this capability is imperative. Excessive emission of visible light from the flare may alert individuals in the area to the existence of the flare, which may in turn significantly reduce the effectiveness of the overall operation.
It has been found with known infrared flare compositions that excessive visible light is in fact emitted. In that regard, the performance of infrared emitting devices can be judged by the ratio of the amount of infrared radiation emitted to the amount of visible light emitted. This ratio is found to be low for many conventional infrared emitting compositions, indicating a high proportion of visible light being emitted from the flare.
Another problem encountered in the use of infrared emitting compositions relates to the burn rate achieved. Many known compositions have burn rates which are lower than would desired, resulting in less infrared radiation than would be desired. In order to provide an effective flare, relatively high burn rates are required.
It is often observed that the burning (surface area) of the flare composition increases dramatically over time. This characteristic is also generally undesirable. In the case of an infrared emitting flare which is launched into the air, this means that less infrared radiation is emitted when the flare is high above the surface, while more infrared radiation is emitted while the flare is near the surface. Indeed, it is often found that the flare continues to burn after it has impacted with the ground.
It will be appreciated that this burn rate curve is just the opposite of that which would be generally desirable. It is desirable to have a high intensity infrared output when the flare is at its maximum altitude in order to provide good illumination of the ground. It is less critical to have high infrared output as the flare approaches the ground simply because the distance between the ground and the flare is not as great (illumination can be expressed by the equation Illumination=(I×4π)/(4πR 2 ) where I is the intensity in watts/steradian, R is the distance in feet from the flare to the object being illuminated, and illumination is expressed in units of watts/feet 2 ). Ultimately, it is desirable that the flare cease operation before impact with the surface in order to reduce detection and obvious problems, such as fire, which may be caused when a burning flare impacts with the ground.
Another problem often encountered with known infrared emitting materials is “chunking out.” This phenomenon relates to breakup or unbending separation of the flare propellant grain during operation. In these situations it is found that large pieces of the infrared emitting composition may break away from the flare and fall to the ground. This is problematic because the flare fails to operate as designed when large pieces of the infrared producing composition are missing, the amount of infrared output over the subject location is curtailed, and falling pieces of burning flare material create a safety hazard.
It has also been found that the use of conventional flare compositions results in soot formation. Soot formation can adversely affect the operation of the flare device in several ways, including causing an increase in visible light emitted. When soot or carbon is heated it may radiate as a blackbody radiator. Soot formation is encountered primarily due to the fuels and binders employed in the infrared producing composition. Conventional infrared producing compositions have generally been unable to adequately deal with the problem of soot formation.
A further problem relates to aging of the IR emitting composition. It is often observed that known compositions substantially degrade over time. This is particularly true if the storage temperature is elevated. In some situations, it may be necessary to store these materials for long periods of time at temperatures at or above 120° F. This has not been readily achievable with known compositions.
In summary, known infrared emitting compositions have been found to be less than ideal. Limitations with existing materials have curtailed their effectiveness. Some of the problem areas encountered have included low overall burn rates, undesirable burn rate curves, chunking out, poor aging, and undesirable levels of visible emissions.
It would, therefore, be a significant advancement in the art to provide infrared emitting compositions which overcame some of the serious limitations encountered with known compositions. It would be an advancement in the art to provide compositions which provided high levels of infrared emissions, while limiting the level of visible light output. It would be another significant advancement in the art to provide such compositions which had acceptably high burn rates.
It would also be an advancement in the art to provide infrared emitting compositions which substantially eliminated soot formation and which also substantially eliminated chunking. It would also be an advancement in the art to provide compositions which did not readily degrade with age, even when stored at relatively elevated temperatures.
Such compositions and methods are disclosed and claimed herein.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
The present invention is related to novel and inventive compositions which produce significant quantities of infrared radiation when burned. At the same time, the compositions avoid many of the limitations of the existing art. The compositions have high burn rates, produce relatively little visible light in proportion to infrared radiation produced (in that they substantially avoid soot formation). The compositions also avoid common problems such as chunking and poor high temperature aging. Finally, the compositions are castable. That is, the compositions are capable of being poured in liquid form into a mold, then taking the shape of the mold without the application of excessive pressure.
The basic components of the compositions include a binder, an oxidizer, and a fuel. In the castable formulations disclosed herein, the binder may act as the fuel. Other optional ingredients may also be added in order to tailor the characteristics of the composition to a specific use. Such optional ingredients include combustion rate catalysts and heat producing materials.
As mentioned above, it is critical to reduce visible light produced. This severely limits the fuels that can be used. Boron and silicon have been used in small amounts and act well as heat sources and as combustion rate catalysts. Hydrocarbon fuels have been evaluated and many tend to produce soot, which can lead to high visible light output. The hydrocarbon fuels/binders used, therefore, must burn cleanly and provide nonluminous fragments that can burn with ambient air in the plume in order to increase the heat output and size of the radiation surface. At the same time, the material must serve to form a composition which is processible, castable, avoids chunking, and is compatible with the oxidizers used.
The hydrocarbon binders (polymers) that have proven to reduce soot formation include polyesters, polyethers, polyamines, polyamides; particularly those with short carbon fragments in the backbone, alternating with oxygen or nitrogen atoms. It has been found that polymer binders which include relatively short carbon chains (about 1-6 continuous carbon atoms) are preferred. These molecules do not generally produce significant soot. Further, the additional desirable features of the invention can be achieved using these materials.
Preferred oxidizers include those compounds which produce large quantities of infrared radiation when the flare composition is burned. Such oxidizers include potassium nitrate, cesium nitrate, rubidium nitrate, and combinations of these compounds. These oxidizers are chosen to contain a metal with characteristic radiation wavelength in the near infrared (0.700 to 0.900 microns). The primary radiation comes from this line, whose width has been greatly broadened by the thermal energy in the plume.
It is believed to be important to provide free metal (potassium, cesium, or rubidium) during the burning of the flare composition in order to produce significant levels of infrared radiation. These metals appear to augment one another when used in certain combinations.
Significantly, high levels of cesium nitrate in the composition are found to greatly increase performance. Cesium nitrate is found to provide several significant advantages. Cesium nitrate is found to accelerate the burn rate. In addition, cesium nitrate broadens the infrared spectral output and improves infrared efficiency. Accordingly, it is preferred that cesium nitrate form from about 10% to about 90%, by weight, of the overall composition. In particular, excellent results are achieved when cesium nitrate is added to make up from about 30% to about 90% of the composition.
It is found that the compositions of the present invention produce relatively high burn rate materials. Burnrates at ambient pressures in the range of from about 0.0300 to about 0.1500 inches/second, and even somewhat higher, are readily achievable using the present invention. The more preferred range is above about 0.060 inches/second. Conventionally, it has been found that burn rates in this range are not readily achievable.
The present invention maintains the capability of tailoring desired characteristics by selecting specific combinations of fuels, oxidizers, and binders. Thus, particular burn rates and burn rate curves can be produced, the ratio of infrared radiation to visible light can be optimized, and the general physical and chemical properties can be carefully selected. Thus, the present invention provides a flexible illuminant material.
Accordingly, it is a primary object of the present invention to provide infrared emitting compositions which overcome several of the serious limitations encountered with known compositions.
It is an object of the present invention to provide compositions which when burned produce high levels of infrared emissions, while limiting the level of visible light output.
It is also an object of the present invention to provide such compositions which have high burn rates.
It is another object of the present invention to provide infrared emitting compositions which produce only limited soot and, therefore, limited visible output.
It is a further object of the invention to provide compositions which substantially eliminate chunking.
It is a further object of the present invention to provide compositions which do not significantly degrade with age, even when stored at relatively elevated temperatures.
These and other objects and advantages of the invention will become apparent upon reading the following detailed description and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 is a graph of the infrared output of a composition within the scope of the present invention.
FIG. 2 is a graph of the visible output for the composition of FIG. 1 .
FIG. 3 is a graph of the infrared output of a composition within the scope of the present invention.
FIG. 4 is a graph of the visible output for the composition of FIG. 3 .
FIG. 5 is a graph showing the infrared and visible outputs of a composition within the scope of the present invention.
FIG. 6 is a graph showing the infrared and visible outputs of a composition within the scope of the present invention.
FIG. 7 is a graph showing the infrared and visible outputs of a composition within the scope of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As mentioned above, the present invention is related to illuminant compositions which emit significant quantities of infrared radiation. The present invention also provides infrared illuminant compositions which exhibit high initial burn rates, burn cleanly, and emit relatively small quantities of visible light in relation to the infrared radiation emitted.
The compositions of the present invention are “castable” compositions. Castable compositions, as the title implies, are capable of being cast into a suitable mold without resorting to the application of excessive pressure. Thus, the material is easy to process and use in a flare device.
A typical castable composition within the scope of the present invention will include the following components in the following approximate percentages by weight:
Materials
Percent
Oxidizing Salt(s)
40-90
(such as Potassium Nitrate
and Cesium Nitrate)
Boron
0-20
Silicon
0-30
Polymer Binder Premix
10-50
In certain embodiments of the invention the oxidizer may comprise up to about 95% of the total composition. It is often preferred that at least 25% of the total composition comprises cesium nitrate, in that high levels of cesium nitrate results in the production of intense infrared radiation without significant visible light.
A specific example of a suitable binder in the composition is Formrez 17-80 polyester of Witco Chemical Corp. and more particularly, a curable polyester resin composition comprising by weight, from about 81% to about 83% to, preferably about 82.5% Formrez 17-80 polyester resin, about 15 to about 17%, preferably about 16.5% epoxy such as ERL 510 of Ciba-Geigy Corporation and about 0 to about 2%, and preferably 1% of a catalyst such as iron linoleate. More preferably, the binder may comprise about 82.5% Formrez 17-80 polyester resin, about 16.5% ERL epoxy and about 1% iron linoleate. Such a binder composition is referred to herein as WITCO 1780.
One exemplary embodiment of the present invention which provides excellent performance is formulated as follows:
Materials
Percent
Potassium Nitrate
37.0
Cesium Nitrate
35.0
Silicon
10.0
Witco 1780 Binder Premix
18.0
In this example, the Witco 1780 binder premix is a commercially available polyester resin based on triethyleneglycol and succinic acid, blended with an epoxide curing agent as described above. Notably, the cesium nitrate content is in excess of 25%, and the composition provides excellent performance.
It will be appreciated that equivalent materials may be substituted for those identified above. Specifically, the nitrate salts may be substituted for one another, depending on the specific characteristics desired. One such example is rubidium nitrate, which may be added to the compositions, or may be substituted for some or all of the identified oxidizers. The ultimate objective in that regard is to provide a strong oxidizer which is also capable of substantially contributing to the output of infrared radiation during burning of the composition. The identified compounds possess those characteristics.
As mentioned above, the use of high levels of cesium salts (such as cesium nitrate) increases the burning rate by as much as 400% and reduces visible output by up to 50%. This occurs while at the same time maintaining high levels of infrared light in the 700 to 1100 nm region. Thus, specifically tailored formulations may include high levels of cesium nitrate in order to achieve specific performance criteria. It is presently preferred that the composition include from about 10% to about 90% cesium nitrate, and in many cases from about 25% to about 90%. It will be appreciated that the cesium nitrate comprises a portion of the total oxidizing salt added to the composition.
As discussed above, the compositions also include a liquid polymer binder which may be cross-linked by reaction with an epoxy or isocyanate curing agent. The binder facilitates the formulation, processing, and use of the final composition. At the same time, the binder provides a source of fuel for the composition. Suitable binders in the present invention also insure a clean burning composition by substantially reducing soot formation.
Binders which are preferred in the present invention include polymers which have relatively short carbon chains (1-6 continuous carbon atoms) connected together by ether, amine, ester, or amide linkages (polyethers, polyamines, polyesters, or polyamides). Examples of such polymers include polyethylene glycol, polypropylene glycol, polybutylene oxide, polyesters, and polyamides. As mentioned above, one such polymer is Witco 1780, manufactured by Witco Corp. Other similar materials are well known to those skilled in the art and are commercially available.
It is also readily possible to add combustion rate catalysts and heat sources to the overall composition. These materials provide for further tailoring of the performance characteristics of the resulting composition. These materials, however, must also fit the other parameters of an acceptable composition such as producing little visible light and not contributing to the other undesirable characteristics identified herein. Two examples of such preferred materials include silicon and boron, while materials such as magnesium are not preferred because of their propensity to emit large quantities of visible light.
In the castable compositions described herein, boron is preferably added to constitute from about 0% to about 20%, by weight of the total composition. Silicon preferably makes up from about 0% to about 25% of the total composition.
One measure of a preferred composition is the ratio of infrared radiation to visible light produced during burning of the composition. Preferably the composition will have an IR/Vis. ratio of at least 3.50, and more preferably greater than 6.0. Indeed, ratios from 10 to 20 are achievable with the present invention. These levels of infrared output per unit of visible output have not been easily achievable using conventional compositions.
It is found that the compositions within the scope of the present invention also provide increased burn rates. Burn rates within the range of about 0.030 to about 0.150 inches per second are characteristic of the compositions of the present invention. As mentioned above, the preferred burn rates are in excess of 0.060 inches/second.
Compositions within the scope of the present invention also age and store well. This is a further feature which has not generally been available in known compositions. Compositions within the scope of the present invention may be stored at elevated temperatures (for example, 135° F.) for up to a year without significant degradation.
Compositions within the scope of the present invention can be formulated and prepared using known and conventional technology. Formulation techniques such as those generally employed in mixing and preparing propellant, explosive, and pyrotechnic compositions are preferably used in the preparation of the compositions within the scope of the present invention.
EXAMPLES
The following examples are given to illustrate various embodiments which have been made or may be made in accordance with the present invention. These examples are given by way of example only, and it is to be understood that the following examples are not comprehensive or exhaustive of the many types of embodiments of the present invention which can be prepared in accordance with the present invention.
Example 1
In this example a composition within the scope of the present invention was formulated and tested. A castable composition was formulated. The formulation included relatively high levels of CsNO 3 .
Material
Percentage (by weight)
CSNO 3
70.0
Silicon
10.0
Witco Binder Premix
20.0
The Witco Binder Premix comprised a mixture of WITCO 1780 liquid polyester (triethyleneglycol succinate), manufactured by Witco Corp, blended with an appropriate amount of an epoxy curing agent to provide adequate cure.
The material was burned and the burn rate, output of visible light, and output of infrared radiation measured. Visible light was measured with a silicon photodiode with photopic response.
Infrared light was measured using a silicon cell with a 695 nm cut on filter.
Tests on the composition yielded the following data:
WEB
0.515 inches
Burn rate
0.0460 in/sec
Burntime
11.19 seconds
Avg. IR
741.2 mV
Avg. Vis.
45.34 mV
IR/Vis.
16.19
All data represent the average of two runs.
As can be seen from the data presented above, the composition provides a useful infrared emitting composition. The composition provides a rapid burn rate, along with high IR output and extremely low visible output.
Example 2
In this Example a composition within the scope of the present invention was formulated and tested. The following ingredients were mixed to produce an infrared emitting composition:
Material
Percentage (by weight)
CSNO 3
70.0
Silicon
10.0
Witco premix (binder)
20.0
The composition was a castable composition and was burned as a flare 2.75 inches in diameter, 13.1 inches in length, and weighing approximately 5.5 pounds. The following results were obtained and are the average for four separate tests:
Burntime
191.4 seconds
Burnrate
0.0667 inches/sec.
Avg. IR
1.393 v
Avg. Vis.
121.5 mv
Area IR
266.3 V sec.
Area Vis.
23.15 V sec.
IR/Vis.
11.5
FIG. 1 is plot of the output of infrared radiation over time for the composition. FIG. 2 is a plot of the output of visible radiation over time for the composition. It can be seen that a high level of infrared output was achieved shortly after burning commenced. This level was sustained over most of the operation of the sample, declining at the end of the burn. This burn rate curve is desirable. At the same time, the ratio of IR to visible was excellent.
It can be appreciated from the results achieved that an acceptable infrared emitting composition was produced and that the level of visible emissions was significantly lower than the level of infrared emissions.
Example 3
In this Example a composition within the scope of the present invention was formulated and tested. The following ingredients were mixed to produce an infrared emitting composition:
Material
Percentage (by weight)
CsNO 3
35.0
KNO 3
35.0
Si
10.0
Witco premix
20.0
This castable composition was burned and the following results were obtained and are the average for four separate tests:
Burntime
139.3 seconds
Burnrate
0.0793 inches/second
Avg. IR
1.857 v
Avg. Vis.
155.8 mv
IR/Vis.
11.9
FIG. 3 is plot of the output of infrared radiation over time for the composition. FIG. 4 is a plot of the output of visible radiation over time for the composition. It can be seen that a high level of infrared output was achieved shortly after burning commenced. This level was sustained over most of the operation of the sample, declining at the end of the burn. This burn rate curve is desirable. At the same time, the ratio of IR to visible was excellent.
It can be appreciated from the results achieved that an acceptable infrared emitting composition was produced and that the level of visible emissions was significantly lower than the level of infrared emissions.
Example 4
In this Example a composition within the scope of the present invention was formulated and tested. The following ingredients were mixed to produce an infrared emitting composition:
Material
Percentage (by weight)
CsNO 3
70.0
Si
10.0
Witco premix
20.0
The composition was burned and the following results were obtained and are the average for four separate tests:
Burntime
14.79 seconds
Burnrate
0.0381 inches/sec.
Avg. IR
606.0 mv
Avg. Vis.
38.65 mV
Area IR
9.05 V sec.
Area Vis.
0.584 V sec.
IR/Vis.
15.50
FIG. 5 illustrates two plots, including a plot of the output of infrared radiation over time for the composition and a plot of the output of visible radiation over time for the composition. It can be seen that a high level of infrared output was achieved shortly after burning commenced. This level was sustained over most of the operation of the sample, declining at the end of the burn. This burn rate curve is desirable. At the same time, the ratio of IR to visible was excellent.
It can be appreciated from the results achieved that an acceptable infrared emitting composition was produced and that the level of visible emissions was significantly lower than the level of infrared emissions.
Example 5
In this Example a composition within the scope of the present invention was formulated and tested. The following ingredients were mixed to produce an infrared emitting composition:
Material
Percentage (by weight)
KNO 3
35.0
CsNO 3
35.0
Si
10.0
Witco premix
20.0
The composition was burned and the following results were obtained and are the average for four separate tests:
Burntime
24.15 seconds
Burnrate
0.0234 m/sec.
Avg. IR
393.10 mV
Avg. Vis.
31.63 mV
Area IR
9.57 V sec.
Area Vis.
0.781 V sec.
IR/Vis.
12.24
FIG. 6 illustrates two plots, including a plot of the output of infrared radiation over time for the composition and a plot of the output of visible radiation over time for the composition. It can be seen that a high level of infrared output was achieved shortly after burning commenced. This level was sustained over most of the operation of the sample, declining at the end of the burn. This burn rate curve is desirable. At the same time, the ratio of IR to visible was excellent.
It can be appreciated from the results achieved that an acceptable infrared emitting composition was produced and that the level of visible emissions was significantly lower than the level of infrared emissions.
Example 6
In this Example a composition within the scope of the present invention was formulated and tested. The following ingredients were mixed to produce an infrared emitting composition:
Material
Percentage (by weight)
CsNO 3
52.5
KNO 3
17.5
Si
20.0
Witco premix
20.0
The composition was burned and the following results were obtained and are the average for four separate tests:
Burntime
19.12 second
Burnrate
0.0295 m/sec.
Avg. IR
503.15 mV
Avg. Vis.
35.54 mV
Area IR
9.70 V sec.
Area Vis.
0.694 V sec.
IR/Vis.
13.97
FIG. 7 illustrates two plots, including a plot of the output of infrared radiation over time for the composition and a plot of the output of visible radiation over time for the composition. It can be seen that a high level of infrared output was achieved shortly after burning commenced. This level was sustained over most of the operation of the sample, declining at the end of the burn. This burn rate curve is desirable. At the same time, the ratio of IR to visible was excellent.
It can be appreciated from the results achieved that an acceptable infrared emitting composition was produced and that the level of visible emissions was significantly lower than the level of infrared emissions.
Example 7
In this Example a composition within the scope of the present invention was formulated and tested. The following ingredients were mixed to produce an infrared emitting composition:
Material
Percentage (by weight)
CsNO 3
35.0
KNO 3
37.0
Si
10.0
Witco Premix
18.0
The composition was burned and the ratio of infrared light to visible light produced was approximately 12.0.
Example 8
In this example, a composition within the scope of the present invention was tested in terms of aging, and compared to a hexamine-containing control formulation. Standard temperature and humidity aging tests were preformed.
The composition within the scope of the present invention contained Witco binder and KNO 3 . The control composition contained Witco binder, hexamine, and KNO 3 . The compositions were formed into standard flares and were aged pursuant to military standard MIL-STD-331B, temperature and humidity cycle single chamber method. The flares were conditioned for two consecutive 14-day cycles, for a total of 28 days. Flight and tower tests were performed. It was observed that the control developed cracking at several locations, while the composition within the scope of the invention exhibited no apparent physical change or performance degradation.
Three flares of each type were tested, and visible energy, infrared energy, and burn rate data were collected.
After the first 14-day cycle, one flare from each formulation was dissected. Two flares were burned. The most notable change was an increase in chunking by the control.
After the full 28-day cycle, one flare from each formulation was dissected. The control was found to have four grain cracks, while the formulation tested had none.
Two flares were burned to measure performance. Data for the baseline, 14-day, and 28-day cycle tests are as shown below:
Control
Baseline
14-Day Cycle
28-Day Cycle
Average IR
2.15 V
2.19 V
2.293 V
Average Vis.
315 mV
303 mV
304 mV
IR/Vis.
6.8
7.2
7.5
Burnrate
0.043 in/sec
0.041 in/sec
0.042 in/sec
Burntime-tower
320 sec
311 sec
317 sec
Burntime-flight
201 sec
—
—
grain cracks
0
3
4
flight chunks
1
—
—
tower chunks
0
1
2
Test Composition
Baseline
14-Day Cycle
28-Day Cycle
Average IR
1.30 V
1.30 V
0.94 V
Average Vis.
260 mV
257 mV
191 mV
IR/Vis.
5.0
5.1
4.9
Burnrate
0.045 in/sec
0.047 in/sec
0.043 in/sec
Burntime-tower
306 sec
276 sec
308 sec
Burntime-flight
236 sec
—
—
grain cracks
0
0
0
flight chunks
0
—
—
tower chunks
0
0
0
Accordingly, it can be seen that compositions within the scope of the present invention provide significantly improved aging characteristics. No chunking or cracking was observed using the invention composition. Using the hexamine-containing control, however, cracking and chunking were observed over the course of the tests.
Summary
In summary, the present invention provides new and useful illuminant formulations which produce large quantities of infrared radiation, but produce relatively small quantities of visible light. Accordingly, some of the major drawbacks with known infrared producing materials are avoided.
The compositions of the present invention have high burn rates. The compositions emit infrared while producing only limited soot and, therefore, limited visible light is produced. The compositions of the present invention also substantially eliminate chunking. The compositions do not significantly degrade with age, even when stored at relatively elevated temperatures. Thus, the compositions of the present invention represent a significant advancement in the art.
The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | Compositions are provided which, when burned, produce significant levels of infrared radiation, but only limited levels of visible radiation. The basic components of the compositions include a binder, an oxidizer, and a fuel, where the binder also acts the fuel. Preferred oxidizers include those compounds which produce large quantities of infrared radiation when the flare composition is burned. Such oxidizers include potassium nitrate, cesium nitrate, rubidium nitrate, and combinations of these compounds. Selection of the binder is important in order to provide the composition with the desirable characteristics identified above. The binder of the present invention does not produce significant soot. At the same time, the binder serves to form a composition which is processible, avoids chunking, and is compatible with the oxidizers used. It has been found that polymer binders which include relatively short carbon chains (1-6 continuous carbon atoms) are preferred. Examples of such polymers include polyesters, polyethers, polyamides, and polyamines. | 8 |
FIELD OF THE DISCLOSURE
[0001] Aspects of the present disclosure relate to tools to facilitate document information access.
BACKGROUND
[0002] Various systems exist that facilitate online access to documents and to information concerning those documents, for example, version information. For example, the Digital Object Identifier System® is a system for identifying content objects in a digital environment. Digital Object Identifiers (DOIs) are names assigned to an entity for use on the digital network. They are used to provide current information, including where the object can be obtained on the Internet. The Corporation for National Research Initiatives describes a Handle System®, which is a system for assigning, managing, and resolving persistent identifiers which they refer to as “handles” for digital objects and other resources on the Internet. The Online Computer Library Center (OCLC) provides software for implementing Persistent Uniform Resource Locators (PURLs). A PURL is like a URL. Instead of pointing directly to the location of an Internet resource, a PURL points to an intermediate resolution service. The PURL resolution service associates the PURL with an actual URL, and returns that URL to the requester.
[0003] There is a need for further features that facilitate online document information access and as well as access to updated versions of documents.
SUMMARY
[0004] In accordance with one embodiment of the disclosure, apparatus are provided. An information repository is provided which holds current document state information. The information repository includes an expiration mechanism to expire state information for documents.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Embodiments of the disclosure are further described in the detailed description which follows, by reference to the noted drawings, in which like reference numerals represents similar parts throughout the several views of the drawings, and wherein:
[0006] FIG. 1 is a block diagram of a network system, which includes a document distribution system in accordance with one embodiment of the disclosure;
[0007] FIG. 2 is a schematic diagram of one or more document requester screens;
[0008] FIG. 3 is a schematic diagram of a document file and/or a document, including document information list (DIL) information; and
[0009] FIG. 4 shows a flow chart of a portion of a process performed by a document processing mechanism, such as a word processor.
DETAILED DESCRIPTION
[0010] Aspects of the disclosure are directed to tools that facilitate, via online systems, access to documents and to document information. Various features are described herein which allow for the ready online access to document information updates. In addition, features are disclosed which allow for the ready online access to the latest version information concerning documents, as well as ready online access to the latest version of the document itself. All this information is accessible, for example, by reference to information provided in a document to which the document requester is provided access. That document may be an outdated document. In embodiments described herein, the outdated document includes document information list information that can be used to facilitate access to document information as described above. This document information list information may be embedded in the overhead portion of the digital file of the document, or embedded into the content of the document itself.
[0011] Referring now to the drawings in greater detail, FIG. 1 shows a networked system 10 . The illustrated networked system 10 includes a document distribution system 12 , a document information management system 14 , and plural document requester computers 16 coupled to document distribution system 12 and document information management system 14 via one or more networks, which networks include, in the illustrated embodiment, the Internet.
[0012] The document distribution system 12 may, for example, be an enterprise system or a document management system. The illustrated document distribution system 12 includes a document provider 18 to provide document requesters with requested documents, and a document event notification mechanism 20 to notify document requesters of certain events concerning a document, for example, a version change. A document access arbiter 22 is also provided. The document access arbiter 22 controls access to requested documents and to the document distribution system 12 more generally. Access may be provided for a given document requester via a URL access 23 . Access may be restricted to only certain document requesters. The restriction of access may be handled by secure connections which may be required to access document distribution system 12 . Access to the document access arbiter 22 via a secure connection may be managed to limit such access to only account holders via an account holder mechanism 24 and guests via a guest mechanism 25 .
[0013] Document distribution system 12 may include a document generator and/or modifier 30 , which either generates or modifies documents. By way of example, document generator and/or modifier 30 may include a document creation and editing application, for example, a presentation application, a word processing application, or an image file application. In addition, or in the alternative, by way of example, document generator or modifier 30 may include a mechanism for modifying either the document content itself or the overhead portion of the document file to include certain information, including a unique document identifier as well as document information list information. For this purpose, document generator or modifier 30 may be provided with a unique identification generator 34 and with a document information list (DIL) information embedding mechanism 36 .
[0014] In the process of document generator or modifier 30 generating or modifying a document, document content and information 32 is created and stored. The illustrated schematic representation of the stored document content and information 32 includes document files 40 , version information 42 , access route information 44 , and other document information 46 .
[0015] The document information management system 14 manages information concerning documents as well as access to such information by document requesters via their document requester computers 16 . The document information management system 14 may include an information repository holding current document state information, and including an expiration mechanism to expire state information for certain documents. In the specific embodiment illustrated in FIG. 1 , the information repository includes one or a plurality of document information list (DILs) 50 . A given DIL 50 includes information including a date of current publication of the DIL, the date of the next expected publication of the DIL, a set of entries for respective documents, and the source of the DIL (e.g., the corporation that has published the DIL or the computer system on which the DIL is held).
[0016] For each document for which information is included in the DILs 50 , a document information entry 56 is included. The document entry 56 , as illustrated in the exampled embodiment, may include records including unique document identifier 61 , the date of the document 62 , the document state information 63 (e.g., document currently open by another user; document in final; final version; etc.), and the access route 64 for the document. The access route 64 for the document may, for example, be identified in the record as a URL. The illustrated document information entry 56 further includes records including version information 65 , one or more version dates 66 corresponding to the version information, and the last date on DIL 67 . The last date on DIL 67 is the date after which the document information in DILs 50 will be expired and will either be deleted from the DIL or no longer accessible by a document requester.
[0017] An expiration management mechanism 58 may be provided to stop access to an entry for an individual document when the entry for the individual document includes a last date on DIL that has been reached. The expiration management mechanism 58 may be further provided with a mechanism to delete the entry from the DIL for that individual document.
[0018] The illustrated document information management system 14 may be further provided with a document requester access manager 60 to manage the access that will be allowed for particular document requesters via their computers 16 . For example, only certain document requesters having a particular digital signature or certain document requesters that can provide certain login information may be provided access to the DIL(s) 50 .
[0019] A given document requester computer 16 includes an interface for interfacing with document distribution system 12 and/or document information management system 14 . The interface may include, for example, a web browser, an application uniquely designed for access to those systems, or another type of interface. The interface may present, to the document requester, one or more document requester screens 70 as schematically shown in FIG. 2 . A schematic representation shown in FIG. 2 includes blocks representing the functions of various graphical tools presented to a document requester via one or more document requester screens. Those graphical tools include a document identifier tool 72 , access information tool 74 , a document access tool 76 , a DIL access tool 78 , and subscription notification access tool 80 . Document identifier tool 72 may include a graphical tool which allows the document requester to indicate the unique document identifier for which information is sought by the document requester. The document identifier graphical tool may be in the form of a free form field, an accessible list presenting to the document requester a list of available documents or available document information, and other fields or buttons allowing the document requester to indicate specific information about that document, such as, for example, the fact that the latest version of the document may be desired by the document requester.
[0020] The access information tool 74 may include a graphical tool for facilitating access to the document or to information, either via document distribution system 12 , or via document information management system 14 . That access information tool 74 may facilitate the input of login information by the document requester, or it may process additional signature information forwarded from the document requester computer 16 in connection with a particular request, or other interactions with the document requester computer or input by the document requester via the screen.
[0021] Document access tool 76 may include a graphical tool for allowing the document requester via a computer screen to specify information required to access the document itself. The document access tool 76 may include a search function which includes a field choice term input for searching for documents meeting certain criteria specified in that field choice term input. In addition, for example, document access tool 76 may allow the user to specify a URL which will take the document requester via the computer screen directly to the document via an HTTP redirect.
[0022] DIL access tool 78 may include a graphical tool to facilitate the document requester's interaction through one or more computer screens to cause secure or public (e.g., via a URL) access to document information within document information management system 14 , particularly, in one or more document information lists DILs 50 .
[0023] Subscription notification access tool 80 may include graphical tools to allow the document requester to input, for example, document parameters, an email address of the document requester, and other notification channels of the requester, through which notification information concerning events of the document can be sent.
[0024] FIG. 3 is a schematic diagram of a document file and/or a displayed or printed version of a document 90 . The illustrated document file and/or document 90 includes DIL information 92 . The DIL information 92 includes a unique document identifier 94 , a date of the document 96 , and the document information access location 98 . The document information access location may, for example, be in the form of a URL. The document information access location may specifically refer to the access route through which the appropriate DIL 50 may be located and accessed by the document requester.
[0025] FIG. 4 shows a flow chart of a portion of the process performed by a document processing application 100 . The document processing application may include, for example, a word processor. The acts shown in the flow chart in FIG. 4 pertain to document information list acts which may be included within the processing performed by a document processing application. Those acts include accessing DIL information at act 102 , which may be embedded within a given document. Upon obtaining the DIL information from a given document, in a next act 104 , the process accesses the appropriate DIL, and updates or populates the document state, content, version, and version date fields associated with that document within the document file or within other fields or overhead storage mechanisms used by the document processing application. In a next act 106 , the application may prompt the user to notify the user that there is a new version to the document that exists. In addition, or in the alternative, the application may prompt the user to alert the user that there is a need to separately obtain an available newer version of the document that is not available via the DIL or via a public link (e.g., URL).
[0026] The illustrated document distribution system 12 may be provided with a firewall, and access thereto may be limited to those entities which have, for example, a private key in accordance with the PKI infrastructure of such a system. One or more portions of document information management system 14 may be provided either inside of the firewall of system 12 or outside of that firewall.
[0027] The illustrated DILs 50 may each include software instantiated by or with document distribution system 12 . For example, each of the DILs 50 in operation with a given document distribution system 12 may be installed (and/or instantiated) at the time of installation of document distribution system 12 as part of that installation. Alternatively, each DIL 50 may be installed (and/or instantiated) subsequent to the installation of document distribution system 12 or a portion thereof, upon the selection of an option within document distribution system 12 software to provide for one or more DILs 50 , or to provide for an additional DIL 50 .
[0028] In accordance with one or more embodiments described above, a document information management system may be provided which allows for temporary document identification and location information. While the information provided within the document information list or lists can be permanent, the illustrated embodiments include expiration features including last date on DIL record as well as an expiration management mechanism. The expiration can be managed in order to increase security and reduce the risk that unauthorized persons will be able to obtain access to certain documents. Another benefit of the features and architecture described in the various embodiments includes the ease with which the system can be implemented.
[0029] The claims as originally presented, and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others. | Apparatus are provided including an information repository and an expiration mechanism. The information repository holds current document state information, and the expiration mechanism expires state information for certain documents in accordance with an expiration scheme. | 6 |
RELATED APPLICATIONS
This application, U.S. patent application Ser. No. 12/815,363 filed Jun. 14, 2010, is a continuation of U.S. patent application Ser. No. 12/151,467 filed on May 6, 2008 now U.S. Pat. No. 7,735,308.
U.S. patent application Ser. No. 12/151,467 is a continuation of U.S. patent application Ser. No. 11/599,817 filed on Nov. 14, 2006, now U.S. Pat. No. 7,367,176 which issued on May 6, 2008.
U.S. patent application Ser. No. 11/599,817 is a continuation of U.S. patent application Ser. No. 10/903,130 filed on Jul. 30, 2004, now U.S. Pat. No. 7,134,267 which issued on Nov. 14, 2006.
U.S. patent application Ser. No. 10/903,130 claims benefit of U.S. Provisional Application Ser. No. 60/530,132 filed on Dec. 16, 2003.
The contents of all applications/patents identified in this application are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to rope systems and methods and, in particular, to wrapped yarns that are combined to form strands for making ropes having predetermined surface characteristics.
BACKGROUND
The characteristics of a given type of rope determine whether that type of rope is suitable for a specific intended use. Rope characteristics include breaking strength, elongation, flexibility, weight, and surface characteristics such as abrasion resistance and coefficient of friction. The intended use of a rope will determine the acceptable range for each characteristic of the rope. The term “failure” as applied to rope will be used herein to refer to a rope being subjected to conditions beyond the acceptable range associated with at least one rope characteristic.
The present invention relates to ropes with improved surface characteristics, such as the ability to withstand abrasion or to provide a predetermined coefficient of friction. Typically, a length of rope is connected at first and second end locations to first and second structural members. Often, the rope is supported at one or more intermediate locations by intermediate structural surfaces between the first and second structural members. In the context of a ship, the intermediate surface may be formed by deck equipment such as a closed chock, roller chock, bollard or bit, staple, bullnose, or cleat.
When loads are applied to the rope, the rope is subjected to abrasion where connected to the first and second structural members and at any intermediate location in contact with an intermediate structural member. Abrasion and heat generated by the abrasion can create wear on the rope that can affect the performance of the rope and possibly lead to failure of the rope. In other situations, a rope designed primarily for strength may have a coefficient of friction that is too high or low for a given use. The need thus exists for improved ropes having improved surface characteristics, such as abrasion resistance or coefficient of friction; the need also exists for systems and methods for producing such ropes.
SUMMARY
The present invention may be embodied as a rope adapted to engage a structural member comprising a plurality of yarns, where at least one of the plurality of yarns is a blended yarn comprising a plurality of first fibers and a plurality of second fibers. Abrasion resistance properties of the blended yarn are greater than abrasion resistance properties of the first fibers. A coefficient of friction of the second fibers is greater than a coefficient of friction of the first fibers. The second fibers substantially define abrasion resistance and coefficient of friction characteristics of the blended yarn and the first fibers substantially extend along the length of the blended yarn and the second fibers do not extend along the length of the blended yarn. The first set of fibers of the blended yarn substantially bear tension loads on the blended yarn and at least a portion of the second fibers of the blended yarn are in contact with the structural member and substantially lie between the set of first fibers and the structural member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a side elevation view of a wrapped yarn that may be used to construct a rope of the present invention;
FIG. 1B is an end elevation cutaway view depicting the yarn of FIG. 1A ;
FIG. 2 is a side elevation view of a first example of a rope of the present invention;
FIG. 3 is a radial cross-section of the rope depicted in FIG. 2 ;
FIG. 4 is a close-up view of a portion of FIG. 3 ;
FIG. 5 is a side elevation view of a second example of a rope of the present invention;
FIG. 6 is a radial cross-section of the rope depicted in FIG. 5 ;
FIG. 7 is a close-up view of a portion of FIG. 6 ;
FIG. 8 is a side elevation view of a first example of a rope of the present invention;
FIG. 9 is a radial cross-section of the rope depicted in FIG. 8 ;
FIG. 10 is a close-up view of a portion of FIG. 9 ; and
FIG. 11 is a side elevation view of a first example of a rope of the to present invention;
FIG. 12 is a radial cross-section of the rope depicted in FIG. 8 ;
FIG. 13 is a close-up view of a portion of FIG. 9 ; and
FIG. 14 is a schematic diagram representing an example process of fabricating the yarn depicted in FIGS. 1A and 1B .
DETAILED DESCRIPTION
Referring initially to FIGS. 1A and 1B of the drawing, depicted therein is a blended yarn 20 constructed in accordance with, and embodying, the principles of the present invention. The blended yarn 20 comprises at least a first set 22 of fibers 24 and a second set 26 of fibers 28 .
The first and second fibers 24 and 28 are formed of first and second materials having first and second sets of operating characteristics, respectively. The first material is selected primarily to provide desirable tension load bearing characteristics, while the second material is selected primarily to provide desirable abrasion resistance characteristics.
In addition to abrasion resistance, the first and second sets of operating characteristics can be designed to improve other characteristics of the resulting rope structure. As another example, certain materials, such as HMPE, are very slick (low coefficient of friction). In a yarn consisting primarily of HMPE as the first set 22 for strength, adding polyester as the second set 26 provides the resulting yarn 20 with enhanced gripping ability (increased coefficient of friction) without significantly adversely affecting the strength of the yarn 20 .
The first and second sets 22 and 26 of fibers 24 and 28 are physically combined such the first set 22 of fibers 24 is at least partly surrounded by the second set 26 of fibers 28 . The first fibers 24 thus form a central portion or core that is primarily responsible for bearing tension loads. The second fibers 28 form a wrapping that at least partly surrounds the first fibers 24 to provide the rope yarn 20 with improved abrasion resistance.
The example first fibers 24 are continuous fibers that form what may be referred to as a yarn core. The example second fibers 28 are discontinuous fibers that may be referred to as slivers. The term “continuous” indicates that individual fibers extend along substantially the entire length of the rope, while the term “discontinuous” indicates that individual fibers do not extend along the entire length of the rope.
As will be described below, the first and second fibers 24 and 28 may be combined to form the example yarn using a wrapping process. The example yarn 20 may, however, be produced using process for combining fibers into yarns other than the wrapping process described below.
With the foregoing understanding of the basic construction and characteristics of the blended yarn 20 of the present invention in mind, the details of construction and composition of the blended yarn 20 will now be described.
The first material used to form the first fibers 24 may be any one or more materials selected from the following group of materials: HMPE, LCP, or PBO fibers. The second material used to form the second fibers 28 may be any one or more materials selected from the following group of materials: polyester, nylon, Aramid, LCP, and HMPE fibers.
The first and second fibers 24 and 28 may be the same size or either of the fibers 24 and 28 may be larger than the other. The first fibers 24 are depicted with a round cross-section and the second fibers 28 are depicted with a flattened cross-section in FIG. 1B for clarity. However, the cross-sectional shapes of the fibers 24 and 28 can take forms other than those depicted in FIG. 1B . The first fibers 24 are preferably generally circular. The second fibers 28 are preferably also generally circular.
The following discussion will describe several particular example ropes constructed in accordance with the principles of the present invention as generally discussed above.
First Rope Example
Referring now to FIGS. 2 , 3 , and 4 , those figures depict a first example of a rope 30 constructed in accordance with the principles of the present invention. As shown in FIG. 2 , the rope 30 comprises a rope core 32 and a rope jacket 34 . FIG. 2 also shows that the rope core 32 and rope jacket 34 comprise a plurality of strands 36 and 38 , respectively. FIG. 4 shows that the strands 36 and 38 comprise a plurality of yarns 40 and 42 and that the yarns 40 and 42 in turn each comprise a plurality of fibers 44 and 46 , respectively.
One or both of the example yarns 40 and 42 may be formed by a yarn such as the abrasion resistant yarn 20 described above. However, because the rope jacket 34 will be exposed to abrasion more than the rope core 32 , at least the yarn 42 used to form the strands 38 should be fabricated at least partly from the abrasion resistant yarn 20 described above.
The exemplary rope core 32 and rope jacket 34 are formed from the strands 36 and 38 using a braiding process. The example rope 30 is thus the type of rope referred to in the industry as a double-braided rope.
The strands 36 and 38 may be substantially identical in size and composition. Similarly, the yarns 40 and 42 may also be substantially identical in size and composition. However, strands and yarns of different sizes and compositions may be combined to form the rope core 32 and rope jacket 34 .
As described above, fibers 44 and 46 forming at least one of the yarns 40 and 42 are of two different types. In the yarn 40 of the example rope 30 , the fibers 44 are of a first type corresponding to the first fibers 24 and a second type corresponding to the second fibers 28 . Similarly, in the yarn 42 of the example rope 30 , the fibers 46 are of a first type corresponding to the first fibers 24 and a second type corresponding to the second fibers 28 .
Second Rope Example
Referring now to FIGS. 5 , 6 , and 7 , those figures depict a second example of a rope 50 constructed in accordance with the principles of the present invention. As perhaps best shown in FIG. 6 , the rope 50 comprises a plurality of strands 52 . FIG. 7 further illustrates that each of the strands 52 comprises a plurality of yarns 54 and that the yarns 54 in turn comprise a plurality of fibers 56 .
The example yarn 54 may be formed by a yarn such as the abrasion to resistant yarn 20 described above. In the yarn 54 of the example rope 50 , the fibers 56 are of a first type corresponding to the first fibers 24 and a second type corresponding to the second fibers 28 .
The strands 52 are formed by combining the yarns 54 using any one of a number of processes. The exemplary rope 50 is formed from the strands 52 using a braiding process. The example rope 50 is thus the type of rope referred to in the industry as a braided rope.
The strands 52 and yarns 54 forming the rope 50 may be substantially identical in size and composition. However, strands and yarns of different sizes and compositions may be combined to form the rope 50 . The first and second types of fibers combined to form the yarns 54 are different as described above with reference to the fibers 24 and 28 .
Third Rope Example
Referring now to FIGS. 8 , 9 , and 10 , those figures depict a third example of a rope 60 constructed in accordance with the principles of the present invention. As perhaps best shown in FIG. 9 , the rope 60 comprises a plurality of strands 62 . FIG. 10 further illustrates that each of the strands 62 in turn comprises a plurality of yarns 64 , respectively. The yarns 64 are in turn comprised of a plurality of fibers 66 .
The example yarn 64 may be formed by a yarn such as the abrasion resistant yarn 20 described above. The fibers 66 of at least some of the yarns 64 are of a first type and a second type, where the first and second types and correspond to the first and second fibers 24 and 28 , respectively.
The strands 62 are formed by combining the yarns 64 using any one of a number of processes. The exemplary rope 60 is formed from the strands 62 using a twisting process. The example rope 60 is thus the type of rope referred to in the industry as a twisted rope.
The strands 62 and yarns 64 forming the rope 60 may be substantially identical in size and composition. However, strands and yarns of different sizes and compositions may be combined to form the rope 60 . The first and second types of fibers are combined to form at least some of the yarns 64 are different as described above with reference to the fibers 24 and 28 .
Fourth Rope Example
Referring now to FIGS. 11 , 12 , and 13 , those figures depict a fourth example of a rope 70 constructed in accordance with the principles of the present invention. As perhaps best shown in FIG. 12 , the rope 70 comprises a plurality of strands 72 . FIG. 13 further illustrates that each of the strands 72 comprise a plurality of yarns 74 and that the yarns 74 in turn comprise a plurality of fibers 76 , respectively.
One or both of the example yarns 74 may be formed by a yarn such as the abrasion resistant yarn 20 described above. In particular, in the example yarns 74 of the example rope 70 , the fibers 76 are each of a first type corresponding to the first fibers 24 and a second type corresponding to the second fibers 28 .
The strands 72 are formed by combining the yarns 74 using any one of a number of processes. The exemplary rope 70 is formed from the strands 72 using a braiding process. The example rope 70 is thus the type of rope commonly referred to in the industry as a braided rope.
The strands 72 and yarns 74 forming the rope 70 may be substantially identical in size and composition. However, strands and yarns of different sizes and compositions may be combined to form the rope 70 . The first and second types of fibers are combined to form at least some of the yarns 74 are different as described above with reference to the fibers 24 and 28 .
Yarn Fabrication
Turning now to FIG. 14 of the drawing, depicted at 120 therein is an example system 120 for combining the first and second fibers 24 and 28 to form the example yarn 20 . The system 120 basically comprises a transfer duct 122 , a convergence duct 124 , a suction duct 126 , and a false-twisting device 128 . The first fiber 24 is passed between a pair of feed rolls 130 and into the convergence duct 124 . The second fiber 28 is initially passed through a pair of back rolls 142 , a pair of drafting aprons 144 , a pair of drafting rolls 146 , and into the transfer duct 122 .
The example first fibers 24 are continuous fibers that extend substantially the entire length of the example yarn 20 formed by the system 120 . The example second fibers 28 are slivers, or discontinuous fibers that do not extend the entire length of the example yarn 20 .
The second fibers 28 become airborne and are drawn into convergence duct 124 by the low pressure region within the suction duct 126 .
The first fibers 24 converge with each other and the airborne second fibers 28 within the convergence duct 124 . The first fibers 24 thus pick up the second fibers 28 . The first and second fibers 24 and 28 are then subsequently twisted by the false-twisting device 128 to form the yarn 20 . The twist is removed from the first fibers 24 of the yarn 20 as the yarn travels away from the false-twisting device 128 .
After the yarn 20 exits the false-twisting device 128 and the twist is removed, the yarn passes through let down rolls 150 and is taken up by a windup spool 152 . A windup roll 154 maintains tension of the yarn 20 on the windup spool 152 .
First Yarn Example
A first example of yarn 20 a that may be fabricated using the system 120 as described above comprises the following materials. The first fibers 24 are formed of HMPE fibers and the second fibers are formed of polyester fibers. The yarn 20 a of the first example comprises between about sixty to eighty percent by weight of the first fibers 24 and between about twenty to forty percent by weight of the second fibers 28 .
Second Yarn Example
A second example of yarn 20 b that may be fabricated using the system 120 as described above comprises the following materials. The first fibers 24 are formed of LCP fibers and the second fibers are formed of a combination of LCP fibers and Aramid fibers. The yarn 20 a of the first example comprises between about fifteen and thirty-five percent by weight of the first fibers 24 and between about sixty-five and eighty-five percent by weight of the second fibers 28 . More specifically, the second fibers 28 comprise between about forty and sixty percent by weight of LCP and between about forty and sixty percent by weight of Aramid.
Given the foregoing, it should be clear to one of ordinary skill in the art that the present invention may be embodied in other forms that fall within the scope of the present invention. | A rope comprising a plurality of yarns, where at least one of the plurality of yarns is a blended yarn comprising a plurality of first fibers and a plurality of second fibers. Abrasion resistance properties of the blended yarn are greater than abrasion resistance properties of the first fibers. A coefficient of friction of the first fibers is less than a coefficient of friction of the second fibers. The second fibers substantially define abrasion resistance and coefficient of friction characteristics of the at least one blended yarn. When the rope contacts a structural member, the first set of fibers of the at least one blended yarn substantially bear tension loads on the at least one blended yarn and at least a portion of the second fibers of the at least one blended yarn substantially lie between the set of first fibers and the structural member. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to a structure of gold bump for a semiconductor chip, and more particularly, to a patterned gold bump structure applied to a semiconductor chip.
BACKGROUND OF THE INVENTION
[0002] A conventional semiconductor chip 1 comprises a chip 25 , an insulating layer 23 , a plurality of aluminum (Al) pads 21 , and a plurality of gold bumps 10 as shown in FIG. 1 . The gold bumps 10 are formed respectively corresponding to the Al pads 21 . Each gold bump 10 is isolated from other gold bumps 10 . A novel structure of gold bumps 10 is thus disclosed by the applicant and could be served as a portion of the circuit design.
SUMMARY OF THE INVENTION
[0003] It is a primary object of the invention to provide a patterned gold bump structure, which can be used as a part of the circuit.
[0004] In accordance with the objects of the invention, a patterned gold bump structure for a semiconductor chip is provided. The structure comprises at least a patterned gold bump disposed on an insulating layer of a semiconductor chip, wherein the gold bump is used as a circuit component or a passing line. In some embodiments, the circuit component is a capacitor, a resistor, or an inductor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The foregoing aspects, as well as many of the attendant advantages and features of this invention will become more apparent by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0006] FIG. 1 shows a conventional gold bump structure disposed on a semiconductor chip;
[0007] FIG. 2 illustrates a patterned gold bump structure according to the first embodiment of the invention;
[0008] FIG. 3 illustrates a patterned gold bump structure according to the second embodiment of the invention;
[0009] FIG. 4 illustrates a patterned gold bump structure according to the third embodiment of the invention; and
[0010] FIG. 5 illustrates a patterned gold bump structure according to the fourth embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] FIG. 2 illustrates a patterned gold bump structure according to the first embodiment of the invention. The patterned gold bump structure is applied to a semiconductor chip 2 . The semiconductor chip 2 includes a chip 25 , an insulating layer 23 and a plurality of Al pads 21 . Optionally, traditional gold bumps 10 are disposed on the semiconductor chip 2 . In this embodiment, a plurality of patterned gold bumps 20 function as passing lines. The patterned gold bumps 20 are connected with one another as illustrated in shaded area of FIG. 2 . Since the patterned gold bumps 20 are conductive, they can serve as passing lines of signals. Furthermore, the patterned gold bumps 20 may be formed corresponding to the Al pads 21 on the semiconductor chip 2 .
[0012] The patterned gold bumps 20 are characteristic of low resistance, and therefore RC delays of the passing lines in critical paths, which are made from the patterned gold bumps 20 , are reduced. Accordingly, the patterned gold bumps 20 can be applied to the passing lines of high-frequency or care-timing signals, so as to enhance the performance of the integrated circuit (IC).
[0013] Because source driver IC has large volume and a rectangular form, IR drop of power passing lines in such IC is usually high. As a result, the pitch of the passing line is widened for low IR drop, and the area of source driver IC is occupied. Fortunately, the patterned gold bumps 20 of the invention can be used as portion of the power passing lines. The effective area of source driver IC is thus increased. Also, IR drop is decreased due to low resistance of the patterned gold bumps 20 , and the performance of source driver IC is improved.
[0014] The conventional method to fabricate power passing lines for electrostatic discharge (ESD) includes surrounding the outer area of source driver IC that is in the form of rectangle, such that ESD is not high. Hence, additional areas are deployed for thunder to increase ESD. Since the patterned gold bumps 20 can further serve as power passing lines for ESD, the space of source driver IC is saved and ESD is also increased. In the trend to develop IC with high pin counts, the aforementioned advantages are more apparent for such long IC because the patterned gold bumps 20 occupy less space and aid in increasing ESD.
[0015] Sometimes, more than one passing lines of source driver IC are required by the whole system. The common way to meet the requirement is to deploy the lines passing through the inner of IC, which wastes on the area thereof. Furthermore, the effective area of IC is decreased when passing lines are wider for low IR drop or RC delay. The area of IC can be utilized more efficiently by substituting the patterned gold bumps 20 for the traditional passing lines. Signal quality of the passing lines made from the patterned gold bumps 20 is also better.
[0016] Additionally, the patterned gold bumps 20 may serve as the auxiliaries of film drawing. For example, the patterned gold bump 20 is applicable when a pad of Function Pin A is positioned at location Y for connection of film but is desired to be positioned at location X for better performance of IC. Under the circumstances, the pad of Function Pin A is deployed at location X, while the passing line of the patterned gold bump 20 is pulled to location Y for connection of film.
[0017] The patterned gold bumps 20 of FIG. 2 further provide various designs for the inner circuit of the chip 25 . The inner circuit may be modified its function, for example, by connecting the patterned gold bumps 20 to high voltage pins or by shorting some of the patterned gold bumps 20 .
[0018] FIG. 3 illustrates a patterned gold bump structure according to the second embodiment of the invention. The semiconductor chip 2 includes a chip 25 , an insulating layer 23 and a plurality of Al pads 21 . Optionally, traditional gold bumps 10 are disposed on the semiconductor chip 2 . In this embodiment, a pair of patterned gold bumps 20 A and 20 B are disposed in parallel to form a capacitor as shown in the shaded part of FIG. 3 . Since the patterned gold bumps 20 A and 20 B are conductive, they can be used as a plate of the capacitor. For instance, a capacitor is composed of the patterned gold bumps 20 A, 20 B, and a dielectric layer disposed there-between. The pair of the patterned gold bumps 20 A and 20 B may be formed on an upper surface of the insulating layer 23 .
[0019] FIG. 4 illustrates a patterned gold bump structure according to the third embodiment of the invention. The semiconductor chip 2 includes a chip 25 , an insulating layer 23 and a plurality of Al pads 21 . Optionally, traditional gold bumps 10 are disposed on the semiconductor chip 2 . In this embodiment, a plurality of patterned gold bumps 20 serve as resistors as shown in shadows of FIG. 4 . The resistors are manufactured by, for example, forming the material of patterned gold bumps 20 containing resistant substances on the upper surface of the insulating layer 23 .
[0020] FIG. 5 illustrates a patterned gold bump structure according to the fourth embodiment of the invention. The semiconductor chip 2 includes a chip 25 , an insulating layer 23 and a plurality of Al pads 21 . Optionally, traditional gold bumps 10 are disposed on the semiconductor chip 2 . In this embodiment, a plurality of patterned gold bumps 20 are used as inductors. Because the patterned gold bumps 20 are conductive and include zigzag geometrical patterns, they can serve as inductors.
[0021] The aforementioned embodiments may be employed on the semiconductor chip 2 spontaneously. Therefore, those devices like capacitors, resistors or inductors are formed on the insulating layer 23 of the semiconductor chip 2 , and these devices are electrically connected with one another by means of the passing lines of the patterned gold bumps.
[0022] The patterned gold bump structure of the present invention can be used as a portion of circuits, which is different and superior to prior arts.
[0023] While the invention has been particularly shown and described with reference to the preferred embodiments thereof, these are, of course, merely examples to help clarify the invention and are not intended to limit the invention. It will be understood by those skilled in the art that various changes, modifications, and alterations in form and details may be made therein without departing from the spirit and scope of the invention, as set forth in the following claims. | A patterned gold bump structure for a semiconductor chip comprises at least a patterned gold bump disposed on an insulating layer of a semiconductor chip, wherein the gold bump is used as a circuit component or a passing line. In some embodiments, the circuit component is a capacitor, a resistor, or an inductor. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to an apparatus and method for the determination of concentrations of biological compounds, such as drugs and their metabolites, in vivo using microdialysis in combination with mass spectrometry.
Sepsis is a major problem in surgical critical care today. Infections, septic shock and multiple organ failure attributed to overwhelming sepsis are among the leading causes of complications, death and excessive financial burdens in tertiary surgical intensive care units. While surgical drainage and debridement techniques are often essential in control of sepsis, antibiotic infusions are usually relied upon as a cornerstone of therapy.
The development and availability of new drugs such as antibiotics and immunosuppressive agents have revolutionized the approach of modern medicine to the treatment of many conditions and diseases. The potency of many new antibiotics is extremely high and they are effective against many new resistant strains. Unfortunately, many of these drugs are also toxic to man and have deleterious effects on various organs and systems in the body. In addition, their metabolic fates can be complex, with some of the metabolites having strong physiological effects as well. This has resulted in many, if not most, critically ill patients being actually underdosed with regard to the antibiotic levels required for optimal inhibition of bacterial growth.
The determination of blood levels of these powerful new therapeutic agents and their metabolites is essential both in their clinical use and their use in the research laboratory. Methods which would allow such analyses in vivo and in real-time would be particularly advantageous in providing i) blood and/or tissue levels of patients during critical periods to maximize therapeutic value and minimize toxic effects, ii) tissue responses at specific sites in the body and in a time-course study, iii) verification of the presence and accumulation of intermediate metabolites which may have significant clinical implications, iv) improved quantification due to decreased sample handling losses and variable extraction efficiencies, and v) ease of use and time saving advantages because individual extraction, purification and derivatization steps are not required.
Modern mass spectrometric techniques, such as fast atom bombardment (FAB) mass spectrometry, offer unique analytical capabilities for quantification of drugs and their metabolites because they are effective in providing mass specific detection of compounds in complex mixtures derived from biological sources without the need for extraction and derivatization methods. However, samples for FAB analysis, for example, are typically prepared with high concentrations of glycerol or other suitable viscous liquids so that the samples remain in a liquid state during the introduction into the high vacuum chamber of the system throughout the analysis period. The presence of the added viscous liquid matrix results in several severe limitations including high background interfering solvent or matrix ion clusters, and relatively poor sensitivity.
SUMMARY OF THE INVENTION
In the disclosed embodiment, the present invention enjoys the advantage of FAB analysis without the above-mentioned disadvantages, by combining microdialysis with continuous flow fast atom bombardment (CF-FAB) to provide in vivo on line analysis of biological compounds, such as drugs and their metabolites. The microdialysis probe is implanted into a blood vessel or tissue of a live animal, and perfusate is passed through the probe and into a CF-FAB system. The invention can also be used to administer optimum doses of antibiotics, and the like, by adjusting an amount of drug being administered based on the CF-FAB analysis. Other mass spectrometric techniques are also usable in combination with microdialysis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the apparatus of the present invention being applied according to the method of the present invention to detect and control drug levels in a rat;
FIG. 2 is the microdialysis probe used in the present invention;
FIGS. 3A and 3B are graphs comparing the in vivo results of the present invention with in vitro results;
FIG. 4 is a graph comparing the results of the present invention with a known analysis technique.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the present invention applied to detect drug and metabolite levels in a rat is disclosed. It should be emphasized that the present apparatus and method can be applied to other animals, including humans. Microdialysis probe 11 is inserted inside a 22-gauge needle cannula (not shown) surgically placed in the jugular vein of a 330 gram Sprague Dawley male rat 12. A microliter syringe pump 13 is connected to microdialysis probe 11 by tube 14 and is used to controllably provide perfusate to microdialysis probe 11 through tube 14. Syringe pump 13 can be a Model 2274 pump available from the Harvard Apparatus Co., of Milford, Mass. In the preferred embodiment, the perfusate is 95% water and 5% glycerol provided at a rate of 4.8+/-0.2 microliters per minute.
The dialysate output from microdialysis probe 11 is connected through tube 16 to injection switch valve 17 which can be, for example, a Rheodyne Model 7410 injection switch valve. During collection, injection switch valve 17 is positioned so that dialysate passing through tube 16 passes through 20 microliter collection loop 18. Excess dialysate passes through waste tube 19 and is collected in waste container 21. Collection loop 18 may contain a trapping agent in order to purify and concentrate the biological compound of interest.
After dialysate is collected in collection loop 18 for approximately ten minutes, injection switch valve 17 is positioned so that the dialysate in collection loop 18 is forced into mass spectrometer 22 for approximately ten additional minutes with the aid of pump 23 and tubes 24 and 26, at a rate of approximately 4.6+/-1.8 microliters per minute. Pump 23 can be a Waters Model 590 HPLC pump.
Thus, the pharmacokinetic data is obtained through a series of collection/analysis cycles using sample collection loop 18 for a 20-minute total collection/analysis cycle time. Longer or shorter cycle times, or faster or slower perfusate and dialysate flow rates can be used without departing from the scope of the invention.
Mass spectrometer 22 is preferably a Finnigan MAT TSQ 70 mass spectrometer available from the Finnigan MAT Corp of San Jose, Calif. FAB mass spectrometer 22 includes a FAB gun 27 and a continuous flow FAB interface 28. The FAB ionization process gives rise to molecular (M+H) + or (M-H) - ions from all or most of the compounds in the continuously flowing sample. The molecular ion species of interest is selected by a first stage quadrupole 29 and is allowed to pass into collision region (second stage quadrupole) 31 where collision activated decomposition occurs as a result of collision of ions with argon gas admitted into region 31. The fragment ions produced in the collision activated decomposition process together with any surviving molecular ion species are then transmitted to third stage quadrupole 32 and then to ion detector 33 for detection and recording. The resulting mass spectrum 34 represents a specific fragment mass map of one specific molecular species which was selected by the first stage 29 of FAB mass spectrometer 22.
Automatic control of the administration of a drug can be accomplished by appropriately connecting the output of ion detector 33 to microliter syringe pump 35 which controls the rate of drug administration to rat 12 through tube 36. Pump 35 can also be a Model 2274 syringe pump available from Harvard Apparatus Co.
Referring now to FIG. 2, the details of microdialysis probe 11 used in the present invention are disclosed. Probe 11 includes an input tube 14 which is connected to an input portion of channel 10 of probe 11. Channel 10 of probe 11 includes perfusate channel 37, dialyzing membrane and channel 41. Perfusate flowing in tube 14 passes through perfusate channel 37 to the bottom portion 38 of probe 11. Perfusate then begins flowing upwardly in probe 11 past dialyzing membrane 39 and continues flowing upward through channel 41 and eventually exits probe 11 as dialysate through tube 16. When probe 11 is implanted in a blood vessel or tissue of a living animal, dialyzing membrane 39 acts to allow extraction of chemical substances from the living animal, without the removal of body fluids, through the process of diffusion of chemical substances from a relatively high concentration in the blood vessel or tissue to a relatively low concentration in the perfusate flowing in probe 11. The preferred source for microdialysis probe 11 is Bioanalytical Systems, Inc. of Lafayette, Ind.
FIG. 3A shows the negative ion mass spectrum of penicillin G taken during an in vivo test using the present invention of FIG. 1 approximately 1.5 hours after the administration of an intramuscular dose. The vertical axis of FIG. 3A is measured in units of relative intensity (intensity relative to the peak detected ion), and the horizontal axis is in units of mass-to-charge (m/z) ratio. The most intense ion at m/z 192 represents the major daughter ion of the parent (M-H) - ion. The proposed structure of this ion is: ##STR1##
Some surviving (M-H) - molecular ion can be seen at m/z 333. For comparison, FIG. 3B shows the same spectrum, with identical axes, taken from the direct injection of penicillin G in a physiological saline. As can be seen, the spectra match quite well.
The efficiency of transfer of a drug in blood and subsequent analysis of the dialysate using the present invention is dependent on a number of factors. These include the time of exposure of a drug, the rate of perfusion of the microdialysis device, and the total sampling time. To determine the efficiency of the analysis of penicillin G under the experimental conditions used in the in vivo studies, a 1 milliliter portion of saline solution containing 30 micrograms of penicillin G was analyzed with the microdialysis device using the flow-injection method of the invention. Peak areas produced by monitoring the fragment ion at m/z 192 were measured, giving an average of 1.85×10 5 ion counts for three measurements. These measurements were repeated using a 20 microliter sample of the same solution for a sample injection, eliminating the microdialysis step. The average of three measurements gave peak areas of 1.16×10 6 ion counts. Thus, for this protocol, the recovery was calculated to be 15.9%. This compares favorably with the literature provided by Bioanalytic Systems which shows an average recovery of a number of low molecular weight compounds of about 14% at a 4 microliter per minute perfusion rate.
The linearity of the response of the analytical procedure of the present invention was measured by analyzing saline solutions containing 5, 10 and 30 micrograms per milliliter of sodium penicillin G. A linear response was observed, with the correlation coefficient for a linear least squares fit being 0.9889. A signal-to-noise ratio of 3.15 was recorded for analyses of samples of the antibiotic containing 5 micrograms per milliliter.
FIG. 4 is a graph of an in vivo pharmacokinetic analysis using the present invention, compared with a prior art analytical technique.
A 330 gram rat was injected with a dose of 15 milligrams of sodium penicillin G dissolved in 0.3 milliliters of physiological saline solution. Negative ions were recorded in the mass spectrometric analysis of the dialysate in order to obtain maximum sensitivity. FIG. 4 shows the time-dependent rise and fall in the concentration of free drug (non-protein bound) in the rat following injection of the drug. The solid curve 42 was produced using a non-linear least squares fit of the data points shown obtained using the present invention. The drug peaked at a concentration of approximately 24 micrograms per milliliter at about 30 minutes. This peak-time is in good agreement with published data (The Pharmacological Basis of Therapeutics, fifth edition, MacMillan, (1975), p. 1130), which has reported the intramuscular administration of this antibiotic to peak in about 26-30 minutes, as shown by the broken curve 43 in FIG. 4.
A combination of microdialysis and mass spectrometry can be used in a wide variety of applications to provide on-line and direct monitoring of aqueous biological samples including in vivo drug monitoring. In addition, the present invention can be used as a fast and efficient method for simultaneously screening complex biological fluids for several low molecular weight compounds of interest since the molecular weight cut-off of the dialysis membrane used in the microdialysis probe of the present invention will preclude dialysis of proteins and other molecules above about 20,000 daltons. In addition, the present invention can also be used in a clinical laboratory for the direct analysis of body fluids, including the detection of illicit substances such as cocaine. Further, the present invention provides a simple and clean method to sample and monitor enzymic reactions, cell cultures, fermentation processes, or other batch processes where the compound of interest is within the mass and sensitivity range of modern mass spectrometers.
In addition, the present invention is particularly applicable to the continuous monitoring of antibiotic levels in infected tissue to indicate the degree of tissue antibiotic penetration, allowing appropriate therapeutic adjustments of the amount of antibiotic administered. Automatic control of the delivery of the drug using data supplied by the microdialysis/mass spectrometry of the present invention is also an important aspect. The monitored antibiotic levels are preferably maintained consistently above those levels necessary for bacterial growth inhibition, and below the toxic levels for the selected antibiotic, thereby enhancing the potential for an early resolution of the infectious process. | The present invention combines microdialysis with mass spectrometry, for example continuous flow fast atom bombardment, to follow the pharmacokinetics of drugs or other compounds directly in the blood stream or tissues of a live animal. After intramuscular injection of the drug, the blood dialysate from a microdialysis probe inserted into a blood vessel or tissue of the animal, is allowed to flow into the mass spectrometer via the continuous flow fast atom bombardment interface. Tandem mass spectrometry allows for isolating and recording the ion fragments produced from the drug as the dialysate is exposed to the ionization process. The detected concentration of the drug or other compounds of interest can be used to adjust the rate of administration of the drug. | 0 |
This is a section 371 application based on International Application No.: PCT/US02/13226, filed Apr. 26, 2002, which claims priority to U.S. Ser. No. 60/287,985 filed May 1, 2001.
FIELD OF THE INVENTION
The present invention relates to water reducing admixtures for hydratable cementitious compositions and to the resultant improved hydratable cementitious compositions, and more particularly to polycarboxylic acid type water reducing admixtures in combination with tertiary amine defoamers, as fully described hereinbelow.
BACKGROUND OF THE INVENTION
Hydratable (or hydraulic) cements, such as Portland cement, are useful in forming structural formations, such as building members, precast members and the like. These hydratable cements are mixed with aggregate to form mortars (cement, small aggregate, such as sand, and water) or concrete (cement, small aggregate, large aggregate, such as stone, and water) and structures made therefrom. It is highly desired to increase the flow (slump) properties of the initially formed hydratable cement composition to aid in placement of the composition and to extend the period of high flowability in order to provide working time to finish the placement of the structure. While extending the period of time that high slump is imparted to a cement composition, it is not desired to have the initial set time significantly delayed as such delay would disrupt the desired work schedule and delay completion of the structural formation.
Increased flowability can be attained by using large dosages of water in the hydrating cement composition. However, it is well known that the resultant cement based structure will have poor compressive strength and related properties which will make it unsuitable as a structural formation. Various additives have been proposed to increase the flowability to hydraulic cement compositions without increasing the water content of the initially formed composition. Such additives have been classified as “water reducing” admixtures or “superplasticizers,” and these include, for example, compounds such as naphthalene or melamine sulfonate formaldehyde condensates, lignin sulfonates and the like. In certain instances, the “water reducers” or “superplasticizers” have been used as a means of reducing the water to cement ratio in the composition (to enhance the strength of the resultant structure) without comprising flow properties.
More recently, copolymers of alkenyl ethers and acrylic acid or maleic anhydride, and derivatives thereof, have been proposed as agents suitable to enhance slump. See. e.g., Japanese Patent Publication (Kokai) Nos. 285140/88 and 163108/90. Further, copolymers formed from the copolymerization of hydroxy-terminated allyether and maleic anhydride or the allyether and a salt, ester or amide derivative of maleic anhydride such as disclosed in U.S. Pat. No. 4,471,100 have been proposed as cement admixtures capable of enhancing slump. Still further, U.S. Pat. No. 5,369,198 teaches the use of maleic acid derivatized polymers as a suitable water reducer.
In each of the above instances, the proposed cement admixture agents when used in a cement composition do not provide the desired combination of properties or only provide them in low degrees. For example, esterified acrylate copolymers, while providing good slump enhancement, also causes the treated cement composition to exhibit excessive set retardation In addition, it has been observed that polycarboxylates, such as described in U.S. Pat. No. 5,369,198, provide good slump but may introduce excessive amounts of air to the resultant structural formation Although a certain degree of intentionally entrained air in the form of microbubbles is desired to enhance freeze-thaw characteristics of the resultant structure, excessive air entrainment is not desired as it can cause reduction in the strength of the structure formed.
Various agents have been proposed to either enhance (air entrainers) or reduce (air detrainers) the air content produced by counteracting the effects other additives have on a particular cement composition. For example, in U.S. Pat. Nos. 5,665,158 and 5,725,657, Darwin et al. disclosed the use of oxyalkylene amine based defoaming agents for formulation with a copolymer of polycarboxylic acid and polyoxyalkylenes of the comb type variety. The general composition claimed was X 2 N(BO) z R, wherein X represented hydrogen, (BO) z R, or mixtures thereof, R represented hydrogen, a C 1 -C 10 alkyl group, or BNH 2 , B represented a C 2 -C 10 alkylene group, and z represented an integer from 5 to 200. An alkoxypolyoxyalkylene ammonium polymer was ionically attached to the carboxylate portion of the comb polymer backbone, so as to impart desired air controlling properties to the hydratable cementitious composition being treated.
In U.S. Pat. No. 6,139,623, Darwin et al. disclosed a combination having a superplasticizer comprising a polyacrylate comb polymer emulsified with an antifoaming agent selected from the group consisting of a composition having the formula (PO)(O—R) 3 wherein R is a C 2 -C 20 alkyl group, a phosphate ester, an alkyl ester, a borate ester, a silicone derivative, and EO/PO type defoamer; and a surfactant that was operative to stabilize the emulsified comb polymer and antifoaming agent. The surfactant was selected from the group consisting of (1) an esterified fatty acid ester of a carbohydrate selected from the group consisting of a sugar, sorbitan, a monosaccharide, a disaccharide, and a polysaccharide; and (2) a C 2 -C 20 alcohol having EO/PO groups.
Short of being attached directly to the superplasticizer polymer, conventional air detraining agents are not readily made compatible with the polycarboxylic acid type superplasticizers, or are not otherwise stable when added together in an aqueous solution. Separation of the polycarboxylate superplasticizers and defoamers can lead to inconsistent air contents in cementitious mixtures which hinders achievement of the desired result. While attempts have been made to achieve single compositions having the ability to enhance flowability without excessive air entrainment, many of these attempts have not generally produced the desired stability for extended periods.
Thus, it is highly desired to have a single, storage stable cement admixture that imparts a high degree of slump or maintains this degree of slump over an extended period of time when administered to a structural hydratable cement composition, while avoiding excessive set retardation and providing suitable air entrainment properties to the resultant hydraulic cement structure. It is desired to have a cement admixture capable of providing slump, set and air entrainment properties which are consistent over an extended period throughout manufacture, storage, shipping and job site storage, without having the problems of dissociation, separation and the like.
Thus, in view of the foregoing, the inventors believe that a novel water reducing admixtures (or “superplasticizer”) and defoaming agent system are needed for modifying hydratable cementitious compositions.
SUMMARY OF THE INVENTION
In surmounting the problems of the prior art, the present invention provides a water reducing admixtures with a tertiary amine defoamer having formulation stability and controllable air entrainment capabilities.
One objective of this invention is to overcome the occasional tendency of typical polycarboxylic acid polymer water reducing admixtures to entrain significant amounts of air in concrete, a tendency that sometimes decreases concrete strength and durability. Another objective is to overcome the problems of defoamers added during formulation and which, due to their hydrophobicity, can sometimes lead to formulations that are unstable in that they can experience phase separation within a few days.
An examplary admixture system of the invention comprises: (A) a water reducing admixtures, preferably one comprising a polycarboxylic acid or salt or derivative thereof, and (B) a tertiary amine defoamer represented by the structural formula R 1 NR 2 R 3 wherein R 1 is hydrophobic and represents a C 8 -C 25 group comprising a linear or branched alkyl, alkene, alkyne, alcohol, ester or oxyalkylene group (e.g., polyoxyalkylene) represented by the formula R 4 -(AO) n — or R 4 —(OA) n - wherein R 4 represents hydrogen or a C 1 to C 25 alkyl group, A represents a C 1 to C 6 alkyl group and “n” is an integer of 1 to 4; and R 2 and R 3 each represent a C 1 -C 6 group comprising a branched or linear alkyl, alkene, alkyne, alcohol, ester or oxyalkylene group (e.g., polyoxyalkylene) represented by the formulae R 4 -(AO) n — or R 4 —(OA) n - wherein R 4 represents hydrogen or a C 1 -C 25 alkyl group, A represents a C 1 to C 6 alkyl group, and “n” is an integer of 1 to 4; and wherein the average molecular weight of the tertiary amine defoamer is 100-1500 and more preferably 200-750. The water reducing admixture, preferably a comb polymer having pendant groups, may optionally contain air defoaming agents ionically bonded to the comb polymer.
The invention also pertains to hydratable cementitious compositions having the admixture system with the water reducing admixtures and tertiary amine defoamers described above, and methods for treating such compositions using the water reducing admixtures and tertiary amine defoamers combination.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The term “cement composition” as may be used herein refers to pastes, mortars, grouts such as oil well cementing grouts, and concrete compositions comprising a hydraulic cement binder. The terms “paste”, “mortar” and “concrete” are terms of art, pastes are mixtures composed of a hydraulic cement binder (usually, but not exclusively, Portland cement, masonry cement, or mortar cement and may also include limestone, hydrated lime, fly ash, blast furnace slag, and silica fume or other materials commonly included in such cements) and water; mortars are pastes additionally including fine aggregate, and concretes are mortars additionally including coarse aggregate. The cement compositions tested in this invention are formed by mixing required amounts of certain materials, e.g., a hydraulic cement, water, and fine or coarse aggregate, as may be applicable to make the particular cement composition being formed.
The term “admixture,” as used herein and in the appended claims, is a term of art referring to compounds and compositions added to cement mixtures or compositions to alter their properties. The term does not imply that the components of an admixture do or do not interact to cause the desired result. Admixtures are generally categorized as “water-reducing agents” if they are capable of modifying fluidity to a limited degree or as “high range water-reducing agents” (so-called “superplasticizers”) if they have the ability to permit large water cuts in the cement mixture while maintaining fluidity or cause large increases in fluidity at constant water content. The terms “water reducer” and “superplasticizer” may be used interchangeably throughout this specification and the claims, although those skilled in the concrete arts generally understand that a superplasticizer is a high range water reducer.
The term “polycarboxylic acid (or salt or derivative thereof)” as used herein refers to the type of water reducer/superplasticizer useful for dispersing cement particles within an aqueous cementitious slurry. Preferably, such water reducers also contain polyether groups, more particularly polyoxyalkylene groups. More preferably, such water reducers have a comb polymer structure wherein the polyether groups include repeating polyoxyalkylene groups located in the carbon-containing backbone and/or in the pendant groups (“teeth”) of the comb structure. Most preferred are comb polymers wherein the polyoxyalkylene groups, such as ethylene oxide and/or propylene oxide, are located in the pendant groups attached to the polymer backbone. Exemplary water reducers or superplasticizers of the invention should preferably have an average molecular weight in the range of 10,000-100,000 and more preferably 20,000-60,000.
Exemplary admixture systems of the invention are aqueous solutions comprising, in addition to dilution water, the following: (A) a water reducer, preferably one comprising a polycarboxylic acid or salt or derivative thereof, and more preferably comprising a comb polymer having a backbone to which are attached pendant cement anchoring groups and oxyalkylene members (See e.g., U.S. Pat. No. 5,393,343 of Darwin; U.S. Pat. No. 5,643,978 of Darwin et al.; U.S. Pat. No. 5,725,657 of Darwin et al.; and U.S. Pat. No. 5,665,158 of Darwin et al., incorporated by reference herein); and (B) a tertiary amine defoamer represented by the structural formula R 1 NR 2 R 3 wherein R 1 is hydrophobic and represents a C 8 -C 25 group comprising a linear or branched alkyl, alkene, alkyne, alcohol, ester or oxyalkylene group (e.g., polyoxyalkylene) represented by the formula R 4 -(AO) n — or R 4 —(OA) n - wherein R 4 represents hydrogen or a C 1 -C 25 alkyl group, A represents a C 1 to C 6 alkyl group and “n” is an integer of 1 to 4; and R 2 and R 3 each represent a C 1 -C 6 group comprising a branched or linear alkyl, alkene, alkyne, alcohol, ester or oxyalkylene group (e.g., polyoxyalkylene) represented by the formulae R 4 -(AO) n — or R 4 —(OA) n - wherein R 4 represents hydrogen or a C 1 -C 25 alkyl group, A represents a C 1 to C 6 alkyl group, and “n” is an integer of 1 to 4; and wherein the average molecular weight of the tertiary amine defoamer is 100-1500 and more preferably 200-750. The water reducing admixture, preferably a comb polymer having pendant groups, may optionally contain air defoaming agents ionically bonded to the comb polymer.
Further exemplary admixture systems of the invention, in addition to the water reducer and tertiary amine defoamer summarized above, further comprise an amine defoamer, such as taught in U.S. Pat. Nos. 5,665,158 and 5,725,657 of Darwin et al. wherein oxyalkylene amine based defoaming agents were ionically attached to the backbone of polycarboxylic acid polymers. The general composition for the amine defoamer is represented by the formula, X 2 N(BO) z R, wherein X represented hydrogen, (BO) z R, or mixtures thereof, R represented hydrogen, a C 1 -C 10 alkyl group, or BNH 2 , B represented a C 2 -C 10 alkylene group, and z represented an integer from 5 to 200. Therefore, further exemplary admixture systems comprise a water reducer and two different amine defoamers. An alkoxypolyoxyalkylene ammonium carboxylate was ionically attached to the comb polymer. In exemplary admixture systems which have this water reducer comb polymer and ionically attached carboxylate, the water reducer and tertiary amine should be combined in a ratio of about 10:1 to 1:10.
Exemplary water reducers can include those mentioned in the Background section above. Thus, water reducers suitable for use in the invention include comb type polymers (having pendant ethylene oxide/propylene oxide, or “EO/PO,” groups) and comprise acrylic polymers or copolymers thereof, which may be imidized, such as those taught in U.S. Pat. No. 5,393,343 assigned to W. R. Grace & Co.-Conn. (incorporated herein by reference). The polymer which may be imidized is an “acrylic polymer” (or which may alternatively referred to as a “polyacrylic polymer”) which refers to, for example, a homopolymer or copolymer of acrylic acid, methacrylic acid, their alkali metal salts, as well as their C 1 -C 30 alkyl esters. Additionally, the acrylic polymer reactant and the resultant imidized acrylic polymer may contain units derived from other singly and doubly ethylenically unsaturated monomers, such as styrene, alpha-methystyrene, sulfonated styrene, maleic acid, acrylonitrile, butadiene and the like. Such other ethylenically unsaturated monomer derived units, when present, can be present in the polymer in amount of up to about 20 (preferably, up to about 10) weight percent of the total polymer, provided that the resultant imidized acrylic polymer is water soluble.
An exemplary imidized acrylic polymer may be formed such as by reacting an acrylic polymer with ammonia or an alkoxylated amine. The amine reactant useful in forming the desired acrylic polymer can be selected from ammonia or an alkyl-terminated alkoxy amine represented by the formula:
H 2 N-(AO) n —R″
in which AO represents a C 2 -C 10 (preferably a C 2 -C 4 ) oxyalkylene group in which O represents an oxygen atom and A represents a C 2 -C 10 (preferably a C 2 -C 4 ) alkylene group; and R″ represents a C 1 -C 10 (preferably C 1 -C 4 ) alkyl group and n is an integer selected from 1 to 200 and preferably from 1 to 70. The reaction conditions and catalysts are generally known. See e.g., U.S. Pat. No. 5,393,343 at Columns 3-4.
An exemplary acrylic comb polymer, preferably one that is imidized, that is suitable for use as comb polymer in the present invention comprises a carbon containing backbone to which is attached groups shown by the following structures (I) and (II), and, optionally in further embodiments, additionally by structures (III) and/or (IV):
wherein each R independently represents a hydrogen atom or a methyl group (—CH 3 ) group; X represents hydrogen atom, a C 1 -C 10 alkyl group, R′ or an alkali or alkaline earth metal cation, an alkanolamine, or a mixture thereof; R′ represents a hydrogen atom or a C 2 -C 10 oxyalkylene group represented by (AO) n R″ in which O represents an oxygen atom, A represents a C 2 -C 10 alkylene group, R″ represents a C 1 -C 10 alkyl and n represents an integer of from 1-200, or mixtures thereof; and a, b, c, and d are numerical values representing molar percentage of the polymer's structure such that a is a value of about 50-70; the sum of c plus d is at least 2 to a value of (100−a) and is preferably from 3 to 10; and b is not more than (100−(a+c+d)). (This polymer may be made in accordance with U.S. Pat. No. 6,139,623 of Darwin et al.). The present inventors prefer that the value of a is 50-100, the sum of c plus d is zero to a value of (100−a), and b is no more than (100−(a+c+d)).
Another exemplary comb polymers suitable for use in the present invention comprise a copolymer of a polyoxyalkylene derivative as represented by the following formula (1) and maleic anhydride, a hydrolyzed product of the copolymer, or a salt of the hydrolyzed product:
wherein “Z” represents a residue of a compound having from 2 to 8 hydroxy groups; “AO” represents an oxyalkylene group having from 2 to 18 carbon atoms; “X” represents an unsaturated hydrocarbon group having from 2 to 5 carbon atoms; “R” represents a hydrocarbon group having from 1 to 40 carbon atoms; “a” represents 1 to 1,000; “l” represents 1 to 7, “m” represents 0 to 2; and “n” represents 1 to 7; “l”+“m”+“n”=2 to 8, “m”/(“l”+“n”) is less than or equal to ½, and “al”+“bm”+“cn” is equal to or greater than 1. The copolymer shown above is taught in U.S. Pat. No. 4,946,904, issued to Akimoto et al. (and assigned to NOF), which patent is incorporated by reference as if fully set forth herein.
Further exemplary comb polymer suitable for use in the present invention is disclosed in U.S. Pat. No. 5,369,198, owned by Chemie Linz Gessellshaft m.b.H., incorporated herein by reference. Such comb polymers are composed of the following structural elements:
whereby M represents H or a cation such as alkaline or a alkaline-earth metal, an ammonium group, or the residue of an organic amino group; R 1 represents C 1 to C 20 alkyl, C 5 to C 8 cycloalkyl or aryl group residue; R 2 represents H, C 1 to C 20 alkyl or hydroxyalkyl, C 5 to C 8 cycloalkyl or aryl group residue in which 1 or more H atoms can be substituted by the structural elements —COOM, —SO 3 M and/or PO 3 M 2 , as well as structural units of the General Formula (C m H 2m O) n R 1 , which optionally can be repeated; R 3 represents H, a methyl or methylene group which can be substituted if necessary and which forms a 5 to 8-member ring or an indene ring which includes R 5 ; R 4 represents H, a methyl or ethyl group; R 5 represents H, C 1 -C 20 alkyl, C 5 -C 8 cycloalkyl or aryl group residue, an alkoxy carbonyl group, an alkoxy group, an alkyl or aryl carboxylate group, a carboxylate group, a hydroxyalkoxy carbonyl group; m represents a whole number from 2 to 4; and n represents a whole number from 0-100, preferably from 1-20. Methods for making the aforementioned copolymer are provided in U.S. Pat. No. 5,369,198, incorporated herein by reference.
Another exemplary comb polymer suitable for use in the present invention comprises water-soluble linear copolymers of N-vinylamides with monomeric addition products of amines, amino acids, amino groups containing aromatic sulfonic acids, amino alcohols of maleic anhydride as well as maleic esters of polyoxyalkyleneglycols or their monoethers. One structural unit is represented by Formula (A) or by Formula (B); the other partial structure unit being represented by Formula (C):
wherein R 1 and R 2 , which may be the same or different, each represent hydrogen, a C 1 -C 20 alkyl residue which may optionally include alkali metal carboxylate or alkaline earth metal carboxylate groups, an aromatic group, an aliphatic or cycloaliphatic residue which may optionally include sulfonic acid groups or alkali metal sulfonate or alkaline earth metal sulfonate groups, a hydroxyalkyl group, preferably a hydroxy ethyl- or hydroxypropyl group, or may together with the nitrogen atom to which they are bound, form a morpholine ring; M represents a hydrogen ion, a monovalent or divalent metal ion or a substituted ammonium group; R represents a hydrogen atom or an alkyl group having 1 to 4 carbon atoms; p, q, and r are integers; a represents an integer ranging from 1 to 100; R 3 and R 4 which may be the same or different, each represent hydrogen, a C 1 to C 12 -alkyl residue, a phenyl residue, or may together form a di-, tri-, or tetramethylene group, which form with the inclusion of the residue of the formula:
a five, six, or seven membered ring; R 5 and R 6 which may be the same or different, each represent hydrogen, a C 1 to C 12 -alkyl residue or phenyl residue; and X represents hydrogen, a C 1 to C 4 -alkyl residue, a carboxylic acid group, or an alkali metal carboxylate group. Such copolymer is known and taught in U.S. Pat. No. 5,100,984 issued to Burge et al., and assigned to Sika AG, which patent is incorporated fully by reference as if set forth herein.
Further known water reducers of the polycarboxylate variety are believed to be suitable for use in the present invention, for example those disclosed in U.S. Pat. No. 4,471,100 of Tsubakimoto et al.; U.S. Pat. No. 4,589,995 of Fukumoto et al.; U.S. Pat. No. 4,870,120 of Tsubakimoto et al.; European Patent No. 0753488A2 (U.S. Pat. No. 6,187,841) of Tanaka et al.; U.S. Pat. No. 5,661,206 of Tanaka et al.; and U.S. Pat. No. 6,214,958 B1 of Bi Le-Khac et al., which are all incorporated fully herein by reference.
An exemplary water reducer was disclosed in U.S. Pat. No. 4,471,100 (owned by Nippon Shokubai KK), wherein Tsubakimoto et al. disclosed a copolymer represented by the general formula I:
wherein, A denotes an alkylene group of 2 to 4 carbon atoms, a denotes an integer of the value of 1 to 100, the subunit —CH 2 —O-(-A-O—) a- H comprises a plurality of oxyalkylene segments having a randomly provided number of carbon atoms in the alkylene moiety, R 1 and R 2 independently denote hydrogen atoms or a methyl group, X and Y independently denote a monovalent metal atom, a divalent alkaline earth metal atom, ammonium group, an organic amine group or (—B—O)— b R 3 (wherein, B denotes an alkylene group of 2 to 4 carbon atoms, b denotes O or an integer of the value of 1 to 100, and R 3 denotes a hydrogen atom or an alkyl group of 1 to 20 carbon atoms), the sub unit —(B—O—) b comprises a plurality of oxyalkylene segments having a randomly provided number of carbon atoms in the alkylene moiety, Z denotes a structural unit derived from a copolymerizable vinyl monomer, m and n each denote 1 where X and Y are each a monovalent metal atom, an ammonium group, an organic amine group or (—B—O—) b R 3 , or 2 where X and Y are each a divalent metal atom, and p, q and r denote numbers such that 25<=p<=75, 25<=q<=75, and 0<=r<=50 are satisfied on condition that p+q+r equals 100, and it is provided that the structural units involved herein may be bonded in any possible order.
The copolymer represented by the general formula I described above is manufactured by copolymerizing: (p) moles, i.e. 25 to 75 moles of a polyalkylene glycol monoallyl ether represented by the general formula II:
wherein, A, a and CH 2 —O-A-O— a are as defined above, (q) moles i.e. 25 to 75 moles of a maleic acid type monomer represented by the general formula III:
wherein, R 1 , R 2 , X, Y, m and n are as defined above, and (r) moles i.e. 0 to 50 moles of a vinyl monomer copolymerizable with the monomers mentioned above (providing that the total of the moles of the moles of p, q and r is 100 moles), in the presence of a polymerization initiator.
An exemplary water reducer was disclosed in U.S. Pat. No. 4,589,995 (owned by Kao Corp.), wherein Fukumoto et al. disclosed a maleic acid copolymer which comprises repeating structural units of the formula (I):
wherein OR represents an oxyalkylene group of 2 or 3 carbon atoms and n represents an integer of from 1 to 50, and repeating structural units of the formula (II):
wherein X and Y each represent hydrogen, an alkali metal, an alkaline earth metal, an ammonium group or an organic amino group, wherein the molar ratio of the total number of units of formula (I) to that of units of formula (II) ranges from 5/100 to 50/100, and the number average molecular weight is from 400 to 20,000.
Still another exemplary water reducer was disclosed in U.S. Pat. No. 4,870,120 (owned by Nippon Shokubai), wherein Tsubakimoto et al. disclosed a water reducer (otherwise referred to as a “cement dispersant”) having as a main component thereof at least one polymer selected from the group consisting of water soluble polymers obtained from (A) 1 to 99 mol % of a sulfonic acid type monomer represented by the formula I:
wherein R stands for hydrogen atom or methyl group, X stands for hydrogen atom, a monovalent metallic atom, a divalent metallic atom, ammonium group, or an organic amine group, A and B independently stand for an alkylene group of 2 to 4 carbon atoms, m stands for 0 or an integer of the value of 1 to 100, and the alkylene oxide group of 2 to 4 carbon atoms in the portion, (AO) m , may be bound in any desired sequence, and (B) 99 to 1 mol % of other monomer copolymerizable with the sulfonic acid type monomer, and polymers obtained by neutralizing the aforementioned polymers with an alkaline substance.
Another exemplary water reducing admixture was disclosed in European Patent 073488A2 and U.S. Pat. No. 6,187,841 B1 (owned by MBT Holding Ag, wherein Tanka et al. disclosed cement dispersant comprising as a main component a polycarboxylic acid type polymer (A) or salt thereof, wherein the polymer (A) has a weight average molecular weight in the range of 10,000 to 500,000 in terms of polyethylene glycol determined by gel permeation chromatography, and has a value determined by subtracting the peak top molecular weight from the weight average molecular weight in the range of 0 to 8,000; the polycarboxylic acid type polymer (A) is obtained by copolymerizing: 5 to 98% by weight of an (alkoxy)polyalkylene glycol mono(meth)acrylic ester monomer (a) represented by the following general formula (1):
wherein R 1 is a hydrogen atom or a methyl group, R 2 O is one species or a mixture of two or more species of an oxyalkylene group having 2 to 4 carbon atoms, wherein when R 2 O is a mixture of two or more species of oxyalkylene group having 2 to 4 carbon atoms, (R 2 O) m is a block or random copolymer, R 3 is a hydrogen atom or an alkyl group of 1 to 5 carbon atoms, and m is the average addition mol number of oxyalkylene groups which is an integer in the range of 1 to 100; 95 to 2% by weight of a (meth)acrylic acid monomer (b) represented by the following general formula (2):
wherein R 4 is a hydrogen atom or a methyl group and M 1 is a hydrogen atom, a monovalent metal atom, a divalent metal atom, an ammonium group, or an organic amine group; 0 to 50% by weight of a monomer (c) which is different than (a) and (b) wherein said monomer (c) is selected from the group consisting of esters of aliphatic alcohols of 1 to 20 carbon atoms with (meth)acrylic acid, unsaturated dicarboxylic acids, unsaturated amides, aromatic vinyls and unsaturated sulfonic acids, and which is copolymerizable with (a) and (b); wherein the total amount of (a), (b) and (c) is 100% by weight.
Another exemplary water reducing admixture was disclosed in U.S. Pat. No. 5,661,206 owned by MBT Holding AG and Nippon Shokubai Co., wherein Tanaka et al. disclosed a “fluidity-controlling admixture” for cementitious compositions comprising an aqueous solution of a polymer, the polymer formed by polymerizing a monomer mixture in the presence of at least one oxyalkylene-based defoaming agent, said monomer mixture comprising (a) 5-98% by weight of an (alkoxy)polyalkylene glycol mono(meth)acrylic acid ester monomer of formula (I)
wherein R 1 and R 2 are independently hydrogen or methyl, R 3 is an alkylene group of from 2-4 carbon atoms, R 4 is hydrogen or an alkyl group of from 1 to 22 carbon atoms, and m represents an integer of 1 to 100, (b) 2 to 95% by weight of a (meth)acrylic acid based monomer of formula (II)
wherein R 1 and R 2 have the meanings given above, and M 1 is hydrogen, a monovalent metal, a divalent metal, an ammonium group or an organic amine group, and (c) 0 to 50% by weight of a monomer capable of being copolymerized with monomers (a) and (b), provided that the sum of (a), (b) and (c) shall be 100% by weight, said oxyalkylene-based defoaming agent selected from the group consisting of (poly)oxyalkylenes, (poly)oxyalkylene alkyl ethers, oxyethylene and oxypropylene adducts of high alcohols of 12 to 14 carbon atoms, polyoxyalkylene(alkyl)aryl ethers, acetylene ethers of alkylene oxide additionally polymerized with acetylene alcohols, (poly)oxyalkylene aliphatic acid esters, (poly)oxyalkylene (alkyl)aryl ether sulfuric acid esters, (poly)oxyalkylene alkyl phosphates, (poly)oxyalkylene sorbitan aliphatic acid esters and (poly)oxyalkylene alkylamines, said defoaming agent being either dissolved in the polymer solution or stably dispersed therein in particles of no more than 20 μM diameter.
Also disclosed in U.S. Pat. No. 5,661,206 was a polymer formed by polymerizing a monomer mixture in the presence of at least one oxyalkylene-based defoaming agent, said monomer mixture comprising (a) 5-98% by weight of an (alkoxy)polyalkylene glycol mono(meth)allyl ether based monomer of formula (III)
wherein R 1 and R 2 are independently hydrogen or methyl, R 3 is an alkylene group of from 2-4 carbon atoms, R 4 is hydrogen or an alkyl group of from 1 to 22 carbon atoms, m represents an integer of 1 to 100, and n is 0 or 1; (b) 2 to 95% by weight of an ethylenically Unsaturated carboxylic acid based monomer of formula (IV)
wherein X and Y are independently selected from hydrogen, methyl and —COOM 3 or X and Y together with —COOM 2 form an anhydride ring, Z is selected from —CH 2 , COOM 3 , hydrogen or methyl, and M 2 and M 3 are independently selected from hydrogen, monovalent metal, divalent metal, an ammonium group, an organic amine group, an alkyl group of 1-20 carbon atoms, an alkylene glycol of 2-4 carbon atoms and a polyalkylene glycol of from 2-100 moles of glycol adduct, provided that a least one of M 2 and M 3 is selected from hydrogen, monovalent metal, divalent metal, ammonium group and an organic amine group, and (c) 0 to 50% by weight of a monomer capable of being copolymerized with monomers (a) and (b), provided that the sum of (a), (b) and (c) shall be 100% by weight, said oxyalkylene-based defoaming agent selected from the group consisting of (poly)oxyalkylenes, (poly)oxyalkylene alkyl ethers, oxyethylene and oxypropylene adducts of high alcohols of 12 to 14 carbon atoms, polyoxyalkylene(alkyl)aryl ethers, acetylene ethers of alkylene oxide additionally polymerized with acetylene alcohols, (poly)oxyalkylene aliphatic acid esters, (poly)oxyalkylene (alkyl)aryl ether sulfuric acid esters, (poly)oxyalkylene alkyl phosphates, (poly)oxyalkylene sorbitan aliphatic acid esters and (poly)oxyalkylene alkylamines, said defoaming agent being either dissolved in the polymer solution or stably dispersed therein in particles of no more than 20 μM diameter.
As mentioned above, an exemplary tertiary amine defoamer of the invention is represented by the formula R 1 NR 2 R 3 wherein R 1 is hydrophobic and represents a C 8 -C 25 group comprising a linear or branched alkyl, alkene, alkyne, alcohol, ester or oxyalkylene group, the oxyalkylene group having the chemical structure R 4 -(AO) n — or R 4 —(OA) n - wherein R 4 represents hydrogen or a C 1 -C 25 alkyl group, A represents a C 1 to C 6 alkyl group and “n” is an integer of 1 to 4; and R 2 and R 3 each represent a C 1 -C 6 group comprising a linear or branched alkyl, alkene, alkyne, alcohol, ester or oxyalkylene group, the oxyalkylene group having the chemical structure R 4 -(AO) n — or R 4 —(OA) n - wherein R 4 represents hydrogen or a C 1 -C 25 alkyl group, A represents a C 1 to C 6 alkyl group, and “n” is an integer of 1 to 4; wherein said average molecular weight of said tertiary amine defoamer is 100 to 1500 and more preferably 200-750.
In further exemplary defoamers of the invention, the groups represented by R 1 , R 2 , or R 3 may comprise alkyl, alkene, alkyne, alcohol, ester, or oxyalkylene (e.g., polyoxyalkylene) groups which are linear or branched. In further exemplary defoamers, R 1 represents a polyoxyalkylene group wherein said A comprises a C 3 -C 4 branched alkyl group, and “n” is an integer of 2-4. In still further exemplary defoamers, R 1 is preferably a long chain (linear or branched) alkyl group, preferably having 14-20 carbons, and R 2 and/or R 3 , and preferably both are alkyl and/or alcohol groups, and more preferably branched alkyl groups and/or alcohol groups (e.g., such as propanol or tertiary butyl). More particularly, exemplary tertiary amine defoamers of the invention may comprise tallowalkyliminobispropanol, dodecyldimethylamine, octadecyldimethylamine, oleyldimethylamine, cocoalkyliminobispropanol, oleyliminobispropanol, tallowalkyldimethylamine, oleyldimethylamine, cocoalkyldimethylamine, soyaalkyldimethylamine, dicocoalkylmethylamine, tridodecylamine, or mixtures thereof.
In particularly preferred defoamers, none of R 1 , R 2 , or R 3 represent hydrogen.
In exemplary admixtures of the invention the water reducer and tertiary amine defoamer are present together in a ratio no less than 9:1 and in a ratio no more than 200:1, and more preferably 11:1 to 100:1, and most preferably 15:1 to 50:1.
The present invention is also directed to hydratable cementitious compositions, comprising: a hydratable cementitious binder such as Portland cement (optionally with fine aggregate and/or coarse aggregate); and the aforementioned combination of water reducer and tertiary amine defoamer, which is preferably combined with the cement binder after during addition of hydration water, and preferably as one premixed component. The present invention is also directed to methods for modifying a hydratable cementitious composition, comprising introducing the water reducer and tertiary amine defoamer to a hydratable cementitious binder, with optional fine and/or coarse aggregates.
The present invention can be further appreciated in view of the following examples, which are provided for illustrative purposes only.
EXAMPLE 1
A sample of polyethylene-polypropylene oxide polymer with a molecular weight of 2000 (80 g) was charged into a round bottom flask purged with argon. The sample was heated and stirred. At 80 degress C., a sample polyacrylic acid with a molecular weight of 5000 in 50% aqueous solution (40 g) was added. The mixture was heated to 180 degrees C. Water contained in the polyacrylic acid and formed during the condensation reaction were collected in a DEAN-STARK condenser. The mixture was reacted at 180 degrees C. for one hour.
EXAMPLE 2
The polymer product of Example 1 above was introduced into water to form a 35% wt percent aqueous solution. Tertiary amines as described below were introduced into separate samples of the solution in various dosages (as weight percent based on polymer in solution). The tertiary amines were:
(a) Tallowalkyliminobispropanol;
(b) Dodecyldimethylamine;
(c) Octadecyldimethylamine; and
(d) Oleyldimethylamine.
Each of the solutions were stirred for 0.5 hours at ambient temperature and the pH of final solution was 4-4.5. The resultant solutions were stored at ambient conditions for 60 days without showing any phase separation. The ammonium salt polymers formed according to Example 2 above were each tested as part of an ordinary Portland cement mortar for slump and air as outline below. The sand/cement/water ratio of 2.5/1/0.38 was used. The mortar was mixed in a Hobart mixer for 9 min. The dosage of the polymer was 0.13% based on solid polymer to solid cement (solids on solids “s/s”) in the mortar. Results were presented in Table 1 below.
TABLE 1
Amine (wt. %
Slump
Air (vol %) at
Air (vol %) at
Example
of polymer)
(mm)
9 min
30 min
2a
1.43
2.6
7.1
2a
2.86
1.7
2.7
2a
5.71
2.1
1.9
2b
5.71
112
5.2
2c
5.71
116
4.8
2d
1.43
114
5.3
6.7
2d
2.51
112
4.2
5.8
2d
2.86
113
4.4
4.5
2d
5.71
111
3.6
4.3
1
0
116
18.6
EXAMPLE 3
The polymer product of Example 1 above was introduced into water to form a 35% wt percent aqueous solution. Primary and quaternary amines as described below were introduced into separate samples of the solution in various dosages (as weight percent based on polymer in solution). The primary and quaternary amines were:
a) Dodecylamine b) Octadecylamine c) Polyoxypropylene terminated with primary amine group (MW=2000) d) Decyltrimethyl ammonium chloride e) Tallowalkyltrimethyl chloride
Each of the solutions were stirred for 0.5 hours at ambient temperature and the pH of final solution was 4-4.5. The resultant solutions were stored at ambient conditions for 60 days without showing any phase separation. Table 2 shows the mortar slump and air results, tested in the same procedure as described in Example 2.
TABLE 2
Primary
Amine (wt. %
Slump
Air (vol %) at
Air (vol %) at
amine
of polymer)
(mm)
9 min
30 min
3a
5.71
127
20.5
3b
6.71
122
19.2
3c
1.43
4.6
6.4
3c
2.51
4.5
4.7
3c
5.71
4.0
3.9
3d
11.4
104
11.8
3e
11.4
108
15.6
1
0
116
18.6
EXAMPLE 4
To provide a water reducer and primary amine/tertiary amine system of the invention, wherein these amines are both ionically attached to the water reducer, one may first make a 35% wt aqueous solution of the polymer product of Example 1 and combine a primary amine, such as polyoxypropylene terminated with primary amine group (MW=2000), with a tertiary amine, such as tallowalkyliminobispropanol. The ratio of primary amine to tertiary amine should preferably be about 1:10 to 10:1, and the total amount of amines should be about 0.5-6% wt based on the water reducer. The solutions should be stirred for 0.5 hours at ambient temperature, and the pH of final solution is expected to be around 4-4.5. It is expected that the resultant solutions may be stored at ambient conditions for 60 days without showing any phase separation.
EXAMPLE 5
An exemplary water reducer/tertiary amine of the present invention may also be made by combining in flask a tertiary amine, such as tallowalkyliminobispropanol, with a water reducing polymer made in accordance with U.S. Pat. No. 4,471,100. This patent describes the making of the. polymer as follows: A reactor made of glass and provided with a thermometer, a stirrer, a dropping funnel and a gas tube was charged with 334 parts of polyethylene glycol monoallyl ether (containing an average of five ethylene oxide units per molecule) and 100 parts of water. The mixture in the reactor was stirred and the air in the reactor was displaced with nitrogen. The stirred mixture was heated to 95° C. under a blanket of nitrogen gas. Then, an aqueous solution obtained by dissolving 139.3 parts of maleic acid and 14.2 parts of ammonium persulfate in 225 parts of water was added to the reactor over a period of 120 minutes. After the end of this addition, 14.2 parts of a 20-percent aqueous ammonium persulfate solution were added thereto over a period of 20 minutes. For 100 minutes after the end of the second addition, the interior of the reactor was held at 95° C. to bring the polymerization to completion. Subsequently, the polymerization system was neutralized by addition of a 40-percent aqueous sodium hydroxide solution to produce an aqueous solution of a copolymer (1). The resultant polymer may be combined with tallowalkyliminobispropanol in solution wherein the tertiary amine is present at 0.5-6.0% by weight based on the polymer. The solutions should be stirred for 0.5 hours at ambient temperature, and the pH of final solution is expected to be around 4-4.5. It is expected that the resultant solutions may be stored at ambient conditions for 60 days without showing any phase separation.
The foregoing examples provided for illustrative purposes only and are not intended to limit the scope of the invention. | An exemplary admixture system for cementitious compositions, comprises a polycarboxylic acid type water reducer and a tertiary amine defoamer having an average molecular weight of 100-1500 and more preferably 200-750. The defoamer permits a stable admixture formulation and helps to achieve a controllable level of entrained air in a concrete mix. Cementitious compositions and methods for modifying the same, using the tertiary amine defoamers, are also described herein. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a method of exploiting deep set, porphyry ore bodies by in situ mining techniques.
Large deep-lying deposits of copper and nickel in the form of low grade prophyry ores are known to be located throughout various regions of the globe. A porphyry deposit is one in which the copper, nickel or uranium bearing minerals occur in disseminated grains or in veinlets through a large volume of rock such as shist, silicated limestone, or volcanic rock. Acid igneous intrusive rocks are usually in close association. The deposits are typically large tonnage but low grade and have an average copper, nickel and uranium concentration of less than about a 1% total. Minerals found in these deposits are usually sulfides, of these, chalcopyrite is the most common. There are also deep-seated deposits which contain discrete blebs containing copper, copper sulfide, or copper-nickel sulfide in association with ion sulfide. In many ores of this type, significant quantities of zeolites, layered silicates, and clay such as the type known as montmorillonite are present. These minerals are present as deposits located in or about the natural microscopic fracture openings of the rock.
In the method of in-situ mining disclosed in U.S. Pat. No. 4,116,488 to Hsueh et al, an access well is drilled to communicate with the ore body and several recovery wells are provided, spaced apart from the access well. The leaching interval, i.e., the volume of rock through which leaching fluids flow between the access and recovery wells, is then subjected to fluids such as oxygen which oxidize the copper and nickel sulfides or chalcopyrite to sulfates. Thereafter, or in some cases simultaneously, an aqueous ammoniacal leach liquor is injected into the access well which, in passing through the leaching interval and contacting the metal sulfates, leaches the metal values as nickel and copper-ammonia complex ions. The leaching fluids may be injected in the form of a two-phase lixiviant, i.e., oxygen bubbles dispersed in an ammoniacal leach liquor, or may be passed sequentially through the leaching interval. One advantage of this technique is that the rock need not be fractured by explosive methods prior to leaching. Instead, the fluids used are forced through the natural fracture openings present in the rock, which typically range in the diameter between about 30 and 300 microns.
For the most efficient use of the lixiviant, it should pass rather uniformly through the leaching interval, so that its potency is not squandered on a few highly permeable passages. Igneous rock does have permeability variations, however, that cause non-uniform flow of the lixiviant through the leaching interval.
An igneous rock deposit having a permeability of 1 to 5 md may be economically mined by the in-situ method, but in such a deposit rock zones having a permeability of 25 to 50 md represent thief zones-zones of relatively high permeability that accept inordinately high amounts of lixiviant to the detriment of the over-all efficient use of the lixiviant in the process.
One technique that has been used in the petroleum industry to smooth flow involves impairing thief zones with solid particles, so that they cannot accept lixiviant so readily. However, utilizing solid particles small enough to fit into the pores of rock having a permeability of 25 to 50 md is not practical.
Furthermore, when the wellbore injection interval is several thousand feet, it can be very time-consuming and expensive to use a preliminary liquid solution to separately treat short intervals of variable permeability.
During such in situ mining efforts, the presence of clays, zeolites, and layered silicates in or about the fracture openings present problems which heretofore significantly diminished the economic feasibility of this type of process. Such minerals absorb copper and nickel as well as other ions such as uranium ions by ion exchange and are capable of taking up as much as 1.5 milliequivalents of copper per gram of ion exchanger. In practice, this uptake of metal represents perhaps as much as 25% of the total metal leached, and thus leads to significantly reduced metal recoveries. It has been discovered that the copper, nickel and uranium ions are sorbed by an in situ ion exchange process wherein calcium or other ions naturally present in the mineral are exchanged for copper, nickel or uranium ions or ammonia complexed ions such as Cu(NH 3 ) 4 ++ or Cu(NH 3 ) 3 OH + . The presence of the clays, e.g., montmorillonite clays, such as Fuller's earth and bentonite, and other absorptive minerals thus cause the uptake of significant quantities of solubilized metal values which would otherwise be recoverable.
In addition to this complication, the presence of these minerals seriously inhibits the rate at which leach liquors may be pumped through a leaching interval during in-situ mining. Also, calcium and other ions are introduced into the lixiviant thereby complicating copper, nickel and uranium recovery at the surface plant. Obviously, whether such deposits can be economically exploited hinges on whether methods can be devised which maximize metal yield, minimize reagent costs, and overcome the problems set forth above.
SUMMARY OF THE INVENTION
The invention provides a staged process for recovering copper, nickel and uranium from deep-set (typically below 1000 feet in depth) porphyry ore bodies utilizing in situ techniques. The process involves five distinct stages: thief zone plugging; permeability stimulation; priming; a steady-state metal recovery stage; and a termination stage. Each stage of the process is designed to deal with the rather unique problems associated with the type of ore body discussed above. Advantageously, no rubblization step wherein the ore is fractured by explosives is required but, of course, may be used if desired.
At the outset, an injection well and, typically, several recovery wells are drilled to provide communication between the surface of the earth and the ore body. The volume of rock between the injection well and the recovery wells defines the leaching interval. To reduce thief zones, a polymeric solution is injected along the entire wellbore of the injection well. The solution contains macromolecules with molecular weights in the order of 5 million. The polymeric solution may be introduced along with the lixiviant.
In the next stage of the process, the permeability of the leaching interval is stimulated by passing an aqueous solution of ammonia and a chloride or preferably a nitrate salt of sodium, potassium, and/or ammonium therethrough. The purpose of this stage is to ion exchange Na + , K + , or NH 4 + ions for Ca +2 ions in the clay and other minerals in the ore to produce a more compact structure and to increase the void volume of the natural rock fractures present in leaching interval. Usually, Ca ++ is the displaced ion. Nitrate is the preferred anion because Ca(NO 3 ) 2 is highly water soluble, and as such, can be removed, thereby permanently increasing the permeability of the leaching interval.
In the next stage, the leaching interval is primed with an oxygen containing gas and an ammonium salt solution containing a calcium sulfate scale inhibitor. This stage flushes calcium ions from the leaching interval which may be removed in a surface facility. A relatively high NH 4 + concentration is maintained so that minerals present in the leaching interval which can absorb copper, nickel and uranium ions instead take up ammonium ions. The oxygen containing gas oxidizes the copper, nickel or uranium sulfides or iron sulfides to render the metal values leachable. The oxidation also results in the formation of sulfate, and to this end a scale inhibitor such as a polyacrylate inhibitor, Calnox® 214, or other known scale inhibitor is included in the priming fluids to inhibit the deposition of calcium sulfate phases.
In the steady state metal recovery stage a two-phase lixiviant is passed through the leaching interval. The lixiviant is designed so that copper, nickel, uranium and other ions are liberated from the ore and then solubilized in the aqueous phase. The nature and concentration of the reagents in the aqueous phase are selected so that a pH low enough to avoid zeolite formation is maintained and metal absorption is kept at a minimum. Under these circumstances, a scale inhibitor is no longer needed. Copper, nickel and uranium (or other metals such as cobalt and molybdenum) are recovered by conventional techniques from the pregnant liquor collected from the production well, and the metal barren raffinate may be reconstituted and reinjected.
In the last stage of the process, a filler solution such as 5% brine is injected into the leaching interval to displace the last of the valuable ammonia and metal value solution.
Accordingly, it is an object of the invention to provide a method for producing more uniform flow of lixiviant through a leaching interval of varying permeability.
Another object of the invention to provide a process for increasing the permeability of porphyry rock of the type containing clays having cations available for ion exchange.
Another object of the invention is to contract calcium montmorillonite clay, in-situ, by ion exchange using ammonium ions, potassium ions, sodium ions, or mixtures thereof, and to shrink or contract sodium montmorillonite by contacting it with ammonium ions, potassium ions, or mixtures thereof.
Another object of the invention is to decrease the characteristic resistance to fluid flow of porphyry rock ore bodies containing clays.
Yet other objects of the invention are to decrease metal uptake by minerals present in ore bodies capable of undergoing ion exchange with copper, nickel or uranium and to provide a procedure whereby the amount of copper, nickel or uranium recoverable from an ore body by in-situ mining techniques may be increased.
Still another object of the invention is to provide a process for in-situ mining of copper, nickel, cobalt, molybdenum and uranium wherein the concentration of metal values in the pregnant solution recovered is more or less uniform throughout the duration of a steady-state metal recovery stage.
Another object is to increase the yield per unit cost in in situ mining of metal such as copper, nickel, cobalt, molybdenum and uranium.
These and other objects and features of the invention will be apparent to those skilled in the art from the following description of some preferred embodiments and from the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates the operation of an in situ mine during the steady-state metal recovery stage of the invention;
FIG. 2 is a graph showing the effects of a scale inhibitor; and
FIG. 3 is another graph showing the effects of a scale inhibitor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The process of the invention is useful in exploiting porphyry ore deposits containing sulfidic copper, nickel, cobalt, molybdenum, uranium and other metal values. These are permeated by a multiplicity of natural fracture openings which provide a pathway through which leaching or other fluids may be forced under hydraulic pressure. In or about the fracture openings, copper nickel and uranium containing minerals such as chalcopyrite, chalcocite, diginite, covellite, pentlandite, heazlewoodite, vaesite, and violarite are present. Unfortunately, these deposits are also characterized by the presence of clays such as bentonites and montmorillonites, naturally occurring zeolites such as stilbite and laumontite, clinoptilolite, and other minerals or biotites and sericites. An example of such a deposit is the ore body located near Safford, Ariz., and is known as Safford rock. The clay, zeolite and biotite components of Safford rock take up copper in the ammine form and in the process become purple. Estimates from ore samples of the clay content of such rock ranges up to about 5%, but averages 1% to 2%. These and other clay-like minerals found in the porphyry formations present unique problems of permeability and loss of reagent and/or metal ion product.
In accordance with the invention, one or more access wells and one or more recovery wells are provided to the ore body. The volume between the access well and recovery wells defines a leaching interval. Typically, a plurality of access wells and recovery wells are drilled in a five-spot pattern wherein each access well is surrounded by four recovery wells. Core samples are taken from the ore body, and these are used to determine optiminum reagent concentrations for the various stages of exploitation as set forth below. If desired, thief zones may be plugged with macromolecules although this step is optional. In the next stage, the permeability of the leaching interval is stimulated and the deposit is preconditioned with scale inhibitor. In a following stage, the leaching interval is primed. In another stage, metal bearing pregnant liquor is recovered over an extended period wherein conditions in the leaching interval are in steady state, and in a fourth stage, a filler solution containing inexpensive reagents is used to displace the last of the valuable in situ solutions. These steps are effected by forcing the various fluids through the leaching interval under pressure. Equipment suitable for use in the process is disclosed, for example, in U.S. Pat. No. 4,116,488, Sept. 26, 1978, to Hsueh et al., the disclosure of which is incorporated herein by reference. Each stage of the process will now be discussed in detail.
Thief Zone Plugging
As stated above, high permeability thief zones may be plugged with macromolecules in order to even out the permeability of the leaching interval. This step may be performed as a first step or may be performed along with the addition of the lixiviant. Of course, if high permeability thief zones are not a problem, then this step may be eliminated completely. A macromolecule that is suitable for plugging high permeability thief zones is one sold by Dow Chemical under their designation DOWELL J-250. This is a polyacrylamide solution. This solution is employed to plug pores with sizes ranging from 0.025 to 14 microns. The molecular weight of the polyacrylamide is about 7 million.
This solution should be utilized in a system having a pH within the range of 7 to 11. The pH of the normal ammoniacal lixiviant used in in-situ mining is around 10. At this point, it should be noted that the use of such macromolecules to plug high permeability thief zones is a technique which has been utilized in the petroleum industry; and thus, forms no part of the invention per se.
Permeability Stimulation
Porphyry rock ore bodies frequently contain inorganic ion exchangers of high exchange capacity (approximately 100-150 meq per 100 grams). It has been discovered that certain of these exchangers, notably montmorillonite clays, may be transformed to a more compact structure if they are treated with certain ions capable of exchanging with the cations naturally present in the clays, typically calcium. As a result of such treatment, the natural resistance to fluid flow of the porphyry ore bodies is significantly decreased, and the rate at which in-situ mining procedures may be conducted increased, i.e., the rate at which fluids may be passed through the leaching interval is increased. An aqueous solution containing a cation such as ammonium, potassium, or sodium, contacts the leaching interval through the injection well, and the cations of the solution are exchanged with the sodium or calcium cations in the clay to induce clay contraction. The preferred anion is nitrate, although chlorides may also be used. Use of nitrate salts results in the solubilization of liberated calcium, which may be removed from the solutions initially collected from the recovery wells.
The basic concept of the stimulation stage of the process is to replace one type of ion in the clay with another to induce clay contraction. Thus, if, as in the typical case, the clay contains a significant amount of calcium ion, then sodium, potassium, or ammonium ions are used to displace the calcium ions and thereby to contract the clay. It has been found that potassium ions and ammonium ions produce about the same effect; thus, either of these ions may be used to replace calcium ions and sodium ions. Of course, ammonium ions are preferred because of their lower molar cost.
As a result of permeability stimulation procedures such as those described above, the rate at which fluids can be pumped into a leaching interval at a given surface pressure is significantly increased, often about seven fold.
Numerous tests have been conducted to determine the effect of injecting aqueous solutions containing various cations into porphyry ore bodies, and a variety of clays have been subjected to X-ray diffraction procedures to determine their lattice spacings before and after treatment with various ion exchange solutions. These tests have shown, inter alia, that ammonia, if present in the solution used to stimulate permeability, potentials the in situ ion exchange reaction. Calcium ion is released in most instances. Since a certain amount of sulfate ion will be naturally present in the porphyry rock, it is often advantageous to include a scale inhibitor in the solution, e.g., at a concentration on the order of 400 ppm, to inhibit the deposition of calcium sulfate phases as anhydrite, bassenite and gypsum in the deposit and production equipment.
The permeability stimulation stage will be further understood from the following non-limiting examples.
EXAMPLE I
Samples of bentonite, a natural montmorillonite, were obtained from the American Colloid Company, and their structure was verified by comparing their X-ray diffraction spectra with authentic samples of natural bentonite obtained from core samples of a porphyry rock ore body located near Safford, Ariz. These samples were slurried with test ion exchange solutions at room temperature, filtered, and their basal spacing was determined using an X-ray diffractometer. The results of these experiments are summarized in Table I.
TABLE I______________________________________Relative Volume of Montmorillonitesat Room Temperature Relative d(001), AU Volume______________________________________montmorillonite 18.3 ± 0.3 100montmorillonite 16.1 ± 0.2 86montmorillonite 15.77 84montmorillonite 13.27 71montmorillonite/3M NH.sub.3 12.66 69______________________________________
As indicated by the data in Table I, the basal spacing of the montmorillonite is strongly dependent on the composition of the fluid with which it is equilibrated. The exact origin of this effect is unknown, although it is hypothsized that it is due to ion exchange substitution. Alternatively, the behavior may be caused by alteration of the degree of hydration of the clays with different cation substitutions. As can be seen from the data in Table I, the lattice spacing of Ca-montmorillonite is greater than that of the other cation-substituted montmorillonites tested. Because much of the montmorillonite clay naturally present in prophyry rocks of the type described is in the calcium form, significant increases in permeability may be effected by ion exchange with hydrogen, sodium, potassium, or ammonium cations, the latter being present together with NH 3 . However, because of the presence of acid consuming minerals such as calcite in the ore body, acid solutions cannot be economically employed. When the clay is present in the sodium form, the addition of an aqueous solution containing sodium ions will, of course, have no effect on the volume of the clay. A solution containing calcium ions will actually swell the clay and increase resistance to fluid flow through the ore body. Accordingly, potassium or ammonium ions must be used to accomplish the desired effect when (if ever) sodium clays are the only type present.
EXAMPLE II
The effects of equilibrating ammonium salts and aqueous ammonia with calcium montmorillonite are set forth in Table II. The calcium montmorillonite was obtained by suspending bentonite in a 10% aqueous solution of CaCl 2 for several days, resulting in calcium ions exchanging for the sodium ions present. The calcium clays produced in this manner were suspended in the various solutions set forth below to effect equilibration, and the lattice spacings of the species formed were measured.
TABLE II______________________________________Ion Exchange Effects on Ca-Montmorillonite Amount Vol- d(100), of ume of Species De- Species Produced creaseSample (AU) (%) (%)______________________________________1. Untreated Ca montmorillonite 18.8 (100) --2. a. 3M NH.sub.4 Cl 15.4 90 20 12.6 10 -- b. 3M NH.sub.4 Cl/1M NH.sub.3 15.5 76 21 12.6 24 c. 3M NH.sub.4 Cl/6M NH.sub.3 12.6 100 333. a. 1.5M (NH.sub.4).sub.2 SO.sub.4 15.4 88 20 12.6 12 b. 1.5M (NH.sub.4).sub.2 SO.sub.4 /1M NH(3) 15.4 68 23 12.6 32 c. 1.5M (NH.sub.4).sub.2 SO.sub.4 /6M NH.sub.3 12.6 100 334. a. 3M NH.sub.4 NO.sub.3 15.7 100 17 b. 3M NH.sub.4 NO.sub.3 /1M NH.sub.3 15.5 76 21 12.6 245. a. 1M NH.sub.3 19.2 91 2 15.6 9 b. 3M NH.sub.3 15.6 100 17 c. 6M NH.sub.3 15.6 100 17______________________________________
As can be seen from the data in Table II, equilibrating the Ca-clay with ammonium salts produced two separate species of montmorillonite: one having about a 15.5 AU basal spacing, the other having a much smaller 12.6 AU spacing. Only the 15.5 A species was produced by NH 4 NO 3 , and the 15.5 AU species was the predominant one produced by pure NH 4 Cl and (NH 4 ) 2 SO 4 salts. This 15.5 AU species can also be produced by equilibrating the calcium clay with 3-6 M ammonia (samples 5 a, b, and c). Advantageously, as can be seen from the data, solutions containing both ammonia and ammonium salts tend to increase the amount of the 12.6 AU species produced. As the concentration of the ammonia approaches 6 M, there is a tendency for the clay to be converted to the 12.6 AU species, and a volume decrease approaching 33% is produced. This example illustrates the potentiating effect observed when NH 3 is combined with an ammonium salt.
EXAMPLE III
The ion exchange effects of equilibrating sodium montmorillonite with various ammonium salts is illustrated in Table III as set forth below. The data in this example were collected in the manner set forth in Example II, except that Na-montmorillonite was used as a starting material.
TABLE III______________________________________Ion Exchange Effects on Na-Montmorillonite d(001), Amount of Volume Au of Species DecreaseSample species (90%) (%)______________________________________Na-Montmorillonite,untreated 15.8 (100) --Na-Montmorilloniteequilibratedwith:1. a. 2M NH.sub.4 NO.sub.3 /0.1M NH.sub.3 15.1 62 10 12.7 38 b. H.sub.2 O 15.4 70 6 12.5 302. a. 3M NH.sub.4 NO.sub.3 /0.1M NH.sub.3 13.8 51 16 12.7 49 b. 3M NH.sub.4 NO.sub.3 /1M NH.sub.3 12.6 100 203. 2M NH.sub.4 NO.sub.3 /1M NH.sub.3 12.9 100 184 a. 1.5M(NH.sub.4).sub.2 SO.sub.4 15.4 94 3 b. 1.5M(NH.sub.4).sub.2 SO.sub.4 /1M NH.sub.3 15.5 72 7 12.6 28 c. 1.5M(NH.sub.4).sub.2 SO.sub.4 /6M NH.sub.3 12.6 100 205. 1M NH.sub.3 15.6 50 11 12.6 50______________________________________
As can be seen from the data in Table III, ammonia alone causes an 11% decrease in the volume of the sodium clay and produces about equal amounts of the two species. The sodium clay can be completely converted to the 12.6 A species in ammoniacal ammonium nitrate, ammonium sulfate, or ammonium chloride solutions. (see 2b and 4c).
EXAMPLE IV
The data in Table IV, as set forth below, were obtained by sequentially equilibrating bentonite samples with the indicated solutions for about one hour each. These data illustrate that the changes in the basal spacing of the clay are reversible.
TABLE IV______________________________________Demonstration of Reversibility of Change in BasalSpacing of BentoniteSequence Solution d(001), Au______________________________________Sample 1 a 1M NH.sub.3 /3M NH.sub.4 NO.sub.3 12.58 b 10% KCl 13.38 c 1M NH.sub.3 /3M NH.sub.4 NO.sub.3 12.62 d 10% KCl 13.10Sample 2 a 10% CaCl.sub.2 18.67 b 1M NH.sub.3 /3M NH.sub.4 NO.sub.3 12.73 c 10% CaCl.sub.2 18.43 d 1M NH.sub.3 /3M NH.sub.4 NO.sub.3 12.80Sample 3 a 1M NH.sub.3 /3M NH.sub.4 NO.sub.3 12.62 b 10% NaCl 15.77 c 1M NH.sub.3 /3M NH.sub.4 NO.sub.3 12.62 d 10% NaCl 15.77Sample 4 a 1M H.sub.2 SO.sub.4 18.95 b 3M NH.sub.4 NH.sub.3 /1M NH.sub.3 12.99 c 1M H.sub.2 SO.sub.4 15.85 d 3M NH.sub.4 NH.sub.3 /1M NH.sub.3 12.86 e 1M H.sub.2 SO.sub.4 15.82Sample 5 a 10% (NH.sub.4).sub.2 SO.sub.4 15.52 b 10% HCl 16.05 c 10% (NH.sub.4).sub.2 SO.sub.4 15.74______________________________________
From the data disclosed above, there is a suggestion that the prehistory of a calcium clay may influence the ease with which the basal spacing can be changed. For example, the calcium clays in Table II were prepared by treating bentonite with calcium chloride for several days, and a solution comprising 3 M NH 4 + and about 6 M NH 3 was required to completely convert this clay to the 12.6 A species. On the other hand, the calcium clays of Table IV were prepared by treating bentonite with calcium chloride for a period of only one hour. This material could be completely converted to 12.6 A species by treatment with 3 M NH 4 + solution containing only 1 M NH 3 . Accordingly, the optimum concentration of the ion exchange solution should be determined from core samples prior to injection.
EXAMPLE V
The effects of miscellaneous additional solutions on bentonite are summarized in Table V set forth below. It should be noted that acidic cupric solutions produce a basal spacing slightly greater than that of the naturally occuring calcium clay. In any event, acidic reagents cannot be economically employed to leach the metal values because of the presence of acid consuming minerals in these formations. It can be further seen from Table V that acids such as are used to stimulate oil wells are not effective for increasing the permeability of the ore bodies of the type disclosed, especially those containing the sodium form of the montmorillonite clay. Ammoniacal cupric solutions (sample 3) are absorbed and collapse the clay almost as much as ammoniacal ammonium salt solutions. This observation is an important consideration in the subsequent priming stage described below.
TABLE V______________________________________Effect of Various Equilibration Solutionson the Specific Volume of BentoniteSample Solution d(001), AU______________________________________1. Bentonite 1M CuCl.sub.2 /1gpl HCl 19.42. Bentonite 1M Cu(NO.sub.3)/Trace HNO.sub.3 19.33. Bentonite 0.03M CuSO.sub.4 /1M NH.sub.3 13.184. Bentonite 6 gpl Fe/7gpl Al/4 gpl Mg as sulfates pH = 2 19.95. Bentonite 10% CaCl.sub.2 18.96. Bentonite 10% KCl 13.37. Bentonite 10% HCl 16.18. Bentonite 1M H.sub.2 SO.sub.4 15.99. Bentonite untreated 15.8______________________________________
From the foregoing, it can be appreciated that Na + , K + , and NH 4 + solutions, especially when potentiated by the presence of NH 3 , are effective in increasing the permeability of porphyry ore bodies. If the anion in these solutions is nitrate or chloride, the released Ca ++ ion will be solubilized, and can be removed at the surface plant by conventional techniques.
Priming Stage
The purpose of the priming stage is to begin the release of copper, nickel, cobalt, molybdenum, uranium and other metals from the porphyry ore and to suppress the uptake of these metal values by the ion absorbing clays and other minerals present in the leaching interval discussed above.
In accordance with the invention, it has been discovered that ammonium ions present in ammonium salt solutions can be induced to be taken up by metal absorbing minerals preferentially to copper, nickel, uranium and other metal ions. Therefore, it is possible to suppress metal uptake by subjecting the leaching interval to treatment with an ammonium ion containing solution, preferably of high concentration, to saturate the absorption sites. This step, in cooperation with the steady-state metal recovery step set forth below, significantly increases yield.
Thus, oxygen gas, a scale inhibitor, and an aqueous solution containing an ammonium salt, e.g., (NH 4 ) 2 SO 4 , NH 4 NO 3 , or NH 4 Cl, is pumped through an access wall into the leaching interval and forced into contact with the clay minerals. It has been determined by experiment that ion exchange is effected rapidly and that various concentrations of the ammonium ion, ranging generally between about 0.2 M and about 7 M, but preferably at least about 1.0 M, are effective to inhibit uptake of metal ions by the clays. The preferred concentration of ammonium ions is 3 M. During this process, only minimal amounts of metal ions are leached since ammonia is not available in abundance for complexing. A calcium rich solution is displaced from the leaching interval. To inhibit the precipitation of one of the many forms of calcium sulfate, a scale inhibitor such as a polyacrylate is included in the solution. One suitable scale inhibitor has a molecular weight of 250 to 10,000 and has an equivalent weight of 150 or less. A suitable polyacrylate scale inhibitor is one sold by Aquaness Chemical Company under the trade name CALNOX® 214. At the outset, inhibitor concentrations in the injected fluids on the order of 400 ppm are required. Thereafter, concentrations can be reduced to maintain on the order of 5-50 ppm in the produced fluids. Subsequently, in the steady state metal recovery stage, a two phase lixiviant comprising oxygen bubbles and an ammoniacal leach liquor or a quantity of oxygen followed by an ammoniacal leach liquor is injected into the leaching interval. In this situation, even the first samples of pregnant liquor recovered during the steadystate stage contain a concentration of copper, nickel and uranium which is normally characteristic of samples taken much later in the leach.
Suppression of metal exchange on montmorillonite clays by the process of the invention renders the rock capable of holding only about 0.01% Cu (20 lb/ton rock) as an exchanged species in contrast to the 0.1% Cu uptake of untreated rock.
To optimize the effect of this procedure, the length of the priming stage may be estimated by percolating a solution of 0.25 M (NH 4 ) 2 SO 4 , 0.6 M NH 3 , and 0.05 M CuSO 4 through a column containing 300 g of minus five mesh crushed core samples characteristic of the leaching interval. The amount of copper sorbed (tons copper/million tons of ore), if divided by twice the projected copper production rate (tons copper/year/million tons of ore) results in a useful estimated length of the priming period. The ammonium ion concentration required may be estimated by measuring the amount of ammonium sorbed per unit mass of ore during the percolation experiment and distributing one-half of this amount, extrapolated to be required by the total mass of the leaching interval, uniformly through the entire volume of solution injected during priming. This volume may be estimated as the product of the injection rate and the estimated length of the priming period. In an appropriate case, ammonia may be included in the priming solution near the end of the priming period to aid in the solubilization of metal values. A typical ammonium ion concentration for use in priming is 3-6 M. The pH of the ammonia containing solution should be maintained below a pH of around 10.2. Above this pH mineral alteration takes place with the production of zeolite-like minerals capable of removing copper and other metals from solution as illustrated in Example VI.
EXAMPLE VI
Effect of high pH upon the formation of copper containing zealite-like minerals.
Rock cubes from the deposit were treated with 3 M NH 6 OH-0.14 M (NH 4 ) 2 SO 4 at 90° C. and 1850 psi O 2 for 3-5 months. On opening the autoclave, a blue deposit had formed on the cube surfaces and also upon the autoclave walls. This phase was shown by chemical analysis to contain copper and shown by X-ray diffraction to resemble the natural zeolite known as phillipsite. Thus, a portion of the leached copper had been reprecipitated and thus became unobtainable.
One way of controlling the pH is to ensure an ammonium ion concentration of at least 0.5 M and preferably of at least 1 M.
Keeping the ammonia level to below 1 M also contributes in keeping the pH value down to below 10.2.
A large number of experiments have been conducted in order to demonstrate the feasibility of this stage of the process of the invention. One of the materials used in these experiments was air purified montmorillonite obtained from American Colloid Company, the exchangeable ion in this material being predominantly sodium. The exchangeable ion in many naturally occurring montmorillonites is predominantly calcium with minor amounts of potassium. However, as noted above, it has been observed that the sodium species is readily converted into the calcium or potassium species, and that this conversion may be reversed by equilibrating the montmorillonite in salt solutions containing the desired ion. In other experiments, various authentic ore samples were tested. As a general rule, the ion exchange process on montmorillonites, either as naturally present in the rock or purified, is quite rapid, only a few minutes being needed for attainment of equilibrium. However, in all experiments, equilibrium was assured by at least a 24 hour exposure to the various solutions.
EXAMPLE VII
Comparison of Cu Uptake on Porphyry Rock Samples
60 grams of 8-12 mm fragments of several types of rock known to be present in porphyry ore bodies were subjected to equilibration with 25 ml aqueous solutions containing 1 M NH 3 , 0.5 M (NH 4 ) 2 SO 4 , and either 4 gpl or 1 gpl solubilized copper. The duration of the treatment and the temperature maintained were varied. The results of these experiments, expressed as milliequivalents (meg) of copper removed from solution per 100 g of rock, are set forth below in Table VII.
TABLE VII______________________________________ Time at Copper Uptake Tem- (meq/100 g) perature 4 gpl copper 1 gpl copper______________________________________Rock Sample (days) 90° C. 50° C. 90° C. 50° C.Safford, Arizona 6 1.36 1.40 0.74 0.52(Andesite) 14 1.40 0.85 0.52Ray, Arizona 4 2.30 2.10 0.91 0.75(Diabase) 11 2.60 2.50 0.96 0.87 75° C. 75° C.Bingham, Utah 4 1.51 0.66(Biotite-Granite) 18 1.76 0.93 43 1.76______________________________________
As can be seen from the data in Table VII, copper uptake from ammoniacal solution is a general characteristic of copper porphyry rock fragments. Uptake varies with cupric ion concentration. Temperature dependency is not apparent from the 4 gpl data, but is evident from the 1 gpl data. A small increase in copper uptake with temperature could be due to increased interaction between chalcopyrite and cupric solutions.
EXAMPLE VIII
Effect of [NH 4 + ] on Copper Uptake On Clay
Two gram samples of air purified bentonite were equilibrated at 25° C. with 20 ml 1 M NH 4 OH initially containing 2 gpl Cu and varying concentrations of NH 4 NO 3 . The amount of copper taken up by the clay is set forth in Table VIII. It is evident that copper loss from solution decreases with increasing ammonium ion concentration.
TABLE VIII______________________________________Ammonium IonConcentration Copper Uptake(M) (Meq/100 g)______________________________________0 1410.33 691 372 183 104 75 3.5______________________________________
EXAMPLE IX
Effect of [NH 4 + ] on Copper Uptake on Rock
50 gram samples of 8-12 mm fragments of Safford Rock were equilibrated for 6 days at 75° C. with 25 ml of various aqueous solutions. Initially, each solution contained 1 gpl copper. The amount of copper taken up by the rock samples is set forth in Table IX below.
TABLE IX______________________________________ Copper UptakeSolution Composition (meq/100 g)______________________________________1M NH.sub.3 1.291M NH.sub.3 --0.5M (NH.sub.4).sub.2 SO.sub.4 0.531M NH.sub.3 --1.0M NH.sub.4 NO.sub.3 0.641M NH.sub.3 --2M (NH.sub.4).sub.2 SO.sub.4 0.041M NH.sub.3 --2.6M NH.sub.4 NO.sub.3 0.111M NH.sub.3 --1.3M NH.sub.4 NO.sub.3 --0.6M (NH.sub.4).sub.2 SO.sub.4 0.143M NH.sub.3 --1M (NH.sub.4).sub.2 SO.sub.4 0.09______________________________________
EXAMPLE X
The procedure of Example IX was repeated except that 30 g samples of 4-8 mm fragments of a different Safford Rock ore sample were equilibrated with 15 ml solution for 4 days, the original solutions containing 2 gpl copper. The results of this experiment are set forth in Table X below.
TABLE X______________________________________ Copper UptakeSolution Composition (meq/100 g)______________________________________NH.sub.3 NH.sub.4 NO.sub.3(M) (M)1 0 0.91 1 0.571 2 0.251 3 0.131 4 0.062 1 0.282 2 0.282 3 0.142 4 0.203 1 0.253 2 0.203 3 <0.044 1 0.424 2 0.16______________________________________
The data in the above two tables clearly demonstrate that Cu uptake decreases with increasing ammonium ion concentration and also decreases, but to a much smaller extent, with increased ammonia concentration. Further, it is apparent from the above that the copper uptake suppression phenomenon is independent of the anion used.
EXAMPLE XI
Effect of Other Cations on Copper Uptake by Rock
Solutions were prepared containing 1 M NH 3 , 0.5 M (NH 4 ) 2 SO 4 , and various other cations as indicated below. Twenty-five ml aliquots of these solutions were then added to 50 grams of 8-12 mm fragments of Safford Rock and equilibrated for 6 days at 75° C. Copper uptake data are set forth in Table XI.
TABLE XI______________________________________Solution Composition1M NH.sub.3 --0.5M (NH.sub.4).sub.2 SO.sub.4 Copper Uptakeplus (meq/100 g)______________________________________ 0.5M (NH.sub.4).sub.2 SO.sub.4 --2 gpl Cu 0.120.4M Na.sub.4 So.sub.4 --2 gpl Cu 0.311.0M MgSO.sub.4 --2 gpl Cu 0.280.5M K.sub.2 SO.sub.4 --2 gpl Cu 0.190.33M MgSO.sub.4 --4 gpl Cu 0.871 gpl Zn.sup.++ --2 gpl Cu 0.49______________________________________
From these data it is apparent that other cations are less effective than ammonium ion in suppressing copper uptake.
EXAMPLE XII
Effect of [NH 4 + ] on Nickel Uptake By Clay
4 gram samples of montmorillonite were equilibrated at 25° C. with 50 ml of ammoniacal solution containing 0.1 gpl nickel. The results, Table XII, show that less nickel is taken up at higher ammonium ion concentrations.
TABLE XII______________________________________NH.sub.3 NH.sub.4 NO.sub.3 Final Ni Concentration______________________________________M M gpl0.2 0.5 0.0261 3 0.099______________________________________
EXAMPLE XIII
Effect of [NH 4 + ] on Nickel Uptake on Rock
30 gram samples of crushed porphyry rock were treated for 7 days at 75° C. with 15 ml of ammoniacal solution containing 0.02 gpl nickel. It is seen, Table XIII, that less nickel is lost to the rock at the higher ammonium level.
TABLE XIII______________________________________NH.sub.3 NH.sub.4 NO.sub.3 Final Ni Concentration______________________________________(M) (M) (gpl)0.2 0.5 0.0071 3 0.020______________________________________
Losses of other metals such as uranium, cobalt and molybdenum are also reduced by preventing uptake of these metals by clays.
Steady State Stage
At the beginning of this stage of the process of the invention, the leaching interval contains a solution containing calcium, some metal values, an ammonium salt, and (optionally) some ammonia. The clay has been contracted, and ammonium ions have been absorbed into the absorption sites of the copper, nickel, cobalt, molybdenum and uranium absorbing minerals. A portion of the metal sulfides has been oxidized by the injection of oxygen gas in the priming stage, and the leaching interval is accordingly ready for productive metal leaching.
Broadly, leaching is effected by forcing a two-phase lixiviant comprising an aqueous ammoniacal solution containing a stabilizing surfactant and minute oxygen gas containing bubbles into the leaching interval by means of a sparger located, for example, in the access well bore at the level of the leaching interval or at the surface plant. Apparatus for effecting this process and further particulars on the lixiviant are disclosed in the aforementioned U.S. Patent No. 4,116,488 to Hsueh et al. and in U.S. Pat. No. 4,045,084, the disclosures of which are incorporated herein by reference.
Briefly, the aqueous phase of the lixiviant comprises an aqueous solution containing a conventional surfactant such as that sold under the tradename Dowfax 2A1 by the Dow Chemical Co. (sodium salt of dodecylated oxydibenzene disulphonate), a polyacrylate scale inhibitor such as CALNOX® 214 (Aquaness Chemical Company), ammonium sulfate, and ammonium. Optionally, up to about 100 ppm thiocyanate ion (SCN - ) may also be included. This anion has been observed to inhibit an in situ reaction between ammonia and oxygen which unnecessarily depleates both reagents. The choice of whether to use thiocyanate will be an economic one balancing the ammonia and oxygen containing gas cost saving and the current cost of thiocyanate.
Oxygen containing gas bubbles, after being introduced into the aqueous phase by a sparger, are maintained as discrete bubbles in the vicinity of the leaching interval by a device known as an exhauster which effects continuous vertical circulaton of the lixiviant in lower portions of the well bore. The device has an ejection nozzle located in a lower portion of the leaching interval and an aspirator passage inlet located in an upper portion of the leaching interval which recaptures and entrains gas. The cooperative interaction between the sparger and exhauster yields an oxygenated lixiviant or leach liquor containing well dispersed, minute oxygen bubbles. This unique two-phase lixiviant is able to effectively penetrate the fractures of the ore body and effect dissolution of the copper ore due to the minute bubble characteristics of the oxygen phase of the leach solution.
An exemplary steady-state operation is schematically illustrated in the drawing. A lixiviant comprising 0.25 M (NH 4 ) 2 SO 4 , 1.0 M NH 3 , 25 ppm DOWFAX® and 75 ppm CALNOX® is mixed with oxygen in a sparger and forced under pressure down an access well and through the leaching interval. In the leaching interval, copper and nickel sulfides are oxidized by oxygen and leached as nickel and copper ammonia complex ions. Some calcium is released. Copper and nickel uptake by metal absorbing minerals is inhibited by the pressence of absorbed ammonium ion and the ammonium ion concentration in the lixiviant. After the pregnant solution is collected from a recovery well, it is treated with lime and stripped of metal values by conventional techniques. Thereafter, the solution is reconstituted and recirculated.
To further discourage absorption of metal values by in situ ion exchange, the lixiviant should have an ammonia concentration no greater than 1.0 M. In this regard, it has surprisingly been discovered that ammonia rich solutions, e.g., 2.5 M NH 3 solutions, have an increased tendency to give up copper ions to the clay minerals noted above. Thus the yield of copper from the leaching interval is actually increased if lower ammonia concentrations are used. The reason for this is believed to involve a secondary mechanism of metal absorption on certain biotites which occurs preferentially in the presence of higher NH 3 concentrations. To avoid zeolite formation, the pH of the aqueous phase should be maintained below about 10.2.
Termination Stage
When the metal content of the leaching interval has been depleted, the valuable ammonia, copper, nickel or uranium solution remaining in the leaching interval is replaced with a less valuable fluid in order to maximize metal recovery and reduce reagent losses. Any environmentally compatible liquid may be used for this purpose. A 5% brine solution is recommended since this is more effective than process water which tends to dilute the remaining reagents.
Emplacement and Scheduling of Scale Inhibitor
There are three basic techniques by which scale inhibitors are utilized in solution mining:
Meter inhibitor into the produced fluids downhole through the annulus or a spaghetti string. This approach provides maximum flexibility as to inhibitor used and permits maximum control of inhibitor at minimum levels. However, it is undesirable because it provides no scale control in the rock and requires special multihole packers.
Squeeze emplacement into the producing zone. This approach will protect at least the producing zone of the deposit and production equipment and requires no special equipment. However, the polyacrylate scale inhibitors are too weakly sorbed by the rock for this approach to be economic.
EXAMPLE XIV
Squeeze Emplacement
Inhibitor was squeezed into a hundred foot zone in the production hole: 10,000 gallons of ammoniacal solution was injected as a preflush, followed by 7500 gallons of 1 M NH 3 -1 M NH 4 NO 3 containing 27 gpl polyacrylate. 15,000 gallons of 1 M NH 3 -1 M NH 4 NO 3 was then added as an overflush to push the inhibitor back into the deposit.
Polyacrylate concentration in the recovered fluid is plotted against time in FIG. 2. Of the 1690 lbs of polyacrylate injected, some 1400 lbs was produced in 18 days. By extrapolation, it was estimated that the inhibitor level would be below 25 ppm after the production of 300,000 gallons of solution.
Addition to the injection fluid. This approach requires that the inhibitor be stable in the lixiviant for long periods of time and that it be but weakly absorbed by the rock forming minerals. This approach has the potential of protecting the injection hole, the bulk of the orebody, the production hole and the production equipment from scale formation. It has been discovered that the polyacrylate inhibitors meet these criteria.
EXAMPLE XV
Stability of Inhibitors
Ammoniacal solutions containing individual phosphonate or polyacrylate scale inhibitors were heated for four weeks at 65° C. and 1000 psi oxygen in the presence of rock fragments to test inhibitor stability. Residual inhibitor effectiveness was assessed by adding aliquots of calcium solution (to supersaturate the treated solutions) and measuring the calcium concentration after 24 hours. Both the polyacrylate and the triethylenediamine penta (methylenephosphonic) acid retained inhibitory powers; less stable phosphonates did not.
EXAMPLE XVI
Stability of Inhibitors
In another series of experiments the polyacrylate and triethylenediamine penta (methylenephosphoric) acid were added at the $5/1000 gallon level to calcium supersaturated solutions containing 0.75 M NH 3 , 0.25 M (NH 4 ) 2 SO 4 and 1.2 gpl Ca; these test solutions were heated for four weeks at 65° C. and 1000 psi O 2 in the presence of rock fragments. After treatment, the calcium levels were 1.00 gpl in the phosphonate experiment; 1.04 gpl in the polyacrylate experiment; and 0.57 gpl in a control experiment with no inhibitor. Analysis of the oxidized phosphonate solutions showed the formation of free ortho-phosphate, due to hydrolysis of 70% of the phosphonate groups.
From these tests it was concluded that the polyacrylate is more chemically stable than are the phosphonates.
EXAMPLE XVII
Adsorption of Scale Inhibitors on Rock
The stability experiments suggested that polyacrylate is sufficiently stable to be added to the injected fluids. The field squeeze test described in Example XIV suggested that the polyacrylate was not strongly adsorbed and would pass through the deposit. To confirm this, further experiments were carried out in which ammoniacal solutions of CALNOX® 214 polyacrylate and A915 polyacrylate were equilibrated with rock fragments fractured to expose the vein materials that "see" the lixiviant in-situ. Table XVII shows that the inhibitors were poorly adsorbed, that adsorption did not increase with inhibitor concentration and that adsorption was not a function of polyacrylate molecular weight.
TABLE XVII______________________________________Adsorption of Inhibitors on Rock, 65° C.60 g of 1/4 to 1 cm rock fragments were treated with 25ml of 0.5M NH.sub.3, 0.25M (NH.sub.4).sub.2 SO.sub.4 for three days Initial Final Sorbed Polyacrylate Polyacrylate PolyacrylateInhibitor ppm ppm lb/ton/rock______________________________________CALNOX® 214 82 79 0.003(Polyacrylate, 38 31 0.0061000 MW) 17 10 0.006A 915 49 42 0.006(Polyacrylate, 23 13 0.0085000 MW) 11 3 0.007______________________________________
As a final demonstration of the preferred mode of utilization of the polyacrylate scale inhibitor consider the following example.
EXAMPLE XVIII
Addition of Polyacrylate to Injected Fluids
CALNOX® 214 was added to the injected fluids at polyacrylate concentration of around 400 ppm. Polyacrylate levels subsequently rose at the production hole, signifying successful passage of inhibitor; cf. FIG. 3. Due to lack of supply, no polyacrylate was added to the injected fluids July 3-23, and polyacrylate levels at the production hole fell to about 40 ppm. Inhibitor addition to the injected fluids was resumed on July 23; levels started to rise in the produced fluids on July 29 and reached about 120 ppm. On August 6, the inhibitor level in the injected fluid was decreased to around 80 ppm. The result was a stabilization of the polyacrylate level in the produced fluid at around 40 ppm. Clearly, the level of scale inhibitor in the produced fluid can be controlled by adjusting the level in the injected fluid.
Produced fluids were supersaturated with calcium at all stages of the test. Moreover, they were stable over a long period of time at ambient temperature, allowing transportation and storage. The supersaturation could be relieved by treating produced fluid with large amounts of gypsum or calcite to remove polyacrylate.
Based on these examples, it will be clear to those skilled in the art that inhibitor application rates are optimally structured into three phases.
A. Polyacrylate is squeezed into the production holes or added to a preleaching stimulation or tracer fluid with the objective of conditioning the production zone prior to leaching. Addition of inhibitor at a high level to a stimulator or tracer fluid is preferred since it is more economical.
B. Once the inhibitor is observed in the produced fluids, the polyacrylate level in the injected fluids is reduced to maintain a minimum level in the produced fluids. The supersaturated calcium is removed in the surface plant by carbonation, or less desirably by liming, prior to reinjection. Towards the end of this period, the produced fluids will become undersaturated in calcium as the ion exchanger minerals become fully accessed; when this occurs, further polyacrylate addition stops.
C. No inhibitor addition is required so long as the produced fluids remain undersaturated in calcium.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | Disclosed is a method of economically exploiting deep set porphyry ore bodies of the type containing metal values such as sulfidic copper nickel or uranium minerals and minerals capable of absorbing copper, uranium and nickel ions. The method involves establishing communication with the ore body through access and recovery wells and passing fluids sequentially therethrough. If necessary, thief zones of as low as 25 to 50 md in igneous rock of 1 to 5 md are prevented from distorting flow, by the injection of a polymeric solution of macromolecules with molecular weights of the order of 5 million along the entire wellbore, the higher permeability zones initially accepting the majority of the flow and being impaired at a much faster rate than the less permeable zones.
In a first stage, the permeability of the leaching interval is stimulated as an ammoniated solution of sodium, potassium, or ammonium nitrate or chloride contacts calcium containing minerals to promote ion exchange, resulting in clay contraction or calcium carbonate dissolution. In a second stage, the leaching interval is primed as calcium ion is displaced with an aqueous solution of ammonium salt, a calcium sulfate scale inhibitor, and oxygen gas. In a third stage, a two-phase lixiviant comprising entrained oxygen containing bubbles and an ammoniacal leach liquor having a pH less than 10.5 and less than 1.0 mole/liter ammonia is passed through the leaching interval to solubilize copper, nickel, uranium and other metal values. | 4 |
[0001] This Patent Application is a continuation-in-part of patent application Ser. No. 09/428,443, which was filed on Oct. 10, 1999.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a laser radar (LADAR) system, which is especially suitable for targeting moving and stationary targets. In particular, the system comprises a laser source and optical configuration in combination with detectors and a processor for obtaining an alignment insensitive system suitable for operation in a hostile environment, for example airborne applications.
[0003] LADAR systems have been operated and characterized since shortly after the invention of the laser. Configurations involving both incoherent (direct detection) and coherent (heterodyne detection) receivers have been used. If maximum sensitivity or retention of phase information is desired, the heterodyne receiver is required. To meet the criteria for successful operation of the coherent system, an optical mixing element to combine a local oscillator beam with the return signal beam is necessary. To be successful, this interferometer must maintain optical alignment to within one-quarter of a fringe. This condition is easily mechanized within the laboratory environment, but is subject to misalignment in environments exhibiting high levels of vibrational and acoustical disturbances.
[0004] The present invention is directed toward providing a single aperture, optical interferometer which is insensitive to misalignment and functions as a transmit/receive LADAR system in either a homodyne or heterodyne mode.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to a laser radar system for targeting moving and stationary targets which comprises: a laser source for projecting a beam of stable, optical, polarized radiation, to a first beam expander, having adjustment means, transmitting the expanded polarized radiation to a thin film polarizer, means for splitting the radiation beam from the thin film polarizer to output optics and internal optics, wherein the radiation beam from the splitting means is transmitted to a quarter-wave plate (output optics) and a third beam expander, having adjustment means, to a target area, reflected radiation beams from the target area are reflected back through the third beam expander, quarter-wave plate (output optics) and polarizing beam splitting means to a 50-50 beam separator where the beam is directed to a first detector containing focusing lens and a second detector containing focusing lens, radiation from the polarizing splitting means is transmitted through an iris containing a quarter-wave plate (internal optics) and a second beam expander, having adjustment means, to a retroreflector where it is reflected back through the second beam expander, internal optics and beam polarizing splitting means to the 50-50 beam separator where it is combined with the reflected radiation beams from the target area and transmitted to first and second detection means and to processor means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a schematic diagram of an alignment insensitive homodyne laser radar.
[0007] [0007]FIG. 2 is a schematic diagram of alignment insensitive offset-heterodyne laser radar.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The present invention resides in a laser radar system, which targets moving and stationary targets, which maintaining optimum optical alignment for heterodyne detection.
[0009] Embodiments of the laser radar system of the present invention are hereinafter described with reference to the drawings, in which identical or corresponding elements are indicated by the same reference characters through the several views.
[0010] [0010]FIG. 1 illustrates a schematic diagram of an alignment insensitive homodyne laser radar system comprising laser 1 , which is a source of monochromatic, optical radiation. Desirable lasers include carbon dioxide lasers and solid state lasers. Radiation from laser 1 is transmitted to first optical beam expander 21 where optical output energy of laser 1 is expanded by lens 2 and lens 3 . It should be noted that the lens of the beam expanders herein are typically constructed from zinc selenide or other types of lens that passes the radiation therethrough. The optical beam expanders herein are optical devices composed of multiple lens combinations, which expand the input beam in size and recollimates the output beam at a larger size.
[0011] First optical beam expander 21 has adjustment means for changing the distance between lens 2 and 3 , wherein the beam wave can be changed from convex to plane to concave in first beam expander 21 . Typical adjustment means include a screw mechanism for either moving lens 2 closer to lens 3 or for moving lens 2 farther from lens 3 .
[0012] The expanded optical beam from beam expander 21 is transmitted to thin film polarizer 4 which is utilized to reject any unwanted backscatter into laser 1 . Thin film polarizer 4 is an optical device used to discriminate between the two planes of optical polarization (P and S). Typical operation of an optical substrate at Brewster's angle permits transmission of the P-plane of polarization and rejection of a high percentage of S-plane polarization. In the infra red region, the thin film polarizers herein contain zinc-selenide plates having plane parallel surfaces. Thin optical film coatings on the film of a substrate, such as the plates herein, are used to further enhance this effect.
[0013] Next, the optical polarized radiation from thin film polarizer is transmitted to polarizing beam splitter 5 which performs a polarization discrimination function by dividing the beam into two beams of differing polarization without changing the beam shape. In the infra red region, the beam splitter 5 is typically constructed from zinc selenide and is configured with thin film coatings to operate at an angle of incidence of 45 degrees.
[0014] Polarizing beamsplitter 5 transmits a predetermined amount of optical radiation to output optics comprised of quarter-wave plate 6 and third beam expander 23 , having adjustment means, which contains lens 7 having expansion properties and lens 8 having collimating properties, optical radiation is transmitted from third beam expander 23 to a target which can be either moving or stationary. The optical radiation is reflected off the target and back through third beam expander 23 and quarter wave plate 6 to beamsplitter 5 . Adjustment means for third beam expander 23 includes a screw mechanism for moving lens 7 either toward or farther away from lens 8 .
[0015] The residual energy reflected by beamsplitter 5 is used as a local oscillator for heterodyne detection. Upon reflection, the local oscillator energy passes through iris 10 to control the intensity level and then, through quarter-wave plate 9 to introduce an optical radiation beam having circular polarization properties to second beam expander 22 which contains lens 11 having expansion properties and lens 12 having collimating properties. The optical radiation beam is transmitted from iris 10 to retroreflector 13 , which comprises three orthogonal planes of reflection. Optical beams or rays entering the aperture of retroreflector 13 , exits with diametrical offset relative to the optical axis thereof. The optical beam is reflected from retroreflector 13 through second beam expander 22 back along the outward pass to quarter-wave plate 9 where upon exiting said quarter-wave plate 9 , the beam is again linearly polarized orthogonally to its entrance state. Beam expander 22 serves to enlarge the beam and also provide curvature adjustment means of the local wavefront returned by retroreflector 13 . Curvature adjustment means is accomplished by moving lens 11 either closer to or farther from lens 12 for example by using a screw mechanism. A predetermined fraction of the optical radiation controlled by iris 10 is transmitted through polarizing beamsplitter 5 and constitutes the local oscillator of the system. The fraction of energy which is reflected at beamsplitter 5 impinges upon thin film polarizer 4 and is nearly completely reflected, insuring that a negligent amount of energy returns to the laser source.
[0016] Signal laser energy returning from the transmit target path is reflected through third beam enlarger 23 and quarter-wave plate 6 where it is orthogonally polarized by quarter-wave plate 6 and combined with the local oscillator beam from retroreflector 13 upon reflection from beamsplitter 5 .
[0017] Since the beamsplitter 5 is a device which has been fabricated with plane-parallel faces to a high precision and the retro reflector 13 always returns the reflected energy back along its outward path with high precision, the signal and local oscillator beams are always aligned with high precision. External disturbances cannot introduce misalignment. This feature provides an alignment insensitive characteristic needed to operate in a hostile environment.
[0018] The combined energies (signal and local oscillator) are propagated to beamsplitter 14 , which divides the total energy. One-half the energy is directed to focusing lens 17 and applied to the detector 19 . One-half the energy is directed to focusing lens 16 and applied to detector 18 . The local oscillator portion is first directed to the retardation plate 15 to introduce a π/2 retardation. This energy combines with the signal energy at detector 18 and provides a signal in quadrature with the output of detector 19 . Both signals are now transmitted to the processor 20 .
[0019] It is to be noted that the detectors ( 18 and 19 ) herein are optical devices, which convert photon energy to electronic energy with a specified conversion efficiency. The processor 20 accepts electronic signals from the detectors and converts the information contained in the signals to a usable format, e.g. analog or digital. Output variables are, the Doppler shift (target velocity), harmonic modulation of the signals and time of flight data (phase or temporal).
[0020] [0020]FIG. 2. Is the same as FIG. 1. with the following exception: a frequency shifter 24 is located in the local oscillator path. Frequency shifter 24 is preferably a frequency generator wherein the frequency desired can be dialed in, thus changing the frequency of optical radiation. This feature converts the laser radar system herein to an alignment insensitive offset-heterodyne laser radar system.
[0021] While the invention has been described in its presently preferred embodiments, it is understood that the words which have been used are words of description rather than words of limitation and that change within the preview of the appended claims may be made without departing from the scope and spirit of the invention in its broader aspects. | This invention resides in a laser radar system for targeting both moving and stationary targets, which is insensitive to alignment errors introduced by mechanical and acoustic perturbations. The laser radar system includes a laser source for projecting a beam of stable, optical, polarized radiation, three separate polarized beam expanders, a think film polarizer, internal optics including a retroreflector, output optics, a 50-50 beam separator, two separate signal detectors for converting electronic signals to analog and a processor for converting analog electronic signals to digital. The optical assembly is configured to compensate for induced misalignment and maintains optimized heterodyne operation in harsh environments. | 6 |
This invention relates to an overload indicator device for use on motor vehicles. More particularly, the invention relates to a load indicator intended for use on large vehicles such as trucks, trailors and the like for determining when a pre-set axle weight load limit has been exceeded.
BACKGROUND OF THE INVENTION
State highway codes of all the states contain legal weight limits for vehicles using the respective roads. These weight limits are established to prevent damage to the pavement and roadbed as well as for safety reasons. The weight limits are normally defined in terms of the maximum allowable pay load for each axle of the vehicle. Most states have check stations along the highways at key points to detect violations of any legal weight limit. The vehicles are required to be driven onto scales wherein the weight limit on each axle is determined. It is possible that the total weight contained within the motor vehicle is within limits. However, the load may be so unbalanced as to cause an overweight on one or more of the axles. If a vehicle is found to be illegally loaded, it is detained until another vehicle can be dispatched to remove part of the load. In addition, the driver is normally fined.
Trucking companies as well as drivers desire to load as much cargo into the truck as legally permissible for economic reasons. Drivers have for the most part learned to balance a load within their trucks. This is gained by experience. Many drivers have learned it is difficult to load a vehicle in a balanced manner. Generally, there is a certain degree of trial and error imposed. Any mistake can be costly. Accordingly, most drivers tend to underload their vehicles.
The need for an overload indicator has been recognized. Various people have attempted to devise idicator devices which can be permanently attached to a vehicle bed so as to determine when a preset load level has been approached or exceeded. Known overload indicator devices are primarily comprised of two parts. One part is attached to the underside of the motor vehicle while the second part is attached to the axle. As additional weight is added to the vehicle, the bed is gradually forced downward until a pre-set limit has been exceeded. At that point contact points of the indicator device touch and set off an alarm of some type. A major draw back with devices of this type is that even though a motor vehicle has been loaded and balanced so as to be within legal limits false readings can occur as the vehicle travels down the road. Unevenness of the surface roadways will cause a certain degree of bouncing of the vehicle. This bouncing will cause the springs to compress and, in effect, cause the contact points of the indicator device to come together and set off the alarm. This false reading can be very annoying to the driver. An on/off switch in the cabs on the motor vehicles has been provided to avoid this. This does avoid one problem; however, the life of the indicator device is substantially reduced when such inadvertent contacts are continually made.
There is a definite need for an axle weight overload indicator device. Such a device must be easy to install and provide accurate readings. The device must also be built so as to withstand continued use over a long period of time. In accord with this need, there has been developed an axle weight overload indicator device.
SUMMARY OF THE INVENTION
An axle weight load indicator device is adapted for ready attachment to a motor vehicle. The indicator device comprises a pemanent stop mounted on a axle of the motor vehicle and a housing with an electrical switch and a retractable probe mounted on the underside of the motor vehicle in operable association with the stop. The probe is connected to a power source which allows it to be retracted during non-use. An alarm means is also provided for signaling when a pre-set load limit has been exceeded. After the motor vehicle is legally loaded, the contact probe is retracted into the housing and substantially out of the way so as to prevent damage during operation of the motor vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in perspective of a motor vehicle utilizing the axle weight overload indicator device of this invention.
FIG. 2 is a side view of the indicator device of this invention with a partial cutaway showing the inside of a cylinder with a probe.
FIG. 3 is a top view of the indicator device of FIG. 2.
FIG. 4 is a front view of the indicator device of FIG. 2.
FIG. 5 is a view in perspective of a permanent stop as mounted on an axle section.
FIG. 6 is a side view with a partial cutaway of the indicator device of FIG. 2 when the probe is retracted.
FIGS. 7 and 8 are side views with partial cutaways of the indicator device of FIG. 2 with a partial cut-away depicting the device when part-loads are experienced.
FIG. 9 is a side view with a partial cutaway of the indicator device of FIG. 2 when a full load is experienced and the probe is extended.
FIG. 10 is a schematic diagram of the indicator device of this invention showing the wiring and air supply source.
FIG. 11 is a front view of bracket attachment means used for attaching the indicator device to a motor vehicle.
FIG. 12 is a side view of the bracket attachment means of FIG. 11.
FIG. 13 is a schematic drawing of the indicator device of this invention wherein an alternative hydraulic activated probe is depicted.
FIG. 14 is a schematic drawing of the indicator device of this invention wherein a vacuum activated probe is depicted.
FIG. 15 is a fragmentary side view of an indicator device of this invention showing the use of a micro switch.
FIG. 16 is a top view of the indicator device of FIG. 15.
DETAILED DESCRIPTION OF THE INVENTION
The load indicator device 10 of this invention is shown generally in FIG. 1 and in detail in FIGS. 2-9. With reference to FIG. 1 there is shown a view of a portion of a load-bearing motor vehicle 11. Such vehicles have at least two axles, and can typically have eight or more axles. Each axle will be limited as to the load which it can bear without exceeding mandated limits. Accordingly, the device of this invention while only shown on axle 12 will be used on each axle for which a load limit is imposed. The motor vehicle has a frame 13 on which is positioned a bed 14. Leaf springs 15 are permanently attached to the frame 13 by shackels 16 and also to the axle 12. The load indicator device 10 is mounted on the underside of the motor vehicle's bed and axle.
FIGS. 2-4 show one part of the load indicator device in detail. A housing 17 has a top cover 18 and a bottom cover 19. Conventional attachment means such as self-threading screws 20 are used to hold the covers to the housing. A sliding cylinder 21 mounted within the housing has a cylinder top 22 and cylinder bottom 23. A piston rod 24 mounted within the cylinder 21 acts as a probe during operation. The piston rod extends the length of the cylinder and out through appropriately sized holes in the cylinder bottom 23 and bottom cover 19. The piston rod is secured to a piston 25 by a nut 26 at it's upper threaded extremity. An O-ring 27 is provided in groove 28 to ensure a tight seal within the cylinder during operation. A rod wiper 29 of a resilient material is also provided in the hole in the bottom cover 19 as an aid in sliding movement of the piston rod. A coil spring 30 extends the length of the piston rod from the cylinder bottom 23 to the piston 25.
Piston 25 is dimensioned to fit within the sliding cylinder 21 and respond to a force such as air pressure to cause its downward movement in the cylinder. For this purpose, a conventional air supply source typically found on larger motor vehicles, e.g. tractor-trailors is connected to the cylinder 21 by means of an union 31. Sealing means are provided at the point where the air hose enters the union 31 to ensure an air tight seal. Coil spring 30 contracts when piston 25 is forced downwardly and returns to rest position when the force is removed, therby retracting the probe at least partially back into the sliding cylinder 21.
A master bolt 33 extends through the cylinder top 22 and the top cover 18. Securing means comprised of a washer 34, adjustment nut 35, and half-nut 36 are used to hold the cylinder 21 in the housing at a pre-set rest position. A coil spring 37 is positioned around the master bolt 33 in the space created between the cylinder top 22 and housing top cover 18. As explained in the operation of the device, the coil spring 37 ensures that sliding cylinder 21 will return to its rest position during non-use.
Attachment means are provided for attaching the housing to the underside of the motor vehicle's bed. Bolts 38 with nuts and brackets 39 are used. Other conventional attachment means can be used for permanently mounting the housing. As evident from FIG. 1, normally the housing will be mounted at the mid-point of the axle. If need be, a J channel extending across the underside of the motor vehicle can first be attached and then the housing slid along the J channel until the desired lateral position is reached.
Slidable hold means 40 comprised of threaded rods 43 and 44 and nuts 42 extending through elongated slots 41 in the side-wall of housing are permanently attached to the cylinder 21. The nuts 42 are tightened sufficiently to hold the cylinder 21 in a spaced sliding relationship with the housing 17. Preferably, rods 43 and 44 are hollow and serve the dual purpose of holding and supplying compressed air to the cylinder. The compressed air enters through rod 43 and air from action of the piston exits through rod 44. The threaded rods pass through elongated slots 41 in the housing. The elongated slots permit limited vertical movement of the cylinder within the housing as described below. Metal back-up plates 45 and rubber gaskets 46 positioned over the elongated slots help to keep the sliding cylinder in a clear working condition.
An adjustable indicator stop 50 best shown in FIG. 6 is threaded into the end of piston rod 24 a desired distance and secured by jam half nut 51. The indicator stop 50 is calibrated as a means of warning when a pre-set load limit is about to be reached. A shoulder 52 extending axially from the indicator stop effectively prevents further movement of the piston rod 24 when contact is made with an axle mounted permanent stop.
With reference to FIG. 5 a pemanent stop 53 is mounted on the axle 12 so as to be in alignment with the above described piston rod and indicator stop 50. A conventional attachment means such as spot welds hold the permanent stop 53 in position to withstand a downward force exerted by the piston rod. The stop 53 comprises an elongated plate 54 with an open-ended slot 55 extending from its outer extremity towards the axle. The slot 55 has a width less than that of the indicator stop's shoulder 52. As readily apparent, the housing and permanent stop are mounted so that the housing clears the axle when lowered.
Contact studs 56 are mounted with the aid of jam nuts 57 on the underside of top cover 18. Such studs extend through the top cover and lead to a power source. An electrically conducting contact plate 58 is positioned on the cylinder top 22 for completing a circuit between the contact studs. In effect, contact studs 56 and contact plate 58 constitute an electrical switch.
FIG. 6 shows the indicator device when in a rest position. That is, no air pressure is being supplied to the sliding cylinder 21. As such, the piston rod 24 is retracted into the cylinder 21 due to coil spring 30's force. The adjustment indicator stop 50 is at its top most position. Coil spring 37 forces the sliding cylinder downwardly to the lower edge of slots 41 in the housing 17 side walls. In this position, the indicator stop 50 is safely distanced from the permanent stop 53 so that no inadvertent contact is possible. Contact studs 56 and contact plate 58 are not touching.
FIGS. 7 and 8 show the position of piston rod 24 and indicator stop 50 when part loads are exerting their weight on the axle and the indicator device is operable. As evident, the load forces being depicted in FIG. 7 are less than that depicted in FIG. 8. Sufficient air pressure is provided to the sliding cylinder 21 to cause piston 25 downward which in turn forces piston rod 24 to fully extend itself from the cylinder. As apparent, the shoulder 52 of the indicator stop 50 has not reached the axle mounted permanent stop 53. However, in FIG. 8 the calibrated portion of the indicator stop has extended partially through the open-sided slot 55 in permanent stop 53. The calibrations on the indicator stop are an indication to the motor vehicle operator of the amount of additional weight which can be added before the axle weight limit is exceeded. The sliding cylinder 21 rests in the lower part of the housing's slotted holes 41 in this mode.
FIG. 9 depicts the indicator device when operable and an excess load is encountered. Thus shoulder 52 of the indicator stop 50 abuts against the axle-mounted permanent stop 53. This causes fully extended piston rod 24 to force sliding cylinder 21 upwardly in the housing 17 until the threaded rods 43 and 44 are restrained from further movement by the top of the slotted openings. In this position, the contact plate 58 rides upwardly with the sliding cylinder 21 and touches the contact studs 56 on the underside of the top cover 18. An alarm is activated signaling the overweight condition. When the air pressure is removed, coil spring 30 causes the piston rod to retract into the cylinder and coil spring 37 causes the sliding cylinder to slide back to a rest position defined by the lower part of the slotted openings 41.
When contact plate 58 touches contact studs 56, an electrical circuit is completed. Current is directed to an alarm (not shown) to signal that the pre-set load limit has been reached. An audible alarm, e.g. a bell or buzzer or a visual alarm is set-off. Such alarms are very common and any commercially available alarm can be used. Normally, the alarm means is positioned in the motor vehicle's cab.
FIG.10 shows a schematic wiring diagram used with the load indicator device. Wires 60 and 61 lead from a negative pole and a positive pole of a battery 62 to the electrical switch. The electrically operated alarm means 63 is connected into the circuit so that when the circuit is completed, it will be activated. An alarm switch 64 is also provided to deactivate the alarm means 63 if desired. Also shown in FIG. 10 is an optional air hose 65 extending from threaded rod 44 to an opening in top cover 18 opposite contact studs 56 and contact plate 58. When compressed air forces movement of the piston, ambient air is forced out rod 44 and through air hose 65. The short blast of air serves the purpose of clearing the contact studs and plate. In-line control valve 66 and an air supply source 67 supply compressed air through line 68 to the cylinder.
The load indicator device is readily installed on a motor vehicle. An embodiment shown in FIGS. 11 and 12 depicts an elongated double bracket 70 initially secured to the underside of the frame 13 of the motor vehicle by bolts 72 and nuts 73. Each bracket 70 has two sets of slots 71 extending lengthwise. Bolts 74 extend through the respective slots and holes provided in the indication device's housing. Spacers 75 maintain the indicator device 10 in a spaced relationship with the brackets 70. Vertical movement of the indicator device for adjustment purposes is readily accomplished by loosening bolts 74, positioning the indicator device 10 and retightening bolts 74. Generally, the device is located at the mid-point of the axle spread. With the maximum load placed over the axle, an air hose is connected to the sliding cylinder and turned on. This forces the piston rod to its full stroke. Next, the indicator stop is screwed into its full adjustment retreat. The axle-mounted permanent stop is now attached and the indicator stop's length adjusted by screwing it out of the piston rod until the shoulder abuts against the permanent stop and the contact studs and plate touch. The jam nut 51 is now tightened to retain this position.
In operation, the load indicator device is first activated by supplying air pressure through the air hose to the cylinder. The motor vehicle is loaded. As the weight forces are transmitted throught the leaf spring, the vehicle's bed gradually drops. This lowers the piston rod until eventually the shoulder of the indicator stop makes contact with the permanent stop. Continued loading will cause the sliding cylinder to move upwardly in the housing's slotted openings until the contact studs and contact plate touch. When this happens, the electric circuit is completed and the alarm is activated.
FIGS. 13 and 14 illustrate alternative sources for moving the piston rod. Thus, in FIG. 13 hydraulic pressure is transmitted from a hydraulic pump and reservoir 75 through control valve 76 and line 77 into a hydraulic cylinder 78. In FIG. 14, a vacuum source 80 such as an intake manifold of the engine supplies vacuum through a line 81 to the cylinder 82. A push-pull control valve 83 is positioned in-line. In both cases, operation of the piston rod is the same as with respect to the air pressure source used in the device described with reference to FIGS. 2-9.
FIGS. 15 and 16 show another electrical switch useful with the indicator device of this invention. A micro switch 90 is mounted to the top cover 18 of the indicator device by use of a bracket 91 and self-threading screws 92. Finger plunger 93 is mounted on cylinder top 22 and extends through an opening in top cover 18 so as to be in alignment with an opening in the micro switch. A coil spring 94 is positioned over the finger plunger 93 to contact the top cover 18 and cylinder top 22 when in a rest position. Electric wires 95 and 96 lead from the micro switch to a power source. Operation of the indicator device is similar to that described with reference to FIGS. 2-9. Thus, an overload will cause cylinder 21 to ride up in housing 17 until stopped by the top of the slotted recesses. This causes finger plunger 93 to rise until it makes contact with the micro switch and completes an electric circuit. Coil spring 94 forces cylinder 21 to a rest position when the probe is retracted thereby breaking the electric circuit.
While the invention has been described with particular reference to the drawings, it should be apparent various modifications can be made without departing fronm the spirit of the invention. Thus, other electrical switches, including optic switches can readily be used as well as other conventional mounting and attachment means. Electrical switches with rheostats for an early warning of when a weight limit is being approached are beneficial. Stops mounted within the housing for limiting upward movement of the sliding cylinder beyond when the electrical circuit is completed prevents permanent damage to the indicator device itself. The use of the indicator device can also be for purposes other than signaling an overload situation. For example, a series of the devices mounted on all the axles of a motor vehicle can be used as an aid in evenly distributing a load over the vehicle's frame. Also premature signals from the device is a good indication springs on the motor vehicle have been weakened and need to be replaced. The claims which follow cover all obvious variations within their scope of coverage. | An axle weight load indicator device for mounting on a motor vehicle to detect when a pre-set axle weight has been exceeded. The device includes an electrical switch, an axle-mounted permanent stop and a retractable probe mounted in a housing which is operably associated with the electrical switch and permanent stop. When not in use, the probe is retracted into the housing to ensure that false signals are not emitted during movement of the motor vehicle. When operable, the probe is positioned to make contact with the permanent stop when a pre-set load limit has been exceeded. Continued loading causes activation of the electrical switch. The electrical switch trips an alarm to warn of the excess load. | 8 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates to clock signal generation and, in particular, to a ring oscillator for generating clock signals.
[0003] 2. Discussion of Related Art
[0004] Modern electronic devices often require coordinating the operation of digital circuits and systems. For example, two or more discrete circuits in a digital system may require that their operations be synchronized with each other in order to function properly. Accordingly, clock signals are widely used to coordinate and synchronize events in and between digital circuits and systems included in electronic devices.
[0005] A clock signal generally consists of a stable signal that oscillates between a high logic level and a low logic level in the form of a square wave having a 50% duty cycle. In some instances, a ring oscillator may be used to generate clock signals. The design and performance of many ring oscillators, however, can be sensitive to imperfections introduced during the manufacturing process. Such imperfections may also adversely affect power consumption.
[0006] Therefore, it is desirable to develop ring oscillator designs that provide for stable clock signal generation that is relatively unaffected by component imperfections introduced during the manufacturing process.
SUMMARY
[0007] Consistent with some embodiments of the present invention, a ring oscillator includes a first set of n series coupled inverters; a second set of n series coupled inverters; a first reset switch configured to couple a last inverter of the first set of inverters to a first inverter of the second set of inverters and to generate a first signal edge; a second reset switch configured to couple a last inverter of the second set of inverters to a first inverter of the first set of inverters; a cross-coupling circuit coupled between an output of an inverter of the first set of inverters to a corresponding output of an inverter of the second set of inverters. In certain embodiments, the cross-coupling circuit may be configured to maintain differential signal levels at the output of an inverter of the first set of inverters and the corresponding output of an inverter of the second set of inverters.
[0008] Consistent with some embodiments of the present invention, a method of generating one or more clock signals using a ring oscillator includes generating a first signal edge at the input of a first inverter of a first set of series coupled inverters, the first set of inverters including n inverters; generating a second signal edge at the input of a first inverter of a second set of series coupled inverters, the second set of inverters including n inverters; and maintaining differential signal levels an output of an inverter of the first set of inverters and a corresponding output of an inverter of the second set of inverters; wherein and the first and second set of inverters are coupled such the input of the first inverter of the second set of inverters is coupled to an output of a last inverter of the first set of inverters and the input of the first inverter of the first set of inverters is coupled to an output of a last inverter of the second set of inverters.
[0009] Further embodiments and aspects of the invention are discussed with respect to the following figures, which are incorporated in and constitute a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates a schematic diagram of a ring oscillator consistent with some embodiments of the present invention.
[0011] FIG. 2 illustrates a schematic diagram of an exemplary inverter consistent with some embodiments of the present invention.
[0012] FIG. 3 illustrates a schematic diagram of a ring oscillator in reset mode consistent with some embodiments of the present invention.
[0013] FIG. 4 illustrates a schematic diagram of a ring oscillator after reset consistent with some embodiments of the present invention.
[0014] FIG. 5 illustrates an exemplary signal timing diagram of a ring oscillator after reset consistent with some embodiments of the present invention.
[0015] FIG. 6 illustrates a schematic diagram of an exemplary cross-coupling circuit that includes a pair of p-channel metal-oxide-semiconductor field effect (“pMOS”) transistors consistent with some embodiments of the present invention.
[0016] FIG. 7 illustrates a schematic diagram of an exemplary cross-coupling circuit that includes a pair of n-channel metal-oxide-semiconductor field effect (“nMOS”) transistors consistent with some embodiments of the present invention.
[0017] FIG. 8 illustrates a schematic diagram of an exemplary cross-coupling circuit that includes a pair of inverters consistent with some embodiments of the present invention.
[0018] In the figures, elements having the same designation have the same or similar functions.
DETAILED DESCRIPTION
[0019] FIG. 1 illustrates a schematic diagram of a ring oscillator 100 consistent with some embodiments of the present invention. Ring oscillator 100 includes inverters 102 - 116 , cross-coupling circuits 118 - 124 , and switches 126 - 156 . In the example illustrated in FIG. 1 , ring oscillator 100 includes inverters 102 - 116 , cross-coupling circuits 118 - 124 , and switches 126 - 156 . In some embodiments, ring oscillator 100 may include any even multiple of the number of inverters 102 - 116 , cross-coupling circuits 118 - 114 , and switches 126 - 156 illustrated in FIG. 1 (e.g., sixteen inverters, eight cross-coupling circuits, thirty-two switches, and the like).
[0020] The outputs of inverters 102 - 116 , corresponding to circuit nodes 158 - 172 , respectively, may be coupled to one of the terminals of switches 126 - 140 , respectively. The inputs of inverters 104 - 116 and 102 may be coupled to the other terminals of switches 126 - 140 , respectively. This configuration allows for the inputs of inverters 102 - 116 to be coupled to the outputs of inverters 104 - 116 and 102 , respectively, when switches 126 - 140 are closed. For example, when switch 126 is closed, the output of inverter 102 is coupled to the input of inverter 104 . In this manner, inverters 102 - 166 may be serially interconnected via switches 126 - 140 to form an inverter ring.
[0021] Switches 142 - 156 may be configured such that when they are closed, the inputs of inverters 104 - 116 and 102 , respectively, are coupled to ground. Alternatively, in certain embodiments, the inputs of inverters 104 - 116 and 102 may be respectively coupled to a power terminal by switches 142 - 156 . In some embodiments, switches 142 - 156 may be selectively closed (e.g., any one of switches 142 - 156 may be closed thereby coupling the input of their corresponding inverter to ground).
[0022] In some embodiments, switches 126 and 142 may be integrated into a single switch capable of coupling the inputs of inverter 104 to the output of inverter 102 or to ground. Switches 128 and 144 , 130 and 146 , 132 and 148 , 134 and 150 , 136 and 152 , 138 and 154 , and 140 and 156 may be similarly configured. Further, switches 126 - 156 may be implemented using any circuit(s) capable of performing these switching operations and/or any physical switching device.
[0023] As illustrated in FIG. 1 , cross-coupling circuit 118 may be coupled between circuit nodes 158 and 166 (i.e., between the outputs of inverters 102 and 110 ). Similarly, cross-coupling circuits 120 - 124 may be coupled between circuit nodes 160 and 168 , 162 and 170 , and 164 and 172 , respectively. In this manner, cross-coupling circuits 118 - 124 couple a pair of ring oscillator 100 circuit nodes that have an equal number of inverters 102 - 116 between them in both directions. As discussed in more detail below, for example, in reference to FIG. 6 , FIG. 7 , and FIG. 8 , cross-coupling circuits 118 - 124 function to counteract imperfections of ring oscillator 100 , helping to make the oscillation of ring oscillator 100 sustainable.
[0024] FIG. 2 illustrates a schematic diagram of an exemplary inverter 200 consistent with some embodiments of the present invention. Inverter 200 may be used as inverters 102 - 116 in ring oscillator 100 shown in FIG. 1 . Inverter 200 utilizes complementary metal-oxide semiconductor field effect (“CMOS”) transistor technology. Alternatively, an inverter (e.g., a NOT gate) implemented using other technologies may be utilized as inverter 200 in ring oscillator 100 . For example, n-channel metal-oxide-semiconductor field effect (“nMOS”) transistor technology, p-channel metal-oxide-semiconductor field effect (“pMOS”) transistor technology, an appropriate combination of NAND gate(s), an appropriate combination of NOR gate(s), and/or any other circuit that functions similarly may be utilized as inverter 200 .
[0025] In the example illustrated in FIG. 2 , inverter 200 includes input 202 , output 204 , nMOS transistor 206 , pMOS transistor 208 , power terminal (e.g., Vdd) 208 , and ground terminal 212 . Input 202 may be coupled to the gates of nMOS transistor 206 and pMOS transistor 208 . The source of pMOS transistor 208 may be coupled to power terminal 208 . Similarly, the source of nMOS transistor 206 may be coupled to ground terminal 212 . The drain of nMOS transistor 206 and pMOS transistor 208 may be coupled to form inverter output 204 .
[0026] Inverter 200 operates to invert the signal provided at its input 202 (e.g., performs logical negation of its input). For example, if a signal having a high logic value (i.e., a logical one value) is provided to the input 202 of inverter 200 , output 204 of inverter 200 is set to a low logic level (i.e., a logical zero value). Similarly, if a signal having a low logic level is provided to the input 202 of inverter 200 , output 204 of inverter 200 is set to a high logic level.
[0027] FIG. 3 illustrates a schematic diagram of the ring oscillator 100 shown in FIG. 1 in reset mode consistent with some embodiments of the present invention. In the reset mode shown in FIG. 3 , switches 128 - 134 and 138 - 140 may be closed, thereby coupling the outputs of inverters 104 - 110 and 114 - 116 to the inputs of 106 - 112 and 116 and 102 respectively. Switches 144 - 150 and 154 - 156 may be opened such that the inputs of inverters 102 , 106 - 112 , and 116 are decoupled from ground. Switches 126 and 136 may be opened such that the inputs of inverters 104 and 114 are decoupled from the outputs of inverters 102 and 112 . Finally, switches 142 and 152 may be closed, thereby coupling the inputs of inverters 103 and 114 to ground.
[0028] When configured in reset mode, ring oscillator 100 is in a non-oscillating steady state (e.g., the logical signal level values at circuit nodes 302 - 316 do not change). For example, in reset mode, circuit nodes 302 , 306 , 310 , 312 , and 316 may be set to a low logic level (i.e., ground or a logical one value) and may remain at low logic level as long as ring oscillator 100 remains in reset mode. Similarly, circuit nodes 304 , 308 , and 314 may be set to a high logic level and remain at a high logic level as long as ring oscillator 100 remains in reset mode.
[0029] The aforementioned operation of ring oscillator 100 in reset mode is described for illustrative purposes with respect to switches 126 and 136 being open, switches 132 and 152 being closed, switches 128 - 134 and 138 - 140 being closed, and switches 144 - 150 and 154 - 156 being open. Ring oscillator 100 , however, may be placed in reset mode by orienting any two pairs of switches having an equal number of inverters between them in either direction, respectively, (e.g., switches 128 and 144 and switches 138 and 154 ) in the same manner described above with respect to switches 126 and 136 and switches 132 and 152 , and orienting all other switches in the same manner as switches 128 - 134 , 138 - 140 , 144 - 150 , and 154 - 156 . In this manner, the two switches having an equal number of inverters between them in either direction, respectively, may be used to generate two propagating signal edges spaced evenly apart across the ring oscillator. In some embodiments, the ring oscillator may include only those switches necessary to generate a reset of the ring oscillator (e.g., generation of two propagating signal edges spaced evenly apart across the ring oscillator). Further, in some embodiments, ring oscillator 100 may be reset utilizing only those switches necessary to generate a single initial propagating signal edge around ring oscillator 100 . Accordingly, in certain embodiments, ring oscillator 100 may use less switches than those illustrated in FIGS. 1 and 3 - 4 .
[0030] FIG. 4 illustrates a schematic diagram of the ring oscillator 100 shown in FIG. 1 after reset consistent with some embodiments of the present invention. After exiting reset mode as described in reference to FIG. 3 , switches 126 - 140 may be closed, thereby coupling the outputs of inverters 102 - 116 to the inputs of inverters 104 - 116 and 102 (i.e., circuit nodes 302 - 316 ) respectively. Switches 142 - 156 may be opened such that the inputs of inverters 104 - 116 and 102 (i.e., circuit nodes 302 - 316 ) respectively are decoupled from ground. In this configuration, ring oscillator 100 after reset may be described as a chain of serially connected inverters 102 - 116 and cross-coupling circuits 118 - 124 that couple a pair of circuit nodes having an equal number of inverters between them in either direction, respectively.
[0031] By switching the ring oscillator 100 from the switch configuration in reset mode, as illustrated in FIG. 3 , to the switch configuration after reset mode illustrated in FIG. 4 , two signal edges begin to propagate around the chain of serially connected inverters 102 - 116 (e.g., ring of inverters), starting from nodes 302 and 312 respectively. After these signal edges propagate around ring oscillator 100 once, signal levels at circuit nodes 302 - 316 will subsequently oscillate between a high logic level and a low logic level at or near a frequency equal to the inverse of the combined delay time of inverters 102 - 116 (e.g., the period of the oscillation). Accordingly, eight clock signals each differing in phase by the delay time of one of inverters 102 - 116 , denoted as t, and having a period of 8 t may be extracted from ring oscillator 100 at circuit nodes 302 - 316 .
[0032] Cross-coupling circuits 118 - 124 may be arranged to ensure that signal levels at circuit nodes having an equal number of inverters 102 - 116 between them in either direction remain differential. For example, with respect to FIG. 4 , cross-coupling circuit 118 ensures that the signal levels at nodes 302 and 310 remain differential (e.g., out of phase by 180° or 4t). Further, cross-coupling circuits 118 - 124 help to ensure that the oscillation of signal levels in ring oscillator 100 remains sustainable and that the oscillating signals generated by ring oscillator 100 have a 50% duty cycle. In this manner, cross-coupling circuits 118 - 124 function to counteract imperfections of ring oscillator 100 .
[0033] FIG. 5 illustrates an exemplary signal timing diagram 500 of a ring oscillator 100 after reset consistent with some embodiments of the present invention. Particularly, FIG. 5 illustrates the signal levels at circuit nodes 302 - 316 of ring oscillator 100 displayed in FIG. 3 starting after reset (i.e., time or ‘t’=0). At t=0, circuit nodes 302 and 312 are at a low logic level. After a time period t (i.e., t=t), circuit node 302 is set to a high logic level as the signal edge propagating around the chain of serially connected inverters generated by the closing of switch 126 after exiting reset reaches circuit node 302 . In some embodiments, t may correspond to the time delay of one of inverters 102 - 118 . In some embodiments, t may correspond to the average time delay of an inverter of inverters 102 - 118 . For illustrative purposes, FIG. 5 is described in reference to the aforementioned signal edge as it propagates around the ring oscillator.
[0034] At t=2t, the propagating signal edge originating from circuit node 302 reaches circuit node 304 , thereby causing the signal level at circuit node 304 to switch from a high logic level to a low logic level. At t=3t, this propagating signal edge reaches circuit node 306 , thereby causing the signal level at circuit node 306 to switch from a low logic level to a high logic level. This signal edge continues to propagate around the ring oscillator, thereby causing the signal level at circuit nodes 308 - 316 to change their state at corresponding time intervals. After a period of 8t, this signal edge makes a complete trip around the ring oscillator, returning to circuit node 302 , and continues to propagate around the ring oscillator in the same manner thereafter.
[0035] As the signal edge originating from circuit node 302 propagates around the ring oscillator, another signal edge originating from circuit node 312 also propagates around the chain of serially connected inverters generated by the closing of switch 136 after exiting reset. Similar corresponding state changes at nodes 308 - 316 occur as this signal edge propagates around the ring oscillator. After a period of 8 t, this signal edge makes a complete trip around the ring oscillator, returning to circuit node 302 , and continues to propagate around the ring oscillator in the same manner thereafter.
[0036] In the aforementioned manner, after the signal edges generated by reset propagate around the ring oscillator, signal levels at circuit nodes 302 - 316 will subsequently oscillate between a high logic level and a low logic level at or near a frequency equal to the inverse of the combined delay time denoted as of inverters 102 - 116 (e.g., the period of the oscillation), as illustrated by the ring oscillator signal levels shown on the right of FIG. 5 . Accordingly, eight clock signals of the same frequency, each differing in phase by the delay time of one of inverters 102 - 116 , denoted as t and having a period of 8t, may be extracted from ring oscillator 100 at circuit nodes 302 - 316 .
[0037] Ideally, the oscillation described above will continue in perpetuity. However, due to mismatches between inverters 102 - 116 and/or other components in the ring oscillator as well as noise introduced into the propagating signals, the oscillation may die out over time as delays and/or noise caused by the imperfections can cause the duty cycle of the oscillating signal to wander to either 0 or 1. Accordingly, cross-coupling circuits 118 - 124 are configured to ensure that signal levels at circuit nodes having an equal number of inverters 102 - 116 between them in either direction remain differential, thereby ensuring that the oscillation of signal levels in the ring oscillator remains sustainable and have a 50% duty cycle. For example, cross-coupling circuit 118 ensures that the signal levels at nodes 302 and 310 remain differential (e.g., out of phase by 180° or 4t). In this manner, cross-coupling circuits 118 - 124 function to counteract imperfections of ring oscillator 100 . Because any imperfections of ring oscillator 100 will generally be small, the relative sizes of cross-coupling circuits 118 - 124 may also be small, thus saving power. In some embodiments, cross-coupling circuits 188 - 124 may be designed such that their inverting functionality is strong enough to compensate for any imperfections of ring oscillator 100 without affecting the functionality of inverters 102 - 116 .
[0038] FIG. 6 illustrates a schematic diagram of an exemplary cross-coupling circuit 600 that includes a pair of pMOS transistors 606 - 608 consistent with some embodiments of the present invention. Cross-coupling circuit 600 may be used as cross-coupling circuits 118 - 124 shown in FIG. 1 . Cross-coupling circuit 600 includes pMOS transistors 602 - 604 , cross-coupling circuit terminals 606 - 608 , and power terminal 208 . The sources of pMOS transistors 602 - 604 may be coupled to power terminal 610 . The drain of pMOS transistor 602 is coupled to the gate of pMOS transistor 604 to form cross-coupling circuit terminal 606 . Similarly, the drain of pMOS transistor 604 is coupled to the gate of pMOS transistor 602 to form cross-coupling circuit terminal 608 . In certain embodiments, cross-coupling circuits 600 may be coupled between pairs of ring oscillator 100 circuit nodes 158 - 172 that have an equal number of inverters 102 - 116 between them in either direction.
[0039] Cross-coupling circuit 600 operates to keep the signal levels at cross-coupling circuit terminals 606 - 608 differential. For example, if a signal having a high logic value (e.g., a logical one value) is provided at cross-coupling circuit terminal 606 , cross-coupling circuit 600 operates to ensure that the signal at cross-coupling terminal 608 is set to a low logic value (e.g., a logical zero value). Similarly, if a signal having a low logic value is provided at cross-coupling circuit terminal 606 , cross-coupling circuit 600 operates to ensure that the signal at cross-coupling circuit terminal 608 is set to a high logic value.
[0040] FIG. 7 illustrates a schematic diagram of an exemplary cross-coupling circuit 700 that includes a pair of nMOS transistors 702 - 704 consistent with some embodiments of the present invention. Cross-coupling circuit 700 may be used as cross-coupling circuits 118 - 124 shown in FIG. 1 . Cross-coupling circuit 700 includes nMOS transistors 702 - 704 , cross-coupling circuit terminals 706 - 708 , and ground terminal 710 . The sources of nMOS transistors 702 - 704 may be coupled to ground terminal 710 . The drain of nMOS transistor 702 is coupled to the gate of nMOS transistor 704 to form cross-coupling circuit terminal 706 . Similarly, the drain of nMOS transistor 704 is coupled to the gate of nMOS transistor 702 to form cross-coupling circuit terminal 708 . In certain embodiments, cross-coupling circuits 700 may be coupled between pairs of ring oscillator 100 circuit nodes 158 - 172 that have an equal number of inverters 102 - 116 between them in either direction.
[0041] Cross-coupling circuit 700 operates to keep the signal levels at cross-coupling circuit terminals 706 - 708 differential. For example, if a signal having a high logic value (e.g., a logical one value) is provided at cross-coupling circuit terminal 706 , cross-coupling circuit 700 operates to ensure that the signal at cross-coupling terminal 708 is set to a low logic value (e.g., a logical zero value). Similarly, if a signal having a low logic value is provided at cross-coupling circuit terminal 706 , cross-coupling circuit 700 operates to ensure that the signal at cross-coupling circuit terminal 708 is set to a high logic value.
[0042] FIG. 8 illustrates a schematic diagram of an exemplary cross-coupling circuit 800 that includes a pair of inverters 802 - 804 consistent with some embodiments of the present invention. Cross-coupling circuit 800 may be used as cross-coupling circuits 118 - 124 shown in FIG. 1 . Cross-coupling circuit 800 includes inverters 802 - 804 and cross-coupling circuit terminals 806 - 808 . As illustrated, the input of inverter 802 may be coupled with the output of inverter 804 to form cross-coupling circuit terminal 806 . Similarly, the input of inverter 804 may be coupled to the output of inverter 802 to form cross-coupling circuit terminal 808 . In certain embodiments, cross-coupling circuits 800 may be coupled between pairs of ring oscillator 100 circuit nodes 158 - 172 that have an equal number of inverters 102 - 116 between them in either direction.
[0043] Inverter 802 operates to invert the signal provided at cross-coupling circuit terminal 806 . Inverter 804 operates to invert the signal provided at cross-coupling circuit terminal 808 . For example, if a signal having a high logic value (e.g., a logical one value) is provided at cross-coupling circuit terminal 806 , inverters 802 and 804 operate to ensure that cross-coupling circuit terminal 808 is set to a low logic value (e.g., a logical zero value). In this manner, cross-coupling circuit 800 operates to keep the signal levels at cross-coupling circuit terminals 806 - 808 differential.
[0044] In the preceding specification, various preferred embodiments have been described with reference to the accompanying drawings. It may, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set for in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense. | A ring oscillator is disclosed for generating one or more clock signals. In some embodiments, the ring oscillator includes a first set of n series coupled inverters, a second set of n series coupled inverters, a first reset switch configured to couple a last inverter of the first set of inverters to a first inverter of the second set of inverters and to generate a first signal edge, a second reset switch configured to couple a last inverter of the second set of inverters to a first inverter of the first set of inverters, and a cross-coupling circuit coupled between an output of an inverter of the first set of inverters to a corresponding output of an inverter of the second set of inverters. In some embodiments, 2n clock signals separated in phase by 360°/2n may be generated. | 7 |
BRIEF DESCRIPTION OF THE INVENTION
The present invention refers to household items in general an in particular to a practical jug, sugar bowl, coffee container and cup set, capable of forming one single demountable assembly in which the jug's handle is used to support the sugar bowl, coffee container and cups by their handles. In addition, a support strip may be attached to two projections located on the jug's handle to permit the carrying of the complete set. The cups each have an annular recess around its base, whereby they can be stacked with the recess located in the top of the next cup down in the stack.
BACKGROUND OF THE INVENTION
The transport or moving of table and camping items such as jugs, glasses and cups is cumbersome and generally requires the use of a basket or similar facilities, the storage of which additionally utilizes space in pantries and closets.
SUMMARY OF THE INVENTION
An object of this invention is to provide an assembly composed of a jug, sugar bowl, coffee container and set of cups in which the handle of the jug, fixed on one of its sides, serves as a support for sugar bowl, coffee container and cups by means of two parallel rails. The sugar bowl, coffee container and cups are attached to the jug by their own handles, and preferably have an annular recess around the bottom end that fits into the top end of the next cup.
There is a projection at the top end of the parallel rails where a strip of flexible thermoplastic polymeric material is attached to form a handle to carry the set.
DESCRIPTION OF THE FIGURES
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a front view of the jug, sugar bowl, coffee container and cups, forming the set, the subject of this invention;
FIG. 2 is a partially cut away side view of the set shown in FIG. 1;
FIG. 3 is a partially sectioned rear view of the set shown in FIG. 1, the sectioned portion being on section line 3--3 of FIG. 4;
FIG. 4 is a plan view of the set shown in FIG. 1;
FIG. 5 is a high side view of the sugar bowl or coffee container with closure; and
FIG. 6 is a part sectional side view on line 5--5 shown in FIG. 4 of the cup set assembled to the jug and showing the manner in which they fit into each other.
DETAILED DESCRIPTION OF THE INVENTION
The present invention consists of cups (21), sugar bowl (19) and coffee container (20) attached to a jug (18), with the jug (18), the sugar bowl (19) and the coffee container (20) being provided with tops (22) and (23) respectively. The front part of the jug is provided with a spout (24). The top rear of the jug is provided with projections attached to which is a carrying handle (25). The cups (21) and the jug (18) are provided, at their lower ends with annular recesses (27) and (26).
There is a vertically disposed pairs of rails (28) on the rear of the jug (18) and with a vertically disposed "T" cross section bar (29) symmetrically intermediate these rails.
There is an opening (30) in the top of each cup (21), sugar bowl (19) and coffee container (20) to receive the annular recess of another cup (26) or, in the case of the bowl and container, the tops (23). Rails (28) and crossbar (29) form a vertically disposed partially closed recess in which handles (31) of cups (21), bowl (19) and container (20), are captively held. The rails (28) have two depending hook-like projections (32) to which the band (25) that serves as a handle for the unit is attached.
A base portion (34) closes the bottom of the partially closed recess.
Crossbar (29) forms a natural handle for the jug (18) and together with the rails (28) is a support for the handles (31) of cups (21), sugar bowl (19) and coffee container (20), the items being inserted downwardly into the partially closed recess for attachment to the jug.
The foregoing disclosure of specific embodiments is illustrative of the broad inventive concepts comprehended by the invention. | Set of jug, sugar bowl, coffee container and cups capable of being assembled into a single unit by attaching the bowl, container and cups to the jug. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to digital communications, and more particularly to demodulators for minimum shift keying (MSK) digital communication systems. The following brief explanation of MSK communication systems is by way of background to a discussion of the prior art and the invention.
MSK In General
Digital information is transmitted as a serial stream of discrete bits of information each bit being either a logic "1" or a logic "0". The bits are presented for transmission at a rate called the clock rate or clock frequency F k . F k is sometimes expressed in terms of the clock period T, where F k =1/T.
Frequency shift keying (FSK) is a method of encoding and transmitting digital data by radio. In an FSK system, the "0" and "1" bits to be transmitted are converted into two tones, one of the tones having frequency F 1 and the other having frequency F 2 . These two tones are used to frequency modulate a radio frequency ("rf") carrier having frequency F c , and the resulting frequency modulated (FM) signal is then transmitted.
At a receiver, the received FSK signal is demodulated to recover the tones, and then the tones are converted back into digital data.
Minimum shift keying (MSK) is a particularly efficient type of FSK system and hence is preferred for satellite communication systems. In MSK, tone frequencies F 1 and F 2 are required to relate to F c and F k in accordance with the equations:
F.sub.1 =F.sub.c -F.sub.k /4 (1)
F.sub.2 =F.sub.c +F.sub.k /4 (2)
MSK Modulation
Data bits are presented to an MSK modulator serially. Each bit has a duration equal to the clock period T. Thus at time 0, the first bit arrives; at time T, the next bit; at time 2T, the next bit; and so on.
The MSK modulator diverts this serial stream of data bits into two parallel channels called the "I" channel and the "Q" channel. The data bits alternate between channels; thus, if the nth bit goes to the I channel, the (n+1)th bit goes to the Q channel.
Because each bit has duration T, but only every other bit is present in the I channel, there is a space of duration T between successive bits in the I channel. The existence of these spaces permits each bit in the I channel to be shaped into a single half-sinusoid of duration 2T, thereby filling in the spaces. The output of the I channel is thus a continuous stream of half-sinusoids, each of duration 2T. Each half-sinusoid is positive if it represents a logic "1" and negative if it represents a "0".
A half-sinusoid of duration 2T corresponds to one-half of a sinusoid having period 4T and frequency 1/(4T)=F k /4.
The I channel output therefore corresponds to a continuous sinusoid I(t) having a frequency F k /4. Because successive bits in the I channel are presented at times that are even multiples of T, I(t) is a cosine function defined by the expression: ##EQU1## where i=+1 when I(t) is representing a logic "1" and i=-1 when I(t) is representing a logic "0".
A similar shaping process is performed on bits in the Q channel. Because successive bits in the Q channel are presented at times that are odd multiples of T, Q(t) is a sine function defined by the expression: ##EQU2## where q=+1 when Q(t) is representing a logic "1" and q=-1 when Q(t) is representing a logic "0".
The rf carrier signal is split into two signals, each being a sinusoid having frequency F c . One of these F c signals is modulated by I(t), resulting in a signal given by the expression: ##EQU3## The other F c signal is shifted 90 degrees in phase and then is modulated by Q(t), resulting in the following signal: ##EQU4## The final step in the modulation process is to add I*F c and Q*F c together to produce an MSK output signal S: ##EQU5## The trigonometric identities
cos A cos B-sin A sin B=cos (A+B),
and
cos A cos B+sin A sin B=cos (A-B)
may be applied to S with the following results: ##EQU6## Hence, if i and q have the same sign, then S will have a frequency F 1 =F c -F k /4, but if i and q have opposite signs then S will have a frequency F 2 =F c +F k /4. These two values of the frequency of S are equal to the required frequencies for tones F 1 and F 2 as given by equations (1) and (2).
To summarize the above process, in an MSK modulator an input stream of digital data having a clock period T and clock frequency F k is divided into two channels designated the I and Q channels. The even-numbered bits go to one-channel, the odd-numbered bits to the other. The bits in each channel are converted into a sinusoidal signal having a frequency of one-fourth the clock frequency. The I and Q channel sinusoidal output signals are 90 degrees out of phase with respect to each other. These I and Q output signals modulate an rf carrier having frequency F c to produce a final MSK output signal S. The phase of S changes back and forth between 0 and 180 degrees from time to time, and the frequency of S changes back and forth between F 1 =F c -F k /4 and F 2 =F c +F k /4 from time to time, according to the values of the data being transmitted. S may therefore be considered as assuming the frequencies F 1 and F 2 at various times, and each of these frequencies may have a phase of 0 or 180 degrees. The signal S takes only one of these four possible forms at any given moment.
Transmission
A double-sideband suppressed-carrier transmission technique is used for the actual transmission of S. In this technique, the carrier at frequency F c is suppressed before transmission, and only frequencies F 1 and F 2 are actually sent. A substitute "carrier" having frequency F c in phase with the transmitter's carrier must be regenerated in the receiver in order to demodulate S and recover I(t) and Q(t). Also, a clock signal at frequency F k =1/T must be regenerated in the receiver in order to convert I(t) and Q(t) back into digital data.
Demodulation
In an MSK receiver, a received MSK signal S is demodulated to extract the I(t) and Q(t) sinusoidal signals. This demodulation process is effected by splitting the signal S into two channels; electronically mixing a regenerated carrier having frequency F c with S in one of the channels to produce I(t); phase-shifting the regenerated carrier 90 degrees; and then mixing the phase-shifted carrier with S in the other channel to produce Q(t).
I(t) is then combined with a regenerated clock signal to reproduce the I channel data bits, and Q(t) is combined with the same clock signal to reproduce the Q channel data bits. Finally the I and Q channel data bits are recombined to yield a reproduction of the original digital data in serial form.
Circuits to regenerate carrier and clock signals in MSK receivers are known to the art. However, these circuits are not practical for time division multiple access (TDMA) applications, such as modern satellite communication systems, as will become apparent from the following discussion of the prior art. The present invention overcomes this problem and provides a practical MSK demodulator for use in TDMA applications.
The Prior Art
It will be apparent that a regenerated carrier signal having the same frequency F c as the transmitter carrier, and precisely in phase with it, is needed to successfully demodulate a received MSK signal S. Also, a regenerated clock signal having frequency F k =1/T is required in order to recover digital data from the demodulated S signal.
The only frequencies actually received by an MSK receiver are F 1 =F c -F k /4 and F 2 =F c +F k /4 as given in equations (1) and (2). These two equations can be solved for F c and F k as follows:
F.sub.c =(2F.sub.1 +2F.sub.2)/4 (5)
F.sub.k =2F.sub.2 -2F.sub.1 ( 6)
The operations described by equations (5) and (6) can be carried out by an electronic circuit to regenerate F c and F k from F 1 and F 2 . The circuit of FIG. 1, developed by de Buda ("Coherent Demodulation of Frequency-Shift Keying With Low Deviation Ratio", IEEE Trans. Commun., Vol. COM-20, No. 6, June 1972, pages 429-435), can be used for this purpose.
In FIG. 1, a received MSK signal S is applied to a squarer 11. Since S is sinusoidal, the effect of squarer 11 is to apply the trigonometric identity
cos.sup.2 A=1/2+1/2 cos 2A (6a)
to S, thereby doubling the frequency of S. The resulting signal, at any given moment, is either
X.sub.1 =cos [2πt (2F.sub.1)] (6b)
is S is then being transmitted at frequency F 1 , or
X.sub.2 =cos [2πt (2F.sub.2)] (6c)
if S is then being transmitted at frequency F 2 .
X 1 and X 2 are applied to phase-locked loop ("PLL") 12 and to PLL 13. PLL 12 locks onto X 1 during those times when F 1 is being transmitted and gives a stable, continuous output signal having frequency 2F 1 . PLL 13 locks onto X 2 during those times when F 2 is being transmitted and gives a stable, continuous output signal having frequency 2F 2 .
The outputs of PLL 12 and PLL 13 are multiplied in mixer 14, yielding an output X 3 composed of the sum and the difference of 2F 1 and 2F 2 . A low pass filter 15 removes the sum, leaving the difference 2F 2 -2F 1 as its output. In accordance with equation (6), this output from filter 15 is the desired clock frequency F k , and recovery of the clock signal is complete at this point in the circuit.
The output of PLL 12 which is a signal having frequency 2F 1 , is reduced to a signal having frequency F 1 in divider 16, and the output of PLL 13 is similarly reduced to a signal having frequency F 2 in divider 17. F 1 and F 2 are added in summing block 18, producing an output signal X 4 that contains
cos (2πt F.sub.c) (6d)
in a form usable to demodulate S so as to recover I(t).
Similarly, output signal X 5 from summing block 19 contains
sin (2πt F.sub.c) (6e)
in a form usable to demodulate S so as to recover Q(t).
The positive or negative sign in front of S is removed by the squaring operation performed by squarer 11, resulting in a 180 degree phase ambiguity in the recovered carrier signal F c . The undesirable effect of this ambiguity on the output digital data can be compensated for by differentially encoding the digital data prior to transmission and differentially decoding the data after reception, a process known to the art.
The phase-locked loops used in the circuit of FIG. 1 require a long interval of time, as much as several seconds, to lock onto their respective signals. This long lock-on time does not matter provided the duration of the transmission is much longer than the acquisition time. However, in satellite TDMA applications, a ground station transmits a burst of data to a satellite receiver during a time interval measured in microseconds. Then the transmission stops until the next burst of data is ready for transmission. In the meantime, the satellite receiver is reassigned to receive a burst of data from a different ground station; when that burst of data has been transmitted, the receiver is reassigned to yet a third ground station, and so on. A significant problem in TDMA systems arises from the randomness of the clock and carrier phase on a burst-to-burst basis. It will be apparent that a receiver using phase-locked loops does not have enough time to lock onto signals coming from various transmitters when each such signal has a duration measured in microseconds.
Attempts have been made to avoid the long lock-on times characteristic of phase-locked loops by replacing them with narrow bandpass filters. However, unlike a phase-locked loop, a narrow bandpass filter does not produce a constant-amplitude output. Rather, the amplitude of the output of such a filter varies, reaching a maximum level only after the desired input frequency has been continuously present for some interval of time. When the input signal vanishes, the amplitude of the filter output starts to decay.
It will be recalled that the frequency of the MSK signal S changes back and forth between F 1 and F 2 , and that only one of these two frequencies is present at any given time. Therefore, if narrow bandpass filters are used to isolate these two frequencies, the amplitude of the output of each filter will continuously vary as S changes back and forth between F 1 and F 2 . This variation in amplitude of the filter outputs constitutes amplitude modulation (AM) of the filter output signals, and the AM thus introduced must be removed by a limiter circuit before further use can be made of these signals. A limiter prevents the amplitude of a signal from exceeding a specified level, while preserving the shape of the waveform at amplitudes less than the specified level.
Current and future satellite communication systems employ high data rates, which require relatively high intermediate processing frequencies. A significant problem for rapid acquisition systems is the need to provide a recovered carrier with constant power. A significant problem resulting from this need is that limiters at these frequencies, while eliminating amplitude modulation, lead to unacceptable levels of phase modulation. This phase modulation causes significant degradation in the accuracy of the processed data. Hence, there has not been any practical way to take advantage of the highly efficient MSK method of transmission in TDMA applications at such high data rates. The present invention satisfies the need for such a circuit.
SUMMARY OF THE INVENTION
The present invention is characterized by a carrier and clock recovery circuit, and a related method, using filters to produce two signals at frequency 2F c . Although each of these signals is amplitude modulated by its respective filter, the modulation patterns are complementary, and thus when the two signals are added together, the result is a constant-amplitude signal at frequency 2F c .
Briefly and in general terms, the present invention uses ringing filters rather than phase-locked loops to lock onto the 2F 1 and 2F 2 components of the doubled input signal S. These filters acquire their respective input signals without the long time delay characteristic of phase-locked loops. The amplitude modulation (AM) introduced by either filter is at all times equal in magnitude but opposite in polarity to the AM introduced by the other.
The output signal of the 2F 1 filter may, by using equation (1) be represented as:
2F.sub.1 =2(F.sub.c -F.sub.k /4)=2F.sub.c -F.sub.k /2
In the present invention, this 2F 1 signal is mixed with a recovered F k /2 signal to yield a sum signal having frequency
2F.sub.1 +F.sub.k /2=2F.sub.c -F.sub.k /2+F.sub.k /2=2F.sub.c.
This signal will hereafter be referred to as 2F c '.
The output signal of the 2F 2 filter may, by using equasion (2), be represented as:
2F.sub.2 =2(F.sub.c +F.sub.k /4)=2F.sub.c +F.sub.k /2
In the present invention, this 2F 2 signal is mixed with a recovered F k /2 signal to yield a difference signal having frequency
2F.sub.2 =F.sub.k /2=2F.sub.c +F.sub.k /2-F.sub.k /2-2F.sub.c.
This signal will hereafter be referred to as 2F c ".
The 2F 1 ringing filter impresses on the 2F 1 signal an AM that varies according to the presence of the F 1 tone in S, and the 2F 2 ringing filter impresses on the 2F 2 signal an AM that varies according to the presence of the F 2 tone in S. But, since either F 1 or F 2 , but not both, is always present in S, the AM of the 2F 2 signal is complementary to the AM of the 2F 2 signal. Two signals with complementary AM have the property that the sum of their amplitudes always equals a constant. The AM on the 2F 1 signal is passed through its mixer onto 2F c ', and the AM on the 2F 2 signal is passed through its mixer onto 2F c ". Since the AM on 2F c ' is equal and opposite to the AM on 2F c ", if the two signals are summed, their respective AM parts cancel each other and the result is a constant-amplitude signal of frequency 2F c . A simple frequency divider yields the desired end result, a constant-amplitude signal having frequency F c .
In accordance with the invention, a received MSK signal S is applied to a frequency-doubling circuit such as a squarer. As discussed previously, the result is a signal having components of frequency twice F 1 and twice F 2 . This signal is applied to two ringing filters, one tuned to 2F 1 and the other tuned to 2F 2 . These ringing filters produce output signals of frequency 2F 1 and 2F 2 , respectively.
It is necessary to recover the clock frequency F k as well as the carrier, and this clock recovery is performed by the same means as in the prior art clock recovery circuit. Specifically, the 2F 1 and 2F 2 signals are mixed to produce a difference signal of frequency F k . Filtering is used to eliminate spurious mixer output frequencies, and, although AM is present in the recovered clock signal, the frequency F k is sufficiently low that the AM may be eliminated by using a conventional limiter without introducing unacceptable PM.
The F k signal is divided by two to produce a signal having frequency F k /2. This signal is mixed with 2F 1 to produce sum and difference frequencies, but only the sum, having frequency 2F c and referred to as 2F c ', is used.
The signal having frequency F k /2 is also mixed with 2F 2 to produce sum and difference frequencies, but only the difference, having frequency 2F c and referred to as 2F c ", is used.
The 2F c ' signal carries the AM caused by the 2F 1 filter, and the 2F c " signal carries the AM caused by the 2F 2 filter. These two signals are algebraically added in a summing circuit, and the equal and opposite AM component cancel each other, yielding a signal of frequency 2F c and constant amplitude. This signal is filtered and divided by two to produce the final output signal F c . Additional filtering of the final F c signal may be performed as needed.
Although the carrier and clock recovery technique of the present invention will work at many frequencies, it has particular value at frequencies where other circuits with limiters present unacceptable phase modulation. At these high frequencies, power dividers must be used at each point in the circuit where the signal is divided into two paths. Also, depending on the frequency and signal strength of the received signal and on whether the signal is preamplified prior to the clock and carrier recovery operation, amplifiers may be needed at various points in the recovery circuit, including before and after the squaring operation and after each filtering operation.
It may also be desirable to filter the clock signal as recovered from the first mixer by the combination of a bandpass filter and a low pass filter, with amplification taking place in conjunction with each filtering operation, prior to the limiter stage.
The carrier and clock recovery circuit may be combined with an I-Q demodulator circuit to produce output signals I(t) and Q(t). In such a demodulator, the F c signal is split by a power divider or other suitable dividing means into two signals. The input signal S is also split into two signals, but one of these signals is phase-shifted 90 degrees. The phase-shifted input signal is mixed with one of the F c signals to produce Q(t), and the other input signal is mixed with the other F c signal to produce I(t). After suitable filtering to remove spurious mixer outputs, I(t) and Q(t) are available for decoding.
In terms of a novel method for recovering clock and carrier signals from a received signal containing two frequency tones F 1 and F 2 , the invention comprises the steps of doubling the frequency of the received signal, filtering the frequency-doubled signal in two ringing filters tuned to frequencies 2F 1 and 2F 2 , respectively, to yield first and second continuous signals at these frequencies, deriving a half-clock-frequency signal from the first and second continuous signals, and mixing the first and second continuous signals with the half-clock-frequency signal, to yield two composite signals containing a component at twice the carrier frequency. The concluding steps needed to recover the carrier are summing the two composite signals to eliminate opposite amplitude modulations, filtering the signal resulting from the summing step, to obtain a signal of constant amplitude and at twice the carrier frequency, and frequency-dividing the latter signal to recover the carrier signal.
In the preferred embodiment of the invention, the step of deriving the half-clock-frequency signal includes mixing the two first and second continuous signals with each other, filtering the signals resulting from the last-mentioned mixing step to obtain a difference component at the clock frequency, limiting the difference component signal to eliminate amplitude variations, and frequency-dividing the clock-frequency signal to obtain the half-clock-frequency signal.
It will be appreciated from the foregoing that the present invention represents a significant advance in the field of digital communications. In particular, the present invention makes possible the transmission of digital data by means of the highly efficient and relatively error-free MSK method at high data rates in a TDMA environment. Other aspects and advantages of the present invention will become apparent from the following more detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a prior art MSK clock and carrier recovery circuit;
FIG. 2 is a block diagram of an MSK clock and carrier recovery circuit according to the present invention; and
FIG. 3 is a detailed block diagram of an MSK demodulator employing a clock and carrier recovery circuit according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
It has not been possible to use the highly efficient minimum shift keying ("MSK") system for transmitting digital data in time-division multiple-access (TDMA) applications because phase-locked loops in the carrier and clock recovery section of the demodulators of MSK receivers are subject to prolonged phase transients and cannot lock onto tone components of the received signal fast enough. Other available methods of signal acquisition introduce unacceptable phase modulation distortion into the recovered carrier signal.
The present invention solves this problem by using ringing filters for signal acquisition in the carrier and clock recovery section of an MSK demodulator; producing two carrier signals having complementary amplitude modulation; and using a summing circuit to eliminate this amplitude modulation without introducing phase modulation distortion.
FIG. 1 illustrates a typical prior art carrier and clock recovery circuit. An MSK input signal S is applied to squarer 11. Since S is sinusoidal, the effect of squarer 11 is to double the frequency of S. The output of squarer 11 at any given moment has frequency either X 1 =twice F 1 or X 2 =twice F 2 , where F 1 and F 2 are the two modulating tones, see equations (1) and (2), which produce S.
X 1 and X 2 are applied to phase-locked loop (PLL) 12 and to PLL 13. PLL 12 locks onto X 1 during those times when F 1 is being transmitted and gives a stable, continuous output at frequency 2F 1 . PLL 13 locks onto X 2 during those times when F 2 is being transmitted and gives a stable, continuous output at frequency 2F 2 .
The outputs of PLL 12 and PLL 13 are multiplied in mixer 14, yielding an output X 3 composed of the sum and the difference of 2F 1 and 2F 2 . A low pass filter 15 removes the sum, leaving as its output a signal having a frequency equal to the difference 2F 2 -2F 1 =clock frequency F k .
The output of PLL 12, 2F 1 , is reduced to F 1 in divider 16, and 2F 2 is similarly reduced to F 2 in divider 17. F 1 and F 2 are added in summing block 18 to produce X 4 , a cosine function of carrier frequency F c , and F 1 and -F 2 are added in summing block 19 to produce X 5 , a sine function of F c .
In accordance with the present invention, ringing filters are substituted for the phase-locked loops as shown in the block diagram of FIG. 2. and the more detailed diagram of FIG. 3. Basically, a ringing filter is a resonant cavity that is responsive to a very narrow band of frequencies. Such a filter is said to "ring at" a particular frequency, meaning that the output the filter will be at the ringing frequency, but at an amplitude dependent on the amplitude and duration of the ringing-frequency component at the input of the filter. The numbers of the elements in FIG. 2 correspond with the comparable elements in FIG. 3.
In FIG. 2, an input MSK signal S is applied to squarer 23, doubling the input signal to produce a signal having, at any given moment, a frequency of either 2F 1 or 2F 2 , just as in the circuit of FIG. 1. Ringing filter 29 rings at 2F 1 , which provides a continuous output signal having frequency 2F 1 but an amplitude that varies according to when F 1 is actually present in S. Likewise, ringing filter 35 rings at 2F 2 and gives a continuous output signal having frequency 2F 2 but an amplitude that varies according to when F 2 is actually present in S. Unlike the relatively slow phase-locked loops 12 and 13 of FIG. 1, ringing filters 29 and 35 are single-cavity filters which provide minimum step-function response time for a given bandwidth. This is a key requirement for rapid carrier recovery.
A clock signal with frequency F k is recovered by mixer 39 and a filter 41, just as the clock signal is recovered in the circuit of FIG. 1 by mixer 14 and filter 15. In FIG. 2, a limiter 49 is used to eliminate amplitude modulation introduced by the action of filters 29 and 35. The limiter 49 prevents the amplitude of the clock signal from exceeding a specified value. Frequency F k is sufficiently low that the limiter 49 does not introduce unacceptable phase modulation distortion into the clock signal.
The clock signal F k is divided in divider 51 to produce a new signal having frequency F k /2. This new signal is mixed with 2F 1 in mixer 55 to produce sum and difference signals. The sum signal, 2F c ', has frequency 2F c and an amplitude modulation that varies according to when F 1 is actually present in S.
The F k /2 signal is mixed with 2F 2 in mixer 57 to produce sum and difference signals. The difference signal, 2F c ", has frequency 2F c and an amplitude modulation that varies according to when F 2 is actually present in S.
The amplitude modulation present in 2F c ' is complementary to the amplitude modulation present in 2F c ". Hence, when these two signals are applied to summer 59, their amplitude modulations cancel, yielding a signal having frequency 2F c and constant amplitude. Bandpass filter 61 removes any other signals introduced by the summer 59, and divider 63 reduces the signal having frequency 2F c to a final recovered carrier at frequency F c .
A preferred embodiment of the present invention is shown in FIG. 3. FIG. 3 is a more detailed diagram than FIG. 2, but each element in FIG. 2 has a corresponding element in FIG. 3, and corresponding elements in the two figures are numbered alike. For example, limiter 49 in FIG. 2 corresponds to limiter 49 in FIG. 3.
In FIG. 3, a directional coupler 20 provides part of input signal S to squarer 23. Squarer 23 doubles the frequencies present in S and, after amplification by amplifier 25, the signal with these doubled frequencies is applied to ringing filters 29 and 35 through power divider 27. The output of filter 29 has a frequency 2F 1 and is applied to the mixer 39 through an amplifier 31 and a power divider 33. The output of filter 35 has a frequency 2F 2 and is applied to the mixer 39 through an amplifier 37 and another power divider 38. The mixer 39 produces a signal having a frequency equal to the difference between 2F 2 and 2F 1 . This difference signal, having frequency F k , is the desired clock signal. The filter 41 removes extraneous frequencies from the output of the mixer 39, and after amplification by amplifier 43, the limiter 49 removes any remaining variations in amplitude of the recovered clock signal F k .
The clock signal F k is divided by frequency divider 51 to produce a signal having frequency F k /2, and this signal is applied to the mixers 55 and 57 through another power divider 53. The mixer 55 produces the sum and difference of 2F 1 and F k /2, of which only the sum, having frequency 2F c , is desired. The 2F 2 signal is applied to the mixer 57 through amplifier 56, and the result is the sum and difference of 2F 2 and F k /2, of which only the difference, having frequency 2F c , is desired. The amplitude modulation added to 2F 1 by the filtering action of filter 29 is complementary to the amplitude modulation added to 2F 2 by filter 35, and these two amplitude modulation components cancel each other in the summer 59, yielding an output having frequency 2F c and constant amplitude.
The bandpass filter 61 removes the unwanted signals from the output of the summer 59, and after amplification by amplifiers 63 and 65, the frequency 2F c is divided by divider 67 to give a recovered carrier signal having the desired frequency F c .
The recovered carrier F c is then applied to mixers 79 and 81 through a filter 69, a variable delay 71, an amplifier 73 and another power divider 75. The received signal S is applied to mixer 79 through power divider 77, and the output of the mixer 79 includes the difference between S and F c , which is a signal I(t) carrying half of the original digital data being transmitted. A low pass filter 85 removes the undesired sum output of the mixer 79.
The phase of signal S is also shifted 90 degrees by power divider 77 and is then applied to another mixer 81. The output of the mixer 81 contains the sum and difference of F c and the phaseshifted S, and the difference signal is a signal Q(t) carrying the other half of the original data being transmitted. A low-pass filter 83 removes the undesired sum output of the mixer 81.
In the preferred embodiment illustrated in FIG. 3, the circuit components have been selected for an input signal S having frequencies F 1 =537.5 MHz and F 2 =662.5 MHz. These two signals correspond to an original transmitter carrier of frequency F c =600 MHz and a clock of frequency F k O=250 MHz. The following specific components can be used for operation at these frequencies:
______________________________________No. Designator Manufacturer Part No.______________________________________20 Directional Coupler Anaren 10014-1021 Amplifier Avantek UTC12-104M23 Doubler Vari-L WD-10225 Amplifier Aertech A467627 Power Divider Anzac DS-31329 Cavity Filter:1,075 MHz31 Amplifier Avantek UT80-0658M33 Sigma/Delta Hybrid Anzac HH-12835 Cavity Filter:1,325 MHz37 Amplifier Avantek UT80-0658M38 Sigma/Delta Hybrid Anzac HH-12839 Mixer Watkins-Johnson M1J41 Cavity Filter:250 MHz43 Amplifier Avantek UT80-0673M49 Comparator Plessey 968551 Flip-Flop Fairchild 11C06and Line Driver Tau-Tron PM501M53 Sigma/Delta Hybrid Anzac HH-12855 Mixer Watkins-Johnson M1J57 Mixer Watkins-Johnson M1J59 Sigma/Delta Hybrid Anzac HH-12861 Cavity Filter: Delta Microwave1,200 MHz63 Amplifier Avantek UT80-0658M65 Amplifier Watkins-Johnson 6202-767 1000 MHz-2 Plessey 860569 Cavity Filter:600 MHz71 Delay Line73 Amplifier Avantek UTC-103375 Power Divider Anaren 4J026477 90 degree Hybrid Anaren 10014-379 Mixer Watkins-Johnson M1J81 Mixer Watkins-Johnson M1J83 Lumped LC Filter:250 MHz85 Lumped LC Filter:250 MHz______________________________________
The present invention is key to efficient use of TDMA/MSK communications. Prior to the present invention, it has not been possible to fully utilize MSK transmission at high data rates in TDMA communication systems.
Although one specific embodiment of this invention has been described and illustrated, it will be understood that the invention is not to be limited to the specific forms or arrangements of parts so described and illustrated, and that various changes can be made within the scope of the invention. For example, by proper selection of parts, operation at many different carrier and clock frequencies can be achieved. Operation at other frequencies might obviate the need for some of the components illustrated in FIG. 3 such as power dividers and directional couplers. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A clock and carrier recovery circuit, and a related method, for use in a minimum shift keying (MSK) receiver demodulator. The clock and carrier recovery circuit uses ringing filters to lock onto two frequency-doubled tone components of a received MSK signal. A signal having the same frequency as the clock is recovered by taking the difference of the outputs of the two filters. The output of each filter is then combined separately with a signal having a frequency to produce to signals, each having a frequency equal to twice the carrier frequency and having complementary amplitude modulation. These two signals are summed to cancel the amplitude modulation and the resulting sum signal, having constant amplitude and a frequency twice that of the carrier, is divided by two to recover the carrier signal. | 7 |
RELATED APPLICATION
This application is a continuation of application Ser. No. 07/482,342, filed Feb. 20, 1990, now U.S. Pat. No. 5,026,488, issued Jun. 25, 1991.
BACKGROUND OF THE INVENTION
The present invention relates to mechanical devices and methods for recycling contaminated liquids.
Demand for recycling of contaminated industrial liquids has increased dramatically in recent years as a result of growing concern over the deleterious environmental impact of unregulated disposal of such liquids. The current costs of proper disposal of certain industrial liquids, such as metalworking coolants and lubricants, frequently exceed their purchase costs. Consequently, maximizing the useful life of such liquids, through recycling, offers significant economic and environmental benefits.
Metalworking coolants and lubricants are but a typical example of a vast array of industrial liquids that pose potential environmental hazards and are amenable to recycling. Other examples include hydraulic fluid for operating hydraulic motors and vehicle lifts, used motor oil, antifreeze and many petroleum-based liquids contaminated with water-based liquids, and vice versa.
Some progress has been made in providing recycling devices for specific needs. Large users of certain liquids have installed on-site recycling systems that utilize fine screens to separate particulate contaminants, and centrifuges to separate components of immiscible liquids. Large manufacturers may employ a recycling processing system that moves within a plant to different metalworking machines to filter the machine tool coolant, as shown in U.S. Pat. No. 4,772,402 to Love. Smaller manufacturers could utilize a trailer or truck borne device, on a periodic basis, that screens, pasteurizes and then centrifuges metalworking coolants, as shown in U.S. Pat. No. 4,636,317 to Lewis.
Unfortunately, none of these alternatives have gained widespread acceptance. The principal impediments to the commercial viability of such recycling devices are, first, the extraordinary variety of environmentally hazardous industrial liquids and, second, the diverse nature of the users of such liquids. From General Motors Corporation to corner automobile service stations and small metalworking "job shops", industrial coolants, lubricants and related liquids are employed in huge quantities under varying conditions.
Some liquids are employed at a specific temperature range that encourages rapid bacterial growth, producing corrosive metabolites and related by-products. Another user may employ the exact same liquid at a different temperature such that the resulting contamination problem is primarily from particulate matter or possibly contamination with an insoluble liquid. A particular user may exhaust a substantial quantity of a first specific liquid while only a smaller quantity of a second hazardous liquid is depleted during the same period of time. Acquisition of an on-site recycling system may not include recycling of both liquids due to the differing characteristics of the liquids. Known mobile recycling devices may not economically recycle both liquids. Therefore, such a user could tend to invest in premature, off-site disposal only, because some off-site disposal would always be necessary.
Additionally, most contaminated industrial liquids are stored in a manner that complicates recycling. Storage containers of the liquids typically produce stratified layers. A top layer may consist of foam with fine particulate matter ("fines") adhering to bubbles. An intermediate layer below the foam may include the lighter of two insoluble liquids, such as a petroleum-based liquid. The bulk of the liquid may be another lower layer of a heavier insoluble liquid, with a final bottom layer of settled fines and precipitated by-products of microbial activity.
Known systems for recycling such contaminated liquids are designed to operate on liquids having specific characteristics. The systems cannot be readily altered to adapt to different liquids or the stratified layers found in specific, contaminated, stored liquids. The systems are designed to set an intake side of the recycling system to a specific flow-rate appropriate to produce specific temperature ranges and centrifugation effects. Once the intake flow-rate is set, the systems operate on a straight-run mode affording no mid-run testing and change to satisfy requirements of changing characteristics of the liquid as a storage container is depleted, or when the intake moves from one storage container (e.g., a fifty-five gallon barrel) to another.
Another reason known recycling systems have not attained wide-spread commercial success is that certain industrial liquids contain a variety of chemical additives in relatively small quantities. These additives are very important in determining the effectiveness of the liquids. They include biocides (bacterial growth suppressing agents), pH buffers, emulsifying agents, anti-foam chemicals, deodorizers, concentrated liquid boosters, among others. The depletion or deterioration of such agents varies with the nature of use and conditions of storage of the liquids. Current recycling systems are unable to monitor the additive requirements of filtered liquids during recycling. Post recycling testing to determine additive requirements is a lengthy, costly and ineffective procedure.
Still another problem with existing recycling systems is the substantial energy requirement to economically operate the systems. The energy required to heat typical contaminated liquids to an effective pasteurizing temperature, at a flow-rate that is commercially viable, requires known mobile trailer or truck borne systems to utilize electrical energy provided at the storage site of the contaminated liquid. Although this is possible at some large facilities, such a requirement presents significant logistical problems in most circumstances. Additionally, the billing complications arising from such an energy-use arrangement deters periodic utilization of a mobile recycling system-contractor.
Consequently, because of structural limitations, known liquid recycling systems are unable to effectively recycle the wide variety of hazardous industrial liquids or service the periodic recycling needs of most hazardous liquid users.
Accordingly, it is the general object of the present invention to provide an improved liquid recycling system that overcomes the problems of the prior art.
It is another general object to provide an improved liquid recycling system that offers an inexpensive alternative to costly premature disposal of hazardous industrial liquids.
It is a more specific object to provide a liquid recycling system that can readily change its filtering capacities to efficiently service a variety of different hazardous industrial liquids.
It is another object to provide a liquid recycling system that can readily change its filtering capacities, while recycling a hazardous industrial liquid.
It is another object to provide a liquid recycling system that affords monitoring of chemical additive requirements of the liquid being recycled, and provides for metering of such additives into the liquid, during recycling.
It is yet another object to provide a liquid recycling system that is mobile and self-powered.
The above and other objects and advantages of this invention will become more readily apparent when the following description is read in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
An improved liquid recycling system is disclosed for recycling hazardous industrial liquids. The system includes mechanical components that are housed within, and transported by, a conventional, medium-sized, enclosed "van" type of truck. All the components are powered by the engine of the van.
In the preferred embodiment, the invention comprises a sequential, dual-loop assembly affixed to a contaminated liquid intake head; a master control panel and test station integrated with the loops; and, a recycled-liquid discharge nozzle. A first, or filter-loop assembly receives contaminated liquid that has passed through fine screen filters. The liquid is pumped from a waste liquid holding tank, through a pasteurizing heater, to kill bacteria and lower the liquid's viscosity, and a centrifuge, to further separate fine particles and undesirable insoluble liquids. Then the liquid is pumped back to the waste liquid holding tank, and cooled, completing the filter-loop.
The master control panel monitors and controls the temperature of the liquid in the filter-loop by measuring the pre-heating and post-cooling temperature and allowing an operator to regulate flow-rates through the heater and cooler to increase or decrease the temperature. The control panel includes a test station which provides for post-centrifuge extraction of a sample of the liquid to test the quality of separation produced by the centrifuge. The operator can adjust the flow-rate into the centrifuge to adjust the separation produced by it to the desired rate. Flow-rate through the centrifuge and resulting separation quality can also be regulated by altering the viscosity of the liquid through pre-centrifuge control of the temperature of the liquid. The operator repeats the testing of the liquid within the filter-loop until the desired flow-rate, post-cooling temperature and liquid quality are attained. The liquid is then directed into a clean liquid holding tank.
Then the liquid is pumped through a second, or additive-loop assembly. The liquid flows from the clean liquid holding tank to a second liquid extraction test valve on the control panel where a sample is extracted for testing. The test determines the quantity of needed additives. Additive-flow control metering valves on the control panel are adjusted to inject into the liquid the required additives at the rates determined by the test. The liquid is then pumped back into the clean liquid holding tank, and circles through the additive-loop, until test liquid satisfies the target requirements for the particular liquid being recycled. When the requirements are met, the liquid is discharged to recycled liquid storage tanks.
In use, an operator first takes a core sample of the liquid to be recycled. A transparent tube extracts the core sample of the liquid as it is stored. From the tube, the operator can visually determine the extent of stratification of the stored liquid and anticipate the sequence of adjustments, if any, that will be needed to compensate for the stratification. For example, if water-based metalworking liquids are being recycled, typically a layer of oil-based contaminants will occupy a top region of the storage container and the layer will have a distinctive color that is different than the color of the lower, water-based liquid.
A vacuum hose for the liquid recycling system is also transparent and an intake head is placed well below the oil-based, liquid layer so that the water-based liquid is withdrawn first. When the operator observes the distinctive color of the oil-based layer in the intake line, adjustments are made to insure its proper recycling. If necessary, further intake is stopped until the liquid already on-board is completely recycled, and then the distinctive colored liquid enters the system and is thoroughly tested within the filter and additive loops prior to discharge.
As the recycling system is operated, the operator administers regular periodic tests of liquid in the filter and additive loops. If any corrections are needed, the operator can make them during the recycling. The loop needing correction may be closed, stopping discharge out of the loop, until the flow-rate or the injection rate of additives is adjusted to again produce satisfactory liquid.
Most pumps and the centrifuge are operated by electrically actuated, mechanical, power takeoffs from the engine of the van. Remaining pumps are operated by electrical energy provided by the van's engine. Coolant from the engine of the van provides heat, raising the temperature of the recycled liquid, while coolant from the air conditioner of the van is used to cool the liquid back down, to inhibit post-filtration bacterial growth and afford immediate utilization of the recycled liquid. Consequently, a wide variety of hazardous industrial liquids in differing conditions of storage can be recycled by this mobile, self-powered, liquid recycling system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side perspective view of a liquid recycling system constructed in accordance with the present invention wherein the system is housed within, powered and transported by a conventional "van" type of truck, with a side and roof of the van partially cutaway to show the system during operation;
FIG. 2 is a fragmentary top plan view of the liquid recycling system of FIG. 1, with the roof of the van cutaway to show a floor plan of the system;
FIG. 3 is a block diagram of the liquid recycling system of the present invention;
FIG. 4 is a block diagram of a vacuum mechanism of the recycling system;
FIG. 5 is a block diagram of a filter-loop assembly used in the recycling system;
FIG. 6 is a block diagram of an additive-loop assembly used in the recycling system;
FIG. 7 is a block diagram of a clean-water wash cycle used in the recycling system; and
FIG. 8 is a plan view of a master control panel and test station of the recycling system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in detail, the preferred embodiment of a liquid recycling system is shown and generally designated by the number 10. FIGS. 1-3 show overall views of the invention and FIGS. 4-8 show portions thereof. The invention basically comprises a filter-loop 12 (FIG. 5) integrally associated with an additive-loop 14 (FIG. 6), both of which are monitored and controlled through a master control panel 16 (FIG. 8) to filter and add depleted and/or rejuvenating compounds to hazardous industrial liquids, thereby recycling them.
As best shown in FIG. 5, in the filter-loop 12, liquid to be recycled (hereafter "recycling liquid") is stored in waste liquid holding tank 18 and then pumped through a pre-heater/cooler 20, and a heater 22 to pasteurize the liquid and change its viscosity. Then the recycling liquid passes through a centrifuge or mechanical separator 24 to separate out fine particles and insoluble unwanted liquids. The liquid is then pumped back to the waste liquid holding tank 18. An operator 26 controls the temperature and flow-rate of the liquid, via the master control panel 16, thereby effecting the quality of the liquid exiting the centrifuge 24. When the quality is satisfactory, the operator directs the recycling liquid to a cooler 28 instead of the waste holding tank 18. The cooler reduces the temperature of the recycling liquid so that it can be used immediately. The lower temperature also inhibits bacterial growth. From the cooler 28, the liquid flows to a clean liquid holding tank 30, completing the filter-loop 12.
As seen in FIG. 6, in the additive-loop 14, recycling liquid is pumped from the clean liquid holding tank 30 through the control panel 16 where a plurality of chemical additives can be selectively metered into the liquid through an additive manifold 32. The liquid flows back to the clean liquid holding tank 30 until tests by the operator 26 at the control panel 16 indicate the recycling liquid meets or exceeds target specifications. Then, the liquid is directed out of the additive-loop 14 and out of the liquid recycling system 10 through a discharge nozzle 34. The liquid recycling system 10 is housed within, transported and powered by a conventional "van" 36 type of truck.
As best shown in FIG. 7, the liquid recycling system 10 includes a vacuum mechanism 38 that allows recycling liquid to be taken into the liquid recycling system 10 with no contact between the liquid and a vacuum blower or pump 40 that creates suction to take in the liquid. Known vacuum blowers are effective for this purpose such as vacuum blower Model No. 65109020, manufactured by Roots/Dresser, Inc. of Pittsburgh, Pa.
A suction side 41 of vacuum blower 40 is in fluid connection with main vacuum line 42 which leads and, in operation, applies suction to waste liquid holding tank 18 through suction inlet 43. Interconnecting vacuum line 44 interconnects the waste holding tank 18 and a waste disposal tank 46. An open end 47 of interconnecting vacuum line 44 is adjacent to, and, in operation, applies suction to, a bottom area (not shown) of waste disposal tank 46. Affixed to, and in fluid connection with, the waste disposal tank 46 is a vacuum intake line 48. Vacuum intake solenoid valve 50 opens up and shuts off flow through vacuum intake line 48 and is actuated by vacuum intake solenoid switch 52 located on the master control panel 16, and in electrical connection with valve 50. Vacuum hose 54 is in fluid connection with vacuum intake line 48 and is mounted on vacuum reel 56. The vacuum hose 54 is made of known transparent plastic materials and has an intake head 58 mounted upon an end of the hose 54 that rolls off of the reel to extend and descend into a storage container (not shown) for liquid to be recycled.
Vacuum mechanism 38 includes a fine filter screen trap box 60 between intake head 58 and vacuum reel 56, in fluid connection with vacuum hose 54. The trap box 60 has a first disposable fine filter screen bag 62 through which all recycling liquid must flow. A second disposable fine filter screen bag 64 is located below, and in fluid connection with, a second recycling liquid inlet 66 in waste disposal tank 46. A third disposable fine filter screen bag 68 is located below, and in fluid connection with, a third recycling liquid inlet 70 in waste holding tank 18. First, second and third disposable fine filter screen bags 62, 64, 68 are constructed of known filter material of varying pore sizes, such as nylon.
Also included in vacuum mechanism 38 is a float switch 72 affixed to a top-side 74 of waste holding tank 18. The float switch 72 is in electrical connection with vacuum blower 40 so that the blower is switched off when the amount of recycling liquid in the waste holding tank 18 exceeds a pre-set level on the switch 72. A vacuum-breaker valve 76 is also affixed to the top-side 74 of the waste holding tank 18. The valve 76 opens to let air into tank 18 when the pressure within the tank drops below a pre-set level.
As seen in FIG. 4, an exhaust side 78 of vacuum blower 40 is in fluid connection with blower exhaust line 80, which leads to, and is affixed to, exhaust pipe 82. Also shown in FIG. 7, an accumulated-waste suction line 84 is affixed to a waste line inlet 85 in waste disposal tank 46. A waste line solenoid valve 86 intersects accumulated-waste suction line 84 and is electrically actuated by waste line switch 88 on the control panel 16. Test liquid drain suction line 90 is in fluid connection with, and affixed to, the accumulated-waste suction line 84, adjacent to the waste line solenoid valve 86, and connects accumulated-waste suction line 84 to a test liquid disposal tray 91 at the master control panel 16. Centrifuge wash suction line 92 is in fluid connection with and affixed to the accumulated-waste suction line 84, adjacent the waste line solenoid valve 86, and connects accumulated waste suction line 84 to a centrifuge wash product storage container 94.
As shown in FIG. 2, vacuum blower 40 is powered by a power takeoff shaft 96. The power takeoff shaft 96 is designed and manufactured by the inventor herein. Essentially, it utilizes a conventional belt-drive pulley mechanism (not shown) with belts interconnecting a pulley on the crank shaft of the van's 38 engine (not shown) and a standard electric clutch on the shaft 96. The shaft spins a first conventional belt drive mechanism 98 and blower electric clutch 100. A blower electric clutch switch 102 located on the control panel 16 actuates the blower 40 by engaging the blower electric clutch 100 while the shaft 96 is spinning.
In operation, the vacuum mechanism 38 applies suction, when the blower 40 is turned on, through the main vacuum line 42, the waste liquid holding tank 18, the waste disposal tank 46, the vacuum intake line 48, the vacuum hose 54, and the intake head 58. When the operator 26 inserts the intake head 58 into a container of liquid to be recycled, the liquid responds to the suction and flows through the intake head 58, vacuum hose 54, intake line 48, waste disposal tank 46 and into the waste liquid holding tank 18. In so traveling, the recycling liquid passes through the first, second and third disposable fine filter bags, 62, 64, 68 respectively without being exposed to any moving parts or any pump components.
After recycling is completed, the operator can close vacuum intake solenoid valve 50 from its switch 52 and open waste line solenoid valve 86 from its switch 88, while the vacuum blower 40 is applying suction to waste disposal tank 46. That allows any recycling liquid discarded to the test liquid disposal tray 91 to be sucked into disposal tank 46, as well as any waste products washed from the centrifuge 24 and stored in the centrifuge wash product storage container 94. The discarded test recycling liquid and centrifuge waste products can then be removed from the waste disposal tank 46 through the waste disposal valve 104 when appropriate.
As best shown in FIGS. 2 and 5, in the filter-loop 12 portion of the liquid recycling system 10, recycling liquid is pumped by, via conventional piping (not shown), and passes through, a filter-loop pump 106. Pump 106 is a commercially available pump, such as pump model number 560 manufactured by Cat Pumps, Inc. of Minneapolis, Minn. As seen in FIG. 2, pump 106 is powered by power takeoff shaft 96, which spins a second conventional belt drive mechanism 108 and filter-loop pump electric clutch 110. A filter pump electric clutch switch 112, located in the control panel 16, actuates the filter-loop pump 106 by engaging its electric clutch 110 while shaft 96 is spinning.
Certain types of recycling liquid tend to produce foam. The filter-loop 12 includes a de-foaming compound container 114. A standard, known de-foaming compound, such as "De Foamer", manufactured by Eviron-Lub, Inc., of Indian Orchard, Mass., stored in container 114, flows, via conventional piping (not shown), from container 114, to a de-foamer metering valve 116 in control panel 16 and then to a de-foamer "T"-joint 118 adjacent to a suction side 120 of filter-loop pump 106. Direct flow of the recycling liquid straight through the "T"-valve 118 provides sufficient suction upon the de-foaming compound, flowing perpendicular to the recycling liquid, to draw the de-foaming compound into the flowing recycling liquid at a rate determined by the de-foamer metering valve 116.
Recycling liquid exits an exhaust side 122 of filter-loop pump 106 and flows, via conventional piping (not shown), to a filter-loop pressure gauge 124; filter-loop flow-rate control valve 126; and recycling abort valve 127, all of which are located in the control panel 16. The recycling liquid then flows to the pre-heater/cooler 20, which is an enclosed box-like structure, that has directional, flow-control baffles (not shown) and coiled piping or tubing 128 within. The recycling liquid flows through the tubing 120 absorbing heat, out of pre-heater/cooler 20 and into the heater 22. The heater is very similar in structure to the pre-heater/cooler 20, including coiled tubing 130, through which the recycling liquid flows absorbing even more heat from a heat-transfer medium, and directional, flow-control baffles (not shown) within a box-like structure. The heat transfer medium within the heater 22 is an antifreeze-based coolant of the van's 36 engine (not shown). The medium is directed through conventional, insulated, heater-type hoses (not shown) from the van's engine to the heater 22, and back to the engine. The medium absorbs heat from the engine of the van, which is running during operation of the liquid recycling system.
From the heater 22, recycling liquid flows back to the control panel 16 to a post-heating temperature gauge 132 and a transparent, glass flow-rate gauge 134. The liquid then flows through a centrifuge "Y"-joint 136 adjacent to solenoid valve panel 138. The "Y"-joint 136 splits the recycling liquid flow to either a centrifuge bypass solenoid valve 140 or a centrifuge entry solenoid valve 142, both of which are on the solenoid panel 138. Both valves 140, 142 are controlled by a centrifuge flow switch 144 located on the master control panel 16. The switch 144 operates such that, if centrifuge entry solenoid valve 142 is open, then centrifuge bypass solenoid valve 140 must be closed, and vice versa.
Depending upon which of the centrifuge valves 140, 142 is open and which is closed, the recycling liquid can either by-pass or enter the centrifuge 24. The centrifuge is a standard "ring-dam" centrifuge for separating fine suspended particles from a liquid and for separating immiscible liquids, such as centrifuge model number 4042230 manufactured by Alfa-Laval, Inc. of Poughkeepsie, N.Y. As seen in FIG. 2, centrifuge 24 is powered by power takeoff shaft 96 that spins a third conventional belt drive mechanism 148 and centrifuge electric clutch 150. A centrifuge electric clutch switch 152, located in the master control panel 16, actuates the centrifuge by engaging the centrifuge electric clutch 150 while shaft 96 is spinning.
When the centrifuge 24 is operating, separated, undesirable liquid, flows through separated liquid pipe 154 to a separated liquid storage container 156. Separated particles are stored within the centrifuge 24 and washed out of it, after recycling, through separated particle pipe 158 to the centrifuge Wash product storage container 94.
Recycling liquid that by-passes the centrifuge, or recycling liquid that is separated by the centrifuge, flows to a roller pump 160. The roller pump 160 is a standard, commercially available pump, such as model number 6500 C, manufactured by Hypro, Corp. of New Brighton, Minn. As seen in FIG. 2, the roller pump is powered by power takeoff shaft 96 that spins a fourth conventional belt drive mechanism 162 and roller pump electric clutch 164. A roller pump electric clutch switch, 166, located in the master control panel 16, actuates the roller pump by engaging the roller pump electric clutch 164 while shaft 96 is spinning.
As seen in FIG. 3, recycling liquid flows from the roller pump 160, via conventional piping (not shown), to a post-centrifuge "Y"-joint 168, which splits the recycling liquid flow to either a waste liquid holding tank entry solenoid valve 170 or a cooler entry solenoid valve 172, both of which valves 170, 172, are on the solenoid valve panel. Both valves 170, 172 are controlled by cooler entry switch 174 located on the master control panel 16. The switch 174 operates such that, if waste liquid holding tank entry solenoid valve 170 is open, then cooler entry solenoid valve 172 must be closed and vice versa.
If waste liquid holding tank entry solenoid valve 170 is open, recycling liquid flows back to waste liquid holding tank 18. If cooler entry solenoid valve 172 is open, recycling liquid flows, as best seen in FIG. 5, to pre-heater/cooler 20 where the recycling liquid becomes a heat transfer medium for recycling liquid passing through the coiled tubing of the pre-heater/cooler 20, thereby losing some of its heat. The recycling liquid flows through the directional-flow baffled interior of the pre-heater/cooler 20 and then into the similarly directional-flow baffled interior of the cooler 28. The cooler includes conventional coiled tubing (not shown) through which flows a cooling medium. The cooling medium is a conventional fluorocarbon compound (e.g., freon) found in air conditioning systems of automobiles and "van" types of trucks. The fluorocarbon compound is directed through conventional insulated hoses from the air conditioning system of the van 38 to coiled tubing (not shown) in the cooler 28, and back to the air conditioning system. The flow-rate of the fluorocarbon compound through the cooler 28 is controlled by conventional air conditioning valves (not shown) and thereby effects the rate of heat absorption from the recycling liquid passing through the cooler 28.
Recycling liquid leaves the cooler 28 and flows to a post-cooler temperature gauge 178 and a filter-loop liquid test valve 180, where operator 26 can extract some of the recycling liquid for quality testing. The recycling liquid then flows to the clean liquid holding tank 30, and extracted test liquid is held in the test liquid disposal tray 91.
In operation of the filter-loop 12 portion of the recycling system 10, the operator actuates filter-loop pump 106 from the switch 112 for its electric clutch on the control panel 16, thereby directing recycling liquid to flow through the filter-loop flow-rate control valve 126 and through the pre-heater/cooler 20, heater 22, post heating temperature gauge 132, transparent flow-rate gauge 134, centrifuge 24, roller pump 160, and back to the waste liquid holding tank 18. The centrifuge 24 may be by-passed by opening centrifuge bypass solenoid valve 140 until the centrifuge is brought up to operating speed, or during flow-rate alterations to change the temperature of the recycling liquid. The de-foamer metering valve 116 is adjusted to supply adequate de-foamer to the recycling liquid.
By observing the recycling liquid passing through the transparent flow-rate gauge 134, the operator can estimate when the recycling liquid has achieved proper separation. Then cooler diversion switch 174 is opened and the recycling liquid flows through the pre-heater/cooler 20, cooler 28 and is extracted at the filter-loop liquid test valve 180 for testing. During testing, test valve 180 and cooler diversion switch 174 are again closed, keeping the recycling liquid out of the clean liquid holding tank 30. If the test results are unsatisfactory, the operator can adjust filter-loop flow-rate control valve 126 until adequate separation is achieved by the centrifuge 24. In the event adequate separation cannot be achieved, the operator terminates recycling by opening the recycling abort valve 127 which directs the recycling liquid out of the liquid recycling system, via conventional piping (not shown), through the recycling abort discharge nozzle 181. When recycling is terminated in this manner, centrifuge bypass solenoid valve 140 is open, allowing the recycling liquid to by-pass the centrifuge 24. When test results are satisfactory, cooler diversion switch 174 is again opened and recycling liquid flows into clean liquid holding tank 30.
As best shown in FIGS. 2 and 6, in the additive-loop 14 portion of the recycling system 10, recycling liquid is pumped by (via conventional piping (not shown)), and passes through, an additive-loop pump 182. Pump 182 is a commercially available pump, such as model number 560, manufactured by Cat Pumps, Inc. of Minneapolis, Minn. As seen in FIG. 2, pump 182 is powered by the power takeoff shaft 96, which spins a fifth conventional belt drive mechanism 184 and additive-loop pump electric clutch 186. An additive-loop pump electric clutch switch 188, located in the master control panel 16, actuates the additive-loop pump 182 by engaging its electric clutch 186, while shaft 96 is spinning.
As seen in FIG. 6, recycling liquid then flows from additive-loop pump 182 to a first additive-loop pressure gauge 190 and an additive-loop liquid test valve 192, where the operator extracts a test sample of the recycling liquid to evaluate what additives are needed to meet target specifications for the recycling liquid. The recycling liquid then flows from the test valve 192, when it is closed, to an additive "Y"-joint 194 adjacent the solenoid valve panel 138. The "Y"-joint 194 splits the recycling liquid to a clean liquid holding tank re-entry solenoid valve 196 and a discharge solenoid valve 198. Valves 196 and 198 are electrically controlled by discharge switch 200 located on the control panel 16, such that when discharge solenoid valve 198 is open, clean liquid holding tank re-entry solenoid valve 196 has to be closed, and vice versa.
When clean liquid holding tank re-entry solenoid valve 196 is open, recycling liquid flows back to the clean liquid holding tank 30. When discharge solenoid valve 198 is open, recycling liquid flows through a disposable discharge micron filter 202, an accumulation meter 204, a discharge hose 206 mounted on a discharge-hose reel 208, and finally through the discharge nozzle into a recycled liquid storage container (not shown). A discharge line "T"-valve 210, adjacent and after discharge solenoid valve 198, diverts some of the recycling liquid to a second additive-loop pressure gauge 212 located on the master control panel 16.
As seen in FIG. 6, a plurality of additive compound containers 214a,b,c,d,e,f,g store a variety of additive compounds for injection into the recycling liquid. Illustrative of such compounds, but not to be understood as limiting, are: synthetic rust inhibitors; soluble rust inhibitors; biocides; extreme pressure additives; deodorant agents; blue color dyes; and, green color dyes. The additives flow, via conventional tubing (not shown) to additive metering valves 216,a,b,c,d,e,f,g located on the master control panel 16. As seen in FIG. 8, the metering valves include transparent glass tubes 217,a,b,c,d,e,f,g through which the additives flow, allowing the operator to precisely measure and monitor flow-rates of the additive compounds. The metering valves are adjustable, to regulate the respective flow-rates of the additive compound.
From the master control panel 16, the additive compounds flow to additive manifold 32, where they are mixed. The mixed additive compounds then flow in a single conventional tube (not shown) to an additive manifold solenoid valve 218 which is electrically controlled by additive flow switch 220 located on the master control panel. When the additive flow switch 220 opens the additive manifold solenoid valve 218, the mixed additive compounds flow to a first additive suction "T"-joint 222. "T"-joint 222 is structured so that the mixed additive compounds flow and intersect the flow of recycling liquid at a direction that is perpendicular to the flow of the recycling liquid. Consequently, a suction force is applied to the mixed additive compounds by the flow of the recycling liquid, thereby drawing the mixed additive compounds into the recycling liquid. First additive suction "T"-joint 222 is positioned adjacent to and upstream of additive-loop pump 182.
One particular additive compound varies significantly with each type of recycling liquid. It is referred to in the art as "neat coolant", and consists of a concentrated form of the particular metal working coolant being recycled. Additionally, certain recycling specifications call for very precise concentrations of neat coolant. Consequently, neat coolant is stored in a specific neat coolant container 224 and is injected into the recycling liquid by flowing to, and being pumped by, a separate neat coolant feed pump 226. The feed pump 226 is a commercially available twelve (12) volt pump powered by the van's 38 electrical system, such as pump model number 2100-112, manufactured by Flojet Corp. of 12 Morgan Street, Irvine, Calif. The feed pump is actuated by a conventional electric feed pump switch 226 located on the master control panel 16.
Neat coolant leaves the feed pump 226 and flows to a neat coolant metering valve 230, in the master control panel, which has the same structure, and flow control features as additive metering valves 216a,b,c,d,e,f,g including a transparent glass tube 231 for operator viewing. From the metering valve 230, the neat coolant flows to a second additive suction "T"-joint 232, which has the same structure as the first additive suction "T"-joint 222. Second suction "T"-joint is also positioned to intersect the flow of recycling liquid upstream of additive-loop pump 182, thereby enabling injection of neat coolant into the recycling liquid.
In operation of the additive-loop 14, the operator 26 actuates the additive-loop pump 182 through additive-loop pump electric clutch switch 188 at the master control panel 16. That causes recycling liquid to flow from the clean liquid holding tank 30 through the pump 182; the additive-loop liquid test valve 192; the clean liquid holding tank re-entry solenoid valve 196; and, back to the clean liquid holding tank 30. The operator extracts some of the recycling liquid through additive-loop test valve 192 and administers tests to determine the exact amount of additive compounds to inject into the recycling liquid. Additive compound metering valves 216a,b,c,d,e,f,g are then adjusted to meter into the additive manifold 32 specific amounts of additive compounds required, while additive compound solenoid valve 218 is open allowing the additive compounds to flow into the recycling liquid. The operator also tests the recycling liquid to determine the proper amount of neat coolant to meter into the recycling liquid; actuates neat coolant feed pump 226 through its switch 228; and sets the neat coolant metering valve 230 to allow injection of the required amount into the recycling liquid.
As the additive compounds and neat coolant are injected, and the recycling liquid circles from, and back to, clean liquid holding tank 30, the operator continues testing recycling liquid extracted from the additive-loop liquid test valve 192 until the recycling liquid satisfies specifications. Then the operator opens the discharge solenoid valve 198 by its switch 200 at the master control panel 16. Recycling liquid then flows through a final particle filter, the disposable discharge micron filter 202; through the accumulation meter 204, to measure the volume of recycling liquid discharged; and out of the liquid recycling system through discharge hose 206 and nozzle 34.
When the desired temperature, filtration and separation are achieved by the filter-loop 12, and the desired specifications achieved by the additive-loop 14, both loops are kept operating in a straight-run or discharge-flow sequence, as best shown in FIG. 3. During the discharge-flow sequence, the operator periodically tests the recycling liquid, and interrupts the discharge-flow sequence to make necessary adjustments.
As shown in FIG. 7, a clean water wash cycle portion 234 of the liquid recycling system allows the operator to clean the liquid recycling system and flush the components that accumulate waste products, after the recycling liquid has been completely discharged. Clean water wash cycle 234 includes a fresh water holding tank 236 located beneath the vacuum reel 56. Water is pumped from the tank 236 by a commercially available twelve-volt clean water pump unit 238, such as pump model number 4300-142A, manufactured by Flojet Corp. of 12 Morgan Street, Irvine, Calif.
The pump unit is powered by electrical energy provided by the van's 38 engine and controlled by a clean water pump switch 239 on the control panel 16. The water then flows, via conventional piping (not shown), to the solenoid panel 138. At the panel, the water is directed to three solenoid valves. The first is a waste liquid holding tank entry solenoid valve 240, which is electrically controlled by a waste tank cleaning switch 242 on the master control panel 16. The second is a pump priming solenoid valve 244, controlled by pump priming switch 246, on the control panel 16. The third is a centrifuge wash solenoid valve 248 controlled by centrifuge wash switch 250 on the panel 16.
When the clean water pump unit 238 is on and waste liquid holding tank entry solenoid valve 240 is open, water flows into the waste liquid holding tank 18 to flush it clean. When pump priming solenoid valve 244 is open, water flows into filter-loop pump 106 to prime it, if needed, to actuate the filter-loop 12. When centrifuge wash solenoid valve 248 is open, water flows into the centrifuge 24 to wash accumulated fine particles out of it, into the centrifuge wash product storage container 94 via a centrifuge wash product pipe 158.
A clean water utility hose entry solenoid valve 254, located adjacent and downstream from, clean water pump unit 238, and controlled by clean water utility hose switch 256, can open to direct the flow of clean water into a utility hose 258 for general cleaning.
When the recycling liquid has been completely discharged, the operator actuates the clean water pump unit 238, by its switch 239; opens waste liquid holding tank entry solenoid valve 240, by its switch 242; and engages the filter-loop 12 and additive-loop 14, with additive manifold solenoid valve 218 and metering valves 116, 216,a,b,c,d,e,f,g, and 230 closed, to completely wash all components of the liquid recycling system 10 and purge any remaining recycling liquids out of the system through discharge nozzle 34. During this time, centrifuge bypass solenoid valve 140 is open, and the centrifuge 24 is on. The operator then opens centrifuge wash solenoid valve 248, permitting water to flush accumulated fines out of the centrifuge 24 and into the centrifuge wash product storage container 94.
When the cleaning is completed, the operator actuates the vacuum blower 40; closes the vacuum intake solenoid valve 50; opens the waste line solenoid valve 86; thereby drawing stored centrifuge wash products in the container 94, and discarded test portions of the recycling liquid in test liquid disposal tray 91, into the waste disposal tank for storage and subsequent discharge through waste disposal valve 104. The operator has then recycled the recycling liquid; washed the liquid recycling system 10; and isolated all waste products.
It should be understood by those skilled in the art that obvious structural modifications can be made without departing from the spirit of the invention. For example, in some instances the heater and therefore the cooler are not necessary and are deleted, especially where the recycling liquid is toxic to bacteria, obviating pasteurization via heating. Also common sub-elements, such as holding tanks additive valves and/or manifolds can be deleted or replaced with functional equivalents known in the art. Accordingly, reference should be made primarily to the accompanying claims, rather than to the foregoing specification to determine the scope of the invention. | An apparatus and method is disclosed for recycling contaminated industrial liquids. In the preferred embodiment, a conventional, medium-sized "van" type of truck houses, transports and powers a dual-loop assembly. A filter-loop assembly receives and stores recycling liquid in a waste liquid holding tank. The liquid is pumped through a pasteurizing heater and a separating centrifuge and back to the tank. Filter-test valves in the filter-loop enable testing to determine desired heating and separation.
When flow-rate adjustments produce satisfactory heating and separation, the recycling liquid is directed through a cooler, out of the filter-loop and into an additive-loop assembly where the liquid is pumped from a clean liquid holding tank, by additive compound injections, and back to the clean tank. Additive-test valves in the additive-loop enable testing to determine required quantities of specific additive compounds. When tests indicate satisfactory levels of the compounds, the recycling liquid is directed out of the additive-loop assembly and out of the system. The filter and additive test valves enable periodic testing during recycling to insure consistency. If the recycling becomes inadequate, the filter-loop and/or additive-loop is closed until changes in the flow-rate or additive injection rates again produce satisfactory recycling. | 1 |
This application is a continuation of application Ser. No. 09/812,370, filed Mar. 16, 2001 now U.S. Pat. No. 6,380,999, which is a continuation of application Ser. No. 09/274,427, filed Mar. 22, 1999, now U.S. Pat. No. 6,204,906 on Mar. 20, 2001.
FIELD OF THE INVENTION
The present invention relates generally to electronic displays, and more particularly to the customization of an original display by physical alteration of the size and/or shape thereof, such that the customized display may be used in installations not considered achievable with the original display.
DEFINITIONS
In this application, COTS is used as an acronym for “Commercial Off-The-Shelf”; FPD is used as an acronym for “Flat-Panel Display”; LCD is used as an acronym for “Liquid Crystal Display”; PDLC is used as an acronym for “Polymer-Dispersed Liquid Crystal”, AMLCD is used as an acronym for “Active Matrix Liquid Crystal Display”; TAB is used as an acronym for “Tape-Automated-Bonding”; COG is used as an acronym for “Chip-On-Glass”; UV is used as an acronym for “ultraviolet”, VLSI is used as an acronym for “Very Large Scale Integration”, and HDTV is used as an acronym for “High-Definition Television”. All of these terms are well-known in the art.
BACKGROUND
Electronic displays are commonly used to portray data in the forms of visual text and/or other images, so the data may be interpreted and/or acted upon. Typically, the operator of equipment associated with the display will control the equipment based in part on the interpretation of the data displayed. A simple example is an airplane pilot who views a control panel display representing surrounding air traffic, and who then controls the airplane to avoid the traffic.
The displays and their associated bezels (face plates) and frames (interfacing and supporting hardware) are typically built to demanding specifications for durability, reliability, and operating life, due to industry requirements, and the resulting displays have relatively complex electrical, chemical, optical, and physical characteristics. Each particular application, for example, may require specific performance characteristics from the display, such as the ability to accommodate or withstand varying conditions of temperature, humidity, radiation, ambient light, shock, vibration, impact, chemicals, salt spray, water and fluid condensation, immersion, or other environmental, electrical, physical, and/or other conditions. Due to the high costs associated with such varying and demanding specifications, for any particular application it is thus economically necessary for manufacturers to produce a common design in high production volume, resulting in COTS displays all having substantially the same characteristics for a variety of physical sizes. The sizes vary, but the shapes are generally rectangular with an aspect ratio of approximately three to four. Common television and computer displays typically have an aspect ratio of approximately three to four, and are typically square. HDTV displays typically have an aspect ratio of nine to sixteen.
For specialized applications where the market may not be large enough for COTS manufacturers to enter, buyers of displays are required to have displays custom-built to fit their size and shape requirements, at a cost up to ten times greater than the cost of a COTS display having identical functionality. Alternatively, buyers may choose to incorporate a COTS display into an existing control panel or dashboard opening by physically altering the size and/or shape of the control panel opening to match the size and/or shape of the COTS display. For most applications, however, such modifications cannot be made without disturbing the surrounding instruments, controls, and displays already incorporated into the control panel. Such is the case, for example, on an airplane control panel or other vehicle control panel where large numbers of instruments and controls are tightly and efficiently packed into a relatively small area to begin with. And even if the appropriate modifications could be made, they are typically cost-prohibitive.
To overcome the above-referenced drawbacks in the prior art, it would thus be desirable to provide systems and methods for customizing a COTS display to meet the size and shape requirements of a target control panel opening, such that the purchaser of the COTS display may avoid paying the extra costs associated with having a display custom-built from scratch. Such systems and methods would be advantageous for displays that have relatively high tooling costs and relatively low volume production associated therewith.
A particular industry where high-cost custom-built displays are used is the avionics industry, which traditionally used square panel openings to house mechanical control devices. To retrofit airplane control panels with electronic displays, the industry began manufacturing square displays, at a relatively high cost and relatively low volume compared to the COTS non-square displays which are commercially used in a wide variety of applications. In fact, the control panels in newly-built airplanes designed to use electronic displays, are still often made with square panel openings, despite the COTS displays being non-square, in order to maintain the well-established and familiar control panel configurations.
Since a completed electronic display is delicate and relatively complex, most experts in the filed would not expect that customization of the displays as desired could be accomplished by physically cutting an original display, changing its size and/or shape, and resealing it, while maintaining its same basic functionality. For example, most experts would not expect that a display designed to be a four-inch by six-inch display with 480 rows by 640 columns of picture elements (pixels) could be cut down to the size of a four-inch by four-inch display with 480 rows by 480 columns, and still operate successfully.
SUMMARY OF THE INVENTION
Typically, a COTS display comprises two plates, front and back, holding drive electronics on the edges. The plates are typically glass or plastic, and may have polarizers, filters, image enhancement films, and/or viewing angle enhancement films attached thereto. Row and column orthogonal electric leads distributed throughout an image-generating medium are contained between the plates, and a perimeter seal holds the plates together while isolating and protecting the image-generating medium from the outside environment. The row and column electric leads transcend the seal to external leads to which electronic drivers are attached. The electronic drivers are typically VLSI circuits bonded to TAB substrates attached to the display, or directly attached to the display as COG. In some instances the VLSI electronic drivers are made in-situ with the display picture elements.
The present invention involves systems and methods for customizing a COTS display by modifying the physical size and/or shape of the COTS display to meet the requirements of a target application. This is accomplished by cutting the physical COTS display to reduce its physical size and/or shape, and then resealing the display to achieve the desired performance. The basic functionality of the COTS display remains intact. That is, the customized display will have a new size and/or shape, and may have altered electronic drivers, image-generating media, rearranged electronics, additional seals, additional films, etc., and may actually have enhanced functionality. However, the customized display will be able to operate in a target application designed to interface with a display of the same type (e.g., AMLCD) as the original (e.g., COTS) display.
When the plates are cut, internal electronics might also be cut, often requiring reestablishment of electrical continuity. Similarly, the display electronics may be removed, reattached, or otherwise modified, and filters, polarizers, and/or other films associated with the display and typically attached externally to the plates may be cut, to conform to the customized display size and/or shape. Thus the opportunity exists to add enhanced functionality to the display. A custom bezel and frame may then be used to house the display, allowing for additional ruggedization of the entire unit.
To reseal the display, an adhesive is applied along at least the cut edge or edges. A second seal may be added to minimize the penetration of humidity and other contaminants into the display media (e.g., liquid crystal material) inside the display cell. A third seal serving as a mask may also be applied to prevent back light typically used with LCDs from passing through the display around the outer edges of the display image area.
Electronic drivers, typically VLSI circuits (bonded to TAB substrates attached to the display, or attached directly to the display as COG) may be added, repositioned and/or reattached as needed, and the circuitry on the display plates may be altered to make electrical connection to the new VLSI circuits. Filters, films, polarizers, etc., may then be cut and/or installed as desired, and additional components such as heaters, optical elements, infrared filters, touch panels, transducers, etc., may be added to alter and/or enhance durability or functionality of the display.
Finally, the reshaped and/or resized, and/or otherwise altered display is placed in a custom bezel and frame with appropriate ruggedization characteristics. The bezel and frame are designed to accommodate the newly sized and/or shaped display in a suitable manner, and to allow for proper mechanical and electrical attachment to the target location, such as an avionics box or display panel. The bezel and frame also are configured for installation such that appropriate lighting, optical elements, transducers, heaters, infrared filters, touch panels, etc., associated with the target application operate properly. The frame thus protects the display and interfaces the display with the target location, such as an avionics box or display panel. Suitable adhesives, sealants, conformal coatings, potting compounds, electrical and thermal conductors, screws, clamps, rivets, connectors, gaskets, etc., may be used as necessary or desired to further ruggedize the unit and install it into its target location. Ruggedization may be required, for example, before installing the customized unit into environments of vehicles, ships, submersibles, missiles, aircraft, spacecraft, portable equipment, etc., which tend to be more restrictive and severe than the environments for which COTS displays are designed. Similarly, simulators for situations such as those described above may also require ruggedization of the customized unit.
One aspect of the present invention thus involves customizing an electronic display by cutting the display along desired dimensions resulting in a target display portion and an excess display portion, and applying a first seal between the plates along an exposed edge of the target display portion, said first seal creating a barrier to prevent the image-generating medium from escaping out of the area between the plates, wherein the basic functionality of the display remains intact. A second seal and/or a third seal may be added.
Another aspect involves customizing an electronic display by cutting the display along desired dimensions resulting in a target display portion and an excess display portion, applying a first seal along an exposed edge of the target display portion between the plates, applying a second seal over the first seal, and applying a third seal over the second seal, wherein the basic functionality of the display remains intact.
Another aspect of the present invention involves creating a customized electronic display comprising a substantially flat front plate having an upper surface and a lower surface, a substantially flat back plate having an upper surface and a lower surface, said back plate positioned behind said front plate and substantially parallel thereto, a perimeter seal positioned between said plates and forming an enclosed cell area defined by the lower surface of the front plate, the upper surface of the back plate, and the perimeter seal, an image-generating medium contained within said cell area, electrical conductors distributed throughout said image-generating medium, a substantially flat first polarizer attached to the upper surface of said front plate, said first polarizer having a perimeter, a second seal positioned over the perimeter seal, and a first silicone bead positioned over the perimeter of the first polarizer. A third seal may be added.
Systems and methods are thus described for customizing an original (e.g. COTS AMLCD) display to meet the size and/or shape requirements of a target location. Other objects and advantages of the present invention will be apparent from the detailed description which follows, when read in conjunction with the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a plan view of a typical COTS AMLCD.
FIG. 1B is a cross-sectional view of FIG. 1A , along line 1 B- 1 B, with the column TABs removed from the cross-section for purposes of clarity.
FIG. 2A is a plan view of a customized display made from the COTS AMLCD shown in FIG. 1A , by cutting along line 2 - 2 in FIG. 1 , and then resealing.
FIG. 2B is a cross-sectional view, along line 2 B- 2 B, of the customized display shown in FIG. 2A , with the column TABs removed from the cross-section for purposes of clarity.
FIG. 3 is a plan view of a customized display, showing additional special cuts that might be required as part of the customization.
FIG. 4A is a partial cross-sectional view of a customized display having staggered cuts on the opposing plates, showing first and second seal layers.
FIG. 4B is a partial cross-sectional view of a customized display having aligned cuts on the opposing plates, showing a third seal layer.
FIG. 4C is a partial cross-sectional view of a customized display having an extended lower plate for use to attach electronic drivers or jumper wires.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1A and 1B show a typical rectangular, non-square COTS AMLCD 10 , before resizing and/or reshaping, but after disassembly from its original bezel, frame, and other associated hardware and electronics. The external components associated with the display 10 other than the circuit boards 15 and the components bonded or attached to the display plates 20 f and 20 b, have been removed for clarity. Such external components would preferably be removed prior to performing the customization of the display 10 as described herein.
The display 10 comprises a front plate 20 f and a back plate 20 b, each preferably made of glass or plastic. The plates 20 are held together by a perimeter seal 25 such as a UV curing urethane as is known in the art, and are also typically further secured within a bezel (not shown) which is in turn secured to a frame or other hardware (not shown) for attachment to the target location. Polarizing films 30 f and 30 b, filters (not shown), image enhancement films (not shown), retardation films (not shown), viewing angle enhancement films (not shown), and/or other films may exist on the front and/or back outer surfaces of the plates 20 . The original display image area 40 defined by the manufacturer of the COTS AMLCD is indicated by dashed perimeter line 45 . (Dashed line 50 represents the desired right edge of the display image area 40 after customization, as will be described shortly). A light-blocking mask (not shown) is typically placed between plates 20 and covers a perimeter area form the outer edge of the display image area 40 , and extending outwardly to a sufficient distance to serve its purpose. Typically, the distance will be up to the edge of the bezel, or to the inner edge 55 of perimeter seal 25 as indicated by arrows 60 in FIG. 1A . Without the mask, light escaping around the edge of the display image area 40 might cause distraction to a person viewing the display 10 .
Row and column electronic drivers 65 r and 65 c respectively are bonded to TAB substrates 70 r and 70 c respectively, which in turn are bonded to the edges of the plates 20 using electrically-anisotropic adhesives 75 as is known in the art. In avionics, bent TABs (not shown) are often used to save panel area. In addition or alternatively, the drivers 65 may be attached directly to the plates 20 as COGs. The electronic drivers 65 are preferably at least VLSI circuits, having corresponding external leads 80 r, 80 c electrically connected through perimeter seal 25 to the row and column electric leads 85 r, 85 c respectively (see FIG. 2A ). For simplicity, only a few leads 80 from only one row TAB 70 r and two column TABs 70 c are shown in FIG. 2A , but it is to be understood that each row TAB 70 r and each column TAB 70 c may have dozens or even hundreds of individual leads 80 as is known in the art. The row and column electric leads 85 are distributed throughout an image-generating medium such as liquid crystal material (normally transparent) contained between the plates 20 , as seen in FIG. 2A . The perimeter seal 25 , in addition to holding the plates 20 together, isolates and protects the image-generating medium from the outside environment. The TABs 70 are bonded or soldered to circuit boards 15 , and are electrically connected to external sources via connections 90 to circuit boards 15 , and as is well known in the art. COGs (not shown) may be electrically connected to the edges of the display plates 20 which are connected electrically via ribbon cables to external sources, as is known in the art. Again, for simplicity only a few connections 90 are shown in FIG. 2A , but it is to be understood that they may be provided as desired or needed.
To customize the COTS AMLCD 10 of FIG. 1A , an example will be described wherein the display 10 (and circuit boards 15 ) are cut along line 2 - 2 in FIG. 1 to reshape the display 10 to fit into a square target panel opening, such as that of an airplane control panel. The resulting customized display 10 ′ is shown in FIGS. 2A and 2B . The customization of a COTS display 10 may be done in varying degrees, as necessary or desired, and the examples provided herein are not to be viewed as setting forth required techniques unless specifically so stated.
The COTS display 10 is preferably first mounted into a fixture (not shown) to stabilize the display 10 in preparation for cutting. The fixture may also be used to maintain cell thickness (the distance between the plates 20 ) and desired dimensions. Part or all of the fixture may be the VPI FAST-24 model glass-cutting machine made by Villa Precision International, Phoenix Ariz.
The display 10 is then cut to its desired shape along the desired dimensions, which in our example is a square. The cut or cuts may be performed in a single step, by laser cutting, sawing, grinding, etc., or in multiple steps wherein the first step is a tracing or preparatory step. For example, the desired dimensions might first be scribed, etched, traced, etc., and the display 10 may then be broken along the scribe dimensions. Any method sufficient to ensure a substantially smooth cut is acceptable. Scribing with a precision glass-cutting machine with vacuum-holding and optical alignment capability has been shown to be sufficient. AMLCDs are typically made with a borosilicate hard glass and approximately 60 pounds of pressure has been shown to be sufficient for scribing the glass. The scribe wheel is preferably made of diamond or is of a hard carbide type. A small wheel (e.g., 1 mm to 4 mm in diameter) with a sharp angle (e.g., approximately 100 degrees) has been shown to be sufficient, at a nominal cutting speed. Each plate 20 should be scribed separately. The optical alignment feature of the machine is helpful to ensure that the corresponding scribe lines on opposing plates 20 f and 20 b are coincident or displaced as desired. Alignment marks placed on COTS displays by manufacturers may be used for alignment in the glass-cutting machine.
Circuit boards 15 may also be cut by techniques known in the art, as indicated by cut-line 2 - 2 , as can TABs 70 . However, if a dimension line calls for cutting through an electronic driver 65 , the driver may need to be relocated and/or replaced. If polarizers 30 or other films are present, it is possible to cut them simultaneously while cutting the plates 20 , but it is preferable that they are scored first to create a target polarizer portion for further use in the customization process, and an excess polarizer portion that may be discarded. The excess polarizer portions are then removed prior to cutting the plates 20 . Doing so allows unobstructed access to the plates 20 for cutting the plates 20 . After scoring the films, simple peeling away of the unwanted portions has been shown to be sufficient.
Thus, the specific dimensions of the score lines to remove the films should be selected to substantially correspond to the target cutting dimensions, but be offset radially inward a slight amount. The goal is to allow the original films to remain intact over the target display image area 40 ′ while still providing unobstructed access to the plates 20 for cutting the plates 20 . For example, in FIG. 1A , the target display image area 40 ′ is defined by the square A-B-C-D, and the target cutting line for the plates 20 is shown as line 2 - 2 . The target score line for the polarizers 30 and other films present might be line 95 . After scoring, all portions of the films to the right of line 95 will be peeled away. Similar procedures would be used for each display plate 20 f, 20 b. That will leave sufficient leeway 100 between the target cutting line 2 - 2 for the plates 20 , and the newly-exposed edge (defined by line 95 ) of the polarizers 30 and films. Additionally, the remaining portions of the original polarizers 30 and films will still cover the target display image area 40 ′.
Immediately, or soon after the display 10 is cut (either by direct cutting or by scribing and breaking, for example), the display 10 is oriented to prevent the liquid crystal material or other image-generating medium from escaping due to any newly-exposed unsealed edges. Precision glass-breaking machines are available from Villa Precision International, Phoenix Ariz. Manual breaking, after scribing, by one skilled in the art, merely using hands and fingers, has been found to be sufficient. After breaking, a simple manual re-orientation of the display 10 ′ has been shown to be sufficiently timely. Typically, the image-generating medium is not viscous enough to escape. The excess display portion ( 105 in FIG. 1A ), may be discarded, while the target display portion ( 110 in FIG. 1A ) is retained for further customization.
The newly-exposed plate edges are then cleaned and wiped dry of any excess liquid crystal material using, for example, a dry cotton swab. Care should be taken to not use fluids, as fluids might contaminate the liquid crystal material. Liquid crystal material is then drained or wicked out of the cell to allow for a replacement seal line 115 to be placed along the then newly-exposed and newly-unsealed plate edges. The replacement seal 115 is installed by applying an adhesive along the cut edge and preferably in between the plates 20 to reseal the display 10 ′. The adhesive is preferably chosen to have proper mechanical properties to preserve the cell spacing. For example, precision micro-spheres may be mixed into the adhesive to ensure spacing. The adhesive should also have a proper viscosity to allow it to flow inwardly sufficiently to fill any void in the cell between the plates 20 and the liquid crystal material. Low-viscosity UV curing urethane of the methacrylate family have been shown to have the desired characteristics. A wetting and/or thinning agent may be used as needed. In addition, these urethanes interface with the liquid crystal material without adverse effects, as is well-known in the field of PDLCs. Curing time of approximately five minutes has been shown to be sufficient.
The adhesive and display 10 ′ may need to be outgased to remove any trapped gases and voids, as the adhesive is being cured. Both the outgassing and the curing may be accomplished by techniques well-known in the art. After curing, a second seal 120 is preferably added, then outgased and cured as necessary. A UV curing lamp(s) and/or heater(s) may be mounted in a vacuum chamber for ease in outgassing and curing. The second seal 120 is preferably silicone, and is applied to minimize the penetration of humidity and contaminants into the liquid crystal material inside the cell. The silicone seal 120 is preferably thermally set, as is known in the art. The silicone seal 120 may have black ink, dye, or pigment added thereto to produce a substantially black-colored silicone, and may be applied up to the outer perimeter of the target display image area 40 ′, to prevent back light from passing through the display 10 ′ around the outer edges of the target display image area 40 ′.
Alternatively, an optional mask or third seal 125 may be added to the newly-exposed plate edges over the silicone seal 120 , and applied up to the outer perimeter of the target display image area 40 ′. The mask 125 is shown partially broken away in FIG. 2A . It should be dark (preferably black), and may be tape, ink, sealant, adhesive, plastic, or any other suitable material. At least one of the dark silicone seal 120 , or the optional mask 125 , are preferred, to replace any of the original mask (not shown) removed during the customization process. Additionally, the mask 125 may be placed around the entire perimeter of the cell, substantially overlaying the original perimeter seal 25 and original mask.
If internal electronics 85 are cut, electrical continuity may need to be reestablished as will be described shortly. Similarly, new VLSI circuits 65 may be needed, or the dimension lines may intersect a TAB 70 or COG location (see FIG. 3 for example), and therefore the TABs 70 or COGs would be removed and reattached with the same or new VLSI circuits 65 by techniques used in the industry for repairing displays. The configuration of the TABs 70 and/or COGs may be changed to accommodate size and packaging requirements. The circuitry on the display plates 20 may be altered to make electrical connection to the new VLSI circuits. The COG circuits may be changed to TABs 70 , and vice versa. The TAB substrate 70 itself may be changed to bent tabs, for example, to accommodate new packaging requirements.
If it is desired to replace the liquid crystal material, the material may be extracted and replaced with another image-generating medium, to enhance or alter performance. If the extraction is to be done first, then only a single break in the seal 25 is needed to drain or suck out the original material. However, two breaks in the seal 25 may be used—one to apply pressure and the other to apply suction for extraction of the material. With two breaks, the new image-generating medium may be pumped or fed into the pressure end concurrently with the suction on the other end, thus allowing the new image-generating medium to displace the old material in a single process. Other techniques are known in the industry for refilling the cell.
Thus, additional modifications and/or enhancements that may be made to the display during reshaping and/or resizing include relocating, adding, and/or removing, TABs 70 or COGs; replacing electric circuits and/or supplementing with circuits having different functionality; altering and/or replacing the display medium; and/or adding, removing, and/or replacing polarizers, filters, and/or films.
Turning now to FIG. 3 , a display 10 ′ with additional special cuts 130 , 135 , and 140 , for a custom avionics application is shown. In this example, the corners 150 and 155 are to be removed to allow for the protrusion of screws and other mechanical and electrical objects from the target control panel, and one edge 160 is to be trimmed as indicated by cut-line 140 . Additionally, circular cuts 145 f and 145 b are required for protrusion of a shaft or other object such as a mechanical indicator. The circuit boards 15 , seals 25 , and most of the TABs 70 have been removed for clarity of the drawing. In this example, one of the dimension lines 140 requires a cut through the present location of a TAB 70 , such that the TAB 70 may need to be removed and reattached, either before or after cutting.
The row and/or column leads ( 85 r and 85 c respectively) are exposed at points 165 by a staggered cut of the plates 20 , and may be cleaned and prepared as is known in the art, prior to being connected to a TAB 70 or COG. The techniques previously described may be used for the special cuts 130 , 135 , 140 , and 145 . However, as exemplified by the circular cuts 145 , this example shows a situation wherein the electrical continuity of the row and/or column leads ( 85 r and 85 c respectively) will need to be reestablished.
The proper electrical connections may be reestablished using a jumper wire which reconnects the broken leads by traversing a path outside of the display image area 40 ′. For example, one such path is along the exposed portion of a plate 20 from one end of the plate 20 to the other (see 170 in FIG. 3 ). Another such path may be through the circular cutouts (see 145 in FIG. 3 ), where there may be an exposed surface portion 175 on the back plate 20 b due to staggered cutting (e.g., the circular cutout 145 f on the front plate 20 f may have a larger diameter than the circular cutout 145 b on the back plate 20 b, as seen in FIG. 3 ). Alternatively, the conductive paths may be mounted on or integrated within the under surface of the mechanical indicator to be placed within the circular cutouts 145 . This may be accomplished using, e.g., a wire, a polyimide tape circuit with anisotropic conductive adhesive, or a circuit board with appropriate electrical connectors.
For desired dimensions such as the circular cutout, some amount of the image-generating medium may escape at virtually any orientation of the display 10 ′ due to gravity. Keeping the plates 20 substantially flat, however, should minimize such escape, due to surface tension between the image-generating medium and the plates 20 , as well as due to the low viscosity of the image-generating medium. Any escaped material, however, may be replaced using techniques described herein and/or known in the art. The exposed edges of the plates 20 due to the circular cutout areas 145 should be sealed using the techniques described herein.
Turning now to FIGS. 4A , 4 B, and 4 C, various sealing techniques will be described in more detail. Each of these drawings shows a partial cross-section of a customized display 10 ′, from a similar perspective as in FIGS. 1B and 2B , and like FIGS. 1B and 2B , the column TABs 70 c have been removed for clarity.
The display 10 ′ may be cut to various pre-sealing arrangements, some of which are shown in FIGS. 4A , 4 B, and 4 C. The staggered cut, shown in FIG. 4A , provides an extra exposed surface 180 on the back plate 20 b to support the second seal 120 , and the second seal 120 will generally be stronger as compared to the second seal 120 on an evenly cut set of plates 20 as shown in FIG. 4B . Though neither the second seal 120 nor the third seal (the light mask 125 ) are required, they are both preferred.
The first seal 115 is an adhesive and serves the purpose of barricading the image-generating medium from leaking out, as well as mechanically holding the plates 20 together at the proper spacing. By way of example, the cell gap (space between the plates 20 ) for AMLCDs is typically 6 micrometers with tolerances of 0.1 micrometers. Glass beads, or suitable objects, may be added to the seal material to aid in preserving the minimum cell thickness. The adhesive must be chemically compatible with the image-generating medium. The compatibility, reacting and mixing of urethanes, epoxies, and water emulsions, with liquid crystal materials, have been studied extensively in the field of PDLC displays. The TV-curing adhesives used to repair automobile glass cracks would be suitable here as the environmental conditions may be similar.
The second seal is a silicone adhesive and serves the purpose of a humidity and moisture barrier. A family of silicone encapsulants and adhesives has been developed for the electronics industry to prevent humidity and moisture from attacking electronic parts. As used with the methods described herein, the use of silicone is designed primarily to keep water molecules away from the liquid crystal material, polarizers, and display electronics. Silicones such as Sylgard brand by Dow Corning Corporation, part numbers 527 and 184, may be used. The humidity and moisture protecting properties of silicone are well-known in the electronics packaging industry.
As a further ruggedizing measure, a silicone seal or bead 185 (similar to the second seal 120 ) may be applied along all cut edges, or all edges, of the polarizers 30 and other films, as seen in FIGS. 4A , 4 B, and 4 C. For example, when submitted to avionics temperature/humidity testing, the polarizers 30 deteriorated at the edges. These seals 185 would further protect the polarizers 30 from such damage. In fact, to ruggedize a COTS display 10 for avionics use, all permeable seam lines and areas sensitive to moisture may be covered with silicone seals. In particular, the polarizer edges, the liquid crystal cell seal 25 , plastic electronics packages, and any exposed conductors or metal electrodes may need to be covered. The silicone has the effect of occupying all chemically active sites and cross-linking to inhibit water molecules from accumulating in the silicone and at the silicone surface interface being protected. Additionally, silicone is used to suppress corona discharge and electrostatic detrimental effect on, around, and near conductors.
These additional silicone seals may be applied at any time during the process, but it is preferred that they are applied after the COTS display 10 is cut and the first seal 115 has been reapplied. It should be done then because silicone chemically attaches to most surfaces and is not easily removed by conventional chemicals or cleaning agents or by surface cleaning techniques. Also, once cured, the silicone is not readily bonded to by other materials. This includes the body of the silicone, as well as any surface the silicone wetted, even after removal by conventional techniques. Because of the unique properties of silicone adhesives and sealants, they should be used sparingly and appropriately by a person skilled in the art of sealants or silicone use. Conformal coatings, such as polyimide, may also be used to cover the exposed electric leads and provide additional protection thereto.
A third seal or mask 125 may also be used to prevent back light from passing through the display 10 ′ around the outer edges of the target display image area 40 ′. Typically, a COTS display 10 has a black mask in the plane of the image or image-generating medium. The third seal 125 should be applied to the top and bottom of the plates 20 , up to the edge of the target display image area 40 ′ (best seen in FIG. 2A ), to trap the light and prevent its escape due to parallax between the plates. Opaque layers in varying degrees of opacity may be used. Alternatively or in addition, black absorbing dyes or pigments may be included in the first seal 115 and/or second seal 120 .
Other seals may be added to further enhance the sealing, ruggedization and performance of the completed display unit. For example, a thermal conductive perimeter seal may be added to conduct heat to or from the display 10 ′. An additional adhesive layer, such as polysulfide, may be used to bond the display glass cell to a metal frame. Conformal coatings such as polyimide may be used to ruggedize various parts.
FIG. 4C shows a cutting arrangement resulting in an extended bottom plate area 190 , which may be used to attach TABs 70 or COGs or jumper wires as desired.
The basic functionality of the original display remains intact. That is, the customized display may have a new size and/or shape, and may have altered electronic drivers, image-generating medium, rearranged electronics, additional seals, additional films, etc., and may actually have enhanced functionality. However, the customized display will be able to operate in a target application designed to interface with a display of the same type as the original display. For example, a COTS AMLCD, having gone through a customization process as described herein, will be able to function in an avionics application designed to interface with an AMLCD. The customized display would respond appropriately to electrical signals designed to be input to the COTS display. Pixels on the customized display would continue to operate as they would in connection with the COTS display. The speed of response, contrast ratio, gray shades, etc., of the customized display would operate as they would in connection with the COTS display. The ultimate image (text, graphics, pictures, etc.) would thus appear appropriately on the display image area of the customized display.
While certain embodiments are illustrated in the drawings and are described herein, including preferred embodiments, it will be apparent to those skilled in the art that the specific embodiments described herein may be modified without departing from the inventive concepts described.
For example, depending upon the specific requirements for a particular application, various combinations of the customizing techniques described herein may be applied. The seals 115 , 120 , 125 , and 185 , may be applied in different combinations, different amounts or ratios, and varying sequences, depending on the application. Some of the seals may be omitted or used redundantly as the application may require.
Additionally, though the examples used herein generally referred to COTS AMLCDs as used in avionics where square displays are used, the concepts are equally applicable to other types of LCDs or other display technologies, and for other industrial applications including those requiring other customized shapes. Furthermore, though the examples used show only one set of row TABs and two sets of column TABS, in practice that may be switched, or there may be two sets of each, and the quantity of each may vary, all as is desired or needed for a specific application.
Accordingly, the invention is not to be restricted except by the claims which follow. | Electronic displays are physically reshaped and/or resized to meet custom specifications for special applications such as avionics, where Commercial Off-The-Shelf (COTS) Liquid Crystal Displays (LCDs) are not typically used. Customization includes cutting the physical display to specified dimensions to fit into a target opening, and resealing the display to preserve proper cell spacing and assure basic functionality. The target opening is typically a control panel or dashboard opening, such as in the cockpit of an airplane. The sealing process may include improving the original seal, and/or providing additional seals. Additional seals may protect sensitive areas against chemical corrosives or contamination, humidity, electrostatic damage, etc., and/or prevent light from passing around the edge of the display image area. Electric continuity may need to be reestablished for electric leads affected during the customization process, and electronic drivers may need to be reattached to the display. Additional modifications and/or enhancements may be made to the display during reshaping and/or resizing. For example, TABs or COGs may be relocated, added, removed, replaced, and/or reoriented; electric circuits may be replaced and/or supplemented with circuits having different functionality; the display medium may be altered and/or replaced; polarizers, filters, and/or films may be added, removed, and/or replaced. The customized display may then be ruggedized by attaching a suitable bezel (face plate) and frame (support hardware) thereto, and the completed, customized display unit may then be installed in the target location and integrated with surrounding hardware and electronics. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a display holder useful in displaying an item in a box that is suspended from the neck of a bottle or the like. More particularly the invention provides an integral bracing system for use with such holders.
2. Description of the Art
To facilitate cross selling, marketers sometimes hang samples of other products around bottle necks. These other products are typically housed in paper boxes that are suspended from a header piece that has a hole to receive the bottle neck. Unfortunately, the weight of the product often tends to cause the box to hang from the bottle in an unattractive manner and/or leads to tearing of the header. While the use of plastic headers has been tried, they are much more expensive to produce.
There is, therefore, a need for an improved holder that can be attached to a bottle in a secure manner, be capable of supporting relatively heavy products in a secure unbended manner, and which is inexpensive to produce.
SUMMARY OF THE INVENTION
The invention provides a secure means of attaching an auxiliary box holding a secondary product to a bottle holding a primary product.
In one aspect the invention provides a blank sheet of foldable material for use in forming a box having a header piece. The blank sheet has a header panel having lateral sides, upper and lower sides, an aperture through the panel, and a lower portion that can form a wall of the box; a brace panel integrally attached to the header panel by a fold line at a lateral side of the header panel, the brace panel also being connected to an integral end flap along a fold line; a generally rectangular carton panel attached to the header panel at a fold line along the lower side of the header panel, the carton panel having at least two internal fold lines that are both generally parallel to a fold line at a junction of the header panel and the carton panel, so as to define three other wall panels of the box that can be formed from the carton panel; and a tab panel connected to the blank sheet by a fold line to facilitate attachment of an end of the carton panel opposite said junction to the header panel when the box is formed, The panels of the blank sheet are juxtaposed such that when the box is assembled by folding the sheet along fold lines and the end flap is positioned inside the box, a portion of the brace panel also forms a cover for a lateral end of the box.
When this blank is folded, a display holder is created that has a header panel having lateral sides, upper and lower sides, and an aperture through the panel; a brace panel integrally attached to the header panel by a fold line at a lateral side of the header panel, the brace panel also being connected to an integral end flap at a fold line; and a generally rectangular box depending from said header panel. When the end flap is positioned inside the box by folding the brace panel and flap along fold lines, a portion of the brace panel forms a cover for an end of the box.
In another aspect, the invention provides a blank sheet of foldable material for use in forming a support wall that carries two boxes. The blank sheet has a header panel having lateral sides, upper and lower sides, an aperture through the panel, and a lower portion that can form a wall of a first box and an upper portion that can from a wall of a second box; a brace panel integrally attached to the header panel by a fold line at a lateral side of the header panel, the brace panel being connected to two integral end flaps at fold lines, the end flaps being positioned above and below the aperture and a first generally rectangular carton panel attached to the header panel at a fold line, the carton panel having at least two internal fold lines that are both generally parallel to a fold line at a junction of the header panel with the first carton panel so as to thereby define three other wall panels of the first box that can be formed from the carton panel.
The sheet also has a connector panel attached to the first carton panel by a fold line, the connector panel having an aperture that can be aligned with the aperture of the header panel; a second carton panel attached at a fold line to the connector panel, the second carton panel having at least two internal fold lines that are both generally parallel to the internal fold lines of the first carton panel so as to thereby define three other walls of the second box that can be formed from the carton panel; and a tab panel connected to the blank sheet for facilitating attachment of the second connector panel to the header panel. The panels are juxtaposed such that when the boxes are assembled and the brace panel end flaps are folded along fold lines to position flaps inside an end of each box, the brace panel forms a cover for these ends of each box and assists in retaining the two boxes in a fixed position with respect to each other.
When folded, this second blank will create the display holder that has a header wall having a substantially centrally located aperture therethrough; two generally rectangular boxes mounted against the underside of the header wall on opposite sides of the aperture so as to define a groove there between; and at least one brace panel being integrally attached to the header at a fold line at a lateral side of the header wall, the brace panel being also connected to two integral end flaps along two fold lines. The parts of the holder being juxtaposed such that end flaps can be positioned inside an end of each box by folding the brace panel and flaps along fold lines, and in this position the brace panel forms a cover for the ends of the boxes, the brace panel maintaining the boxes in a fixed position with respect to each other.
It will be appreciated that the invention provides improvements in auxiliary product boxes. A main improvement is that the box(es) are provided with end panels that double as brace members, the blank can therefore be preferably formed from paper.
In another aspect, the invention provides an auxiliary box which is totally enclosed yet still securely supported using only a single sheet of paper. The enclosed box outer surfaces provide many surfaces for placing printed advertisements.
With respect to the second embodiment, the invention also provides two compartments capable of securely and separably housing two products.
It is therefore an object of the invention to provide an auxiliary box that is readily attachable to a bottle or the like to house a secondary product.
It is another object of the invention to do so in a manner that limits bending of the display holder and box.
It is a further object of this invention to provide an auxiliary box which is sturdy and compact and reduces the risk of container collisions.
It is another object of the invention to provide an auxiliary box which may be formed from a single blank of paper board having printed indicia on only one surface thereof.
It is another object of this invention to provide a holder capable of securely and separately housing secondary products.
A further object of the invention is to provide a holder of the type set forth above which is durable, reliable, well braced, and easy to manufacture.
The foregoing and other objects and advantages of the invention will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown by way of illustration preferred embodiments of the invention. Such embodiments do not represent the full scope of the invention, however. Reference should therefore be made to the claims for interpreting the full scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a preferred embodiment of a paper blank that can be used to form a holder in accordance with the present invention;
FIG. 2 is a perspective view of the blank of FIG. 1, partially folded;
FIG. 3 is a perspective view of the blank of FIG. 1, almost completely folded;
FIG. 4 is a perspective view of a holder formed from the blank of FIG. 1, about to be installed on a bottle;
FIG. 5 is a view similar to FIG. 1, but showing a blank suitable to create a second preferred embodiment;
FIG. 6 is a perspective view of the blank of FIG. 5, shown during one stage of folding; and
FIG. 7 is similar to FIG. 4, but showing the second preferred embodiment of the holder.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a blank (generally 10) is of thin gauge paper board. When fully set up, it forms the holder (generally 11) shown in FIG. 4.
Blank 10 is provided with a plurality of fold lines and cuts which are adapted to cooperate with one another so as to form a header panel 13. The header panel 13 is generally rectangular and has an upper edge 19, a first lateral side defined by fold line 17, a second lateral side defined by fold line 18 and a lower side defined by fold line 20. A lower portion 21 of the header panel 13, located between the aperture 14 and fold line 20 forms one wall of the box 22 (seen in FIG. 4).
An enlarged laterally central aperture 14 is provided in the blank 10. The aperture 14 is sized so as to tightly fit around the neck of a bottle (see FIG. 4). The aperture 14 is provided with a series of circumferentially spaced radial slits 15. The slits 15 provide tongues 16 for engaging the bottle.
A square box panel 25 is connected to the header panel 13 along fold line 20. Panel 25 has two fold lines 26, 27 equally dividing the area of the box panel 25 into a bottom panel 29, front panel 30 and top panel 31. Fold lines 26, 27 are substantially parallel to fold line 20.
A tab panel 33 is connected to the lower end of the box panel 25 along fold line 35. The tab panel 33 is constructed with a centrally located aperture 36 substantially similar to the header panel aperture 14. The tab panel aperture 36, like the header panel aperture 14, has circumferentially spaced radial slits 37 that define tongues 38. When the box is formed, the shown surface of tab panel 33 is in full contact with the shown surface of header panel 13, so that the tab panel aperture 36 aligns with the header panel aperture 14.
In keeping with one of the primary objects of the invention, a first brace closure panel 39 is connected to a lateral side of header panel 13 along fold line 17. A second brace closure panel 40 is connected to the opposite lateral side of header panel 13 along fold line 18. The first brace closure panel 39 has a first edge defined by fold line 17, a second edge 42 adjacent the first edge at a 90° angle, the second edge 42 being collinear with fold line 20 when the blank 1 is flat, a third edge defined by fold line 44, fold line 44 being parallel to fold line 17, and a fourth edge 46.
The second brace closure panel 40 is similar in construction to panel 39. Edge 47 is adjacent line 18 at a 90° angle and is collinear with fold line 20 when the blank is flat. Another edge is defined by fold line 48 and is parallel to fold line 18. There is also edge 49. Arcuate end flaps 51, 53 are provided on each brace closure panel 39, 40 along the brace closure panels respective distal fold lines 44, 48.
In an especially preferred form, four protection closure flaps are provided on the lateral edges of the box panel 25. Two protector flaps 54a, 54b are connected to the front panel 29, one on each lateral edge defined by fold lines 28A and 28b. Two more protector flaps 54c, 54d are connected to opposite lateral edges of panel 31 one on each lateral edge defined by fold lines 28c and 28d.
Turning now to FIGS. 2-4, in folding the box, panel 29 is folded into an upright position with respect to header panel 13. Panel 31 is then folded relative to bottom panel 30 so as to assume a position parallel to header panel 13. Tab panel 33 is then folded back so as to be perpendicular to back panel 31. As best seen in FIG. 3, panel 30 is then folded relative to panel 29 so as to assume a position wherein panel 30 is parallel to header panel 13 and a surface of tab panel 33 is in full contact with a surface of header panel 13. After this fold, the tab panel aperture 36 is in complete registration with the header panel aperture 14 and a box chamber 34 is defined by header panel 13, panel 29, panel 30 and panel 31.
Referring still to FIG. 3, flap 54a can be folded inward relative to front panel 29 so as to partially close the end of the box chamber 34. In a like fashion, flap 54c can be folded so as to close the end of the box chamber 34. Next, end flap 51 can be folded to an upright position with respect to brace closure panel 39 and brace closure panel 39 can be folded into a position so that end flap 51 is frictionally received inside the box chamber 34.
In a like manner, protection flaps 54b and 54d cooperate with brace closure panel 40 and end flap 53 to close the other end of box chamber 34. It will be appreciated that a promotional item can be inserted in the box before closure, and suitable advertisements for the item can be printed on the opposite side of the blank form that is shown in FIG. 4. The completely formed box 11 about to be installed on a bottle is shown in FIG. 4.
Referring now to FIG. 5, there is shown a blank 56 of thin gauge paper board which is adapted, when fully set up, to form the second embodiment of this invention. A dual compartment holder 57 formed from the FIG. 5 blank is shown in FIG. 7. For convenience in studying the present disclosure, those parts of the second embodiment which are analogous to the first embodiment are identified by the same reference numerals which identify the corresponding parts of the first embodiment, albeit with an A listed thereafter.
Blank 56 has a header panel 13A which is provided with an enlarged centrally located aperture 14A. The header panel 13A is generally of a square shape and has an upper edge defined by fold line 62, a first lateral side defined by fold line 17A, a second lateral side defined by fold line 18A and a lower side defined by fold line 20A. A lower portion 21A of the header panel 13A, disposed between the aperture 14A and fold line 20A, is used to form one wall of a first box 22 as shown in FIG. 7. An upper portion 63 of header panel 13A, disposed between the aperture and fold line 62, is used in a like manner to form one wall of a second box 66 as shown in FIG. 7. The aperture 14A should be sized so as to tightly fit around the neck of a bottle (see FIG. 7). In the preferred embodiment, aperture 14A is provided with a series of circumferentially spaced radial slits 15A. The slits 15A provide tongue 16 for engaging the neck of the bottle.
A square first box panel 25A is connected to header panel 13A along fold line 20A. The first box panel 25A has two fold lines 26A, 27A equally dividing the area of the first box panel 25A into panels 29A, 30A and 31A, the fold lines 26A, 27A being substantially parallel to fold line 20A.
A connector panel 33A is connected at the lower end of the first box panel 25A along fold line 35A. The connector panel 33A is constructed with a centrally located aperture 36A substantially similar to aperture 14A of the header panel 13A. The tab panel aperture 36A, has circumferentially spaced radial slits 37A that define tongues 38A.
A second square box panel 68 is provided connected to connector panel 33A along fold line 69 from which the three remaining second box 66 walls are constructed. The second box panel 68 has two fold lines 70, 71 equally dividing the area of the second box panel 68 into panels 72, 73 and 74. The fold lines 70, 71 are substantially parallel to fold line 69.
In keeping with one of the primary objects of the invention, a first brace closure panel 39A is connected to one lateral side of header panel 13A along fold line 17A, and a second brace closure panel 40A is connected to the opposite lateral side of header panel 13A along fold line 18A on blank 56. Both brace closure panels 39A, 40A have a rectangular shape. The first brace closure panel 39A has a long edge defined by fold line 17A, a second long edge 76 parallel to the first, a first short edge 77 collinear with fold line 62 and a second short edge 78 collinear with fold line 20A (when the blank 56 is flat as in FIG. 5).
The second brace closure panel 40A has a first long edge defined by fold line 18A, a second long edge 80 parallel to the first, a first short edge 81 collinear with fold line 62 and a second short edge 82 collinear with fold line 20A when the blank 56 is flat as in FIG. 5. Four arcuate end flaps 83a-d, are provided on the blank, two each on the second long edge 76, 80 of each brace closure panel as shown in FIG. 5.
Eight protector flaps 54aA-h are preferably provided on the lateral edges of the first 25A and second 68 box panels. Two protector flaps 54aA, 54bA are connected to the first front panel 29, one on each lateral edge defined by fold lines. Two protector flaps 54cA, 54dA are connected to the panel 31A, one on each lateral edge defined by fold lines. Two more protector flaps 54e, 54f are connected to the panel 72, one on each lateral edge defined by fold lines 28e, 28f. Two more protector flaps 54g, 54h, for a total of eight protector flaps, are connected to the panel 74, one on each lateral edge defined by fold lines. A tab 75 is preferably connected at the top edge of the header panel 13 along tab fold line 62.
Turning now to FIGS. 6 and 7, in setting up the blank 56, panel 29A is folded into an upright position with respect to header panel 13A. Panel 31 is then folded relative to panel 30A so as to assume a position parallel to the header panel 13A. Connector panel 33 is then folded back so as to be perpendicular to panel 31A. Then panel 30A is folded relative to panel 29A so as to assume a position wherein panel 30A is parallel to header panel 13A and a surface of connector panel 33A is in full contact with a surface of header panel 13A. After this fold, the aperture 36A is in complete registration with aperture 14, and a first box chamber 34A is defined by header panel 13A, and panels 29, 30 and 31.
Next, panel 72 is folded into an upright position with respect to panel 33A. Panel 73 is then folded into a horizontal position, parallel to portion 63 of header panel 13A, tab 75 is folded into a vertical position perpendicular to header panel 13A. Then, front panel 74 is folded into a vertical position relative to bottom panel 73, so that the bottom edge 84 of panel 74 makes contact with the tab 75. A suitable adhesive can glue the tab 75 against an inside wall of panel 74. By this, a second box chamber 85 is defined by the upper portion 63 of header panel 13, the panel 74, the panel 73 and the panel 72.
Protector flap 54aA can then be folded inward relative to front panel 29A so as to partially close one end of box chamber 34A. In a like fashion, protector flap 54cA can be folded so as to close the same end of first box chamber 34A. Now, the other protector flaps can also be folded in a like fashion. Next, end flaps 83a-d are folded to an upright position with respect to brace closure panels 39A and 40. Brace closure panel 39A is then folded into a vertical position so that end flaps 83a, 83b are frictionally received inside their respective box chambers 34A, 85. In a similar manner, end flaps 83c, 83d are folded to close the other ends of first box chamber 34A and second box chamber 85. The completely formed box of the second preferred embodiment is shown in FIG. 7.
Prior to the blank assuming the condition of FIG. 7, the products to be packaged may be located within the box chambers 34A, 85. The embodiment of FIG. 7 has all the exposed surfaces thereof formed by a single side of blank 56. Thus, the blank need have only one printed surface. Furthermore, the various panels, flaps, tabs and portions cooperate with one another to form a very strong and sturdy box, not withstanding the calliper of the material used.
The above description has been that of a preferred embodiment of the present invention. It will occur to those who practice the art that many modifications may be made with out departing from the spirit and scope of the invention. For example, various modifications besides those shown and discussed may be made with regard to the shape and size of the various panels and with regard to the apertures in the header 13 and tab 33 panels. For example, in the second embodiment, the various panels that form box chambers 34A, 85 could be of different sizes so that two different size chambers 34A, 85 result. Also, the direction up and down with respect to the blank are arbitrary and are only intended to provide relative direction between parts of the blank.
Moreover, when double header panels are used and are glued together this gives even greater strength to the hanger. Note also that the end panels can be glued in place instead of being locked in place if desired. | Display holders and blank sheets for forming them are disclosed. When assembled, the holders have one or more boxes supported by a header piece. A brace member forms both an end flap for one or more of the boxes and provides a rigid brace to support the box(es). | 8 |
TECHNICAL FIELD
The invention relates in general to dispatching strategies for elevator systems of the hydraulic or traction type, and more specifically to a method of more efficiently assigning hall calls to a group of elevator cars using calculated arrival times of the cars at the floor of a hall call to be assigned.
BACKGROUND ART
Hall calls have been assigned to a group of elevator cars by a large number of different strategies. A common strategy estimates the time of arrival (ETA) of each elevator car for a specific hall call to be assigned. A count is computed for each car which represents the time estimated for the car in question to reach the call floor with the proper service direction to serve the hall call. The hall call assignment is given to the car having the lowest ETA count.
DISCLOSURE OF THE INVENTION
The present invention recognizes the criticality of door cycle time in the calculation of ETA. Door cycle time is the time to open the doors, plus the time to load and unload passengers, plus the time to close the doors. Although door open time is consistently the same at every floor, the time the doors remain open for loading and unloading is variable, and even the door close time is variable as passengers re-open or stall the doors by actuating the door safety edge.
Thus, instead of using a constant value for door cycle time, as in prior art ETA strategies known to us, which is based upon the false assumption that the average door cycle time is the same for every floor of a building, the present invention provides a more precise door cycle time by taking this variability into account. This results in a more accurate ETA calculation enabling more efficient assignments to be made to the cars, and hence a lower average call waiting time, which is the industry standard in measuring elevator efficiency.
More specifically, the door cycle time of each car is measured at each floor of the building. A profile of the building is developed depicting the average door cycle time at each floor over a suitable period of time. For example, from 8:30 AM to 8:45 AM the average door cycle might be 6 seconds at floor #2, while from 8:45 AM to 9:00 AM the average might rise to 9 seconds. These averages are stored, periodically updated, and available to the dispatching function which makes the ETA calculations.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become more apparent by reading the following detailed description in conjunction with the drawings, which are shown by way of example only, wherein:
FIG. 1 is a diagrammatic representation of an elevator system which may utilize the dispatching methods of the invention;
FIG. 2 is a RAM map listing per-car status information;
FIG. 3 is a RAM map listing per-car floor enable information;
FIG. 4 is a RAM map of a hall call table;
FIG. 5 is a RAM map of a car table;
FIG. 6 is a RAM map of an assignment register;
FIG. 7 is a RAM map of a trip list;
FIG. 8 is a ROM map listing various time periods to be used b a hall call assignment program;
FIG. 9 is a flowchart of a program which assigns hall calls to a plurality of elevator cars;
FIG. 10 is a subroutine ASSIGN called by the program shown in FIG. 9 to make specific assignments of hall calls to the elevator cars;
FIG. 11 is a flow chart of a subroutine ETA-A which establishes a first travel path for an elevator car to service a hall call to be assigned;
FIG. 12 is a flow chart of a subroutine ETA-B which establishes a second travel path for an elevator car to service a hall call to be assigned;
FIG. 13 is a flow chart of a subroutine ETA-C which establishes a third travel path for an elevator car to service a hall call to be assigned;
FIG. 14 is a flow chart of a subroutine COMPUTE which may be used by subroutines ETA-A, ETA-B and ETA-C in computing the ETA travel time for a car to service a trip list prepared for the selected travel path;
FIG. 15 is a chart which illustrates the operation of the programs in selecting travel paths for a car in which its farthest committed stop is for a car call;
FIG. 16 is a chart which illustrates the operation of the programs in selecting travel paths for a car in which its farthest committed stop is for a hall call; and
FIG. 17 is a RAM map of a door cycle time (DCYT) building profile maintained for use in the ETA calculation program shown in FIG. 14.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will be described relative to a specific, exemplary ETA dispatching system. It is to be understood, however, that the invention may be used to enhance any ETA type dispatching system.
Referring now to the drawings, and to FIG. 1 in particular there is shown an elevator system 20 which may benefit from the teachings of the invention. Elevator system 20 includes a plurality of elevator cars #0 through #N mounted for guided movement in hatchways 22 of a building 24 to serve the floors therein numbered 1 through N. Elevator cars #0 through #N, which cars may be of the hydraulic type, or of the traction type, as desired, each have a car controller, such as car controller 26 associated with car #0. The plurality of elevator cars #0 through #N are placed under group control by a system processor 28. A car controller which may be used for car controller 26 is shown in U.S. Pat. No. 3,750,850, with modifications thereof for group control by a system processor, including data links, being shown in U.S. Pat. No. 3,804,209. U.S. Pat. Nos. 3,750,850 and 3,804,209, which are assigned to the same assignee as the present application, are hereby incorporated into the specification of the present application by reference.
Car calls are registered in the elevator cars #0 through #N via suitable pushbutton arrays, such as pushbutton array 30 in car #0.
Hall calls are registered from suitable pushbuttons located at the various floors of building 24, such as an up hall call pushbutton 32 located at the lowest floor (floor #1), a down hall call pushbutton 34 located at the highest floor (floor #N), and up and down hall call buttons 36 located at each of the intermediate floors. The up and down hall calls may be serialized and transmitted to an input interface 38 of system processor 28 as signals 1Z and 2Z. The car calls registered in each of the cars may be serialized and transmitted to input interface 38 along with other per-car related information as signal 3Z. The per-car information includes car status signals, such as a signal INSV which is true when the associated car is in service; a signal UPTR which is a logic one when the associated car is set for up travel and a logic zero when it is set for down travel; a signal AVAS when an in-service elevator car is stationary, not busy and available for assignment, i.e., the car has no car calls and no assigned hall calls; a signal AVP which gives the advanced position of the associated elevator car in binary; a signal ACC which indicates the car is to accelerate away from a floor; a signal DEC which indicates the car should start decelerating to land at a target floor; a signal DCL which indicates that the car doors are closed; and a signal ACCX which is a start command. The per-car information also includes floor enable signals FEN which indicate which floors of the building 24 the associated car is enabled to serve. The floor enable signals may be set in memory tracks in the car controllers, or at a traffic director's station (not shown), as desired.
System processor 28, in addition to input interface 38, includes a central processing unit (CPU) 40, a read-only memory 42 (ROM), a random-access memory 44 (RAM), and an output port 46.
As shown in the RAM maps of FIGS. 2 and 3, system processor 28 stores the per-car information in suitable tables in RAM 44, including a car status table 48 (FIG. 2) and a floor-enable table 50 (FIG. 3).
System processor 28 additionally prepares a hall call table 52 shown in FIG. 4, a car table 54 shown in FIG. 5, an assignment register 56 shown in FIG. 6, and a trip list table 58 shown in FIG. 7. The hall call table 52 may be integrated into the assignment register 56 if desired, by adding a "call" bit next to the assignment bit in both the up and down call portions of the register.
FIG. 8 is a ROM map 60 which includes a list of constants stored in ROM which pertain to the specific elevator system 20. The constants include the time T in seconds by which the lowest ETA for a hall call must be lower than the ETA of a different car which was previously assigned to serve the hall call being considered, before the assignment will be switched to the different car. The constants also include a listing of times in seconds for the specific elevator cars in system 20 to perform the various functions required to serve the floors, including the time ACCT to accelerate from a floor to full speed; the time DECT to decelerate from full speed and land at a target floor; the time HS to travel from one floor level to another at full speed; the time OFTT for a car to make a one-floor run; the time ADT to land at a target floor when the car being considered is already in the process of decelerating; the time DOT for the elevator car door and associated hatchway door to fully open; and the door cycle time DYCT.
Door cycle time DYCT is a default value used before a building profile of floor and time related average door cycle times are developed according to the teachings of the invention, as set forth in a RAM map 260 shown in FIG. 17. Hardware or software timers are used to time the door cycle of each car at each floor of the building. The door cycle times are stored for each car and averaged over predetermined portions of each day the building has normal use. For example, as shown in FIG. 17, which is a RAM map 260 of average door cycle times for one of the elevator cars, the time periods may be one hour long over the business day; or, they may be shorter during busy periods of the day and longer during off-peak hours, as desired.
A simple program for calculating the average DCYT is entered periodically, such as by timer interrupt, with each updating replacing the prior average. When the elevator system is initialized, the default value for DCYT is used, and the default value may be used off-hours, when only one or two cars of a bank of cars is operational.
FIG. 9 is a detailed flowchart of a hall call assignment program 62 stored in ROM 42. Program 62 is entered at 64 and step 66 initializes the system, such as by setting table pointers to initial positions. For example, step 66 places pointer 68 at the lowest up scan slot position so the program starts by looking for an up hall call at the lowest floor. When this pointer is incremented, it will go upwardly through the up hall call table. When it is incremented from the up scan slot for floor N-1 it will jump to the highest scan slot in the down hall call portion of the table. When the pointer is incremented downwardly through the down hall call table, it will jump back to the lowest scan slot in the up hall call portion of the table when it is advanced from the scan slot associated with the next to the lowest floor. Thus, the up scan slots are numbered 0 through N-1, and the down scan slots are numbered from N through 1. In like manner, pointer 70 is initialized at up scan slot 0 in the assignment register 56 shown in FIG. 6. Additional pointers to be initialized by step 66 include pointer 72 to the floor enable table 50 shown in FIG. 3, and pointer 74 to the car table 54 shown in FIG. 5.
After the initialization step 66, step 76 checks pointer 68 of the hall call table 52 for a registered up hall call. If no hall call is found, step 78 increments pointers 68, 70 and 72 of tables 52, 56 and 50, respectively, and the program returns to step 76. The program 62 thus loops through the up and down hall call tables continuously until step 76 finds a registered up or down hall call.
When step 76 finds a registered hall call, step 80 checks pointer 74 of the car table to determine which car is presently being considered for the hall call, it obtains the car status information associated with this car from the RAM map 48 shown FIG. 2, and it obtains the floor enable data FEN for this car from the floor enable table 50 shown in FIG. 3.
Step 82 checks the logic level of signal INSV to determine if the car being considered is in service. It this car is not in service, step 84 sets the ETA time for this car to the maximum value OFFH, and the program will not consider a car having the maximum ETA for assignment. Step 86 increments the car pointer 74 in the car table 54 of FIG. 5, and step 88 determines if the whole car table has been considered relative to the call in question. If one or more cars remain to be considered, step 88 returns to step 80 to obtain information relative to the newly selected car. If step 88 finds that all of the cars have been considered relative to the hall call in question, the program calls subroutine ASSIGN in step 90. Subroutine ASSIGN is shown in FIG. 10 which is a flowchart of an assignment program 92 which will be hereinafter be described in detail.
Returning to step 82, if step 82 finds that the car being considered is in service, step 94 checks the floor enable bit FEN to see if this car is enabled for the floor of the hall call. If this car is inhibited from serving hall calls at this floor, step 94 returns to step 84 and proceeds through steps 86, 88 and 90, which were previously described.
If step 94 finds that the car being considered is enabled for the floor of the hall call being considered, step 96 checks signal AVAS to determine if the car is busy serving a call, or if it is idle and available for assignment. If the car is idle, step 96 proceeds to step 98 which calls a subroutine ETA-A for computing the ETA time for the car to serve the hall call. FIG. 11 is a flowchart of a program 100 which implements the ETA-A subroutine, and it will be hereinafter described in detail.
Step 98 returns to program step 86 after running subroutine ETA-A, to determine if all of the cars have been considered relative to the call to be assigned or reassigned.
If step 96 finds that the car being considered is not an idle car available for assignment, step 102 checks to see if the car has a car call 3Z or an assigned up or down hall call 1Z or 2Z, respectively. If the car has no car call and no hall call assignment, it may be considered to be the same as an available car and the program calls subroutine ETA-A in step 98.
If step l02 finds that the car is busy, i.e., it has at least one car call or at least one assigned hall call, step 104 determines the floor of the farthest committed stop (FC floor) in the travel path of the car in serving its present workload. For example, if the car is traveling upwardly and its highest car call is for floor N-2, and it has no assigned hall calls which require further travel of the car, the FC floor would be N-2. If in addition to the car call at N-2, the car has been assigned a down hall call at floor N-4, then the FC floor would be N-4.
After the FC floor is determined, step 106 checks to see if the FC floor is related to a car call or an assigned hall call. If the FC floor is related to a car call, step 108 determines if the car travel direction is the same as the scanning direction through the hall call table 52 shown in FIG. 4. If the car is set for up travel and the scanning direction is upwardly through the up hall call table, or if the car is set for down travel and the scanning direction is downwardly through the down hall call table, step 108 proceeds to step 110. Step 110 determines if the scan slot floor (the floor of the hall call being considered) is closer to the AVP floor of the car than the previously determined FC floor. If the car will arrive at the scan slot floor before the FC floor, step 110 proceeds to step 98 to call subroutine ETA-A. If the car will arrive at the FC floor before reaching the scan slot floor, then step 110 proceeds to step 112. Step 112 calls a subroutine ETA-8 to compute the ETA time for the car to arrive at the hall call floor. FIG. 12 is a flowchart of a program 114 which implements the ETA-B subroutine, and it will be hereinafter described in detail. Step 112 returns to step 86 to check for another car after subroutine ETA-B runs.
If step 108 found that the car travel direction was opposite to the scanning direction through the hall call table 52, then step 108 proceeds to step 112 to call subroutine ETA-B.
If step 106 found that the FC floor was not associated with a car call, then the FC floor is associated with a hall call assignment and the program branches to step 116. Step 116 is similar to step 108, determining if the car travel direction is the same or opposite to the scanning direction through hall call table 52. If the travel direction is the same as the scan direction step 118 checks to see if the car travel direction UPTR is the same as the service direction of the hall call at the FC floor. If the car travel direction is the same as the service direction of the hall call it had been previously assigned to serve, which call is located at the FC floor, step 118 returns to step 110 previously described. If the car travel direction is opposite to the direction of the hall call at the FC floor, then step l18 proceeds to step 98 to call subroutine ETA-A.
If step 116 finds the car travel direction UPTR is opposite to the scanning direction through the hall call table 52, step 116 proceeds to step 120. Step 120 determines if the car travel direction UPTR is the same as the direction of the hall call at the FC floor. If the directions are the same, step 120 proceeds to step 122 to call a subroutine ETA-C for computing the ETA time for the car to arrive at the scan floor. FIG. 13 is a flowchart of a program 124 which implements the ETA-C subroutine, and it will be hereinafter described in detail. Step 122 returns to step 86 after running subroutine ETA-C.
If step 120 finds that the car travel direction UPTR is opposite to the direction of the hall call at the FC floor, step 120 proceeds to step 126 to determine if the scan floor of the hall call being considered is farther from the AVP floor of the car than the previously determined FC floor. If the scan slot floor is farther from the AVP floor than the FC floor, step 126 proceeds to step 98 to call subroutine ETA-A. If the scan slot floor is not farther from the AVP floor than the FC floor, step 126 proceeds to step 112 to call subroutine ETA-B.
Subroutines ETA-A, ETA-B and ETA-C establish three different potential travel travel paths for determining ETA time. Subroutine ETA-A is entered at 128 and step 130 prepares a trip list for the car being considered from the advanced floor position AVP of the car to the scan slot floor. FIG. 7 illustrates the trip list 58, and it would be made out for the car in question, listing all stops between the AVP floor and the scan slot floor. If the car's AVP is the second floor and the scan slot floor is N-1, for example, all of the stops which the car is presently committed to make between these two floors would be listed. Step 132 computes the time for the car to complete its trip list and arrive at the scan slot floor. Step 132 calls a subroutine COMPUTE shown in FIG. 14, with FIG. 14 being a flowchart of a program 134 for computing ETA which will be hereinafter described. Subroutine ETA-A returns to the main program at 136 after computing and storing the ETA for the car in question for comparison with the ETA's of the remaining cars.
Subroutine ETA-B is entered at 138 and step 140 prepares a trip list for the car being considered from the AVP floor of the car to the FC floor, and from the FC floor to the scan floor. Thus, unlike ETA-A, which prepared a trip list from the car directly to the scan floor, ETA-B prepares a trip list from the car to the floor of the farthest committed call, i.e., the FC floor, and then from the FC floor to the floor of the hall call being considered for assignment, i.e., the scan floor. Step 142 calls the subroutine COMPUTE shown in FIG. 14 to compute the time for the car to complete its trip list, and the subroutine returns to the main program at 144.
Subroutine ETA-C is a subroutine used only when the FC floor is related to a hall call. Subroutine ETA-C is entered at 146 and step 148 prepares a trip list for the car being considered from the AVP floor of the car to the FC floor, from the FC floor to the terminal floor which is in the direction of the service direction of the hall call at the FC floor, and from this terminal floor to the hall call scan floor. Thus, unlike ETA-A, which prepares a trip list from the car directly to the scan floor, and unlike ETA-B which prepares a trip list from the car to the floor of the farthest committed call, i.e., the FC floor, and then from the FC floor to the floor of the hall call being considered for assignment, i.e., the scan floor, ETA-C prepares a trip list from the car to the FC floor, from the FC floor to a terminal floor, and then from the terminal floor to the scan floor. Step l50 calls the subroutine COMPUTE shown in FIG. 14 to compute the time for the car to complete its trip list, and the subroutine returns to the main program at 152.
The program 134 for the subroutine COMPUTE shown in FIG. l4 is entered at 154 and the purpose of the subroutine is to compute the ETA for the specific trip list prepared for the car. Step 156 checks to see if the car is moving. If either signal ACC or signal DEC is true, the car is moving. If the car is not moving, step 158 checks signal DCL to see if the car doors are closed. If the car doors are closed, step 160 checks start command signal ACCX to determine if the car has just arrived or is preparing to leave the floor. If the car is not leaving it has just arrived, or is parked at the floor with its doors closed. Step 162 determines if the floor at which the car is located is the scan floor, i.e., the floor of the hall call to be assigned. In this instance it is not the scan floor, as the hall call would have been cancelled when the car started decelerating to stop at the floor, and step 162 proceeds to step 164 to see if the car is a busy car or an available car by checking signal AVAS. If the car is not available, then it just stopped at the floor and step 166 adds the door cycle time DCYT to any previous ETA time computed for this car.
According to the teachings of the invention, the door cycle time DCYT is obtained from RAM 44, as set forth in RAM map 260 shown in FIG. 17 for the specific car being considered for assignment. If the system was just initialized, the default value for DCYT (ROM map 60 - FIG. 8) would be used until a building profile of door cycle times is developed. While the building profiles of door cycle times are developed on a per car basis, it is to be understood that it would also be suitable to average the per car door times for each floor and use the bank average instead of the per car average for DCYT.
If the car is available, then no door time is required as the car can start on its trip list without opening its doors. Step 166 and the "yes" branch from step 164 proceed to step 168 which checks to see if the next stop on the trip list is one floor from the present car position, i.e., a one-floor run. If the next stop is a one-floor run, step 170 adds the one-floor run time OFTT to any prior computed value of ETA, and stores the new ETA at a temporary location in RAM. Step 162 checks to see if this next stop, i.e., the one floor run, will bring the car to the scan floor. If not, step 166 adds the door cycle time DCYT to the car's ETA and returns to step 168. If the next stop on the trip list is not a one-floor run, step 172 adds the acceleration time ACCT to the car's ETA and proceeds to step 174. Step 174 determines how many floors will be passed at rated speed before reaching the next stop on the trip list, and multiplies this number by the time HST required for the car to travel between two floors at rated speed. This time, plus the deceleration time DECT to stop at the next stop are added to the car's ETA. Step 174 proceeds to step 162 to determine if the car has completed its trip list. When step 162 finds that the stop being considered is the scan slot floor, step 176 adds the time DOT to open the door at the scan slot floor to the car's ETA.
If step 158 finds the doors open, step 159, according to the invention, subtracts the door open time DOT (ROM map 60 - FIG. 8) from the door cycle time DCYT (RAM map 260, FIG. 17), and adds the difference to the car's ETA value. Step 158 proceeds to step 168.
If step 156 finds that the car is moving at the time its trip list is initiated, the car is accelerating, or it is at full speed, or it is already decelerating. Step 186 determines if the car is accelerating, and if it is, step 172 adds the accelerating time ACCT to the car's ETA, and advances to step 174, which was previously described. If the car is not accelerating, step 188 determines if the car is traveling at full speed. If it is traveling at full speed, step 188 advances to step 174. If the car is not accelerating and is not traveling at full speed, it is already decelerating and step 188 advances to step 190 which adds the "already decelerating" time ADT to the car's ETA. Step 190 advances to step 162. Thus, when all of the floor stops on the trip list have been considered, the car's ETA has been completed, and the subroutine returns to the main program 62 shown in FIG. 62.
When program 62 finds that the ETA times for all of the cars have been computed for the hall call in question, step 88 branches to step 90 which calls subroutine ASSIGN. Subroutine ASSIGN is a program 92 shown in FIG. 10 which is entered at 192. Step 194 compares the ETA values for all of the cars and determines which car #has the lowest ETA value. Step 196 determines if this hall call is a new call, or one which had been previously assigned to a car, by checking the assignment bit in assignment register 56 shown in FIG. 6. If the call is a new hall call, step 188 assigns the call to the car having the lowest ETA and the subroutine exits at 200 to return to the main program to consider the next hall call in the hall call table 52.
If the call had been previously assigned, step 196 advances to step 202 which determines the car #to which the call was assigned. Step 204 checks to see if the car # with the lowest ETA is the same car # to which the call had been previously assigned. If it is the same car, step 188 returns to the main program at 200.
If step 204 finds that the car having the lowest ETA is not the same as the car with the prior assignment, step 208 determines the difference between the ETA's of the two cars and step 208 determines if the new car's ETA time is lower than the ETA time of the prior assigned car by a predetermined number T. If the new car's ETA is not lower by T seconds, the assignment to the prior car is retained and step 208 returns to the main program. If the new car's ETA is lower than the prior car's ETA by more than T seconds, step 210 assigns the call to the new car and removes the assignment from the assignment register of the prior car. Step 210 returns to the main program 200.
The chart of FIG. 15 lists examples of the travel paths for different relative positions of the AVP floor, the scan slot floor and the FC floor when the FC floor is related to a car call. The car call floor has no service direction, which simplifies the travel paths to those of subroutines ETA-A and ETA-B.
If the scan slot floor is between the AVP floor and the FC floor, the travel path and thus the trip list will be between the AVP floor and the scan slot floor, as indicated by dotted line 212. This is implemented by subroutine ETA-A. In the remaining examples, the travel path and trip list extends from the AVP floor to the FC floor, and from the FC floor to the scan floor, which is implemented by subroutine ETA-B.
More specifically, when the FC floor is between the AVP floor and the scan slot floor, the travel path if from the car to the FC floor and from the FC floor to the scan floor regardless of the car travel direction or scan direction. This is indicated by travel paths 214 and 216 for like travel and scan directions, and by travel paths 218 and 220 for unlike travel and scan directions.
When the scan floor is between the AVP floor and the FC floor, and the scanning direction is opposite to the car travel direction, the travel path extends from the AVP floor to the FC floor, indicated by travel path 222, which by-passes the scan floor, and then the travel path reverses, indicated by travel path 224, to extend from the FC floor to the scan floor.
When the FC floor is on one side of the AVP floor and the scan floor on the other side, with unlike travel and scan directions, travel path 226 is followed from the AVP floor to the FC floor, and the travel path then reverses, following path 228 from the FC floor to the scan floor.
The chart of FIG. 16 lists examples of the travel paths for different relative positions of the AVP floor, the scan slot floor and the FC floor when the FC floor is related to a hall call. The hall call floor has a service direction, which requires the travel path provided by subroutine ETA-C in addition to the travel paths provided by subroutines ETA-A and ETA-B.
More specifically, if the FC floor is between the AVP floor and the scan floor, and the hall call at the FC floor has the same service direction as the car travel direction, subroutine ETA-B is selected which provides a travel path 230 from the AVP floor to the FC floor, and a travel path 232 from the FC floor to the scan floor.
When the FC floor is between the AVP floor and the scan floor, and the hall call at the FC floor has a service direction which is opposite to the car travel direction, subroutine ETA-A is selected, establishing a travel path 234 from the AVP floor to the scan floor. The assigned hall call at the FC floor is ignored during this determination, and if it should result that the car is assigned the hall call at the scan floor, the down hall call previously assigned to this car will probably be reassigned to another car.
In like manner, if the scan floor is closer to the AVP floor than the FC floor, the car travel direction is the same as the scan direction and opposite to the service direction of the hall call at the FC floor, travel path 236 will be followed from the AVP floor to the scan floor, with the assigned down hall call at the FC floor being ignored. This result will be provided by calling subroutine ETA-A.
When the FC floor is closer to the AVP floor than the scan floor, the car travel direction is the same as the service direction of the assigned hall call at the FC floor, and the scan direction is opposite to the car travel direction, the travel path includes a leg 238 from the AVP floor to the FC floor to service the up hall call. Since is is not known at this point how far the up hall call passenger will wish to travel in the up direction, it is assumed that the prospective passenger will place a car call for the longest trip, i.e., to the upper terminal floor N, providing a travel path 240 from the FC floor to the terminal floor N, and a travel path 242 from the terminal floor N to the scan floor. This result is provided by calling subroutine ETA-C.
When the scan floor is closer to the car than the FC floor and the car travel direction is opposite to both the scan direction and the service direction of the hall call at the FC floor, a travel path having a leg 244 extends from the AVP floor to the FC floor, and leg 246 extends from the FC floor to the scan floor. This requires subroutine ETA-B.
When the scan floor is closer to the AVP floor than the FC floor, and the car travel direction is opposite to both the scan direction and the service direction of the hall call at the FC floor, subroutine ETA-A is called which establishes travel path 248 from the AVP floor to the scan floor.
When the car's AVP floor is between the scan floor and the FC floor, and the car travel direction is opposite to both the scan direction and the service direction of the hall call at the FC floor, the travel path includes a leg 250 from the AVP floor to the FC floor, and a leg 252 from the FC floor to the scan floor. | An elevator dispatching method which estimates the time of arrival (ETA) of each car at the floor of a hall call to be assigned. A building profile of average door cycle times per floor, over predetermined periods of the day, is tabulated and used in the ETA calculations, to provide more accurate ETA values and thus a lower average call waiting time. | 1 |
BACKGROUND OF THE INVENTION
The invention relates generally to searching for relevant data entities based on a search query, specifically in the context of ambiguous or under-specified queries. More particularly, the invention relates to helping users to refine their search queries by identifying search concepts related to the user's search query, providing the means for the user to use these concepts to refine their query and submit an enhanced query based on such concepts, and thus access information more specific to their needs.
One of the greatest strengths and greatest weaknesses of the Internet is the vast amount of information that is distributed over all the computers connected on the Internet. This is one of the Internet's greatest strengths in that individuals have access to great amounts of information on almost any topic imaginable. However, this is also one of the Internet's greatest weaknesses in that, because of the vast amount of information, it is difficult to know what information on a desired topic is available, and where to go to find the information.
Search engine technology attempts to overcome this weakness of the Internet by providing an indexed access to a collection of web pages that a user can search. The user typically enters a search query. The search engine then finds the web pages that contain or otherwise relate to the search query, and this list of web pages is presented to the user. There are a number of different ways that search engines determine which web pages are relevant to a given search query, such that those web pages are presented to the user.
First, one type of search engine constantly scans the Internet, in a process referred to as spidering. This type of search engine has been popularized by ALTA VISTA and GOOGLE, among others. Each page of a web site that is visited by the spider is cataloged for the words that appear in the web site. This information is indexed and stored in a search engine database. When a user enters a search query, the search engine matches the query against the search engine database to find the web pages that are most relevant to the query by some measure. For example, the search engine may determine the number of times the query appears in a given web page to determine its relevance, or the search engine may determine the number of other web pages that link to the given web page in which the query appears to determine its relevance.
This type of search engine is disadvantageous in that many search queries contain words that are related to more than what the user is searching. For example, the user may be looking for web pages regarding the golfer Tiger Woods. However, if the user just enters the word Tiger as the search query, the search engine is likely to return many web pages related to the animal tiger, as well as to the golfer Tiger Woods. Furthermore, if the user enters the words Tiger Woods, the search engine may also return web pages that include the words tiger and woods, but which do not necessarily relate to the golfer Tiger Woods.
Another type of search engine compares a search query to web pages cataloged in a topical directory. This type of search engine has been popularized by YAHOO! and LOOKSMART. A team of people assigns web sites to one or more different categories within the directory. When a user enters a search query, the search engine matches the query against the directory of web pages, and returns both the categories and the individual web pages that are relevant to the query. For example, in response to a Tiger Woods query, the search engine may return the category Sports:Golfers:Tiger Woods and the category Animals:Tigers, as well as web pages that contain both the words tiger and woods.
This type of search engine also has its disadvantages. If the user enters a query too broad to find adequately specific and targeted results, it is often difficult to guess a query that would easily and accurately narrow the query to the desired area.
Other failings are common to all of these and other types of search engines. Most are unforgiving as to misspelled words, or abbreviated variants for desired topics. For example, if the user enters in tigr woods instead of Tiger Woods, search engines are likely not to return many relevant pages regarding the golfer. Search engines may also provide results that are considered inappropriate by many users, or, in the case of children, their parents. For example, a user may enter in as a query the name of his or her favorite singer. Besides web sites geared towards providing information about the singer, search engines may also return X-rated sites that claim to provide inappropriate pictures of the singer.
Another failing of existing types of search engines is that they assume a level of searching experience or sophistication on the part of their users that may not exist. In other words, the quality of search results they return frequently corresponds to how good the search query is that the user entered. Users who are less competent in formulating search queries are therefore likely to receive poorer search results from search engines as compared to users who are more competent in formulating queries. For example, less knowledgeable users may enter queries that are overly broad, or alternatively, overly specific. Overly broad queries are likely to generate search results that contain a number of irrelevant web pages, whereas overly specific queries are likely to generate search results that may not include a number of relevant web pages.
For these and other reasons, therefore, there is a need for the present invention.
SUMMARY OF INVENTION
The invention relates generally to refining a user query. In a method of one embodiment, a query is received from a user, and then mapped to one or more search concepts. A list of search concepts associated with the query is then displayed. Alternatively or additionally, the search concepts associated with the query are used to provide a set of improved search results instead of being displayed. In a method of still another embodiment, a number of queries from a number of users are analyzed to identify two or more search concepts, and a popularity value is assigned to them based on the queries. Thus, the relative popularity of the respective search concepts can be determined. Alternatively or additionally, a preferred search query for the search concepts can be determined.
Furthermore, one specific embodiment of the invention relates to searching and query refinement based on matching user's queries to key phrases of concepts that have a popularity measured by the appearance of the concept's title and key phrases within the search engine's log of all queries. In particular, this embodiment relates to helping users to refine their search queries by identifying popular concepts related to the user's search query, providing the means for the user to use these concepts to refine their query and submit an enhanced query based on such concepts, and thus access information more specific to their needs.
For example, a concept may be Tiger Woods. The key phrases associated with this concept may include tiger, tigr, greatest golfer; tiger woods the golfer, as well as other key phrases. Another concept may be the animal tiger, with its own key phrases. Each concept may have one or more data entities (web page links, other information) considered most relevant to the concept associated with it.
To determine the popularity of each concept, the key phrases and concept words can be matched to a query log of past queries. The popularity of each concept is based on at least the number of different query phrases within the query log that match the key phrases of the concept, and the number of times each of these query phrases appears within the query log. More particularly, a number of popularity points proportional to the number of times a query phase appears in the query log is added to the concept where the query phase matches a key phrase that is unique to the concept. For a key phrase that appears in more than one concept, a number of popularity points proportional to the number of times a query phrase appears in the query log that matches the key phrase is apportioned among such concepts.
When a user enters a query, the query is matched against the key phrases and titles of the concepts to yield matching concepts. Matching concepts are those having one or more key phrases that match the query. For example, a user entering in tiger may have returned to him or her two concepts, Tiger Woods, and tiger(the animal).
A general popularity measure of each concept may also be determined and returned to the user. The popularity measure of a concept reflects its popularity within the query log as indicated by the number of popularity points that have been added for the concept. For example, in one implementation, the popularity measure can be determined as five times the log of the popularity points of the concept divided by the log of the popularity points of the most popular overall concept. This popularity measure returns a number from one to five indicating the relative popularity measure of the concept. Note that other implementations of the popularity measure may be devised and used.
A preferred search query of each concept is also determined and returned to the user. For example, the key phrase of a concept that is uniquely associated only with the concept, and that has a greatest popularity of any key phrase of the concept within the query log, may be selected as the preferred search query for that concept. The use of this preferred search query as the user's next query is aimed at obtaining the best results related to the associated concept. The popularity of a key phrase is determined by the number of popularity points added to the concept as a result of the key phrase matching a query phase within the query log. The invention is not restricted to data entities of type web links, but can be used to access data or data entities of a number of different types including documents, document links, web pages, video files etc. Although the invention described is for data entities that are web page links, this is for the purposes of example only, and does not represent a limitation of the invention in anyway.
The invention overcomes some of the disadvantages of the prior art indicated in the background. For example, overly broad search queries entered by users can be refined such that the users receive links to get relevant search results while the number of irrelevant web pages is significantly reduced. Additionally, since the concepts displayed are editorially chosen, these are free of pornography or other undesirable material, and may safely be used as steps in refinement.
The invention includes methods and computer-readable media of varying scope. Still other aspects, advantages, and embodiments of the invention, besides those described in this summary, will become apparent by reading the detailed description that follows, and by referring to the drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a diagram showing the structure of a concept, along with its key phrases and associated web sites, according to an exemplary embodiment of the invention.
FIG. 2 is a flowchart showing the overall methodology of an exemplary embodiment of the invention.
FIG. 3 is a flowchart of a method showing the popularity calculation stage of FIG. 2 in more detail, according to an exemplary embodiment of the invention.
FIG. 4 is a diagram showing the structure of a query log, according to an exemplary embodiment of the invention.
FIG. 5 is a diagram showing the results of matching the query log to the key phrases of a concept, according to an exemplary embodiment of the invention.
FIG. 6 is a flowchart of a method showing the imaging stage of FIG. 2 in more detail, according to an exemplary embodiment of the invention.
FIG. 7 is a flowchart of a method showing the query stage of FIG. 2 in more detail, according to an exemplary embodiment of the invention.
FIG. 8 is a flowchart of a method showing how the results of the query stage of FIG. 7 can be output, according to an exemplary embodiment of the invention.
FIG. 9 is a diagram of an exemplary web page depicting the integration of search results obtained in accordance with a preferred embodiment of the invention with other search results.
FIG. 10 is a diagram of a web page showing another way as to how the search results of the invention can be output, according to an exemplary embodiment of the invention.
FIG. 11 is a diagram of a system that implements an exemplary embodiment of the invention.
FIG. 12 is a diagram of another system that implements an exemplary embodiment of the invention, as compared to FIG. 11 .
FIG. 13 is a block diagram of a representative computing system environment in accordance with which exemplary embodiments of the invention may be implemented.
DETAILED DESCRIPTION
In the following detailed description of exemplary embodiments of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized, and logical, mechanical, electrical, and other changes may be made without departing from the spirit or 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 only by the appended claims.
Concepts, key phrases, and associated data entities
FIG. 1 shows a diagram 100 of a concept 102 , its key phrases 104 , and its associated web site 106 , or other associated data entities. The concept 102 is one or more concept words that are the title of the concept that a user may wish to search for with a search engine. A concept may be a topic, for example. It is typically manually determined. The key phrases 104 for the concept 102 are other phrases of one or more words that a user may enter as a search query to find information regarding the concept 102 . The key phrases 104 may be alternative key words for the concept 102 , misspellings of the concept 102 , shorthand notation for the concept 102 , or other phrases for the concept 102 . The key phrases 104 are typically manually determined or edited, by examining, for example, query logs of past search queries to determine how users search for the concept 102 . The associated web sites 106 are the data entities that are returned to the user when he or she searches for the concept 102 . They can be links to web sites related to the concept 102 , or other types of data entities. For example, they may be music file links, image file links, or other types of files or links. The associated web sites 106 are typically manually determined or edited as well.
An example of a concept 102 may be the popular singer Britney Spears. The title of the concept 104 are the words Britney Spears. The key phrases 104 for this concept may be just the word Britney, britneyspears.com, the name of her albums, as well as misspellings of her name, such as Brittney, Brittany, and so on. The associated web sites 106 may include the official Britney Spears web site, as well as various fan sites, and sites at which fans can purchase her music. The web sites 106 may also be edited, to ensure that no inappropriate, adult-oriented web sites are included, so that the web sites 106 are children friendly.
FIG. 2 is a flowchart of a method 200 showing the overall process followed by an exemplary embodiment of the invention. This process is described in summary, with a detailed description provided for each stage in subsequent sub-sections. In the popularity calculation stage 202 , query logs that provide frequency of occurrence of each query on a historical basis, as well as a list of concepts and their associated key phrases, are used to determine the popularity of each key phrase of each concept. This popularity is used in turn to determine the popularity of each concept. The popularity of a concept is based on the queries that match the key phrases associated with the concept, and the occurrence of each of those queries within the query log.
In the imaging stage 204 , the output of the refinement stage is indexed, and added to the data image, or database, used by the search engine to answer queries entered by users. Both the refinement stage 202 and the imaging stage 204 occur before a user has entered a query. That is, they are offline stages. They can be performed on a periodic basis to update the popularity of concepts based on newly generated query logs.
The query stage 206 is performed each time a query is entered by a user, and is considered an online stage. A search query is a query phrase that includes one or more words entered by the user. The search engine searches the database for related concepts by textually matching the words of the query phrase against the key phrases of the concepts, as well as the words in the concept titles, resulting in zero or more matching concepts. A concept is said to match a query if the query matches a keyphrase and/or one or more words in the title. Note that the keyphrases and the title words may be matched in different ways to the query. For example, we may use exact string match on the keyphrases, while we may require each of the words in the query to be contained (as a whole word) in the title without regard to order. The use of different matching schemes is not a required part of finding matching concepts. The returned list of matching concepts is sorted by decreasing popularity, such that the most popular choice is listed first. The associated data entities of these concepts may also be shown, or may be displayed when the user selects a concept. A visual measure of the relative popularity of a concept as compared to the other concepts may also be displayed, as well as a preferred search query for each concept.
Refinement Stage
FIG. 3 is a flowchart showing the refinement stage 202 of FIG. 2 in more detail. First, the concept words of the concepts and the key phrases are matched against the query phrases of the query log ( 300 ). An example query log is shown FIG. 4 . The query log 400 has a number of queries 400 a, 400 b, and 400 m. Each query is a query phrase that includes one or more words. A query may appear more than once in the query log 400 . Alternatively, each query in the query log 400 may be a unique query, and have associated therewith the number of times the query was entered during the logging period. For example, in the former case, if the query golf balls was entered 700 times during the logging period, it would appear 700 times in the query log 400 . In the latter case, however, the query would appear once, along with the number 700 to indicate that it was entered 700 times during the logging period.
The term query log is used generally. A query log may be a historical log of queries that have been entered by users during a logging period, and this is how it is predominantly used. However, a query log may also be modified to actively affect the popularity of concepts. For example, a query log may be populated with queries that were not actually entered so that the popularity of concepts are predictively modeled. For example, if it is known that the Super Bowl will be a popular search query in the coming months, the query log may be modified to add this query a large number of times to the log. Other ways to affect the ensuing popularity of concepts, for other predictive modeling, or for demographic or for other reasons, are also encompassed within the term query log.
Referring back to FIG. 3 , a popularity point is added to a concept for the number of times each query phrase appears in the query log that matches a key phrase unique to the concept ( 302 ). That is, a popularity point is added to a concept for the number of times each query phrase matches the concept words of a concept or a key phrase that is unique to the concept. For example, the query Brittany may appear 350 times in the query log. For the concept Britney Spears, there may be a key phrase Brittany that is unique to this concept, such that no other concept has this key phrase. Therefore, 350 popularity points are added to the concept Britney Spears. As another example, the query Britney Spears may appear 200 times in the query log. Because this query matches the concept words of the concept Britney Spears, 200 popularity points are added to the concept.
Next, for query phrases in the query log that match key phrases of more than one concept, a number of popularity points equal to the number of times such a query phrase appears in the query log is divided among such concepts ( 304 ). For example, the query tiger may appear 400 times in the query log. There may be two concepts that have the key phrase tiger, the concept Tiger Woods, and the concept wild tiger. Therefore, the 400 popularity points for the query tiger are apportioned between these two concepts. One way to apportion the popularity points is to proportionally divide the points among the concepts based on their amassed popularity points resulting from 302 . For example, the concept Tiger Woods may have 900 popularity points so far, and the concept wild tiger may have 100 popularity points so far. Therefore, 90% of the 400 popularity points for the query tiger are added to the concept Tiger Woods, and 10% are added to the concept wild tiger. Other ways to apportion the popularity points can also be used, however, such as equally dividing the points among the concepts that have such matching key phrases.
The result of 300 , 302 , and 304 is that each concept has a number of popularity points added thereto, based on the matching of query phrases to the key phrases of the concept. This is shown in the diagram 500 of FIG. 5 . The concept 102 has a number of popularity points 502 . Each key phrase 104 a, 104 b , . . . , 104 n contributes a number of popularity points 502 a, 502 b , . . . , 502 n, respectively, to the number of popularity points 502 of the concept itself. Adding the popularity points 502 a, 502 b , . . . , 502 n together yields the number of popularity points 502 of the concept 102 itself.
Referring back to FIG. 3 , two other parts of the refinement stage 202 may be performed, but are optional. First, a relative popularity measure of each concept may be determined ( 306 ). This popularity measure reflects the popularity of each concept as compared to the other concepts, as the concepts appear in the query log by their concept words and key phrases. This popularity may be calculated in many different ways. For example, the popularity measure may be measured on a scale from zero to five, where zero means the concept is least popular, and five means the concept is most popular. In such a case, the popularity measure of a concept can be determined in this implementation as five times the log of the popularity points attributed to the concept divided by the log of the popularity points attributed to the most popular concept.
Second, a preferred search query for each concept may be determined ( 308 ). This is the search query that is most likely to result in useful search results for a concept. The preferred search query may be determined for a concept by selecting a key phrase that is unique to the concept, and which has the greatest popularity as compared to any other unique key phrase for the concept and the concept words of the concept. The popularity of a key phrase is indicated by the number of popularity points added to the concept as a result of the key phrase matching a query phrase within the query log. For example, if for the concept Britney Spears the key phrase Britney is unique to the concept and has more popularity points than the concept words Britney Spears and the other unique key phrases do, then the key phrase Britney is selected as the preferred search query. If no unique keyphrase is identified by this method, editorial means may be used to add such a keyphrase.
Imaging Stage
FIG. 6 is a flowchart showing the imaging stage 204 of FIG. 2 in more detail. First, the output of the refinement stage is indexed ( 600 ). The output may also then be compressed. The output of the refinement stage is the list of concepts and their determined popularity, as well as their key phrases and associated data entities. This output is indexed and optionally compressed in such a way that it is compatible with the data image or database that is used by the search engine at query time, to run a search query entered by the user. The resulting indexed and optionally compressed output is then added to the database or data image used by the search engine at query time ( 602 ). The database or data image may also include other ways to find relevant data entities for search queries. For example, the database or data image may include the data for the techniques used by current search engines as described in the background section.
Query Stage
FIG. 7 is a flowchart showing the query stage 206 of FIG. 2 in more detail. First, a query is received ( 700 ). For example, a user may enter a search query, such that the user wishes to receive relevant data entities, such as web page links, for the search query. The received query is next matched against words in the concept title and/or associated key phrases of concepts, to determine concepts that match the query ( 702 ). As mentioned earlier, a concept is said to match a query if the query matches a keyphrase and/or one or more words in the titles. Note that the keyphrases and the title words may be matched in different ways to the query an exact string match on the key phrases may be used, while each of the words in the query may be required to be contained (as a whole word) in the title without regard to order. For example, if the search query is the word tiger, the query may match the key phrase tiger for the concept Tiger Woods, as well as the key phrase tiger for the concept wild tiger. The matching concepts are sorted by and in descending order of their popularity ( 704 ). Their popularity is measured by the number of popularity points that were added to each concept. The sorted matching concepts are then output ( 706 ). If there are a large number of matching concepts, only a predetermined number, such as the first two or three, may be output, or alternatively all the concepts may be output. The output may also include the relative popularity of each of the matching concepts, and/or the preferred search query for each of the matching concepts.
FIG. 8 is a flowchart of a method 800 showing how the output of the query stage 206 of FIG. 2 can be presented to the user, where the associated data entities of the concepts are web page links. First, the matching concepts and their relative popularity are displayed ( 802 ). Where the relative popularity is a number from zero to five, this may be indicated to the user by displaying an equal number of icons, such as shaded stars. One or more featured web sites may optionally next be shown ( 804 ).
One or more web sites, that is, web page links, associated with one or more of the matching concepts may also optionally be displayed ( 806 ). For example, there may be ten places reserved for showing such web page links. An equal number of associated web page links may be shown from each matching concept, or the places may be divided proportionally among the matching concepts based on their popularity. Finally, one or more web pages returned from other types of search engines may be optionally displayed ( 808 ). Such web pages may have been returned by current search engines as have been described in the background section.
FIG. 9 is a diagram of a window 900 that shows an example of the output resulting from the method 800 of FIG. 8 . The user's search query is shown in the box 901 . The matching concepts and their relative popularities that are displayed by performing 802 are shown in section 902 of the window 900 . The featured web site or sites that are displayed by performing 804 are shown in section 904 . The web sites, that is, web page links, associated with the matching concepts that are displayed by performing 806 are shown in section 906 of the window 900 . Finally, any other relevant web pages that are displayed by performing 808 are shown in section 908 .
If one of the matching concepts displayed in section 902 is selected by the user, another window may appear, as shown as the window 1000 of FIG. 10 . The preferred search query for the selected concept is shown in the box 1002 . The associated web sites, or web page links, for the selected matching concept are then displayed in section 1006 of the window 1000 . FIGS. 8 , 9 , and 10 only depict an example of the display of associated data entities of matching concepts that can be used in accordance with the invention. Other manners by which associated data entities of matching concepts can be displayed are also contemplated by the invention.
System and Device Implementation
FIG. 11 is a diagram of a system 1100 that can implement the invention as has been described. The concepts, key phrases, and associated data entities 1102 , as well as the query log 1104 , are used by the popularity tool 1106 to perform the refinement stage 202 of FIG. 2 as has been described. The output of the popularity tool is used by the imaging tool 1108 to perform the imaging stage 204 of FIG. 2 as has been described. The imaging tool 1108 results in a data image or a database that can be integrated into the search engine database 1112 , along with other search engine data 1110 .
The query run time tool 1114 runs a search against the search engine database 1112 for the search query 1116 , as has been described as the query stage 206 . The output of the query run time tool 1114 includes query results 1118 based on the query 1116 . The query 1116 can also be added to the query log 1104 , for future periodic use of the popularity tool 1106 , and so on. Each of the tools 106 , 1108 , and 1114 may be a separate computer or computerized device, a separate computer program, or part of the same computer program.
FIG. 12 is a diagram of an environment 1200 in which the invention can be used. A client 1202 and a server 1206 are both communicatively connected to the Internet 1204 . The server 1206 has access to the search engine database 1112 . A user enters a search query on the client 1202 , which is sent to the server 1206 over the Internet 1204 . The server 1206 performs the query stage 202 of FIG. 2 as has been described, matching the search query received from the client 1202 against the database 1112 . The results are then returned back to the client 1202 over the Internet 1204 , where they can be displayed for the benefit of the user.
FIG. 13 illustrates an example of a suitable computing system environment 10 on which the invention may be implemented. For example, the environment 10 may implement the client 1202 , the server 1206 , and/or the system 1100 that have been described. The computing system environment 10 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Neither should the computing environment 10 be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment 10 . In particular, the environment 10 is an example of a computerized device that can implement the servers, clients, or other nodes that have been described.
The invention is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well known computing systems, environments, and/or configurations that may be suitable for use with the invention include, but are not limited to, personal computers, server computers, hand or laptop devices, multiprocessor systems, microprocessorsystems. Additional examples include set top boxes, programmable consumer electronics, network PCs, minicomputers, cell phones, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
The invention may be described in the general context of computerinstructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. The invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer storage media including memory storage devices.
An example of a system for implementing the invention includes a computing device, such as computing device 10 . In its most basic configuration, computing device 10 typically includes at least one processing unit 12 and memory 14 . Depending on the exact configuration and type of computing device, memory 14 may be volatile (such as RAM), non-volatile (such as ROM, flash memory, etc.) or some combination of the two. This most basic configuration is illustrated by dashed line 16 . Additionally, device 10 may also have additional features/functionality. For example, device 10 may also include additional storage (removable and/or non-removable) including, but not limited to, magnetic or optical disks or tape. Such additional storage is illustrated in by removable storage 18 and non-removable storage 20 .
Computer storage media includes volatile, nonvolatile, removable, and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules, or other data. Memory 14 , removable storage 18 , and non-removable storage 20 are all examples of computer storage media. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CDROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by device 10 . Any such computer storage media may be part of device 10 .
Device 10 may also contain communications connection(s) 22 that allow the device to communicate with other devices. Communications connection(s) 22 is an example of communication media. Communication media typically embodies computer readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. The term computer readable media as used herein includes both storage media and communication media.
Device 10 may also have input device(s) 24 such as a keyboard, mouse, pen, voice input device, touch input device, etc. Output device(s) 26 such as a display, speakers, printer, etc. may also be included. All these devices are well known in the art and need not be discussed at length here.
The methods that have been described can be computer-implemented on the device 10 . A computer-implemented method is desirably realized at least in part as one or more programs running on a computer. The programs can be executed from a computer-readable medium such as a memory by a processor of a computer. The programs are desirably storable on a machine-readable medium, such as a floppy disk or a CD-ROM, for distribution and installation and execution on another computer. The program or programs can be a part of a computer system, a computer, or a computerized device.
CONCLUSION
It is noted that, although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement that is 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 equivalents thereof. | Refining a user query is disclosed. In one method, a query is received from a user, and then mapped to one or more search concepts. A list of search concepts associated with the query is then displayed. Alternatively or additionally, the search concepts associated with the query are used to provide a set of improved search results. In another method, a number of queries from a number of users are analyzed to identify two or more search concepts, and a popularity value is assigned to them based on the queries. Thus, the relative popularity of the respective search concepts can be determined. Alternatively or additionally, a preferred search query for the search concepts can be determined. The popularity and preferred queries can be used to allow automatic or user-initiated refinement. | 8 |
FIELD OF THE INVENTION
The present invention relates generally to a projectile, and more particularly to a projectile having two sections decoupled about a roll axis, a first section having a stator and the second section having a rotor and a static spin imparting member (e.g., fins), wherein the spin rate of the projectile is controlled by utilizing the rotor and stator in combination as a generator to brake the spin or as a motor to establish spin.
BACKGROUND ART
In the past, roll control devices for projectiles used either reaction jets and/or actuated aerodynamic surfaces. However, the use of such devices has presented several drawbacks. First, the devices generally included explosive elements or other high pressure devices. As those skilled in the art will appreciate, the use of explosives tends to disturb the projectile trajectory. Additionally, the use of propellant creates a limiting time factor to the control of the projectile, due to the predetermined burn time of the quantity of propellant stored on the projectile.
U.S. Pat. Nos. 4,568,039 and 4,438,893 disclose a guidance system for a spinning projectile. In the disclosed system the main housing spins and a front canard frame is despun. Two stator windings are disposed within the main housing and a cooperative pair of rotors are arranged within the canard frame. The first stator winding and rotor set generate power to provide control of the rotational position of the canard frame. The second stator winding and rotor set generates power for control of the deflectable canards. The disclosed device, however, includes several drawbacks. First, the device requires that the spin be imparted on the projectile by the launching device. By imparting the spin upon launch, the amount of energy available is limited and decreases over the duration of the flight. This is especially true while utilizing the spin for the purpose of despinning the front canard frame and generating power for the deflectable canards to steer the shell. In order to store the necessary energy a large rotational mass for the main housing must be used.
Therefore, there is a need for a new and improved roll control device which minimizes disturbance to the projectile trajectory, and provides on-demand, available torque for roll control during the entire projectile flight--for a variety of flight lengths.
SUMMARY OF THE INVENTION
The present invention provides an improved method and apparatus for roll control that overcomes the foregoing and other difficulties associated with the prior art. In accordance with the principles of the invention, there is provided an electro-mechanical roll control system ("EMRCS"), wherein a front (or first) section includes a stator and a rear (or second) section includes a rotor which is mounted in electromagnetic cooperation with the stator to form a motor. The first and second sections of the projectile are decoupled about the roll axis. The rear section of the projectile also includes a fixed torque application means to obtain a nominal steady state spin rate for the rear section. When the rear section spins, the electromagnetic interaction of the rotor and stator generates a control current which interacts with magnets cooperatively mounted in the rear section. A controller senses the interaction and provides control signals to adjust the rate of spin of the front section by applying a resistive load across the armature coil or by supplying current to the armature coil.
In a preferred embodiment of a device constructed according to the principles of the present invention, a front and rear section of the projectile are decoupled about the projectile longitudinal (or roll) axis using bearings or some other means for providing rotation between the front and rear sections while minimizing friction. When current is supplied to the armature coil, an equal and opposite force (i.e., a roll torque) is exerted on the projectile sections. These forces tend to accelerate the two sections in opposite directions. Folding fins on the rear of the projectile act as the fixed torque application means (e.g., the static spin imparting member), and are designed with cants or slight bevels. Therefore, when the projectile moves through the atmosphere, a relatively fixed torque is applied to the rear section, whereby a nominal steady-state spin rate for the rear section is established. Those skilled in the art will appreciate that the rate of travel of the projectile, as well as the density of the atmosphere (among other factors), affects the torque applied by the fins. Accordingly the torque is a nominal torque with a range about the nominal value.
When a control current is supplied to the armature coil, a torque balance is achieved between the two sections at a slightly perturbed spin rate. At this spin rate, a new level of a damping torque which matches the applied electromagnetic and fixed bevel torques is required. Active feedback is utilized to control the electromagnetic torque control.
To accelerate the front of the projectile to a spin rate away from the spin rate of the rear projectile, a battery is used to supply the current. To change the spin rate to a value closer to the rear projectile spin rate, a dynamic braking mode is used, in which the electro-mechanical system operates in a generator mode. In the latter mode, the current is preferably dumped to a resistive network. It will be appreciated by those skilled in the art that in the preferred embodiment described herein, the only aerodynamic roll torque acting on the front section is due to negligible surface drag. Thus, the front section accelerates as long as the torque is applied. One or more sensors mounted on the front section supplies a feedback signal for active damping of the control loop.
One feature of the present invention is that no electrical power is required in the rear projectile section. This eliminates any requirements for batteries or a power connection with the front section, thereby reducing weight and complexity.
An additional feature of the present invention is that the device provides control torque about a roll axis without disturbing the projectile trajectory. Therefore, a stabilized roll can be established on a missile or other projectile, as well as providing high-speed roll pointing control.
Another feature of the present invention is that during spin-up, de-spin and pointing maneuvers, the EMRCS can operate as a generator, potentially giving rise to lowered requirements for the power-up of front-end electronics and the use as a power source for the roll rate sensor--while the battery in the front section is being initiated and braking energy is generating power.
It will be appreciated by those skilled in the art that while the terms stator and rotor are used herein, such terms do not connote that either of the sections (in which such elements are located) are not spinning. To the contrary, each of the front and rear sections, with the stator and rotor attached thereto, may rotate since neither is fixed when the projectile is in flight. Those skilled in the art will also appreciate that while projectile spin provides for in-flight stability of the projectile and provides energy to accomplish in-flight pointing ability, it is often desireable or necessary for the front section of the projectile to spin at a lower rate (or to not spin) in order to provide for effective warhead detonation and explosion patterns.
Therefore, according to one aspect of the invention, there is provided a roll control apparatus for a projectile, comprising: a) a first section, said first section including a stator; and b) a second section including a rotor and a static spin imparting member operatively connected to said second section, wherein said two sections are rotatably connected about a longitudinal axis and wherein said rotor and stator are electro-mechanically connected to form an armature, wherein the spin rate of the projectile is controlled by utilizing the rotor and stator in combination as a generator to brake the spin or as a motor to establish spin.
According to another aspect of the invention, there is provided an electro-mechanical roll control system for a projectile, comprising: a) a front section including a stator having a coil; b) a rear section including a rotor which is mounted in electromagnetic cooperation with said stator, wherein said first and second sections are rotatably connected to one another about a longitudinal axis and wherein each of said first and second sections are rotatable about said longitudinal axis; c) a fixed torque application means, cooperatively connected on the exterior of said rear section, for applying a force to said rear section, whereby a nominal steady state spin rate for the rear section is established, and wherein when said rear section spins, then the electromagnetic interaction of said rotor and said stator generates a control current; d) one or more sensors, cooperatively located in said front section, for sensing said control current and generating an input signal; and e) a controller for receiving said input signal, determining the actual spin rate of said front section, comparing said actual spin rate with a predetermined target rate, and for generating a control signal to adjust the rate of spin by applying a resistive load across the armature coil or by supplying current to the armature coil.
These and other advantages and features which characterize the present invention are pointed out with particularity in the claims annexed hereto and forming a further part hereof. However, for a better understanding of the invention, its advantages and objectives obtained by its use, reference should be made to the Drawings which forms a further part hereof and to the accompanying descriptive matter, in which there is illustrated and described a preferred and an alternative embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the Drawings wherein like parts are referenced by like numerals throughout the several views.
FIG. 1 is a side elevational view (with portions taken in cross section) of a projectile 30 in which the electro-mechanical roll control apparatus and method constructed according to the principles of the present invention might be employed;
FIG. 2 is a side plan view of the projectile 30 of FIG. 1 illustrating deployment of the fins 44 after the projectile 30 is in flight;
FIG. 3 is an enlarged section of a portion of the projectile 30 of FIG. 1;
FIGS. 4a and 4b are views of the fin(s) 44 illustrating the cant and/or bevel of the fins 44 of projectile 30;
FIG. 5 is a functional block diagram of the various torsion and electro-mechanical elements of the projectile 30 and including the components of an electro-mechanical roll control apparatus and method constructed in accordance with the principles of the present invention;
FIG. 6 is a block diagram illustrating in greater detail the electro-mechanical elements of FIG. 5;
FIG. 7 is an illustrative response curve of the electro-mechanical roll control apparatus and method, plotted as a function of the spin rate of the rear section versus time during a despinning operation of the front section; and
FIG. 8 is an alternative embodiment electro-mechanical roll control apparatus and method wherein the front section includes oppositely directed spin imparting members to provide for generation of power for the entire flight.
DETAILED DESCRIPTION
The principles of this invention apply particularly well to controlling roll in a projectile or other missile. A preferred application for this invention is in a projectile device fired from or at a tank type vehicle. Such preferred application, however, is typical of only one of the innumerable types of applications in which the principles of the present invention can be employed. Since the EMRCS replaces previously used reaction jet torque control systems, it will be appreciated that many of the same general requirements are desirable. For example the reliability, maintainability, safety, temperature environment, gun hardening, etc. are preferably considered.
As will also be appreciated by those skilled in the art, in order to apply a roll torque to a projectile using an electro-mechanical device, a multiple-part body may be used. In order to more clearly describe the present invention, the detailed descriptions of the theoretical operation, the elements utilized in the preferred embodiment, and the temporal events which occur during operation will be deferred pending a discussion of a projectile in which the present invention may be employed. After a discussion of such a projectile, each of the other three topics will be discussed in turn.
PROJECTILE 30
Referring first to FIGS. 1, 2, 3 and 4a and 4b, there is illustrated a projectile, referred to generally by the designation 30, in which a preferred embodiment electro-mechanical roll control apparatus and method may be utilized. The front section 31 (i.e., the forward section of the projectile 30 body) contains a payload section 33 (in which certain electronics devices may also reside), various electronics devices (discussed below in connection with FIG. 5), and power supply/battery 50 (discussed in more detail below). Also illustrated in FIG. 1 is the projectile case 34, the material 35 which propels the projectile 30 from the launching device (not shown), and bearings 36.
The front section 31 further includes the coils 38 for the armature of the control device brushless DC machine 52 (best seen in FIG. 5). The magnets 41 of the armature are connected to the rear section 32 (i.e., the aft section of the projectile 30 body) and are preferably permanent magnets.
Tail boom 43 extends from a first end proximate the front section 31 to a second end which is at the aft end of the projectile 30. At the second end, fold-out fins 44 are hingedly attached and are biased into a flight position after the projectile 30 is in flight (best seen in FIG. 2). The fins 44 provide flight stability for projectile 30 and operate as the fixed torque application means (i.e., also the static spin imparting member).
Referring now to FIGS. 4a and 4b, views of the fins 44 which illustrate the bevel 40 (FIG. 4a) and cant (FIG. 4b) of the fins 44 is provided. For the purpose of clarity, a cant will be discussed herein, however, a bevel might also be used. Each fin 44 is similarly canted in order to apply a torque as the projectile 30 moves through the atmosphere. It will be appreciated that the greater the cant, the larger the torque which will be generated. In the preferred embodiment, in view of the speed of the projectile, only a fraction of a degree θ of cant is required to impart the necessary torque and, therefore, the necessary spin.
The approximate spin rate of the preferred embodiment is in the 20 Hz range, however, other frequency/speeds might be used as those skilled in the art will appreciate. In view of the various masses and the projectile speed, among other factors, the cant or bevel of the fin must generally be found empirically for the specific projectile on which the present invention will be utilized. In the preferred embodiment, the fins are canted or beveled in order to establish a clockwise rotation as viewed looking along the projectile flight path from the rear to the front.
THEORY OF OPERATION
Although discussed in more detail below, FIG. 5 depicts a functional block diagram schematic of an EMRCS suitable for embodying the principles of the present invention, while FIG. 6 is a block diagram schematic of typical hardware interfaces suitable for implementing the functions of the embodiment of FIG. 5. As noted above, the EMRCS may be disposed onboard a projectile 30 and be operative during the flight of the projectile 30 in order to orientate the front section 31 of the projectile 30 to point in a desired orientation about the projectile roll axis.
As illustrated in FIG. 5, the projectile is divided into front and rear sections or assemblies 31 and 32. Equal and opposite torques can be applied to the sections via the coupling field established between the coils 38 and magnets 41 of the preferred brushless DC machine 52. The torques acting on the rear section 32 about the roll axis are due primarily to the four sources set forth in Table 1.
TABLE 1
1. The coupling field of the DC machine;
2. The aerodynamic damping torque imparted on the rear body by the fixed fins;
3. The aerodynamic torque due to the cant or beveling of the fixed fins; and
4. Friction on the bearing surfaces between the front and rear projectile sections.
Those skilled in the art will appreciate that the torque due to the electromechanical system is proportional to the current, i, flowing in the coils 38, that is:
T.sub.e =K.sub.T i
where K T is the torque constant of the brushless DC machine 52.
The aerodynamic damping torque is proportional to the spin rate of the rear section 32 relative to the surrounding air:
T.sub.d =(qSd.sup.2 /2V)C.sub.1p p.sub.r
where:
p r is the spin rate of the rear projectile body,
d is the projectile reference diameter,
q is the dynamic pressure,
S is the projectile reference cross-sectional area,
V is the forward velocity of the projectile, and
C 1p is the dimensionless roll damping coefficient.
The aerodynamic torque due to the cant or beveling of the fixed fins 44 is given by:
T.sub.b =qSdC.sub.1
where C 1 is the aerodynamic roll moment coefficient of the rear section/assembly 32. The total torque acting on the rear projectile is:
T.sub.r =T.sub.e +T.sub.d +T.sub.b +T.sub.f
where T f is the frictional torque.
When no current is applied to the coils 38 the rear section 32 spin rate will tend towards a value given by:
R.sub.r =2V((qSdC.sub.1 +T.sub.f)/qSd.sup.2 C.sub.1p
When current is applied to the motor coils 38, the rear section 32 will accelerate according to:
Φ=(K.sub.T i+(qSd.sup.2 /2V)C.sub.1p p+qSdC.sub.1 +T.sub.f)/I.sub.r
where I r is the roll moment of inertia of the rear section 32.
When a fixed torque is applied to the rear section 32, the spin rate of the rear section 32 tends towards a spin rate Δp away from the equilibrium spin rate p, given above. The deviation of the spin rate from equilibrium is given by:
Δp=(2VK.sub.T i/qSd.sup.2 C.sub.1p)
Besides providing the required stability to the projectile, the fin design must result in values of C 1p and C 1 such that p r is at an acceptable value bounded away from the projectile 30 resonant frequency throughout the flight regime and that p r ±Δp is an acceptably small range for the applied torques required for controlling the roll rate and roll orientation of the front section 31.
EMRCS FUNCTIONAL BLOCKS
In general, in the preferred embodiment, the input signal to the drive electronics is an analog signal proportional to the desired torque. The controller utilizes current feedback control to ensure that the torque is developed. Even though the motor only rotates in one direction, both positive (accelerating) and negative (braking) torques are controlled. It will be appreciated that during the braking mode, the motor acts equivalent to a generator, and a resistive load must be provided to dissipate the energy. Protection circuitry is also preferably provided in order to prevent recharging the battery.
In the preferred embodiment, there is driver board in the front section 31 which converts a digital signal in the digital processor block 59 into a current drive for the motor controller circuit block 51. The block 59 also includes proper digital to analog and analog to digital convertors.
More specifically, FIGS. 5 and 6 illustrate the various electrical functional blocks and logical data flow of the projectile and EMRCS. While not specifically detailed in FIGS. 5 and 6, it will be understood that the functional blocks, and other devices are properly connected to appropriate bias and reference supplies so as to operate in their intended manner. Further, appropriate memory, buffer, timing and other attendant peripheral devices are to be properly connected for the devices to operate as intended.
Referring first to FIG. 5, there is illustrated the various components, in functional block form, of the rear section 32 and the front section 31. In the rear section 32, the fixed fin aerodynamics block 56 applies a torque to the rear projectile dynamics block 54a. It will be appreciated that the rear projectile dynamics block 54a includes all of the net forces (i.e., as discussed above in Table 1). The applied torque 53 from the rear projectile dynamics block 54a is applied to the front section 31 via magnets 41 of the armature of the motor (preferably a brushless DC machine 52) to the coils 38. As utilized herein, the term brushless DC machine 52 is used to emphasize that an electromagnetic device is used in both a generator and alternator mode. It will be appreciated that an electromagnetic coupling exists between the magnets 41 and the coils 38. The coupling field is generally designated by the numeral 65.
As noted above, the front section 31 includes coils 38 as part of the armature of the brushless DC machine 52. The applied torque designated by the numeral 66 is provided to the front projectile dynamics block 54b. Similar to the rear projectile dynamics block 54a, the front projectile dynamics block 54b is illustrative of the net forces on the front section 31 of the projectile 30.
The resulting physical parameters are measured by the front projectile angular rate sensor block 61 (e.g., to measure the roll rate) and a front projectile angular orientation sensor block 62 (e.g., to measure the roll position). It will be well understood by those skilled in the art that these sensors may comprise various gyros, radars, lasers, etc. The sensor blocks 61 and 62 provide digital signals, via switches 60a and 60b respectively, to a roll control digital processor block 59. This functional block provides a command signal to the motor controller circuit 51 to provide appropriate feedback control loop signals to stabilize the projectile 30. Those skilled in the art will appreciate that such feedback control loops are well known in the art and may include proportional, integral and derivative components (or combinations thereof), fuzzy logic, and other types of control process algorithms.
Voltage/torque control command switch 55 is interposed between the motor control circuit 51 and the roll control digital processor 59. Motor controller circuits are also well known in the art and so will not be described in detail herein. Battery 50 provides the necessary power to the motor controller circuit block 51 when operating the brushless DC machine 52 as a motor. The motor controller circuit 51 also includes a resistive network for dumping current from the coils 38 when the brushless DC machine 52 is operating as a generator.
Turning now to FIG. 6, there is illustrated in more detail blocks 50, 51, and 52 of FIG. 5. First, the voltage command signal 55 is summed at block 70 with a command voltage offset and the output from current compensation block 79. The resulting signal is provided to a scaling block 71 and from there is provided to current compensation block 72. The signal from current compensation block 72 is stepped up at pulse width modulator gain block 73 and is provided to battery induced voltage limiter block 74.
Battery 50 includes a battery model block 78, battery no load voltage block 77, and summing block 93. The output of the summing block 93 is in turn summed with diode losses block 75 at summing block 76. The diode losses block 75 diodes are utilized for circuit protection during use of the resistive network during generator operation. The output of summing block 76 is also provided to the battery induced voltage limiter 74. Duty cycle losses block 83 provides the voltage limited signal to summation block 84. The motor controller block 51 further includes transistor losses block 81 and gain block 82 which is summed at summation block 84.
The various elements of the brushless DC machine 52 include summation block 85 which provides a signal to the motor impedance block 86, the output of which includes the controlled current (for current feedback gain block 80 and current compensation 79 block). Additionally, the output of the motor impedance block 86 is provided to the RMS type losses block 88. This signal is multiplied by the torque constant K t of the brushless DC machine 52 and is summed at summation block 90.
The relative spin rate (in radians per second) is provided as an input signal to the voltage constant K e at block 87. The resulting back EMF signal is provided to summation block 85. The relative spin rate signal is provided to sliding friction block 100 which decreases the output summed at block 90 discussed above. Torque ripple block 91 is subtracted from the output at summation block 92 and provided as a motor torque output signal 53.
For proper control responses for a projectile fired from a 120 mm gun the required torque is in the range of ±30 in.-lb. and shaft power of approximately 3 bursts of 500-600 watts for 0.1 second durations (needed for de-spin, vertical orientation and terminal pointing).
As noted above, during spin-up and during the braking portion of each pointing maneuver, the brushless DC machine 52 acts as a generator. During spin-up, the power generated may be used for warm-up and initialization of front-end electronics. Also as noted above, it will be appreciated that the protection circuitry and resistive loads must be established such that excess power generated during braking does not recharge and destroy the thermal battery 50. It is currently believed by the inventors that the motor ripple torque at amplitudes of 100% will not impact the response and accuracy of the control system as long as the frequency is three times the roll rate of the rear section 32.
In the preferred embodiment, the EMRCS weighs approximately 161/2 lbs. and preferably has a volume of less than 300 cubic inches. The available volume and size of the housing for the EMRCS is driven by the thickness of the housing required to withstand a 21,000 g setback load. This has been determined to be approximately 0.4 inch. In the preferred embodiment, the boom is a solid aluminum boom having a diameter of 1.4 inches. Other style booms such as a cursor form shaped boom might also be used.
The bearings 36 are designed to withstand the friction generated by the system. In the preferred embodiment roller bearings are utilized. A seal is provided to protect the electronics from gases generated when firing the projectile. In the preferred embodiment, the seal includes a grooved washer.
IN OPERATION
Turning now to the operation of the EMRCS, Table 2 illustrates a listing of the temporal events which occur during the flight of projectile 30.
TABLE 2
Time Line of Temporal Events
1. Projectile is fired from gun.
2. The onboard thermal battery 50 is initiated.
3. The tail fins 44 on the rear projectile section 32 are deployed into the airstream.
4. The rear section 32 spins up to the equilibrium roll rate.
5. The system power level comes up and the motor controller 51 is operable.
6. Either clockwise or counter-clockwise torques are applied about the projectile roll axis by supplying the corresponding command 55 to the motor controller circuit block 51.
7. Angular rate sensor 61 and position sensor 62 which are mounted on the front section 31 continuously supply measurement data to a roll control digital processor 59 which, in turn, commands the motor controller circuit block 51 with the desired feedback torque.
FIG. 7 illustrates a simulation of the response of the control system. First, the inertial rotation of the rear section 31 is illustrated as ramping up very quickly and at area designated by the letter A decreases. This decrease corresponds to a command to speed up the front section 31. At the section of the curve designated by the letter B, the spin rate of the rear section decreases further as the front section 31 spin rate is slowed. A second overshoot to settle the front section is illustrated at the section designated by the letter C. Thereafter, a steady state nominal spin rate is achieved. It will be appreciated by those skilled in the art that the curve illustrated in FIG. 7 is illustrative only and is provided herein for the purpose of depicting the temporal sequence of events which occurs when applying a step command to the front section.
ALTERNATIVE EMBODIMENT
Next referring to FIG. 8, an alternative embodiment is illustrated. The alternative embodiment includes fins 110 on the front end 31' of the projectile 30' to cause the drive to operate as a generator for the duration of the flight. It will be appreciated that this can completely eliminate the need for thermal batteries on board the projectile 30', thereby reducing cost and increasing reliability.
Those skilled in the art will appreciate, when the electric drive is in the braking mode (i.e. the mode in which it generates power) it produces a clockwise torque on the front end 31' of the projectile 30'. If a net torque of ±30 in.-lb. is desired for control purposes, then additional torque to generate more power must be delivered. Assuming that electrical power requirement of 10 amps and 30 volts is required for the duration of the flight to power the front end 31', the motor is 80% efficient, and the fins 44' on the rear section 32' provide a steady state nominal spin rate of 20 Hz, then a torque of 26 in.-lb. is required to generate the electrical power.
Accordingly, the fins 110 on the forward section 31' of the projectile 30' have to be sized to produce a counter-clockwise torque of 56 in.-lbs. The fins 110 on the forward section would be sized by the minimum dynamic pressure condition. Motor torque at this condition would vary from 26 to 86 in.-lbs. in order to produce the desired net torque of ±30 in.-lbs. for control purposes. For the maximum dynamic pressure condition, the torque produced by the forward fins 110 would increase by about a factor of 2 (e.g., a counter-clockwise torque of 122 in.-lbs.). Under this maximum dynamic pressure condition, the motor must produce a torque of 82 in.-lbs. to 142 in.-lbs. Accordingly, the peak torque of the motor would range from 26 to 142 in.-lbs. instead of the ±30 in.-lbs. required in a system which makes use of thermal batteries. The fins 110 on the forward end 31' would have a total area of roughly 4 square inches. Drag on the projectile would be increased by roughly 1%.
Other alternative designs for the EMRCS are possible. For example, the permanent magnets for the motor may be mounted on the outside of the coils. This is commonly known as an inverted motor design. With this design, the magnets are mounted on the inside of the housing and the entire housing rotates with the rear end of the projectile. However, it is believed that a design with the permanent magnets mounted on the inside shaft is preferable. Most motors utilize this configuration because of the reduced motor inertia. In both implementations, however, the magnets rotate with the rear section, thereby eliminating any need for slip rings and electrical power in the rear end of the projectile.
A configuration with the magnets on the inside is preferred for several other reasons as well. First, it appears that smaller seal is easier to construct robustly, and the smaller bearings required are lighter and less costly. Additionally, magnets constructed of samarium cobalt do not lose their magnetism when shocked. However, those skilled in the art will appreciate that care must be taken to assure the material stays in compression, as it readily fails mechanically when in tension.
It is to be understood that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, this disclosure is illustrative only and changes may be made in detail, and to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | An apparatus and method for controlling roll of a projectile is disclosed. The projectile includes two sections decoupled about a roll axis. The front section includes a stator and the rear section includes a rotor and a static spin imparting member. The spin rate of the projectile is controlled by utilizing the rotor and stator in combination as a generator to brake the spin or as a motor to establish spin. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing of U.S. Provisional Patent Application No. 61/779,125, filed on Mar. 13, 2013, the disclosure of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to drawer slides, and more particularly to drawer slide member structures.
[0003] Drawer slides are commonly used to extendably mount casings in a structure, for example drawers in a cabinet or computer equipment in a rack. The use of drawer slides often allows for compact storage of casings, while providing relative ease of user access to the casings or items in the casings when desired.
[0004] The loads carried by drawer slides can at times be significant. The loads can exert significant forces on the drawer slides, particularly when the members of the drawer slides are extended from the structure. In addition, in some applications space allowed for drawer slides, particularly in width, may be limited, placing a premium on relative strength of drawer slide components. Unfortunately, a requirement for a thin drawer slide may prohibit the use of thicker and therefore stronger material in drawer slides, which may be undesirable in any event for cost reasons.
[0005] In rack mounted computer equipment applications, in particular, very little room may be allocated in width for a drawer slide, and the computer equipment itself may be heavy. Complicating matters, computer equipment may be in varying sizes. For example, often computer equipment is sized in a one rack unit ( 1 U) size or a two rack unit ( 2 U) size, and the different equipment sizes may often correlate with increased weight of equipment. The use of equipment of different rack sizes complicates drawer slide design, and, inconveniently, different drawer slides may be required for the different rack sizes.
BRIEF SUMMARY OF THE INVENTION
[0006] Aspects of the invention provide for a slim drawer slide.
[0007] In some aspects the invention provides a slide member for a drawer slide, comprising: a pair of longitudinal raceway structures separated by a longitudinal web, each of the raceway structures having an S-shaped cross section, with an outward facing portion about a first end of the S-shape being indented to form an outward facing raceway and an inward facing portion about a second end of the S-shape being indented to form an inward facing raceway.
[0008] In one aspect, the invention provides a slide member for a drawer slide, comprising: a pair of longitudinal raceway structures separated by a longitudinal web, each of the raceway structures having a cross section with: an inwardly facing arcuate raceway extending from about a longitudinal edge of the web, the inwardly facing arcuate raceway having a proximate edge about the longitudinal edge of the web and a distal edge distal from the web; a first abutment extending outward from the distal edge of the inwardly facing raceway; an outwardly facing arcuate raceway extending from the first abutment; a second abutment extending from the outwardly facing arcuate raceway and towards the proximate edge of the inwardly facing arcuate raceway; and a base extending from the second abutment, the base extending along and generally conforming to an outwardly facing surface of material forming the inwardly facing arcuate raceway.
[0009] In another aspect, the invention provides a telescopic drawer slide, comprising: an outer slide member having a longitudinal web bounded by inwardly facing arcuate raceways; an inner slide member having a longitudinal web bounded by outwardly facing arcuate raceways; and an intermediate slide member, the intermediate slide member extendably coupled to the outer slide member by bearings running in the inwardly facing arcuate raceways of the outer slide member, the intermediate slide member extendably coupled to the inner slide member by bearings running in the outwardly facing arcuate raceways of the inner slide member, the intermediate slide member having a longitudinal web bounded by inward facing arcuate raceways receiving the bearings running in the outwardly facing arcuate raceways of the inner slide member, with abutments extending outwardly from about edges of material forming the inward facing arcuate raceways, and outward facing arcuate raceways between the abutments, the outward facing arcuate raceways receiving the bearing running in the inwardly facing arcuate raceways of the outer slide member, and an extra layer of material abutting and conforming to an outer surface of the inward facing raceways. In some aspects a first of the abutments extends from an outer edge of the inward facing arcuate raceway, the outer edge being distal from the longitudinal web, and a second of the abutments extends from the extra layer of material about an inner edge of the inward facing arcuate raceway. In some aspects the intermediate slide member is integrally formed of a strip of material. In some aspects the intermediate slide member includes at least one pair of opposing angled transitions. In some aspects at least one pair of opposing angled transitions is separated by an offset platform of the longitudinal web. In some aspects at least one pair of angled transitions includes two pairs of angled transitions.
[0010] These and other aspects of the invention are more fully comprehended on review of this disclosure.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 A is a cross-sectional view of a telescopic drawer slide in accordance with aspects of the invention.
[0012] FIG. 1B illustrates a cross-section of a further drawer slide member in accordance with aspects of the invention.
[0013] FIG. 2 illustrates a cross-section of a further drawer slide in accordance with aspects of the invention.
[0014] FIG. 3 illustrates the drawer slide of FIG. 1 in a partially extended position.
[0015] FIG. 4 illustrates an example of use of a drawer slide in a rack application.
[0016] FIG. 5 illustrates a cross-section of a two member drawer slide in accordance with aspects of the invention.
[0017] FIG. 6 illustrates a cross-section of a further two member drawer slide in accordance with aspects of the invention.
[0018] FIG. 7 illustrates a partial cross-section of a drawer slide member in accordance with aspects of the invention.
[0019] FIG. 8 illustrates a cross-section of a still further drawer slide member in accordance with aspects of the invention.
[0020] FIG. 9 illustrates portions of a friction drawer slide in accordance with aspects of the invention in a partially extended position.
[0021] FIG. 10 illustrates portions of a friction drawer slide in accordance with aspects of the invention in a partially extended position.
[0022] FIG. 11 illustrates a cross-section of a further friction drawer slide in accordance with aspects of the invention.
[0023] FIG. 12 illustrates the drawer slide of FIG. 12 in a partially extended position.
[0024] FIG. 13 illustrates a cross-section of a still further friction drawer slide in accordance with aspects of the invention.
[0025] FIG. 14 illustrates an intermediate slide member of a yet still further friction drawer slide in accordance with aspects of the invention.
[0026] FIG. 15 illustrates a cross-section of a drawer slide with a further intermediate slide member in accordance with aspects of the invention.
DETAILED DESCRIPTION
[0027] FIG. 1A is a cross-sectional view of a telescopic drawer slide in accordance with aspects of the invention. Generally telescopic drawer slides include slide members, sometimes called rails, nestled within one another and extendable in a telescopic manner. Telescopic drawer slides may be, for example, two member drawer slides or three-member drawer slides. In a two member drawer slide an inner slide member is generally nestled within and telescopically extendable from an outer slide member. In a three-member drawer slide, an intermediate slide member is generally nestled within and telescopically extendable from the outer slide member, and the inner slide member is generally nestled within and telescopically extendable from the intermediate slide member.
[0028] The drawer slide of FIG. 1A is a three member drawer slide, and includes an outer slide member 111 , an intermediate slide member 113 , and an inner slide member 115 . The outer slide member generally includes a longitudinal web 121 longitudinally bounded by opposing arcuate raceways 123 , 125 . The opposing arcuate raceways may be considered inwardly facing, as they generally face towards each other (and towards a center plane bisecting the slide members). The intermediate slide member 113 is generally between the arcuate raceways of the outer slide member. The intermediate slide also has a generally longitudinal web longitudinally bounded by arcuate raceways. In some embodiments, and as shown in FIG. 1A , the web of the intermediate slide member generally includes an inset platform 116 bounded by longitudinal strips 118 , with the platform and the strips coupled by a transition 120 . The strips are generally closer to the web of the outer slide member, while the platform is offset from the web of the outer slide member, for example to provide clearance for various items, which in some embodiments may include mounting hardware associated with the outer slide member or other items.
[0029] The raceways of the intermediate slide member include a first set of arcuate raceways 127 , 129 facing inwardly, and a second set of arcuate raceways 131 , 133 facing outwardly towards the raceways of the outer slide member. The outwardly facing raceways of the intermediate slide member are slidably or rollably coupled to the inwardly facing raceways of the outer slide member, for example by way of bearings, which may be held, as in FIG. 1A , by a bearing spacer or retainer 117 . In turn, nestled within the inwardly facing raceways of the intermediate slide member is the inner slide member 115 . The inner slide member, like the outer slide member, has a longitudinal web 135 longitudinally bounded by arcuate raceways 137 , 139 , with the raceways of the inner slide member being generally outwardly facing. The outwardly facing raceways of the inner slide member are slidably or rollably coupled to the inwardly facing raceways of the intermediate slide member, for example, by way of bearings 119 .
[0030] Considering the intermediate slide member, the inward facing raceways extend from longitudinal edges of the longitudinal web. The outwardly facing raceways are outward of the inwardly facing raceways. The raceways of the intermediate slide of FIG. 1A are formed of triple thickness material. The triple thickness material may be considered, in some respects, as forming an S-shape, with an outward facing portion about one end of the S being indented to form an outwardly facing raceway, and an inward facing portion about another end of the S also being indented to form an inwardly facing raceway.
[0031] Referring for simplicity to only one set of the raceways of the intermediate slide member, the opposing sets of raceways having a symmetrical shape, as shown in the embodiment of FIG. 1A , the inwardly facing arcuate raceway 127 extends out from a longitudinal edge of the longitudinal web. The inwardly facing raceway forms a first layer of material. A first vertical spacer 141 extends outwardly from an end of the inwardly facing arcuate raceway. A second layer 143 of material of the slide member extends generally towards a plane defined by the longitudinal web. In some embodiments, and as shown in FIG. 1A , the second layer of material is in contact with and generally conforms to the shape of an outward surface of the material forming the inwardly arcuate raceway. A second vertical spacer 145 extends outwardly from the end of the second layer of material. The arcuate outwardly facing raceway 131 , forming a third layer of material, extends from an outward end of the second vertical spacer and away from the plane defined by the longitudinal web.
[0032] FIG. 1B illustrates a further drawer slide member in accordance with aspects of the invention. The drawer slide member is similar in shape to the intermediate slide member of FIG. 1A , and may be used, for example, as an intermediate slide member in the drawer slide of FIG. 1A . The intermediate slide member of FIG. 1B is symmetrical about a longitudinal center plane, and for simplicity, and as done for FIG. 1A , only one set of raceways will be specifically discussed below.
[0033] As with the intermediate slide member of FIG. 1A , the drawer slide member of FIG. 1B includes a longitudinal web 149 and raceways formed of triple thickness material that may be considered as forming an S-shape, with a flattened top and bottom to form arcuate raceways. Accordingly, the drawer slide member of FIG. 1B includes an inwardly facing arcuate raceway 151 , a first vertical spacer 153 , a second layer of material 155 , a second vertical spacer 157 , and an outwardly facing arcuate raceway 159 . The inwardly facing raceway extends from a longitudinal edge of the longitudinal web, with the first vertical spacer 153 extending outward from an end of the inwardly facing raceway. The second layer of material 155 extends back towards a plane generally defined by the web, with the second layer of material also generally conforming to the shape of the material forming the first raceway. The second vertical spacer extends outward from an end of the second layer of material, and the outwardly facing raceway extends from an outward end of the second vertical spacer.
[0034] The drawer slide member of FIG. 1B also includes a stub abutment 161 at the end edge of the outwardly facing raceway. The stub abutment extends inwardly from the end edge of the raceway, and rests, at least partially, on portions of the top of the first vertical spacer, and/or in some embodiments on the second layer of material 155 . The stub abutment provides for increased support for the outwardly facing raceway.
[0035] FIG. 2 illustrates a further drawer slide in accordance with aspects of the invention. The further drawer slide of FIG. 2 is a three-member telescopic slide, with an outer slide member 211 , an intermediate slide member 213 , and an inner slide member 215 . A set of bearings in a bearing retainer 214 couple the outer slide member and the intermediate slide member, and a set of bearings 216 couple the intermediate slide member and the inner slide member. The outer slide member and the inner slide member are as discussed with regards to FIG. 1A , having longitudinal webs 217 , 219 , respectively, longitudinally bounded by arcuate raceways 221 a,b , 223 a,b , respectively. The arcuate raceways 221 a,b of the outer slide member are inwardly facing, and the arcuate raceways 223 a,b of the inner slide member are outwardly facing.
[0036] The intermediate slide member includes a longitudinal web 225 , similar to the longitudinal web discussed with respect to the intermediate slide member of FIG. 1A . The intermediate slide member also includes inward facing raceways 227 , 229 and outward facing raceways 231 , 233 .
[0037] Generally referring to only one set of raceways of the intermediate slide member, with the discussion applying to both sets of raceways, the inward facing raceway 227 extends from a longitudinal edge of the longitudinal web. As may be seen in FIG. 2 , the inward facing raceway extends generally transverse to a plane defined by the longitudinal web. A first abutment 241 extends outwardly from an edge of the inward facing raceway that is distal from the longitudinal web. The outward facing raceway 231 extends substantially horizontally from a top of the first abutment. As such, the outward facing raceway also extending generally transverse to the plane defined by the longitudinal web. A second abutment 237 extends inwardly from the opposing end of the outwardly facing raceway, with the second abutment extending towards an edge of the inwardly facing raceway about the longitudinal edge of the web. A base 239 extends outwardly from the second abutment towards the first abutment, with the base generally in contact with and conforming to a shape of an outer surface of material forming the inwardly facing raceway. The base is located between the two arcuate raceways, and also provides support for the outwardly facing arcuate raceway.
[0038] In some embodiments the raceways of the intermediate slide member may be viewed as being formed of a double-hem along a longitudinal edge of the material of intermediate slide member, with opposing sides of the hem being made concavely arcuate to form the arcuate raceway. As discussed above, the double hem may be considered transverse to the longitudinal web, and may therefore be considered a transverse double hem. In some embodiments the outwardly facing raceway of the intermediate slide member may be viewed as being formed of an integrally formed pedestal extending outwardly from the inwardly facing raceway of the intermediate slide member.
[0039] FIG. 3 illustrates the drawer slide of FIG. 2 in a partially extended position, although it should be recognized that the drawer slide of FIG. 1A , or other drawer slides discussed herein, may also be so similarly extended. As may be seen in FIG. 3 , the inner slide member of 215 is partially extended from the intermediate slide member 213 . In turn, the intermediate slide member 213 is partially extended from the outer slide member 211 . If the outer slide member is fixably mounted to a structure, with the inner slide member attached to a casing, extension of the intermediate slide member and inner slide member generally extends the casing from the structure, allowing for easier access to the casing. Alternatively, the roles of the inner slide member and outer slide member may be reversed, with the inner slide member fixedly mounted to the structure and the outer slide member attached to the casing.
[0040] In use, the drawer slide of FIG. 1A or 2 may be mounted to a rack, for example as shown in FIG. 4 . The rack will generally include four posts, of which two posts 421 , 423 are shown in FIG. 4 . The posts are generally arranged to form an outline of an enclosure of rectangular cross-section. As shown in FIG. 4 , a drawer slide 411 is mounted between the racks, generally using mounting hardware 417 , 419 . An opposing drawer slide (not shown), mounted to opposing rack posts (also not shown), is generally also used, with for example computer equipment mounted to the opposing drawer slides. Extension of the drawer slide members extends the computer equipment from the rack.
[0041] FIG. 5 illustrates a further drawer slide in accordance with aspects of the invention. The drawer slide of FIG. 5 is a two member telescopic drawer slide with an outer slide member 511 and an inner slide member 513 . The inner slide member is generally nestled within, and telescopically extendable from the outer drawer slide member. The inner slide member has a longitudinal web 519 bounded by outwardly facing arcuate raceways 521 . The outer slide member includes a longitudinal web 523 longitudinally bounded by inwardly facing arcuate raceways 525 , generally formed in a double hem. Again, and largely throughout without further mention, referring to only one of the raceway related structures, the double hem includes the inwardly facing arcuate raceways 525 , a first offset 527 effectively forming a bend accounting for the width of the material of the outer slide member, an outer edge 529 , a second offset 531 also effectively forming a bend arcuating for the width of the material of the outer slide member, and an interior portion 533 of the hem. Bearings 515 a , 515 b , couple the outer slide member and the inner slide member. The bearings, as illustrated in FIG. 5 , are conveniently maintained in position with respect to one another by use of a bearing retainer 517 .
[0042] FIG. 6 illustrates a further drawer slide in accordance with aspects of the invention. In FIG. 6 , an outer slide member 611 includes a longitudinal web 617 generally longitudinally bounded by arcuate raceways 619 a,b containing bearings held in bearing retainers 615 a,b , as illustrated in the embodiment of FIG. 6 . An inner slide member 613 includes a longitudinal web 621 longitudinally bounded by outwardly facing raceways 627 formed on a top of a pedestal extending from the longitudinal edges of the web. The pedestal in the case of the slide of FIG. 6 includes a base 623 extending from longitudinal edges of the web, a first sidewall 625 extending outward from an edge of the base distal from the web, a concavely formed top providing the raceway 627 , a second side wall 629 extending inwardly from a side of the top opposite the first sidewall, and a support 631 extending from the second sidewall and having a first surface in contact with and generally conforming in shape to the base and a second abutment at least partially supporting the top.
[0043] FIG. 7 illustrates a partial cross-section of a slide member in accordance with aspects of the invention. The slide member of FIG. 7 may be used, for example, as the intermediate slide member of FIGS. 1A or 2 , the outer slide member of FIG. 5 , or the inner slide member of FIG. 6 .
[0044] The slide member of FIG. 7 includes a longitudinal web 707 bounded by a raceway structures 710 , one of which is shown in FIG. 7 . The raceway structure includes an inwardly facing arcuate raceway 711 extending from a longitudinal edge of the longitudinal web. A first abutment 713 extends outwardly from an end of the inwardly facing raceway distal from the longitudinal web. An outwardly facing arcuate raceway 715 extends from a top of the first abutment, with the outwardly facing raceway extending back towards a plane generally defined by the longitudinal web. The outwardly facing raceway extends to a second abutment 717 . The second abutment extends between an edge of the outwardly facing raceway to a partial base 719 . The partial base extends partway along an outer surface of the inwardly facing arcuate raceway 711 . As shown in FIG. 7 , the partial base generally approaches, but does not reach, a center line of the inwardly facing arcuate raceway 711 , while reaching, and supporting, a center line of the outwardly facing arcuate raceway 715 .
[0045] FIG. 8 illustrates a further drawer slide member in accordance with aspects of the invention. The slide member of FIG. 8 includes a generally longitudinal web bounded by raceway structures 811 . As illustrated, the raceway structures have a configuration the same as the raceway structures of the intermediate slide member of FIG. 2 , although in various embodiments the raceway structures may have a configuration the same as raceways structures discussed with respect to the other figures.
[0046] The longitudinal web includes longitudinal edge portions, for example edge portion 813 , bounding a central longitudinal platform 815 . A pair of opposing angled transitions, for example opposing angled transitions 817 , separate the edge portions from the platform 815 . The opposing angled transitions, which together may be of serpentine shape in cross-section, are believed to provide for increased strength of the longitudinal web.
[0047] FIG. 9 illustrates a friction drawer slide in accordance with aspects of the invention. The friction drawer slide, shown in an extended position, is a three member telescopic drawer slide. The drawer slide includes an inner slide member 911 generally nestled within and telescopically extendable from an intermediate slide member 913 , which in turn is generally nestled within and telescopically extendable from an outer slide member 915 . The inner, intermediate, and outer slide members are as discussed with respect to FIG. 2 . In other embodiments, however, the intermediate slide member may be as discussed with respect to any of FIGS. 1A, 1B, 7 , or 8 .
[0048] Coupling the slide members, however, are friction rods. Rods, for example rod 917 , are fixed in the raceways of the outer slide member about a front of the outer slide member, with the rod 917 supporting the intermediate slide member during travel, for example extension or retraction of the intermediate slide member. Rods, for example rod 918 , fixed in the outward facing raceways of the intermediate slide member about a rear of the intermediate slide member also supports the intermediate slide member during travel.
[0049] Similarly, rods, for example rod 919 , are fixed in the inward facing raceways of the intermediate slide member about a front of the intermediate slide member, with the rod 919 supporting the inner slide member during travel. Rods, for example rod 920 , fixed in the raceways of the inner slide member about its rear also supports the inner slide member during travel.
[0050] In some embodiments the rods may not be fixed in position with respect to the slide members. For example, in some embodiments the rods may float with the slide members during travel of the slide members, with recycling stops used to reposition the rods appropriately when the slides reach a fully extended position or a closed position. In such embodiments, generally rods with longer lengths are used, as compared to lengths of rods having fixed positions.
[0051] FIG. 10 illustrates an embodiment of a drawer slide with floating rods. A first pair of rods 1021 a,b couple an outer slide member 1011 and an intermediate slide member 1013 . A second pair of rods 1023 a,b couple the intermediate slide member and an inner slide member 1015 . Stops (not shown) at fronts and rears of raceways of the slide members serve to prevent the rods, which are not fixed in position, from exiting the raceways. In addition, the stops provide a recycling feature, in that the stops stop forward or rearward movement of the rods at particular positions, for example fully forward or rearward in the raceways with respect to particular slides, when the slide is in a fully extended or fully retracted position.
[0052] FIG. 11 illustrates a cross-section of a friction drawer slide in accordance with aspects of the invention. The friction drawer slide is a three member telescopic drawer slide, and includes an outer slide member 1111 and an inner slide member 1113 as described with regard to the slide of FIG. 1A . An intermediate slide member 1115 extendably couples the outer slide member and the inner slide member. In some embodiments the intermediate slide member is dimensioned so as to be replaceable with the intermediate slide member and bearings of the slide of FIG. 1A .
[0053] In the slide of FIG. 11 , the intermediate slide member includes a generally longitudinal web 1117 , which as illustrated includes a central offset platform bounded by longitudinal edges. Referring to what is seen in FIG. 11 as a top half of the slide, the intermediate slide member includes an inward angled bend 1119 forming an inward frictional contact surface for riding in an outwardly facing arcuate raceway of the inner slide member. The intermediate slide member also includes an outward frictional contact surface for riding in an inwardly facing arcuate raceway of the out slide member. The outward frictional contact surface is formed in a hemmed edge 1121 , 1123 of the intermediate slide member, with the hemmed edge extending outward from the inward frictional contact surface provided by the angled bend. In the embodiment of FIG. 11 , the outward extension of the hemmed edge is also slightly angled towards a plane generally defined by the longitudinal web of the intermediate slide member, to account for a slight lateral offset between raceway centers of the outwardly facing raceway of the inner slide member and the inwardly facing raceway of the outer slide member. A potential benefit of the friction slide shown in FIG. 11 , is that the intermediate slide member may be formed with a sheet strip using a roll form process.
[0054] FIG. 12 illustrates the friction drawer slide of FIG. 11 in a partially extended position. As may be seen in FIG. 12 , an inner slide member 1215 is partially extended from an intermediate slide member 1213 , which in turn is partially extended from an outer slide member 1211 .
[0055] FIG. 13 illustrates a cross-section of a further friction drawer slide in accordance with aspects of the invention. The friction drawer slide of FIG. 13 is similar to the friction drawer slide of FIG. 11 , but with an intermediate slide member of a different form. Thus, the friction drawer slide of FIG. 13 , like the slide of FIG. 11 , is a three member telescopic drawer slide, and includes an outer slide member 1311 and an inner slide member 1315 as described with regard to the slide of FIG. 1A . An intermediate slide member 1313 extendably couples the outer slide member and the inner slide member, and in some embodiments is dimensioned so as to be replaceable with the intermediate slide member and bearings of the slide of FIG. 1A .
[0056] The intermediate slide member of FIG. 13 includes a longitudinal web generally longitudinally bounded by generally triangular lobes, for example triangular lobe 1325 . An interior of the triangular lobe may be hollow, as illustrated in FIG. 13 . An apex of the triangular lobe provides an outward frictional contact to ride in an inwardly facing arcuate raceway of the outer slide member. The intermediate slide of FIG. 13 may be formed, for example, by way of extrusion, with possibly post extrusion sizing performed, and possibly hard anodizing of contact surfaces.
[0057] A wall including a protruding sloping ledge 1323 couples the web and the triangular lobe. The wall connects to a base 1327 of the triangular lobe, with the connection somewhat offset from a center of the base. The connection is offset in a first direction, with the ledge generally extending from the wall in a direction opposite the first direction. A surface of the ledge, a portion of the wall, and a bottom of the base together define a notch. The notch has a shape matching a flange of the inner slide member providing an outwardly facing raceway. The notch receives the outwardly facing raceway, with a base corner of the triangular lobe providing an inward frictional contact for riding in the raceway. As the notch has a slightly curvilinear shape to match that of the outward facing raceway, and as the intermediate slide member includes notches for both outward facing raceways of the inner slide member, the notches serve to further maintain relative position of the inward frictional contact of the intermediate slide member and the raceways of the inner slide member. For example, the notches generally entraps the outwardly facing raceway of the inner member 1315 , restricting and preventing a separation of the members by twist or tension.
[0058] FIG. 14 illustrates a further intermediate slide member in accordance with aspects of the invention. The intermediate slide member of FIG. 14 is generally for use in a friction drawer slide, for example the friction drawer slide of FIG. 12 . As with the intermediate slide members of FIGS. 11 and 13 , the intermediate slide member of FIG. 14 is in some embodiments dimensioned so as to be replaceable with the intermediate slide member and bearings of the slide of FIG. 1A .
[0059] The slide member of FIG. 14 includes a longitudinal web 1411 longitudinally bounded by generally oval opposing lobes, one of which for example is lobe 1413 . The lobes may be formed by extrusion or by injection molding, in some embodiments. The lobe 1413 includes an outward facing surface 1415 , providing an outward frictional contact surface for riding in an inwardly facing raceway of an outer slide member, and an inward facing surface 1417 , providing an inward frictional contact surface for riding in an outwardly facing raceway of an inner slide member.
[0060] In some embodiments the web and the opposing lobes are unitarily formed, for example of extruded aluminum. In some embodiments the frictional contact surfaces are coated, for example with Teflon, to decrease frictional forces or to decrease wear on the contact surfaces over time. In some embodiments, for example as illustrated in FIG. 14 , the web and lobes are separately formed, with the lobes attached to the web by way of fasteners 1419 , which for example may be rivets or the like. In such an embodiment the web may be formed of steel, for example, with the lobes formed of a rubber or plastic, for example.
[0061] FIG. 15 is a cross-sectional view of a three member telescopic drawer slide including an intermediate slide member similar to that of FIG. 14 . The slide includes an outer slide member 1511 , an intermediate slide member 1513 , and an inner slide member 1515 . The outer slide member and the inner slide member are as described with respect to, for example, FIG. 1 .
[0062] As can be seen in FIG. 15 , the intermediate slide member has an integrally formed web 1517 and bounding opposing heads 1521 . C-shaped covers 1519 are seated over the heads, with the C-shaped covers providing frictional contact surfaces for riding in the raceways of the outer slide member and the inner slide member. Together the C-shaped covers and heads provide a structure similar to the oval lobes discussed with respect to FIG. 14 . The presence of the heads provide for increased strength for the lobes, as well as providing for increased depth of material, as compared to merely the longitudinal web, for receiving fasteners or the like coupling the covers and the heads.
[0063] Although the invention has been discussed with respect to various embodiments, it should be recognized that the invention comprises the novel and non-obvious claims supported by this disclosure. | A drawer slide member including raceways formed of folded or solid material providing additional thickness while utilizing thin material may provide for increased strength of the drawer slide. | 5 |
BACKGROUND OF THE INVENTION
The subject matter disclosed herein relates to the art of turbomachines and, more particularly, to a turbomachine component having an airfoil core shape.
Many system requirements must be met for each stage of a turbomachine in order to meet design goals including an overall improvement in system efficiency. In particular, third stage nozzles must meet system requirements including airfoil loading and manufacturability. These third stage nozzles must operate within a particular set of boundary conditions based on operating conditions of the turbomachine while maintaining a shape that meets design specifications.
BRIEF DESCRIPTION OF THE INVENTION
According to one aspect of the exemplary embodiment, a turbomachine component includes a turbine stator nozzle member having an airfoil core shape. The airfoil core shape includes a nominal profile substantially in accordance with Cartesian coordinate values of X, Y, and Z set forth in TABLE 1, and wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches, the profile sections at the Z distances being joined smoothly with one another to form a complete airfoil core shape.
According to another aspect of the exemplary embodiment, a turbomachine includes a turbine portion, and a turbine stator nozzle member provided in the turbine portion. The turbine stator nozzle member includes an airfoil core shape. The airfoil core shape includes a nominal profile substantially in accordance with Cartesian coordinate values of X, Y, and Z set forth in TABLE 1, and wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches, the profile sections at the Z distances being joined smoothly with one another to form a complete airfoil core shape.
These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWING
The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a partial cross-sectional view of a turbomachine including a nozzle assembly having an airfoil core shape in accordance with an exemplary embodiment
FIG. 2 is a perspective view of a nozzle assembly FIG. 1 ;
FIG. 3 is a perspective view of a nozzle member of the nozzle assembly of FIG. 2 illustrating the airfoil core shape defined at a plurality of sections;
FIG. 4 is another perspective view of the nozzle member of the nozzle assembly of FIG. 3 ;
FIG. 5 is a cross-sectional view of the nozzle member of FIG. 3 taken at one of the plurality of sections; and
FIG. 6 is a partial plan view of the one of the plurality of sections in FIG. 4 indicating a design envelope of the airfoil core shape in accordance with an aspect of the exemplary embodiment.
The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 , a turbomachine 2 , constructed in accordance with an exemplary embodiment, includes a compressor portion (not shown) and a turbine portion 4 . Turbine portion 4 is enclosed by a turbine housing 6 and has an axial flow path 8 . Turbine portion 4 includes a plurality of nozzle assemblies 16 , 18 , and 20 . Each nozzle assembly 16 , 18 , and 20 is positioned upstream of a corresponding rotor blade assembly 22 , 24 , and 26 . Nozzle assembly 16 and rotor assembly 22 combine to establish a first turbine stage 30 ; nozzle assembly 18 and rotor assembly 24 combine to form a second turbine stage 32 ; and nozzle assembly 20 and rotor assembly 26 combine to form a second turbine stage 34 . Of course it should be understood that each of the first, second and third turbine stages 30 , 32 , and 34 include additional nozzle and rotor assemblies. It should be also understood that turbine portion 4 includes additional turbine stages that collectively establish, for example, a 9FB PP2 gas turbine frame.
As best shown in FIG. 2 , third turbine stage nozzle assembly 20 includes a base portion 36 and a tip or shroud portion 38 between which extends a plurality of third stage nozzle members 40 - 42 each having an associated airfoil core shape 44 - 46 . As each nozzle member 40 - 42 is similarly formed, and includes substantially similar airfoil core shapes 44 - 46 a detailed description will follow with reference to FIGS. 3 and 4 in describing third stage nozzle member 40 and airfoil core shape 44 with an understanding that nozzle members 41 - 42 and associated airfoil core shapes 45 - 46 include corresponding structure/design. Third stage nozzle member 40 includes a first end 50 that extends to a second end 52 through an airfoil portion 54 that is defined by airfoil core shape 44 . Third stage nozzle member 40 also includes a leading edge 58 and a trailing edge 60 between which extend a suction side 62 and a pressure side 64 .
Airfoil core shape 44 in accordance with an exemplary embodiment is configured for enhanced turbine performance. A list of X, Y, and Z coordinates or points for airfoil core shape 44 is presented in TABLE 1, and meets requirements for interaction between adjacent stages, aerodynamic efficiency and provides an improved aeromechanics margin over prior shapes. Moreover, the particular airfoil core shape 44 in accordance with the exemplary embodiment meets system requirements for flow dynamics, loading, and frequency response. The points are arrived at by iteration between aerodynamic and mechanical design improvements and are the only loci of points that allow turbomachine 2 to operate in an efficient, smooth manner. As will become more fully evident below, airfoil core shape 44 is represented as a set of 1920 points listed in TABLE 1. The 1920 points represent 15 airfoil sections. The X, Y, and Z coordinates, which represent a profile of airfoil core shape 44 , are created in a coordinate system which is defined relative to a cold engine part. The origin of the coordinate system on the cold centerline axis is X=0.0, Y=0.0 and Z=0.0. The Z coordinate axis is defined as a radial line from the Y coordinate axis; the X coordinate axis is defined as being normal to a plane defined by the Y-Z axis. The airfoil sections are cut normal to the Z coordinate axis. X and Y points, which make up the airfoil core profile shape 44 at each section, are in inches. The radial Z values in inches for the section planes have an origin of Z 0 .
The radial distance between each section varies however a total radial distance of airfoil core shape 44 is 15.0 inches. The bottom and top sections Z 0 and Z 1 , may be obscured by cast-in features that are not included in the X, Y, and Z points that define airfoil core shape 44 . All of the 1920 points are taken from a nominal cold or room temperature for each airfoil section of airfoil core shape 44 . Each airfoil section is joined smoothly with adjacent airfoil sections to form the airfoil core shape 44 .
It should be appreciated that as nozzle assembly 20 heats up during operation of turbine portion 4 , airfoil core shape 44 may change as a result of stress and temperature. Thus, the X, Y and Z points are provided at cold or room temperature for manufacturing purposes. Since the manufactured airfoil core shape may be different from a nominal airfoil core shape defined in Table 1, a tolerance of ±0.100 inches from the nominal profile is allowed and thus defines an overall design envelope for airfoil core shape 44 . The overall design is robust to this design envelope without impairment of mechanical or aerodynamic properties of third turbine stage 34 .
It should also be appreciated that the airfoil core shape 44 can be scaled up or scaled down geometrically for introductions into similar turbine designs, with smaller or larger frame sizes. Consequently, the X, Y, and Z coordinates in inches may be multiplied or divided by the same constant or number/factor to provide a scaled up or scaled down version of third stage nozzle 40 while retaining the airfoil core profile shape and unique properties.
As best shown in FIG. 2 , a coordinate system for airfoil core shape 44 in accordance with exemplary embodiment is indicated generally at 100 . As discussed above, coordinate system 100 is defined relative to a cold nozzle. Coordinate system 100 includes an X-axis 105 , a Y-axis 110 , and a Z-axis 115 . The origin of coordinate system 100 is centered at first end 50 of nozzle member 40 . X-axis 105 is directed axially along a centerline axis (not separately labeled) of turbomachine 2 and Z-axis 115 is directed along a radial line normal to the centerline axis. The positive direction of X-axis 105 , Y-axis 110 , and Z-axis 115 is identified by label placement in FIG. 2 .
As best shown in FIGS. 3-5 , airfoil core shape 44 includes a plurality of sections 150 - 164 . Section 150 is located at Z 0 and the airfoil core shape 44 extends through sections 163 before terminating at section 164 located at Z 1 . As discussed above, sections 150 - 164 are cut normal to Z c -axis 115 . The X and Y coordinates which make up each section are presented in Table 1 are in inches.
FIG. 6 illustrates a design envelope for airfoil core shape 44 . The X, Y, and Z values listed in TABLE 1 illustrate ideal point location for each point of each section of airfoil core shape 44 . However, there exist variations from the ideal point location attributed to manufacturing tolerances and the like which must be taken into account. Thus, a design envelope is established which sets forth an acceptable outer boundary or distance from a nominal profile 250 for each section 150 - 165 . Therefore it should be understood that each X, Y, and Z point includes a tolerance or ±value. In consideration of process capability, a tolerance 260 of ±0.100 inches is allowed in the formation of airfoil core shape 30 . Tolerance 260 includes an upper limit 270 defined as a 0.100-inch deviation from nominal profile 250 and a lower limit 280 , defined as a −0.100-inch variation from nominal profile 250 . The design envelope or tolerance 260 is robust such that this variation does not impair mechanical and aerodynamic performance of third stage nozzle member 40 .
In no way limiting of the exemplary embodiment, airfoil core shape 44 provides an increased efficiency as compared to previous individual airfoil core shapes for third stage nozzle member 40 . Moreover, and in no way limiting of the exemplary embodiment, in conjunction with other airfoil core shapes, which are conventional or enhanced (similar to the enhancements herein), airfoil core shape 44 , as embodied by the invention, provides an increased efficiency as compared to previous individual sets of airfoil core shapes for third stage nozzle member 40 . This increased efficiency provides, in addition to the above-noted advantages, a power output with a decrease the required fuel, therefore inherently decreasing emissions to produce energy. Of course, other such advantages are within the scope of the exemplary embodiment.
TABLE 1
Section 1
Section 2
Section 3
Section 4
X
Y
Z
X
Y
Z
X
Y
Z
X
Y
Z
0.624
−0.3966
60.864
0.493
−0.2812
59.864
0.3094
−0.0617
58.864
0.3745
−0.1484
57.864
0.2077
−0.0357
60.864
0.7264
−0.4304
59.864
0.6313
−0.3378
58.864
0.6855
−0.3418
57.864
1.903
−1.3094
60.864
2.5861
−1.2323
59.864
0.6939
−0.2092
58.864
0.42
−0.0559
57.864
2.0022
−0.9341
60.864
0.258
−0.1345
59.864
0.398
−0.0649
58.864
1.3701
−0.7919
57.864
0.2649
−0.0423
60.864
0.3581
−0.0666
59.864
2.6118
−1.2222
58.864
0.3584
−0.129
57.864
1.0422
−0.674
60.864
1.9419
−1.2921
59.864
0.3438
−0.0463
58.864
1.0772
−0.5947
57.864
0.1807
−0.0637
60.864
0.2665
−0.0431
59.864
0.3251
−0.0507
58.864
0.4773
−0.2118
57.864
2.3312
−1.6755
60.864
0.2456
−0.1223
59.864
1.6169
−1.0039
58.864
0.4011
−0.0541
57.864
0.8719
−0.3432
60.864
1.7222
−1.1221
59.864
0.5055
−0.2586
58.864
0.4376
−0.0631
57.864
0.4126
−0.2613
60.864
1.481
−0.6325
59.864
2.0694
−0.9224
58.864
1.6591
−0.9949
57.864
0.227
−0.0312
60.864
0.3229
−0.0493
59.864
0.4155
−0.0733
58.864
0.3828
−0.0589
57.864
1.6816
−1.1352
60.864
0.2397
−0.0707
59.864
2.6081
−1.8048
58.864
2.2157
−1.4149
57.864
0.1764
−0.0829
60.864
2.5737
−1.8349
59.864
0.2987
−0.0778
58.864
0.4433
−0.1904
57.864
0.1791
−0.1002
60.864
0.6404
−0.2049
59.864
1.9041
−1.2185
58.864
0.3531
−0.1044
57.864
2.5603
−1.2428
60.864
0.2855
−0.0387
59.864
1.0281
−0.5953
58.864
0.5116
−0.2331
57.864
0.2827
−0.0512
60.864
1.0896
−0.6706
59.864
0.3794
−0.1798
58.864
0.3573
−0.0859
57.864
0.834
−0.534
60.864
0.2378
−0.1067
59.864
1.5225
−0.6308
58.864
2.637
−1.2112
57.864
2.1197
−1.4893
60.864
0.3756
−0.2076
59.864
2.1441
−1.4075
58.864
1.0199
−0.3496
57.864
0.1873
−0.1159
60.864
2.3682
−1.6481
59.864
0.3807
−0.0563
58.864
0.3676
−0.07
57.864
1.4392
−0.6346
60.864
2.0359
−0.9281
59.864
0.3159
−0.1411
58.864
2.1021
−0.9163
57.864
0.2001
−0.128
60.864
0.3404
−0.0581
59.864
0.5685
−0.298
58.864
0.472
−0.0798
57.864
0.2466
−0.0343
60.864
0.2505
−0.0544
59.864
0.2965
−0.1134
58.864
0.7465
−0.2135
57.864
1.3651
−0.9001
60.864
0.6099
−0.3555
59.864
0.304
−0.1288
58.864
2.4818
−1.633
57.864
0.1916
−0.0471
60.864
0.9217
−0.3452
59.864
0.2943
−0.0965
58.864
0.4547
−0.0715
57.864
2.5367
−1.868
60.864
0.3048
−0.0415
59.864
0.9713
−0.3474
58.864
0.4087
−0.1697
57.864
3.1125
−1.5619
60.864
0.2354
−0.0896
59.864
1.3247
−0.7964
58.864
1.5631
−0.629
57.864
0.3005
−0.0599
60.864
1.4088
−0.8922
59.864
0.4423
−0.2193
58.864
1.9437
−1.2043
57.864
2.9284
−2.2726
60.864
2.1574
−1.4673
59.864
0.3629
−0.0487
58.864
4.5333
−4.0976
57.864
5.1631
−2.9798
60.864
5.5353
−3.257
59.864
2.379
−1.6028
58.864
4.148
−2.1138
57.864
3.7788
−3.3862
60.864
4.3769
−2.336
59.864
4.0043
−3.4168
58.864
3.4973
−1.7093
57.864
3.9304
−2.0686
60.864
3.7661
−3.2141
59.864
3.0463
−2.2301
58.864
4.0546
−3.3325
57.864
3.2916
−2.7027
60.864
3.3948
−2.7182
59.864
4.9583
−2.7193
58.864
4.2235
−3.5816
57.864
4.7175
−2.6212
60.864
4.3987
−4.2782
59.864
4.4728
−4.2035
58.864
5.612
−3.2054
57.864
4.0631
−3.8603
60.864
5.1633
−2.9295
59.864
3.6462
−2.9221
58.864
3.2343
−2.3383
57.864
3.3876
−1.7268
60.864
3.1961
−2.4806
59.864
5.6137
−3.2681
58.864
4.7145
−2.497
57.864
2.736
−2.067
60.864
3.7614
−1.9297
59.864
3.1493
−1.5309
58.864
2.9919
−2.0941
57.864
5.3516
−3.1461
60.864
4.2545
−4.0041
59.864
5.1981
−2.9083
58.864
4.4672
−2.3254
57.864
3.6256
−3.1559
60.864
3.9383
−3.4717
59.864
4.1697
−3.6734
58.864
3.1673
−1.5144
57.864
4.197
−2.2468
60.864
3.5849
−2.9629
59.864
3.2542
−2.4537
58.864
4.3831
−3.8368
57.864
4.3544
−4.425
60.864
4.677
−2.5504
59.864
4.1417
−2.1434
58.864
3.4673
−2.5914
57.864
3.1136
−2.4846
60.864
3.131
−1.5463
59.864
5.4319
−3.1049
58.864
4.958
−2.674
57.864
4.9699
−2.819
60.864
5.3517
−3.0905
59.864
3.8145
−1.9335
58.864
3.8767
−3.0897
57.864
3.9246
−3.6211
60.864
2.9889
−2.2503
59.864
3.8297
−3.1663
58.864
2.7408
−1.8592
57.864
3.6605
−1.8955
60.864
4.0714
−2.1295
59.864
2.8307
−2.0137
58.864
5.4302
−3.0475
57.864
5.5348
−3.3182
60.864
4.9705
−2.7737
59.864
3.4834
−1.7297
58.864
3.8244
−1.9087
57.864
3.4623
−2.9266
60.864
4.101
−3.7351
59.864
4.3259
−3.9358
58.864
3.6903
−2.8534
57.864
4.4596
−2.4307
60.864
2.7734
−2.0277
59.864
4.7132
−2.5369
58.864
5.1969
−2.8572
57.864
4.1945
−4.1036
60.864
3.4476
−1.7356
59.864
3.4543
−2.6845
58.864
6.5692
−4.272
57.864
6.7854
−4.9958
60.864
7.2502
−6.0195
59.864
4.464
−2.3605
58.864
6.1251
−3.7137
57.864
6.0561
−3.8834
60.864
5.2305
−6.622
59.864
6.8133
−4.7778
58.864
6.8203
−4.6726
57.864
4.5027
−4.7521
60.864
5.0734
−6.0075
59.864
5.2698
−6.3382
58.864
7.1139
−5.2898
57.864
5.0779
−6.4512
60.864
4.6596
−4.8401
59.864
6.6936
−4.5699
58.864
5.5261
−7.321
57.864
7.0808
−5.6746
60.864
6.7999
−4.8864
59.864
4.7383
−4.7535
58.864
7.3221
−5.9411
57.864
6.5228
−4.532
60.864
6.0604
−3.8036
59.864
6.5646
−4.3676
58.864
6.9276
−4.8738
57.864
5.7121
−3.4964
60.864
5.2968
−6.9397
59.864
7.184
−5.6245
58.864
5.3364
−6.1937
57.864
4.7655
−5.4205
60.864
5.1547
−6.3065
59.864
5.9606
−3.612
58.864
7.2623
−5.721
57.864
5.2466
−7.223
60.864
7.0983
−5.5523
59.864
5.4596
−7.3652
58.864
6.2829
−3.8956
57.864
6.893
−5.218
60.864
6.5335
−4.4335
59.864
7.017
−5.193
58.864
5.2531
−5.8671
57.864
6.2209
−4.0928
60.864
5.7134
−3.4292
59.864
5.0872
−5.679
58.864
5.7889
−3.3688
57.864
4.9845
−6.1045
60.864
4.9832
−5.7111
59.864
6.2809
−3.9807
58.864
5.9602
−3.5381
57.864
7.1607
−5.9083
60.864
4.8843
−5.4175
59.864
5.3444
−6.6783
58.864
5.3968
−6.4731
57.864
6.6592
−4.761
60.864
6.9088
−5.104
59.864
4.8567
−5.035
58.864
4.8043
−4.6352
57.864
5.8828
−3.6808
60.864
6.2272
−4.0066
59.864
7.2535
−5.8452
58.864
5.4481
−6.7544
57.864
4.6396
−5.0841
60.864
7.1785
−5.7822
59.864
6.1244
−3.7932
58.864
5.0472
−5.2252
57.864
5.1684
−6.8358
60.864
6.6719
−4.6569
59.864
6.9197
−4.9832
58.864
4.6738
−4.3639
57.864
6.9915
−5.4444
60.864
5.8853
−3.6076
59.864
5.1845
−6.007
58.864
5.491
−7.0371
57.864
6.3766
−4.3091
60.864
4.7764
−5.1271
59.864
4.6103
−4.4762
58.864
6.6995
−4.4694
57.864
4.8804
−5.7607
60.864
5.3544
−7.2592
59.864
5.7901
−3.437
58.864
5.1567
−5.544
57.864
5.3137
−7.6124
60.864
7.0083
−5.3262
59.864
5.4073
−7.0208
58.864
4.9247
−4.9111
57.864
6.6286
−10.3829
60.864
4.5337
−4.557
59.864
7.1051
−5.4069
58.864
7.0255
−5.0797
57.864
5.5047
−9.0275
60.864
6.3851
−4.2166
59.864
4.9779
−5.3549
58.864
7.1929
−5.5037
57.864
6.9085
−10.0286
60.864
5.7522
−9.8737
59.864
6.4269
−4.1711
58.864
6.4302
−4.0807
57.864
5.6804
−9.858
60.864
6.3168
−10.326
59.864
7.2331
−8.8735
58.864
6.1553
−9.9265
57.864
7.2356
−9.2557
60.864
6.9525
−9.7267
59.864
6.8731
−9.633
58.864
6.7816
−9.5344
57.864
5.912
−10.3033
60.864
6.6954
−10.0912
59.864
5.5364
−8.0578
58.864
7.4709
−7.0039
57.864
7.4341
−8.141
60.864
7.0345
−9.5703
59.864
7.4485
−7.8404
58.864
5.8126
−9.693
57.864
6.1871
−10.5054
60.864
7.1728
−9.2456
59.864
6.5495
−10.0015
58.864
5.5964
−8.2936
57.864
7.3866
−6.8872
60.864
7.1078
−9.4098
59.864
7.4312
−6.7121
58.864
7.3783
−8.1376
57.864
6.4588
−10.4953
60.864
5.7963
−9.9688
59.864
6.2386
−10.129
58.864
5.9116
−9.8086
57.864
5.4227
−8.3951
60.864
6.7467
−10.0323
59.864
5.9339
−9.9957
58.864
7.0839
−9.0333
57.864
6.7242
−10.2862
60.864
5.404
−7.58
59.864
5.7159
−9.6124
58.864
7.4081
−6.3624
57.864
5.575
−9.4466
60.864
5.4467
−7.9019
59.864
7.1015
−9.2124
58.864
7.4379
−6.5753
57.864
7.0489
−9.759
60.864
7.4601
−7.4877
59.864
5.6146
−9.0254
58.864
6.0956
−9.9144
57.864
5.7582
−10.0555
60.864
6.8215
−9.9348
59.864
7.3339
−8.5242
58.864
6.9118
−9.3472
57.864
7.3361
−8.8544
60.864
7.4328
−6.9929
59.864
6.7355
−9.8189
58.864
5.615
−8.6964
57.864
6.0264
−10.4139
60.864
6.6406
−10.147
59.864
7.4707
−7.3783
58.864
7.3263
−8.3596
57.864
7.4474
−7.6385
60.864
5.6373
−9.4718
59.864
6.427
−10.0798
58.864
5.7129
−9.4686
57.864
6.2898
−10.529
60.864
7.403
−6.7468
59.864
7.3613
−6.2815
58.864
6.7091
−9.6223
57.864
7.2939
−6.393
60.864
6.0769
−10.2721
59.864
6.1174
−10.1084
58.864
7.4188
−7.9132
57.864
6.5757
−10.4259
60.864
6.5186
−10.2451
59.864
5.834
−9.8778
58.864
7.4481
−7.6872
57.864
5.4758
−8.817
60.864
5.951
−10.1789
59.864
5.6701
−9.4238
58.864
5.7721
−9.6218
57.864
6.8416
−10.1339
60.864
5.4836
−8.2246
59.864
6.9344
−9.5349
58.864
6.5782
−9.7537
57.864
5.649
−9.7565
60.864
7.4572
−7.7356
59.864
5.5687
−8.4656
58.864
5.5539
−7.6058
57.864
7.1812
−9.4264
60.864
6.4507
−10.284
59.864
7.4214
−8.0701
58.864
6.3357
−9.9036
57.864
5.8633
−10.2401
60.864
5.8972
−10.1216
59.864
6.6053
−9.9548
58.864
5.7393
−9.5465
57.864
7.4107
−8.3912
60.864
5.5265
−8.6416
59.864
7.4532
−6.9292
58.864
7.1564
−8.8695
57.864
6.1385
−10.4843
60.864
6.2544
−10.3284
59.864
6.3001
−10.1232
58.864
5.5752
−7.8911
57.864
7.4174
−7.1367
60.864
6.5818
−10.1987
59.864
5.9941
−10.0444
58.864
6.4637
−9.84
57.864
6.3949
−10.5176
60.864
5.6851
−9.6756
59.864
5.7471
−9.7044
58.864
5.6499
−9.1466
57.864
5.3714
−8.0033
60.864
7.4519
−7.24
59.864
7.1714
−9.0446
58.864
7.4738
−7.232
57.864
6.6779
−10.336
60.864
6.011
−10.2295
59.864
5.6315
−9.1771
58.864
7.0025
−9.1928
57.864
5.5372
−9.2375
60.864
5.5053
−8.4331
59.864
7.2871
−8.6998
58.864
6.0386
−9.8929
57.864
6.9696
−9.9197
60.864
7.3116
−6.2596
59.864
6.807
−9.728
58.864
6.4015
−9.8755
57.864
5.7165
−9.9579
60.864
6.8897
−9.8326
59.864
5.5022
−7.711
58.864
7.3695
−6.1508
57.864
7.2833
−9.0829
60.864
5.8499
−10.0588
59.864
7.4649
−7.6096
58.864
6.5226
−9.799
57.864
5.9664
−10.3616
60.864
7.2806
−8.9092
59.864
6.4901
−10.0437
58.864
6.2769
−9.9203
57.864
7.4462
−7.8899
60.864
6.1334
−10.2992
59.864
7.4006
−6.4961
58.864
5.661
−9.228
57.864
6.2377
−10.5211
60.864
7.2302
−9.0785
59.864
6.1771
−10.1238
58.864
7.2772
−8.5319
57.864
7.3454
−6.6391
60.864
5.5729
−9.058
59.864
5.8804
−9.9398
58.864
6.6308
−9.7051
57.864
6.5191
−10.464
60.864
5.6593
−9.5741
59.864
5.6907
−9.5186
58.864
7.4663
−7.4599
57.864
5.449
−8.6061
60.864
7.3625
−6.5022
59.864
7.0227
−9.3761
58.864
5.6344
−8.9969
57.864
6.7678
−10.2341
60.864
7.4171
−8.2294
59.864
5.6006
−8.8734
58.864
5.9719
−9.8554
57.864
5.6214
−9.6539
60.864
5.5486
−8.8499
59.864
7.3833
−8.2982
58.864
5.8583
−9.7541
57.864
7.1192
−9.5944
60.864
7.3823
−8.458
59.864
6.6578
−9.9045
58.864
7.2207
−8.7021
57.864
5.8066
−10.1501
60.864
7.443
−7.983
59.864
7.4664
−7.147
58.864
5.6917
−9.3893
57.864
7.3785
−8.6236
60.864
6.3782
−10.3126
59.864
6.36
−10.1076
58.864
6.8489
−9.4424
57.864
6.092
−10.459
60.864
5.6014
−9.2655
59.864
7.3135
−6.0687
58.864
7.4588
−6.7893
57.864
7.4377
−7.3873
60.864
6.1928
−10.3187
59.864
6.0606
−10.0844
58.864
5.6748
−9.3089
57.864
6.3427
−10.5274
60.864
5.7157
−9.7757
59.864
5.7858
−9.7935
58.864
6.2164
−9.9284
57.864
7.2323
−6.1493
60.864
7.3368
−8.6848
59.864
5.653
−9.3282
58.864
5.6233
−8.8467
57.864
Section 5
Section 6
Section 7
Section 8
X
X
Y
Z
X
X
X
Y
Z
X
Y
Z
2.1341
−0.9097
56.864
1.9143
−1.0939
55.864
0.5679
−0.0795
54.864
0.596
−0.1669
53.864
0.5049
−0.0752
56.864
0.6653
−0.2718
55.864
0.5859
−0.0778
54.864
2.734
−1.153
53.864
0.8354
−0.4071
56.864
0.8484
−0.2223
55.864
0.5366
−0.1574
54.864
1.7177
−0.6183
53.864
0.4336
−0.1566
56.864
2.6919
−1.6799
55.864
0.6363
−0.0981
54.864
0.5889
−0.1269
53.864
2.176
−1.3329
56.864
0.4771
−0.1474
55.864
1.6389
−0.8671
54.864
0.6909
−0.1041
53.864
1.0674
−0.3521
56.864
1.2695
−0.6566
55.864
0.8093
−0.3338
54.864
1.9741
−1.0561
53.864
0.5465
−0.2262
56.864
0.5795
−0.2186
55.864
0.531
−0.1166
54.864
2.2272
−0.8831
53.864
0.4575
−0.0623
56.864
0.5485
−0.076
55.864
0.6032
−0.0824
54.864
0.9559
−0.3974
53.864
1.4242
−0.7934
56.864
1.6412
−0.6253
55.864
2.5023
−1.4729
54.864
2.7651
−1.6177
53.864
0.4155
−0.0953
56.864
2.1653
−0.9027
55.864
2.7098
−1.1714
54.864
1.2975
−0.6135
53.864
2.6391
−1.7033
56.864
0.4819
−0.0896
55.864
0.8985
−0.2265
54.864
0.6693
−0.0937
53.864
2.6617
−1.1994
56.864
0.4705
−0.124
55.864
0.5386
−0.1001
54.864
0.6234
−0.0884
53.864
0.5275
−0.086
56.864
2.6858
−1.1866
55.864
1.9566
−1.0821
54.864
0.6128
−0.1836
53.864
0.6592
−0.296
56.864
0.4956
−0.0774
55.864
1.0643
−0.4944
54.864
2.3074
−1.285
53.864
0.4251
−0.0793
56.864
2.23
−1.3222
55.864
2.1962
−0.894
54.864
0.9488
−0.2304
53.864
1.9383
−1.1554
56.864
0.5653
−0.0841
55.864
0.6199
−0.0902
54.864
0.6468
−0.086
53.864
0.4176
−0.1376
56.864
0.5128
−0.0708
55.864
0.5514
−0.0872
54.864
0.5879
−0.1447
53.864
1.6027
−0.6271
56.864
0.751
−0.3253
55.864
0.5292
−0.1345
54.864
1.6371
−0.8327
53.864
0.4903
−0.191
56.864
1.1137
−0.3546
55.864
2.7308
−1.6476
54.864
0.6076
−0.097
53.864
0.4821
−0.0648
56.864
0.4732
−0.1058
55.864
1.3181
−0.6568
54.864
0.5957
−0.1104
53.864
1.1479
−0.6089
56.864
1.5938
−0.8724
55.864
1.6794
−0.6225
54.864
1.2058
−0.3583
53.864
2.4098
−1.5154
56.864
0.5311
−0.0704
55.864
1.1596
−0.3568
54.864
2.5378
−1.4493
53.864
0.798
−0.2179
56.864
2.463
−1.4985
55.864
2.2703
−1.3028
54.864
4.7171
−2.3122
53.864
0.6029
−0.261
56.864
0.4935
−0.1656
55.864
0.5533
−0.1747
54.864
4.8805
−3.8852
53.864
0.4397
−0.0678
56.864
0.8366
−0.379
55.864
4.8893
−2.484
54.864
4.2364
−2.9759
53.864
1.6974
−0.9824
56.864
0.582
−0.0921
55.864
4.0659
−1.9515
54.864
3.2086
−1.9691
53.864
0.4119
−0.1135
56.864
4.9555
−2.5809
55.864
4.7877
−3.8981
54.864
5.4115
−2.8001
53.864
3.9124
−2.9938
56.864
4.6002
−3.7847
55.864
4.0095
−2.8342
54.864
3.6557
−1.6651
53.864
4.0923
−2.0436
56.864
3.7679
−2.6896
55.864
2.9552
−1.8275
54.864
4.6411
−3.5058
53.864
3.3073
−2.3174
56.864
5.7788
−3.2349
55.864
3.2199
−1.4553
54.864
3.8469
−2.5519
53.864
4.9696
−2.637
56.864
3.8436
−1.8549
55.864
4.6181
−2.3014
54.864
4.9524
−2.4694
53.864
4.2732
−3.4788
56.864
4.3086
−3.352
55.864
3.5037
−1.6176
54.864
4.3773
−3.1479
53.864
3.4899
−1.6751
56.864
3.3531
−2.263
55.864
4.5095
−3.4663
54.864
5.7633
−3.085
53.864
5.6647
−3.1923
56.864
4.4729
−2.2513
55.864
3.606
−2.41
54.864
3.4274
−2.1568
53.864
3.7186
−2.7615
56.864
4.7338
−4.0088
55.864
5.7712
−3.1637
54.864
5.5895
−2.94
53.864
4.3889
−2.2351
56.864
3.9639
−2.9132
55.864
4.3435
−2.1241
54.864
5.1842
−2.6317
53.864
4.5952
−3.9898
56.864
3.2025
−1.4777
55.864
4.1992
−3.0572
54.864
4.7633
−3.6915
53.864
3.0909
−2.1058
56.864
2.9163
−1.8669
55.864
3.175
−2.013
54.864
4.0458
−2.7601
53.864
5.2068
−2.8151
56.864
5.4222
−2.9326
55.864
5.4169
−2.8701
54.864
2.9889
−1.7907
53.864
4.0976
−3.2331
56.864
4.4583
−3.5657
55.864
3.7858
−1.7828
54.864
4.479
−2.1594
53.864
3.7925
−1.8571
56.864
3.5641
−2.4729
55.864
4.6529
−3.6795
54.864
4.0699
−1.908
53.864
3.5167
−2.536
56.864
5.6028
−3.0811
55.864
3.8115
−2.6186
54.864
4.5123
−3.3245
53.864
4.6816
−2.4326
56.864
3.5242
−1.6643
55.864
5.1559
−2.6731
54.864
3.2376
−1.4289
53.864
4.4392
−3.7311
56.864
4.16
−2.0503
55.864
4.3581
−3.2589
54.864
3.6404
−2.3509
53.864
3.1851
−1.4967
56.864
4.1515
−3.1438
55.864
3.3936
−2.2082
54.864
5.5901
−6.0317
53.864
2.8679
−1.9012
56.864
4.7158
−2.4137
55.864
5.5962
−3.0143
54.864
5.3466
−4.9145
53.864
5.4389
−2.9999
56.864
3.1356
−2.0599
55.864
5.5625
−6.1745
54.864
7.2717
−5.4515
53.864
4.7407
−4.2545
56.864
5.1912
−2.7536
55.864
7.0923
−4.9575
54.864
6.0953
−3.3928
53.864
5.2924
−5.6343
56.864
7.0183
−4.8656
55.864
5.3092
−5.0399
54.864
6.7847
−4.2664
53.864
7.1765
−5.3388
56.864
5.5325
−6.3712
55.864
6.5491
−3.9978
54.864
5.6263
−6.7507
53.864
5.5615
−7.1203
56.864
5.1778
−4.9521
55.864
5.6115
−6.9044
54.864
5.5198
−5.5707
53.864
6.7082
−4.387
56.864
7.1068
−5.0684
55.864
7.2966
−5.5781
54.864
5.1854
−4.4916
53.864
6.0358
−3.5456
56.864
7.2547
−5.4856
55.864
5.4869
−5.7066
54.864
7.1488
−5.0408
53.864
4.9965
−4.7956
56.864
5.6015
−7.26
55.864
6.9071
−4.5632
54.864
5.9322
−3.2358
53.864
5.4343
−6.2223
56.864
6.6912
−4.2791
55.864
5.1361
−4.5848
54.864
6.536
−3.8981
53.864
7.0154
−4.9471
56.864
5.4287
−5.7913
55.864
6.2629
−3.6481
54.864
5.6114
−6.2708
53.864
6.4601
−4.0341
56.864
4.9745
−4.4716
55.864
5.5874
−6.4172
54.864
5.4136
−5.1307
53.864
5.2052
−5.3508
56.864
5.5663
−6.6666
55.864
7.1703
−5.1609
54.864
7.3508
−5.8479
53.864
7.2442
−5.5396
56.864
6.4206
−3.9082
55.864
5.3774
−5.2597
54.864
4.9902
−4.0832
53.864
5.5295
−6.8195
56.864
5.2743
−5.2279
55.864
6.6794
−4.1825
54.864
7.0725
−4.8405
53.864
6.8203
−4.5713
56.864
7.3602
−5.9025
55.864
4.9134
−4.122
54.864
5.6218
−6.9908
53.864
6.1835
−3.703
56.864
6.9202
−4.6672
55.864
5.6125
−7.1484
54.864
5.5588
−5.7936
53.864
4.8752
−4.5249
56.864
6.2728
−3.7325
55.864
7.3422
−5.7785
54.864
5.2704
−4.7014
53.864
5.3694
−5.9269
56.864
6.1147
−3.5603
55.864
5.5283
−5.9329
54.864
7.2153
−5.2447
53.864
7.1002
−5.1412
56.864
5.4866
−6.0775
55.864
7.0045
−4.7581
54.864
6.9863
−4.6443
53.864
6.588
−4.2079
56.864
5.081
−4.7098
55.864
5.2322
−4.823
54.864
6.6652
−4.0791
53.864
5.8828
−3.3934
56.864
5.9498
−3.3945
55.864
6.41
−3.8196
54.864
5.6232
−6.5107
53.864
5.1065
−5.0711
56.864
7.3137
−5.699
55.864
6.1054
−3.4802
54.864
5.4714
−5.3496
53.864
7.3065
−5.7556
56.864
6.8126
−4.4739
55.864
5.9412
−3.3189
54.864
7.3158
−5.6488
53.864
5.4874
−6.5201
56.864
5.5888
−6.963
55.864
5.6035
−6.6606
54.864
5.0919
−4.2854
53.864
6.922
−4.757
56.864
7.1856
−5.2752
55.864
7.2385
−5.368
54.864
6.2518
−3.5564
53.864
6.3251
−3.8657
56.864
6.5603
−4.0905
55.864
5.4366
−5.482
54.864
6.8903
−4.4528
53.864
5.785
−9.5041
56.864
5.358
−5.5079
55.864
6.8001
−4.3735
54.864
6.398
−3.7238
53.864
7.4439
−7.4999
56.864
4.8587
−4.2379
55.864
5.0297
−4.351
54.864
5.6111
−7.2307
53.864
6.0674
−9.7168
56.864
6.4223
−9.4233
55.864
6.3097
−9.2671
54.864
7.3768
−6.0483
53.864
7.4333
−6.4172
56.864
6.0909
−9.5238
55.864
5.9993
−9.3131
54.864
6.1999
−9.0967
53.864
6.3734
−9.6714
56.864
7.4547
−6.731
55.864
5.7547
−9.1631
54.864
5.9175
−9.0971
53.864
6.6667
−9.4419
56.864
5.8272
−9.4013
55.864
5.6043
−8.827
54.864
6.5743
−8.865
53.864
5.6129
−8.4823
56.864
7.3451
−7.8294
55.864
7.3181
−7.675
54.864
5.6935
−8.9247
53.864
7.0533
−8.8729
56.864
5.6553
−9.0927
55.864
6.9133
−8.6648
54.864
6.969
−8.341
53.864
5.6836
−9.2634
56.864
7.0309
−8.6885
55.864
5.5704
−8.3059
54.864
5.5654
−8.5647
53.864
7.342
−8.0828
56.864
5.5973
−8.6321
55.864
7.4328
−6.5943
54.864
7.2788
−7.5441
53.864
5.8835
−9.6171
56.864
7.3976
−6.1079
55.864
6.5246
−9.1278
54.864
5.5587
−7.9869
53.864
7.4689
−7.0771
56.864
6.641
−9.2426
55.864
6.1732
−9.3122
54.864
7.401
−6.6354
53.864
6.1871
−9.7265
56.864
6.2664
−9.499
55.864
5.8901
−9.2727
54.864
6.0299
−9.1185
53.864
7.3588
−5.9742
56.864
5.9757
−9.4977
55.864
5.6788
−9.0497
54.864
6.3542
−9.0299
53.864
6.5003
−9.5922
56.864
7.4443
−7.1734
55.864
7.1461
−8.2077
54.864
5.8156
−9.0451
53.864
5.5987
−7.7242
56.864
5.7509
−9.3108
55.864
5.5816
−8.6718
54.864
6.7208
−8.7087
53.864
6.8167
−9.2607
56.864
7.236
−8.2091
55.864
7.3975
−7.2466
54.864
5.621
−8.789
53.864
5.6276
−8.8835
56.864
5.6227
−8.9366
55.864
6.7515
−8.8936
54.864
7.1152
−8.0378
53.864
7.1902
−8.5649
56.864
6.8509
−8.9858
55.864
5.5917
−7.7772
54.864
5.5516
−8.4111
53.864
5.7424
−9.428
56.864
5.5953
−8.3396
55.864
7.406
−6.1844
54.864
7.352
−7.184
53.864
7.4166
−7.71
56.864
6.4937
−9.3737
55.864
6.3853
−9.2271
54.864
5.5946
−7.4829
53.864
6.0104
−9.6975
56.864
6.1503
−9.5233
55.864
6.0571
−9.3207
54.864
7.3938
−6.2497
53.864
7.4554
−6.6408
56.864
7.4449
−6.5225
55.864
5.7954
−9.2049
54.864
6.1441
−9.1102
53.864
6.3046
−9.7007
56.864
5.8725
−9.4394
55.864
5.6227
−8.9033
54.864
6.4932
−8.935
53.864
6.6141
−9.495
56.864
7.3897
−7.6126
55.864
7.2608
−7.8852
54.864
5.7295
−8.9694
53.864
5.6093
−8.2295
56.864
5.6797
−9.1686
55.864
6.9995
−8.517
54.864
6.8828
−8.4857
53.864
6.9729
−9.0209
56.864
7.1074
−8.5323
55.864
5.57
−8.4498
54.864
5.5783
−8.6408
53.864
5.6641
−9.1781
56.864
5.6052
−8.7781
55.864
7.4319
−6.8122
54.864
7.2293
−7.721
53.864
7.2982
−8.2455
56.864
6.7158
−9.1611
55.864
6.6054
−9.055
54.864
5.5517
−8.1282
53.864
5.8304
−9.564
56.864
5.6057
−7.5572
55.864
6.2299
−9.2978
54.864
7.3925
−6.8189
53.864
7.4612
−7.2888
56.864
6.3466
−9.466
55.864
5.9432
−9.2969
54.864
5.973
−9.1117
53.864
6.1267
−9.7266
56.864
6.0323
−9.5153
55.864
5.7189
−9.117
54.864
6.279
−9.0677
53.864
7.4011
−6.1949
56.864
7.4549
−6.9523
55.864
5.591
−8.7497
54.864
5.8648
−9.0745
53.864
6.4386
−9.6347
56.864
5.7866
−9.3582
55.864
7.3636
−7.4618
54.864
6.65
−8.7892
53.864
5.5842
−7.422
56.864
7.2887
−8.0434
55.864
6.8176
−8.8068
54.864
5.653
−8.8592
53.864
6.7445
−9.3536
56.864
5.6366
−9.0151
55.864
5.5744
−8.1621
54.864
7.0463
−8.1914
53.864
5.6195
−8.7353
56.864
6.9455
−8.8399
55.864
7.4241
−6.3891
54.864
5.5568
−8.488
53.864
7.1256
−8.7207
56.864
5.5947
−8.4859
55.864
6.4569
−9.1802
54.864
7.3196
−7.3649
53.864
5.7091
−9.3471
56.864
6.5609
−9.3187
55.864
6.1154
−9.3201
54.864
5.5759
−7.7348
53.864
7.3792
−7.9184
56.864
6.2091
−9.5147
55.864
5.8407
−9.2417
54.864
7.4017
−6.4516
53.864
5.9438
−9.6622
56.864
7.4259
−6.3147
55.864
5.6472
−8.9779
54.864
6.0872
−9.1177
53.864
7.4672
−6.8652
56.864
5.9222
−9.4719
55.864
7.2073
−8.0478
54.864
6.4256
−8.9852
53.864
6.2468
−9.7175
56.864
7.4226
−7.3937
55.864
7.077
−8.3644
54.864
5.7703
−9.0098
53.864
6.5587
−9.5454
56.864
5.7112
−9.2419
55.864
5.5753
−8.5935
54.864
6.787
−8.6243
53.864
5.6053
−7.9768
56.864
7.1756
−8.3723
55.864
7.4202
−7.0298
54.864
5.5964
−8.7158
53.864
6.8841
−9.1641
56.864
5.6124
−8.8575
55.864
6.6809
−8.9766
54.864
7.1761
−7.8808
53.864
5.6415
−9.0313
56.864
6.7855
−9.0752
55.864
5.6077
−7.3924
54.864
5.5486
−8.2697
53.864
7.2477
−8.4063
56.864
5.6016
−7.9483
55.864
7.3787
−5.9807
54.864
7.3762
−7.0019
53.864
Section 9
Section 10
Section 11
Section 12
X
Y
Z
X
Y
Z
X
Y
Z
X
Y
Z
0.6467
−0.1544
52.864
1.3916
−0.615
51.864
1.1303
−0.2547
50.864
0.9121
−0.1279
49.864
0.7022
−0.0936
52.864
2.6185
−1.023
51.864
2.4035
−1.2353
50.864
0.8321
−0.2013
49.864
1.7562
−0.6127
52.864
0.7213
−0.1163
51.864
0.7921
−0.1155
50.864
2.4343
−1.2155
49.864
1.3449
−0.6145
52.864
0.7056
−0.1636
51.864
1.5999
−0.7166
50.864
2.6696
−0.9793
49.864
0.6532
−0.1204
52.864
1.7203
−0.8249
51.864
0.7645
−0.1725
50.864
1.3921
−0.3587
49.864
2.0117
−1.0466
52.864
0.7141
−0.1849
51.864
1.1953
−0.4617
50.864
0.8234
−0.181
49.864
0.7458
−0.1101
52.864
1.0501
−0.2374
51.864
0.7749
−0.1298
50.864
1.3789
−0.5461
49.864
2.7584
−1.1315
52.864
0.7056
−0.1464
51.864
1.3453
−0.3593
50.864
1.1522
−0.2432
49.864
1.6793
−0.8289
52.864
1.9599
−0.6886
51.864
2.0028
−0.9742
50.864
0.848
−0.2165
49.864
0.6551
−0.1761
52.864
2.0475
−1.0373
51.864
1.9958
−0.6785
50.864
2.0315
−0.6677
49.864
0.6793
−0.0974
52.864
0.801
−0.1161
51.864
0.8137
−0.1092
50.864
0.8699
−0.117
49.864
1.2521
−0.3592
52.864
1.0616
−0.4071
51.864
0.7652
−0.1501
50.864
0.8238
−0.159
49.864
0.6719
−0.1923
52.864
0.7307
−0.2007
51.864
0.7731
−0.1932
50.864
0.849
−0.1242
49.864
1.009
−0.4025
52.864
0.7802
−0.1061
51.864
2.6444
−1.0014
50.864
0.8327
−0.1389
49.864
0.6472
−0.1369
52.864
0.711
−0.1301
51.864
0.7894
−0.2088
50.864
0.8919
−0.1189
49.864
2.3411
−1.2687
52.864
1.2987
−0.3595
51.864
0.8564
−0.122
50.864
1.908
−0.8787
49.864
0.7246
−0.0999
52.864
0.7578
−0.1014
51.864
0.9934
−0.1883
50.864
3.6538
−2.0797
49.864
2.2584
−0.87
52.864
0.7356
−0.1065
51.864
0.8359
−0.1124
50.864
5.8
−2.7861
49.864
0.6643
−0.1067
52.864
2.3724
−1.253
51.864
3.6924
−1.5417
50.864
5.5221
−2.5734
49.864
0.9993
−0.234
52.864
4.7192
−2.1852
51.864
4.8103
−3.4217
50.864
4.8136
−3.3347
49.864
3.2555
−1.3984
52.864
4.8022
−3.5093
51.864
5.8979
−2.9515
50.864
4.151
−2.5256
49.864
4.9513
−2.403
52.864
5.7458
−2.9071
51.864
4.1394
−2.5919
50.864
3.301
−1.8079
49.864
4.6669
−3.4162
52.864
4.1243
−2.6583
51.864
5.1704
−2.4048
50.864
5.934
−2.8986
49.864
3.874
−2.4894
52.864
3.2596
−1.8894
51.864
3.281
−1.8493
50.864
4.7133
−2.0526
49.864
2.6449
−1.4813
52.864
3.6813
−1.5844
51.864
5.3912
−2.5563
50.864
4.4857
−1.9217
49.864
4.078
−1.8611
52.864
5.1771
−2.4826
51.864
4.5657
−3.0794
50.864
4.5723
−3.0003
49.864
5.4063
−2.7228
52.864
4.5546
−3.159
51.864
3.8097
−2.2793
50.864
4.0957
−1.7067
49.864
4.404
−3.0673
52.864
3.7922
−2.3355
51.864
4.4871
−1.9824
50.864
3.8245
−2.2227
49.864
3.4548
−2.1087
52.864
2.6727
−1.4587
51.864
2.7
−1.4343
50.864
2.7267
−1.4078
49.864
4.7183
−2.2513
52.864
4.4861
−2.0432
51.864
3.2899
−1.3306
50.864
4.9259
−3.512
49.864
4.7886
−3.5977
52.864
4.9176
−3.6947
51.864
4.9243
−3.6031
50.864
4.3052
−2.6862
49.864
5.755
−2.9989
52.864
5.575
−2.7709
51.864
5.7334
−2.8142
50.864
5.1607
−2.327
49.864
4.0729
−2.6907
52.864
4.2815
−2.8283
51.864
4.2953
−2.7571
50.864
3.479
−1.9417
49.864
2.9438
−1.7006
52.864
3.4409
−2.0336
51.864
3.4609
−1.9881
50.864
4.9385
−2.1873
49.864
3.6685
−1.6266
52.864
3.2733
−1.3648
51.864
4.0918
−1.7583
50.864
5.3791
−2.4725
49.864
5.1809
−2.5599
52.864
4.9498
−2.3313
51.864
4.6914
−3.2482
50.864
3.3052
−1.296
49.864
4.5386
−3.2393
52.864
4.6817
−3.3318
51.864
3.9773
−2.4327
50.864
4.6963
−3.1651
49.864
3.6676
−2.2955
52.864
5.9118
−3.0491
51.864
2.993
−1.6383
50.864
5.6625
−2.6778
49.864
4.4826
−2.1037
52.864
3.961
−2.4941
51.864
5.0309
−3.7889
50.864
3.9905
−2.3712
49.864
4.9052
−3.7871
52.864
2.9689
−1.6702
51.864
4.9456
−2.2593
50.864
3.0161
−1.6046
49.864
5.5827
−2.8583
52.864
4.0859
−1.8099
51.864
5.5643
−2.6827
50.864
3.7018
−1.4988
49.864
4.2633
−2.9001
52.864
5.4003
−2.6399
51.864
4.4336
−2.9156
50.864
5.0309
−3.6939
49.864
3.2365
−1.9283
52.864
4.4211
−2.9911
51.864
4.7176
−2.1188
50.864
4.4419
−2.8406
49.864
5.2083
−4.3812
52.864
3.6186
−2.1821
51.864
3.6374
−2.1313
50.864
6.607
−3.6475
49.864
5.9226
−3.1454
52.864
7.1494
−4.9818
51.864
6.8067
−4.0628
50.864
6.1892
−3.1379
49.864
6.6486
−3.9688
52.864
5.588
−5.5298
51.864
7.1185
−4.8723
50.864
6.8539
−4.0881
49.864
7.1213
−4.915
52.864
5.3015
−4.4783
51.864
5.5895
−5.4006
50.864
5.6435
−6.2228
49.864
5.6284
−6.1289
52.864
6.4511
−3.6115
51.864
5.3037
−4.3704
50.864
7.1154
−4.8973
49.864
5.4349
−5.0084
52.864
6.9373
−4.3993
51.864
6.535
−3.6314
50.864
5.5833
−5.2718
49.864
5.0143
−3.981
52.864
5.6479
−6.2217
51.864
6.9541
−4.3776
50.864
5.2997
−4.2631
49.864
6.2396
−3.4574
52.864
5.501
−5.1019
51.864
5.6503
−6.0791
50.864
6.3023
−3.258
49.864
6.87
−4.3359
52.864
5.1257
−4.0786
51.864
5.5021
−4.9813
50.864
6.981
−4.4043
49.864
5.5785
−5.6597
52.864
6.0721
−3.1974
51.864
5.1298
−3.979
50.864
5.6423
−5.8411
49.864
5.2927
−4.587
52.864
6.6536
−3.8884
51.864
6.209
−3.246
50.864
5.496
−4.8613
49.864
6.5211
−3.7915
52.864
7.0887
−4.784
51.864
6.7215
−3.9113
50.864
6.5118
−3.5128
49.864
7.0475
−4.7177
52.864
5.6185
−5.7594
51.864
7.0711
−4.705
50.864
5.1283
−3.8798
49.864
5.6382
−6.3647
52.864
5.3768
−4.6833
51.864
5.6204
−5.6257
50.864
6.41
−3.383
49.864
5.4923
−5.2233
52.864
6.3411
−3.4797
51.864
5.3783
−4.5712
50.864
7.0777
−4.731
49.864
5.1154
−4.1791
52.864
6.8463
−4.2137
51.864
6.432
−3.4982
50.864
5.6107
−5.4607
49.864
6.0844
−3.298
52.864
5.5492
−5.3149
51.864
6.8842
−4.2184
50.864
5.3734
−4.4597
49.864
6.7664
−4.1527
52.864
5.2178
−4.2766
51.864
5.6497
−6.3063
50.864
6.9213
−4.2446
49.864
7.1852
−5.1157
52.864
6.5555
−3.7477
51.864
7.1589
−5.0415
50.864
5.6466
−6.0319
49.864
5.6086
−5.8937
52.864
7.0181
−4.5897
51.864
5.5505
−5.19
50.864
6.064
−3.0157
49.864
5.3684
−4.7962
52.864
5.6384
−5.9902
51.864
5.2208
−4.1729
50.864
7.1492
−5.0817
49.864
6.3845
−3.6209
52.864
5.4434
−4.8913
51.864
6.0568
−3.0953
50.864
5.5443
−5.0656
49.864
6.9637
−4.5245
52.864
5.0255
−3.8845
51.864
6.6316
−3.7691
50.864
5.2179
−4.0697
49.864
5.5402
−5.4406
52.864
6.2258
−3.3526
51.864
7.0164
−4.54
50.864
7.033
−4.5666
49.864
7.3604
−6.4835
52.864
6.7452
−4.0334
51.864
5.6406
−5.852
50.864
5.6303
−5.6506
49.864
5.7972
−8.8495
52.864
6.1588
−8.6945
51.864
5.4446
−4.775
50.864
5.4389
−4.6592
49.864
7.2421
−7.3769
52.864
7.3073
−5.954
51.864
6.3232
−3.3697
50.864
6.6953
−3.7867
49.864
5.601
−8.6018
52.864
5.8337
−8.6805
51.864
6.5035
−8.2801
50.864
6.7786
−3.9353
49.864
6.9838
−8.0772
52.864
7.2677
−6.8557
51.864
5.6394
−6.5333
50.864
6.7576
−7.7466
49.864
5.5338
−8.2306
52.864
5.6201
−8.4827
51.864
6.1451
−8.4931
50.864
5.5311
−7.3012
49.864
6.6228
−8.599
52.864
7.0662
−7.639
51.864
7.2577
−5.7994
50.864
6.4088
−8.1442
49.864
5.5945
−7.3196
52.864
5.5248
−8.126
51.864
5.8257
−8.4832
50.864
6.0705
−8.307
49.864
6.2544
−8.8679
52.864
6.7333
−8.2485
51.864
7.2197
−6.6842
50.864
7.2106
−5.8283
49.864
7.3385
−5.9066
52.864
5.568
−7.4007
51.864
5.6114
−8.2945
50.864
5.7509
−8.2492
49.864
5.9533
−8.9114
52.864
6.3785
−8.5906
51.864
7.0292
−7.4544
50.864
7.1431
−6.6768
49.864
7.3362
−6.8437
52.864
7.2394
−5.3733
51.864
5.5152
−7.9457
50.864
5.5556
−8.0016
49.864
5.7109
−8.7771
52.864
6.0223
−8.7166
51.864
6.7077
−8.0548
50.864
6.9411
−7.3898
49.864
7.1503
−7.6858
52.864
7.3126
−6.3261
51.864
5.5648
−7.2347
50.864
5.5061
−7.6939
49.864
5.5584
−8.4565
52.864
5.7396
−8.6227
51.864
6.3605
−8.391
50.864
6.6211
−7.9357
49.864
6.8411
−8.3223
52.864
7.2011
−7.204
51.864
7.1953
−5.2293
50.864
5.5913
−6.8364
49.864
5.5385
−7.9528
52.864
5.5619
−8.3459
51.864
6.0114
−8.5156
50.864
6.2788
−8.2305
49.864
6.4669
−8.7403
52.864
6.9531
−7.8935
51.864
7.262
−6.1645
50.864
7.1753
−5.2673
49.864
5.6307
−6.8366
52.864
5.5223
−7.9152
51.864
5.732
−8.4289
50.864
5.938
−8.3132
49.864
7.2391
−5.3194
52.864
6.5989
−8.4059
51.864
7.1571
−7.0264
50.864
7.2017
−6.169
49.864
6.1215
−8.9086
52.864
5.6204
−6.916
51.864
5.5522
−8.1613
50.864
5.6502
−8.1628
49.864
7.3614
−6.303
52.864
6.2354
−8.6675
51.864
6.9208
−7.7051
50.864
7.0699
−7.0097
49.864
5.8462
−8.8772
52.864
7.2928
−5.7595
51.864
5.5142
−7.7389
50.864
5.5231
−7.8809
49.864
7.2815
−7.2007
52.864
5.8856
−8.6996
51.864
6.5764
−8.2096
50.864
6.8256
−7.6312
49.864
5.6336
−8.6704
52.864
7.2898
−6.6798
51.864
5.621
−6.7598
50.864
5.5178
−7.4318
49.864
7.0454
−7.9493
52.864
5.6617
−8.5442
51.864
6.2202
−8.4665
50.864
6.4847
−8.08
49.864
5.5381
−8.3063
52.864
7.1137
−7.5081
51.864
7.2446
−5.6086
50.864
5.6334
−6.4134
49.864
6.6933
−8.5206
52.864
5.5321
−8.2001
51.864
5.877
−8.5009
50.864
6.1353
−8.2915
49.864
5.5705
−7.5668
52.864
6.8139
−8.1348
51.864
7.2404
−6.5115
50.864
7.2058
−5.6409
49.864
6.3288
−8.8316
52.864
5.5415
−7.6429
51.864
5.6536
−8.3539
50.864
5.8096
−8.2804
49.864
7.3141
−5.7095
52.864
6.4448
−8.5437
51.864
7.0744
−7.3255
50.864
7.1689
−6.5083
49.864
6.0093
−8.9172
52.864
5.6474
−6.4534
51.864
5.5222
−8.0184
50.864
5.5807
−8.059
49.864
7.352
−6.6639
52.864
7.2002
−5.1823
51.864
6.7861
−7.9428
50.864
6.9896
−7.265
49.864
5.7519
−8.8159
52.864
6.0911
−8.7098
51.864
5.5359
−7.4721
50.864
5.5085
−7.7565
49.864
7.1941
−7.551
52.864
7.3137
−6.1489
51.864
6.4255
−8.345
50.864
6.6822
−7.8572
49.864
5.5763
−8.5302
52.864
5.7849
−8.6546
51.864
6.0789
−8.5085
50.864
5.5607
−7.0688
49.864
6.9159
−8.2017
52.864
7.2383
−7.0306
51.864
7.2633
−5.9906
50.864
6.3455
−8.1899
49.864
5.5329
−8.0916
52.864
5.587
−8.416
51.864
5.7771
−8.459
50.864
6.0045
−8.3147
49.864
6.5475
−8.6726
52.864
7.0128
−7.7676
51.864
7.1921
−6.856
50.864
7.209
−5.9988
49.864
5.6157
−7.0722
52.864
5.5213
−8.0516
51.864
5.5776
−8.2297
50.864
5.6974
−8.2096
49.864
6.1765
−8.8956
52.864
6.6684
−8.3292
51.864
6.9781
−7.5811
50.864
7.1102
−6.8441
49.864
7.3543
−6.1045
52.864
5.596
−7.1585
51.864
5.5121
−7.8728
50.864
5.5367
−7.942
49.864
5.8985
−8.898
52.864
6.3087
−8.6323
51.864
6.6444
−8.1342
50.864
6.8866
−7.512
49.864
7.3128
−7.0228
52.864
7.2702
−5.5659
51.864
5.595
−6.9975
50.864
5.5086
−7.5627
49.864
5.6746
−8.734
52.864
5.9533
−8.7135
51.864
6.292
−8.4319
50.864
6.5553
−8.0102
49.864
7.1007
−7.8187
52.864
7.3046
−6.5032
51.864
7.2238
−5.4185
50.864
5.6173
−6.6036
49.864
5.546
−8.3817
52.864
5.6984
−8.5857
51.864
5.9436
−8.5134
50.864
6.2087
−8.2648
49.864
6.7592
−8.4382
52.864
7.1556
−7.3753
51.864
7.2544
−6.3382
50.864
7.1941
−5.4538
49.864
5.5481
−7.814
52.864
5.5441
−8.2736
51.864
5.6906
−8.3936
50.864
5.8725
−8.3018
49.864
6.3996
−8.7887
52.864
6.887
−8.0161
51.864
7.1141
−7.1949
50.864
7.1884
−6.3389
49.864
5.6386
−6.6007
52.864
5.5298
−7.7789
51.864
5.5342
−8.0906
50.864
5.6122
−8.1131
49.864
7.281
−5.5136
52.864
6.5244
−8.4777
51.864
6.8569
−7.826
50.864
7.0324
−7.1382
49.864
6.0656
−8.9161
52.864
5.6378
−6.6849
51.864
5.523
−7.6053
50.864
5.514
−7.8189
49.864
Section 13
Section 14
Section 15
Section 16
X
Y
Z
X
Y
Z
X
Y
Z
X
Y
Z
1.8435
−0.8028
48.864
2.1023
−0.6442
47.864
2.5262
−1.144
46.864
2.4083
−1.0297
45.864
1.5317
−0.609
48.864
1.0043
−0.1322
47.864
1.0215
−0.1492
46.864
1.222
−0.1896
45.864
1.2193
−0.4161
48.864
0.9415
−0.1969
47.864
1.3546
−0.4362
46.864
1.5731
−0.5343
45.864
2.4651
−1.1937
48.864
1.1
−0.313
47.864
1.2494
−0.2233
46.864
1.0789
−0.1576
45.864
0.8825
−0.1892
48.864
0.9638
−0.141
47.864
1.0233
−0.238
46.864
1.3767
−0.4185
45.864
0.9065
−0.224
48.864
0.9649
−0.2311
47.864
1.0006
−0.2043
46.864
1.0822
−0.2449
45.864
0.9264
−0.1248
48.864
1.505
−0.5595
47.864
1.6856
−0.6349
46.864
2.4667
−0.7524
45.864
0.891
−0.209
48.864
1.0242
−0.1395
47.864
1.0607
−0.1391
46.864
1.6711
−0.5923
45.864
0.948
−0.1255
48.864
2.4957
−1.1698
47.864
1.5332
−0.354
46.864
1.1362
−0.1507
45.864
2.067
−0.6563
48.864
0.9413
−0.1758
47.864
1.0075
−0.1644
46.864
2.6821
−1.1949
45.864
0.968
−0.1337
48.864
1.3701
−0.4772
47.864
1.465
−0.5023
46.864
1.2784
−0.3608
45.864
2.6941
−0.9566
48.864
2.7179
−0.9334
47.864
1.165
−0.1842
46.864
1.3311
−0.2394
45.864
0.8825
−0.1676
48.864
0.9832
−0.1325
47.864
1.1338
−0.3039
46.864
1.1805
−0.3026
45.864
2.1548
−0.9975
48.864
1.4861
−0.356
47.864
2.7411
−0.9096
46.864
1.0966
−0.1481
45.864
0.8908
−0.1477
48.864
2.0683
−0.9049
47.864
1.0087
−0.2233
46.864
2.1335
−0.8661
45.864
0.9062
−0.1327
48.864
0.9499
−0.2163
47.864
2.1064
−0.8886
46.864
1.0592
−0.192
45.864
1.439
−0.3576
48.864
1.235
−0.3951
47.864
1.0401
−0.1402
46.864
1.0599
−0.2122
45.864
4.6966
−3.0824
48.864
1.2551
−0.2479
47.864
1.2441
−0.3702
46.864
1.1792
−0.1701
45.864
4.9225
−3.4215
48.864
0.949
−0.1561
47.864
1.3339
−0.2624
46.864
1.0657
−0.173
45.864
5.3639
−2.3884
48.864
1.6398
−0.6419
47.864
1.0002
−0.1837
46.864
1.4749
−0.4764
45.864
4.446
−2.7659
48.864
3.8455
−1.4768
47.864
1.5753
−0.5686
46.864
1.5794
−0.3518
45.864
3.3195
−1.7652
48.864
4.3134
−2.5452
47.864
1.0805
−0.1452
46.864
1.1165
−0.146
45.864
4.3112
−2.6155
48.864
5.1032
−2.1533
47.864
2.1373
−0.6315
46.864
1.068
−0.2306
45.864
5.0256
−3.5993
48.864
3.8459
−2.1086
47.864
5.4902
−2.3254
46.864
5.9539
−2.5907
45.864
4.0005
−2.3096
48.864
3.3366
−1.7213
47.864
3.6895
−1.9214
46.864
5.1024
−2.0224
45.864
4.0975
−1.6551
48.864
4.9141
−3.3314
47.864
3.3437
−1.1904
46.864
3.6632
−1.8434
45.864
3.4953
−1.8943
48.864
4.6924
−3.0002
47.864
4.8526
−3.1645
46.864
3.6639
−1.2991
45.864
5.5054
−2.4851
48.864
4.1007
−1.6052
47.864
4.7719
−1.9009
46.864
3.1348
−1.4781
45.864
4.159
−2.4594
48.864
2.779
−1.349
47.864
4.1647
−2.3276
46.864
5.7114
−2.4052
45.864
4.9286
−2.1153
48.864
5.3458
−2.304
47.864
5.8112
−2.5522
46.864
2.9542
−1.363
45.864
4.5745
−2.9216
48.864
3.6798
−1.9747
47.864
3.3523
−1.6762
46.864
4.5888
−1.7476
45.864
3.6679
−2.0276
48.864
6.1408
−2.9171
47.864
3.9195
−1.4655
46.864
4.5755
−2.7126
45.864
3.7096
−1.4558
48.864
5.109
−3.6832
47.864
4.5989
−2.8067
46.864
3.4899
−1.7176
45.864
5.7805
−2.6892
48.864
5.6774
−2.5314
47.864
5.3246
−2.2195
46.864
6.0694
−2.6904
45.864
4.7063
−1.9863
48.864
4.8564
−2.0094
47.864
3.8527
−2.051
46.864
5.0207
−3.3928
45.864
3.8366
−2.1658
48.864
4.446
−2.6915
47.864
6.1121
−2.8048
46.864
3.9969
−2.1119
45.864
5.6443
−2.5852
48.864
5.5133
−2.4153
47.864
2.8045
−1.3168
46.864
5.3096
−2.1432
45.864
2.7531
−1.3794
48.864
4.3545
−1.7364
47.864
4.9663
−3.3521
46.864
3.9739
−1.4451
45.864
5.9134
−2.7974
48.864
3.5098
−1.8459
47.864
4.4899
−1.7517
46.864
3.8325
−1.9746
45.864
4.4819
−1.8611
48.864
5.8375
−2.6533
47.864
4.3119
−2.4752
46.864
4.4451
−2.5564
45.864
5.148
−2.249
48.864
3.5892
−1.3505
47.864
5.6526
−2.436
46.864
3.3135
−1.5961
45.864
4.812
−3.2481
48.864
4.1635
−2.3934
47.864
3.5224
−1.7967
46.864
4.9213
−3.2152
45.864
3.0384
−1.5692
48.864
3.0598
−1.5321
47.864
3.6321
−1.327
46.864
5.8343
−2.4958
45.864
3.3193
−1.2611
48.864
3.3321
−1.2259
47.864
4.7301
−2.9826
46.864
4.3075
−2.4065
45.864
6.0423
−2.9103
48.864
4.5724
−2.8433
47.864
5.0506
−2.0562
46.864
4.8924
−1.9065
45.864
6.3853
−3.2657
48.864
4.6066
−1.8708
47.864
4.0114
−2.1863
46.864
4.6986
−2.8747
45.864
6.8863
−4.1088
48.864
4.0074
−2.248
47.864
5.9648
−2.6749
46.864
3.3529
−1.1552
45.864
5.6222
−5.5762
48.864
5.9924
−2.7815
47.864
3.0803
−1.4935
46.864
6.1801
−2.7953
45.864
6.1665
−3.0282
48.864
4.8057
−3.162
47.864
5.0709
−3.5449
46.864
5.513
−2.2703
45.864
6.8212
−3.955
48.864
5.0152
−3.5053
47.864
4.2056
−1.6068
46.864
5.1069
−3.5642
45.864
5.2094
−3.967
48.864
5.2738
−4.05
47.864
4.4594
−2.6375
46.864
4.2824
−1.5942
45.864
6.7481
−3.8051
48.864
5.6019
−5.4386
47.864
6.2225
−2.9127
46.864
4.8139
−3.0424
45.864
5.2897
−4.1563
48.864
6.4575
−3.2692
47.864
5.5817
−6.1341
46.864
4.1555
−2.2557
45.864
7.0698
−4.7496
48.864
6.6356
−3.53
47.864
6.6798
−3.5375
46.864
5.5717
−5.7624
45.864
5.1213
−3.7813
48.864
7.0566
−4.8205
47.864
5.5521
−5.094
46.864
6.9788
−5.1485
45.864
7.1247
−5.1126
48.864
6.2521
−3.0292
47.864
6.9423
−4.2882
46.864
6.9078
−4.2438
45.864
6.9434
−4.2656
48.864
6.3579
−3.1466
47.864
5.3213
−4.1282
46.864
5.5702
−5.5483
45.864
5.601
−5.3592
48.864
5.463
−4.6226
47.864
6.4262
−3.1447
46.864
6.6918
−3.5247
45.864
5.6261
−6.2298
48.864
5.58
−5.2265
47.864
5.5942
−5.7175
46.864
5.2573
−3.9171
45.864
7.1009
−4.9306
48.864
5.6114
−6.0779
47.864
6.8094
−3.8289
46.864
6.2853
−2.9059
45.864
5.6334
−5.794
48.864
6.8491
−3.97
47.864
5.4825
−4.6951
46.864
5.5421
−5.121
45.864
5.6345
−6.012
48.864
6.7864
−3.8192
47.864
7.0035
−4.6621
46.864
6.9696
−4.7852
45.864
5.4266
−4.5439
48.864
5.6143
−5.6515
47.864
5.1662
−3.7424
46.864
6.8365
−3.9275
45.864
6.2786
−3.1444
48.864
7.0221
−4.5987
47.864
5.5647
−6.3527
46.864
6.5589
−3.2723
45.864
5.5696
−5.1435
48.864
6.5502
−3.3971
47.864
6.6018
−3.3984
46.864
5.5657
−5.9765
45.864
6.6666
−3.6596
48.864
5.1952
−3.8649
47.864
5.5748
−5.3012
46.864
5.5148
−4.9086
45.864
5.3621
−4.3487
48.864
5.5975
−6.2907
47.864
6.9056
−4.133
46.864
5.1857
−3.7391
45.864
6.4859
−3.3921
48.864
5.3447
−4.2382
47.864
5.3828
−4.3149
46.864
6.9356
−4.4235
45.864
5.5307
−4.9416
48.864
6.9503
−4.2803
47.864
7.0362
−5.0995
46.864
5.5535
−6.1806
45.864
6.5799
−3.5234
48.864
7.0803
−5.0437
47.864
6.3275
−3.0259
46.864
6.747
−3.6564
45.864
5.4829
−4.7417
48.864
5.51
−4.8181
47.864
5.5916
−5.9259
46.864
6.384
−3.0223
45.864
6.9927
−4.425
48.864
5.4078
−4.4292
47.864
6.7489
−3.6812
46.864
6.9771
−4.9668
45.864
7.0347
−4.5865
48.864
6.9897
−4.4387
47.864
5.5205
−4.8879
46.864
6.8716
−4.0658
45.864
7.1529
−5.8568
48.864
6.7153
−3.6724
47.864
6.9723
−4.4449
46.864
5.3783
−4.2812
45.864
7.1429
−6.0513
48.864
5.6173
−5.8648
47.864
5.2522
−3.9442
46.864
6.6291
−3.3965
45.864
7.1416
−5.2954
48.864
6.9036
−4.1239
47.864
6.5178
−3.2689
46.864
5.3215
−4.0979
45.864
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45.864
At this point it should be understood that the points disclosed in Table 1 are exemplary, variations/deviations from the points in Table 1 at one or more sections that do not substantially affect the desired properties obtained by the airfoil core shape of the exemplary embodiments fall within the scope of the exemplary embodiments of the invention.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. | A turbomachine component includes a turbine stator nozzle member having an airfoil core shape. The airfoil core shape includes a nominal profile substantially in accordance with Cartesian coordinate values of X, Y, and Z set forth in TABLE 1, and wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches, the profile sections at the Z distances being joined smoothly with one another to form a complete airfoil core shape. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to a method of reducing the allergenicity of natural latex rubber prior to its vulcanization. In doing so, the potential for allergic reactions due to the protein content of the natural latex rubber has been greatly reduced while maintaining its desirable physical properties when used in such products as latex gloves and similar medical and consumer goods.
BACKGROUND OF THE INVENTION
[0002] Beginning in the late 1980's allergic reactions associated with the use of latex gloves began to receive widespread recognition. These reactions varied greatly in degree but seemed to exhibit similar characteristics to acquired sensitivity reactions seen with other allergens. Although latex gloves have enjoyed a long history of usage dating back to the 1800's, the perceived need for protection from AIDS and HIV exposure during the 80's caused a tremendous increase in the use of gloves. This, in turn, resulted in a much-heightened exposure to the naturally occurring antigenic proteins contained in raw latex.
[0003] The last decade and a half has seen a great change in latex use as a result of publicity concerning these allergies. Today in the U.S. there is almost universal awareness of the risks associated with repeated latex exposure, particularly in the healthcare fields where exposure is more profound. Awareness of the risks, however, extends into the industrial glove market, and even to the general public, who have received risk warnings from various government and health-watch groups. As a result there exists much interest in the market, fueling a strong trend to reduce exposure to latex-associated allergens.
[0004] Manufacturers have responded in several ways: 1) reduction or elimination of donning powder, 2) utilization of chlorinated glove washing and additional processing steps to reduce antigenic protein load, 3) use of coatings to reduce actual contact with latex, and 4) introduction of alternative materials that mimic, natural latex performance characteristics. Each of these industry reactions represents compromises either from ease of use, performance, or cost standpoint. In short, nothing beats the tactile, comfort, and barrier protection that is provided by natural latex products.
[0005] In the last ten years there has been an increasing awareness of the possible immunologic and other reaction risks associated with the use of latex gloves. This awareness is the result of the proliferation in glove usage among healthcare workers in order to avoid potential exposure to HIV/AIDS transmission sources.
[0006] An increase in the reported incidence of latex allergic sensitivity and other skin reactions has been concomitant with increased glove usage. This has spurred an effort by industry leaders and manufacturers to reduce exposure to latex. Glove makers have initiated latex substitution in the manufacturer of gloves, elimination of donning powder (antigenic proteins leach in to the cornstarch powder and become airborne-a source of respiratory exposure and subsequent sensitization), and the introduction of methods to reduce overall protein content of gloves.
[0007] Latex rubber in its natural form consists of polymer, long chain molecules consisting of repeating units of isoprene:
R and R1 are unidentified terminal units; n-value is in the range of 600-3000
[0008] When it is harvested from the rubber tree, Hevea brasiliensis, the liquid, sticky substance also contains proteins like heavamine, hevein, and rubber elongation factor (REF). Although the basic isoprene polymer is non-antigenic, the associated proteins are highly antigenic. It is important to note this difference in order to minimize the antigenic impact of natural latex without destroying its underlying structure.
[0009] In its natural state, natural latex does not possess characteristics that are commercially useful. In order to achieve utilitarian value, including strength, elasticity, and memory, the chains of isoprene must be cross-linked to one another. Depending on the type of rubber end product desired, this is achieved with either application of heat and sulfur, or in the case of latex rubber used in the manufacture of gloves, various chemical accelerators that donate or bind sulfur, thus speeding the cross-linking process. The major accelerators are thiurams, mercaptobenzothaizoles (MBTs), and carbamates.
[0010] In addition to accelerators, latex glove manufacturers utilize another class of additives, called sensitizers, which most frequently consist of substituted phenols. These substances are used to impede oxidation, and resultant degradation, of natural latex.
[0011] Foreign materials, natural latex proteins, accelerators, and sensitizers can all provoke human reactions, but the allergenic reactions due to the proteins are considered to be by far the most problematic in the healthcare field. The following briefly describes three major types of foreign material reactions most commonly associated with latex use:
[0012] Irritant dermatitis is skin irritation that does not involve the body's immune response, that is, it is not an allergic response. Frequent hand washing and inadequate drying, aggressive scrubbing technique or detergents, mechanical abrasive effect of powder, climatic irritation, and emotional stress can all cause this condition. Even though this is not an allergic reaction, irritant hand dermatitis can cause breaks in the skin which can facilitate entry of the sensitizing latex protein or chemicals found in the commercial product, and in turn lead to latex allergy.
[0013] Delayed cutaneous hypersensitivity (type IV allergy) is contact (hand) dermatitis generally due to the chemicals used in latex production. It is mediated via T-cells causing a skin reaction that is typically seen 6-48 hours after contact. The reaction is local and limited to the skin that has contact with the glove. While not life threatening, those with type IV allergy are at increased risk to develop type I allergy. As in irritant dermatitis, the broken skin barrier can provide an entry site into the body for foreign materials. This can produce sensitization to latex proteins leading to a more serious type of reaction.
[0014] The third and potentially most serious type of reaction associated with latex use is a true IgE/histamine-mediated allergy to protein (also called immediate, or type I hypersensitivity). This type of reaction can involve local or systemic symptoms. Local symptoms include contact urticaria (hives), which appears in the area where contact occurred, i.e., the hands, but can spread beyond that area and become generalized. More generalized reactions include allergic rhinoconjunctivitis and asthma. The presence of allergic manifestations to natural latex indicates an increased risk for anaphylaxis, a rare but serious reaction experienced by some individuals who have developed an allergy to certain proteins (e.g., insect stings, natural rubber, penicillin). This type I reaction can occur within seconds to minutes of exposure to the allergen. When such a reaction occurs, it can progress rapidly from swelling of the lips and airways, to shortness of breath, and may progress to shock and death, sometimes within minutes. While any of these signs and symptoms may be the first indication of allergy, in many workers with continued exposure to the allergen, there is progression from skin to respiratory symptoms over a period of months to years. Some studies indicate that individuals with latex allergy are more likely than latex non-allergic persons to be atopic (have an increased immune response to some common allergens, with symptoms such as asthma or eczema). Once natural latex allergy occurs, allergic individuals continue to experience symptoms, which have included life-threatening reactions.
[0015] There are several classes of people known to be at increased risk for latex allergy. Medical patients who have had multiple hospitalizations and have been exposed numerous times to latex medical products, healthcare workers, and atopic individuals comprise this high-risk group. Current estimates are that 8-17% of healthcare workers become sensitized. Despite the recent emphasis on universal precautions, the marked increase in glove usage due to commutable disease prevention is largely blamed for the increase in latex allergies among these groups. Atopic individuals (those with other allergies or asthma) are at significantly greater risk to develop latex allergy than the general population. It is estimated that as many as 25-30% of atopic healthcare workers may become sensitized.
[0016] The problems presented by allergic reactions to latex are exacerbated by the proliferation and widespread use of latex-based products. Latex presents great risk to persons in the health care industry where latex products are used extensively in the form of gloves, casts, dressings, tapes, catheters, tubes, drains, airway management devices, med delivery, tourniquets, monitoring devices, and others. One persistent threat lies in the cornstarch powder used to lubricate and ease donning of rubber gloves. The proteins absorb onto the powder and become aerosolized during use and when the gloves are donned and removed.
[0017] Products containing latex are also found throughout the home in the form of balloons, art supplies, toys, swimming equipment, contraceptive devices, cosmetics, bottle nipples, pacifiers, clothing, chewing gum, rubber bands, and others. Groups at risk include particularly children with spina bifida, those who have been shown to have a very high risk of latex sensitivity, patients with congenital urologic abnormalities, healthcare providers and rubber industry workers.
[0018] Since the severe allergic reactions to latex are due to their naturally occurring proteins, the prior art offers little in the way of solutions. For example, “hypoallergenic” latex products are free from the vulcanization accelerator compounds that can cause dermatitis, but do not prevent immediate hypersensitivity reactions. Likewise, ammonia treatment of the natural rubber latex proteins can cause breakdown and precipitation of some latex proteins, but the allergenicity appears to be preserved and other antigenic latex proteins are unextractable. In short, the literature recommends that the only treatment available for latex allergy is avoidance.
[0019] The Food and Drug Administration (FDA), as well as other state and federal agencies, has received requests to ban the use of glove powder. It has been suggested that experimental and clinical studies demonstrate that glove powder on medical gloves can enhance foreign body reactions, increase infections and act as a carrier of natural latex allergens. The National Institute of Occupational Safety and Health (NIOSH) recently issued a safety alert recommending the use of powder-free, reduced protein content latex gloves to reduce exposure to natural latex proteins (allergens).
[0020] Experimental and clinical data demonstrate that natural rubber latex (NRL) proteins are allergenic. Further, natural latex proteins bind to cornstarch while aerosolized powder on NRL gloves is allergenic and can cause respiratory allergic reactions. Published studies support the conclusion that airborne glove powder represents a threat to individuals allergic to natural rubber latex and may represent an important agent for sensitizing non-allergic individuals. There are also published data (although limited) and clinical experience that cornstarch powder on NRL gloves may also be a contributing factor in the development of irritation and type IV allergy.
[0021] In addition to dusting powder, other lubricants may also be used in the manufacturing process. Latex and some polymers are tacky and gloves made of these materials stick to the mold or former. A mold-release lubricant such as calcium carbonate or a mixture of calcium carbonate and cornstarch is used to enable the removal of gloves from molds. The other side of the glove may be coated with a donning lubricant, such as cornstarch or silicone oils, to make donning gloves easier and to prevent gloves from sticking during the manufacturing process.
[0022] Over the past three years, the FDA has received requests to ban the use of all glove powders. These requests have been based on repeated clinical and experimental studies reporting that cornstarch on surgical gloves can damage tissue's resistance to infection, enhance the development of infection, serve as a potential source of occupational asthma, and provide a source of natural latex protein exposure to natural latex allergic individuals. The issues regarding the use of glove powder, except for the transport of natural latex protein allergens, apply to the use of glove powder on both natural rubber latex and synthetic gloves. Several states, acting on their own initiative have banned the sale and use of glove powders.
[0023] Current applicant as well as others have suggested protocols for reducing the allergenicity of latex rubber by removing allergenic proteins from natural rubber compositions. For example, applicant's previously issued U.S. Pat. No. 6,906,126 directed to a method for reducing allergenicity of natural latex rubber by admixing the natural latex rubber, prior to its vulcanization, with mineral oil which is extracted together with proteins. The disclosure contained within published application no. 2002/0156159 teaches the use of fumed silica, a known thickener, to increase the viscosity of vulcanized natural rubber latex. The '159 application, now abandoned, further notes that the fumed silica addition reduces allergenicity by reducing the amount of allergenic protein present in latex articles dipped from compositions which include fumed silica. Theoretically, the applicant of the cited application proposes that the silica particles attached to the surface of the rubber particles thereby displacing allergenic proteins.
[0024] It is an object of the present invention to employ silica-based compounds such as described in published U.S. Application No. 2002/0156159 in a way which significantly increases their efficacy.
[0025] As a further object of the present invention to teach a protocol for reducing the allergenicity of natural latex rubber prior to vulcanization to enable the creation of commercial products relatively free of allergenicity with no apparent loss of physical properties.
SUMMARY OF THE INVENTION
[0026] The present invention is directed to a method of reducing allergenicity of natural latex rubber. The method comprises subjecting the natural latex rubber, prior to vulcanization, to silicon contained compounds dissolved in a fixed alkali solution to reduce protein levels in it or by adding liquid sodium silicate directly to natural rubber latex. These silicon compounds include; -silica SiO 2 (fumed silica, silica, quartz), silica acid H 4 SiO 4 (or Si(OH) 4 ), silane SiH 4 and silicon halides such as SiCl 4 and SiF 4 , silicates both individual and mixtures such as Na 2 SiO 3 , K 2 SiO 3 , CaSiO 3 , MgSiO 3 , CaMg(SiO 3 ) 2 , K(AlSi 3 O 8 ,), Na 2 (Al 2 Si 3 O 10 )●2H 2 O, and organo-silicones, for example 1,1,1,3,3,3-hexamethyldisilazane.
DETAILED DESCRIPTION OF THE INVENTION
[0027] These compounds of use herein can be solid (silica, silica acid, silicates), gaseous (silane and silicon halides) or liquid (organic-silicon). Many of them are natural compounds and some are synthesized (organosilicones, silica acid, some zeolites). All these compounds as well as silicon itself, are more or less soluble in strong alkalis, due to hydrolysis and chemical interaction of silica ions, such as SiO 3 2− , SiO 4 4− , Si 2 O 7 6− , Si 3 O 9 6− etc. The structures of possible complex silica-based ions that are formed due to this interaction and hydrolysis are indicated below
[0028] It is preferred that at least approximately 0.05% of SiO 2 in a silicon compound (by weight) is admixed with the natural latex rubber and, ideally, approximately 0.001-0.1% of SiO 2 in a silicon compound by weight is employed. The silicon compound is dissolved with either potassium hydroxide(KOH) or sodium hydroxide(NaOH), then is admixed with the natural latex rubber up to 72 hours, and ideally approximately 24 hours, with agitation or in the case of liquid sodium silicate, can be added to the natural latex rubber directly. The antigenic protein is denatured thus enabling the natural latex rubber to be further processed.
[0029] The reaction and structure for this denaturing is illustrated below:
[0030] As a preferred embodiment, the natural latex rubber is subjected to a specific silicon compound mixed in a fixed alkali solution with agitation to produce an intimate admixture. Further, a specific amount of liquid sodium silicate (solution of Na 2 SiO 3 in H 2 O) can be added directly to natural latex rubber to reduce the antigenic protein value. Ideally, at least approximately 0.05% of SiO 2 in a silicon compound by weight is admixed with the natural latex rubber and, preferably, 0.001-0.1% of SiO 2 in a silicon compound by weight is employed.
[0031] Once the suitable admixture is created, it is found that at least some agitation is required to enable appropriate denaturing of the antigenic protein content from the natural latex rubber whereupon, the treated latex containing denatured protein is vulcanization into a latex article. Agitation can be carried out for up to 72 hours, with 24 hours being ideal.
[0032] Although there are various suitable candidates for use herein, it has been found that fumed silica having a density of approximately 2.2 g/cm 2 and a surface area of approximately 255 m 2 /g is ideal. Specifically, the use of liquid silicate Na 2 Si 3 O 7 and organic silicon, particularly, hehamethildisilazane was tested to determine the affect on protein removal. After the protein has been denatured pursuant to the present invention, vulcanizing the latex is possible without disrupting the physical or chemicals properties of the natural latex rubber.
[0000] Experimental Data
[0033] A series of films were created, a first being a control sample of natural latex rubber not involving the teachings of the present invention. This material was applied to a glass plate.
[0034] A series of six additional films were created, in each instance, using the same natural latex rubber which was employed to make the above-reference film. 0.01% fumed silica by weight having a density of 2.2 g/cm 2 and surface area of 255 m 2 /g was dissolved in a KOH solution then agitated with the natural latex rubber for 24 hours. Next, this sample was processed into a film on a glass plate and labeled “CSP-11”. A second film was created labeled “CSP-10”. Sample CSP-10 differed from sample CSP-11 in that 0.02% fumed silica by weight was dissolved in KOH and mixed with natural latex rubber for 24 hours. This sample was processed into a film on a glass plate. A third film was created labeled “CSP-9”. Sample CSP-9 differed from the other samples in that 0.03% fumed silica by weight was dissolved in KOH and mixed with natural latex rubber for 24 hours. This sample was processed into a film on a glass plate. A fourth film was created labeled “CSP-8”. Sample CSP-8 differed from sample CSP-9 in that 0.05% fumed silica by weight was dissolved in KOH and mixed with natural latex rubber for 24 hours. This sample was processed into a film on a glass plate. A fifth film was created labeled “CSLP-1”. Sample CSLP-1 contained 0.05% by weight liquid sodium silicate (Na 2 Si 3 O 7 ) and was mixed directly into natural latex rubber for 24 hours. This sample was processed into a film on a glass plate. A sixth film was created labeled “CSOP-1”. Sample CSOP-1 contained 0.05% by weight organic silicon (1,1,1,3,3,3-Hexamethyldisilazane) that was mixed with natural latex for 24 hours. This sample was processed into a film on a glass plate.
[0035] Films CSP-11, CSP-10, CSP-9, CSP-8, CSLP-1 and CSOP-1 were analyzed by conducting LEAP assays. The following results were measured noting that, in addition to the films, the control sample of latex film was also scrutinized.
[0036] ELISA Inhibition Assay (ASTM D6499-03). The data is expressed as antigenic latex protein in micrograms/gram of sample. The untreated liquid latex contained 1,341.8 μg/g while the control film from untreated liquid latex contained 33 μg/g of antigenic protein. The CSP-11 latex film sample contained 1.2 μg/g of antigenic protein. The CSP-10 latex film sample contained 0.8 μg/g of antigenic protein. The CSP-9 latex film sample contained 0.4 μg/g of antigenic protein. The CSP-8 latex film sample contained 0.6 μg/g of antigenic protein. The CSLP-1 latex film sample contained 1.4 μg/g of antigenic protein. The CSOP-1 latex film sample contained 3.9 μg/g of antigenic protein.
[0037] It is quite apparent from the test data which was developed and reported above that dramatic reduction in protein levels is achieved by the relatively simple processes of denaturing protein found in natural latex rubber by either dissolving silicon compounds in a fixed alkali solution or by introducing liquid sodium silicate into latex as previously described. Unlike the teachings of published and abandoned application serial no. 2002/0156159, this process is employed prior to vulcanization of the natural latex rubber. In doing so, products can be produced while reducing risks imposed upon users of natural latex rubber products, including healthcare professionals, as a result of type I hypersensitivity. Most importantly, this is accomplished without diminishing the physical properties of natural latex rubber which makes commercial products made from this material so desirable. | A method for reducing allergenicity of natural latex rubber. The natural latex rubber, prior to its vulcanization, is admixed with silica compounds dissolved an alkali solution to denature the antigenic protein thus reducing the total protein level. Alternatively, liquid sodium silicate is added directly to natural rubber latex to reduce antigenic protein value. Ideally, when fumed silica is used as the silica compound, it is characterized as having a density of approximately 2.2 g/cm 2 and surface area of 255 m 2 /g. | 2 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] Statement as to Rights to inventions made under Federally sponsored research and development: Not applicable.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention.
[0003] This present invention relates generally to shelters and to anchoring devices for shelters.
[0004] 2. Background Information.
[0005] Temporary shelters are commonly used for recreation, community events as well as in emergencies. In emergencies it is desirable to be able to quickly erect shelters for a variety of purposes. Often emergency shelters are inflated on site. Inflatable shelters have the advantage of being quick to erect and do not require a separate heavy frame. Shelters with inflatable beams give shelter that is quick to erect, strong and that have a maximum area of covered space for the transportation weight. However, inflatable shelters do have problems. The light weight of the shelters gives a shelter that can move easily. One problem with inflatable shelters is that they tend to fill into the shape of a sphere or cylinder like a balloon. Such a shelter has a minimum of usable floor space. Even if heavy objects are placed on the floor of an inflatable shelter to hold the floor down, the upward force of the shelter combined with movement of people in the shelter can cause movement of even fairly heavy objects. Another problem with inflatable shelters is the need for destructive stakes. Stakes are used to tie the structure down to force the inflated structure to have a flat section of floor. This can require a tremendous amount of force and requires a very substantial staking process. Even when staked, there tends to still be unusable space near the walls where the floor still lifts up into a non-flat configuration. Another problem with inflatables is that they can be damaged during the inflation process when they are typically not yet tied down. If inflated on a parking lot, a wind can rake havoc. Another problem with existing inflatable shelters is that the movement of the floors and walls can cause motion sickness to those inside. To solve these problems, the prior art has used tie downs and stakes to secure temporary shelters. However, in emergency situations it is common to erect shelters on pavement such as in a parking lot or even inside a larger building such as a warehouse, gymnasium or sports stadium. In these cases driving stakes into concrete or other floor surfaces is destructive to the facility and also eliminates much of the benefit of an easy to erect building.
[0006] A further problem with positively pressured inflatable structures is the tendency for an inflatable shelter to form rounded edges instead of square edges. This tends to yield a floor that does not lay flat all the way to the edges of the floor, rather the edges curl up and as a result usable floor area is reduced. There is often a trip hazard in doorways where the floor of the shelter tends to lift off the underlying surface. Personnel movement on lifted areas result in shelter motion. To correct this problem with the prior art, more staking has been used. To get a truly flat floor it is necessary to stake frequently around the entire perimeter of the structure which greatly increases the time and cost of installation as well as the destructive aspect to the existing concrete surface, floor or pavement. Stake loads increase dramatically with internal pressure on an inflatable shelter. Stresses in the shelter material increase dramatically as the floor/wall interface approaches a sharp corner.
[0007] Accordingly, there is a need for an improved method and apparatus to affix a flexible fabric shelter to a surface.
SUMMARY OF THE INVENTION
[0008] The present invention solves the problems outlined above. The invention anchors the shelter to the deployment surface by applying vacuum beneath the shelter floor causing atmospheric pressure bearing on the shelter floor to hold it against the deployment surface.
[0009] In one aspect of the invention a shelter for use on a deployment surface has a flexible wall and a skirt surrounding the flexible wall and connected to a bottom edge of the wall. A source of vacuum supplied to a plurality of points beneath the skirt to hold the entire flexible skirt and the bottom edges of the wall flat on the surface. The atmosphere can exert a net hold down force upon the shelter being equal to the vacuum pressure multiplied by the shelter floor area. Additional features and benefits will become apparent from the detailed disclosure and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a view of the shelter;
[0011] FIG. 2 shows details of the invention;
[0012] FIG. 3 shows additional details of the invention;
[0013] FIG. 4 shows details of the prior art; and
[0014] FIG. 5 shows an alternate embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] FIG. 1 illustrates a preferred embodiment of the shelter 100 . The shelter 100 is supported by air pressure in the shelter 100 such that the shelter 100 can be erected in the field simply by inflating the shelter 100 . The shelter could also be supported by positive pressure filling air beams 102 or alternatively the shelter could be supported by a frame. The shelter includes a flexible skirt 104 connects to the wall ( 120 in FIG. 2 ) along the perimeter of the wall. A peripheral border having a width ‘W’ is formed around the interior portion of the shelter 100 . A source of vacuum 106 is supplied under the flexible sealing skirt 104 . The shelter 100 can include openings such as a door 110 . The source of vacuum 106 vacuums the flexible sealing skirt 104 down to a deployment surface ‘S’ that the shelter 100 is erected upon. The surface ‘S’ can be a concrete floor inside a building, asphalt, a wood floor or a composite gymnasium floor for example. The device has been tested and shown to be successful on concrete, asphalt, wood, or carpet surfaces. The system also works on other surfaces. The skirt 104 material is important. Some fabric materials are relatively rigid or stiff, these con be strong but will not conform to a deployment surface as well as a soft material that easily conforms to a surface.
[0016] FIG. 2 shows a partial cross section of the shelter 100 revealing details of the invention. The shelter 100 includes a flexible wall 120 and a floor 130 . The wall 120 is connected to a skirt 104 that surrounds the floor 130 and living space within the shelter 100 . The shelter 100 sits on a deployment surface ‘S’ such as a floor or parking lot for example where the temporary shelter 100 might be required. Vacuum channel 140 propagates vacuum beneath the entire perimeter of the skirt 104 . The skirt 104 is sealed to the deployment surface S by the crushing force of atmospheric pressure. Additional seals 150 may be applied beneath the skirt 104 where discontinuities exist on the deployment surface S for example. Additional sealing may consist of compressible seal 150 for example and seal enabler 160 . The compressible seal 150 can be any light weight compressible material such as foam rubber. The auxiliary seal 160 can be any weight and could consist of sand or sand bags for example.
[0017] The cross section of FIG. 2 shows a vacuum channel 140 that carries the vacuum to areas covered by the skirt 104 . The skirt 104 can be sealed by a flexible seal 150 and an auxiliary seal enabler material 160 as an option to improve anchoring. The auxiliary seal enabler material 160 could be loose sand or sand bags stacked along the edge of the skirt 104 to improve sealing. When vacuum is applied, vacuum will communicate with the spiral openings 144 ( FIG. 3 ) in the channel 140 and the skirt 104 will pull down around the vacuum channel 140 and the seal 150 , which can be a flexible material such as a sponge like foam for example, will flatten. It will be understood by those in the art that the skirt can be attached to the floor surface of the shelter interior. It will also be understood that the vacuum could be applied under the floor of the shelter instead of using a perimeter skirt. The channel 140 could be a part of the skirt 104 , it is known to supply material that includes channels to communicate vacuum.
[0018] FIG. 3 shows that the vacuum channel 140 receives vacuum source 142 connected to a source of vacuum 106 . The vacuum channel 140 propagates vacuum to the under surface of the skirt 104 which is shown partially cutaway in FIG. 3 . The seal 150 is shown as it will appear when vacuum is applied, the skirt has wrapped tight around the vacuum channel 144 . The purpose of the vacuum channel 144 is to provide a conduit around the entire perimeter of the wall 120 . In this case the vacuum channel 140 is shown as a plastic spiral conduit material with openings 144 . The channel 140 provides a skeleton that will not collapse under the force of the vacuum and atmospheric pressure and yet allows is porous and allows a portion of the vacuum to be applied at regular intervals around the shelter perimeter. The spiral wrap shown has a diameter of about ½ inch and a wall thickness of about 1/16 th inch and a 1/16 inch spiral opening at about ½ inch intervals over the entire length of material. When covered with the skirt 104 the vacuum channel 140 forms a vacuum conduit.
[0019] FIG. 4 shows a portion of a prior art shelter 1000 including a door 1002 The shelter 1000 can have stakes 1006 at multiple points along its length to the surface ‘S’. The stakes 1006 can support ropes 1007 that exert tremendous pressure on the shelter 1000 to hold it in a near half cylinder shape against internal positive pressure. As can be seen, edges and corners 1008 still curl up off the deployment surface. Going inside the shelter 1000 and stepping on one of these corners 1008 will cause the entire shelter 1000 structure to move and will cause other parts of the shelter floor to lift up. The raised areas substantially reduce the useful area inside the prior art shelter 1000 and as can be seen can create walking problems such as the trip hazard at the door 1002 where the bottom of the door 1002 can be raised up off the ground.
[0020] FIG. 5 shows an alternate embodiment of the shelter 200 . In this case a flexible wall 220 sits on top of a flexible skirt 230 that extends to both sides of the wall 220 . Vacuum is supplied through a channel 240 that runs along the length of the wall 220 just beneath the wall 220 . An optional seal 250 and 252 is provided on each side of the vacuum channel 240 and runs the length of the wall 220 and channel 240 . An additional seal enabler 260 , 262 can be provided at the edge of or on top of the skirt 230 furthest removed from the wall 220 . The additional seal enabler 260 , 262 might, for example be a material used to enhance the seal on rough concrete or grass for example. For example, the additional seal material could be a liquid material or sand or sand bags or gravel or dirt for example. Many materials would work. It will be understood that the wall 220 might separate the interior of a shelter from the exterior for example such that the vacuum is applied both under a skirt and a floor of the shelter 200 . FIG. 5 also shows that the skirt 230 can have an optional seal formed by fabric overlap 270 formed along its length. It has been found that this overlap 270 can also help in forming the seal.
[0021] It will be obvious to those skilled In the art that modifications may be made to the embodiments described above without departing from the scope of the invention. Thus the scope of the invention should be determined by the claims in the formal application and their legal equivalents, rather than by the examples given. | An air supported positively pressurized flexible material shelter for use on a surface comprising a flexible wall and a skirt connected to the wall and surrounding the flexible wall. A source of vacuum being propagated beneath the skirt along the flexible wall, to vacuum the skirt down to the surface to secure the temporary shelter to the surface. The skirt forms a continuous connection with the surface around the entire perimeter of the shelter. An optional flexible seal is provided essentially parallel to a vacuum channel and on an exterior edge of the skirt spaced from the flexible wall. | 4 |
FIELD OF THE INVENTION
The present invention relates to methods and systems of information management, and, more particularly to Hypertext information retrieval and display.
BACKGROUND OF THE INVENTION
In information management, there is an ever increasing need for systems which provide easy access to information, with minimum time spent in ordering or retrieving the information. In computing, several systems, such as databases and Hypertext, are known for facilitating the organisation of information.
A computer database typically comprises a number of records which are grouped in a single file. Each record comprises information stored as a set of fields; each record having the same field types. Proprietary software applications are available for creating and manipulating databases, such as: DBase™, Paradox™, and Approach™ which are available to run on IBM™ compatible machines running DOS or Windows™. Such applications allow data in a database to be rearranged, sorted, presented and printed according to criteria set by the user. The criteria may be, for example, to present a particular subset of records, or to reorder all records in the database. Prior art database manipulation techniques are thus useful for rearranging data which is easily categorisable into different fields. However, such techniques do not allow large quantities of textual data to be presented for easy digestion by the user. Moreover, manual manipulation of the data is necessary, which requires knowledge of the structure of the database.
A second, rather different method for managing information, is to cross-reference documents. Textual documents are more easily digested by cross-referencing than by re-ordering with database applications, as portions of text are cross-referenced to other relevant portions of text, allowing fast and easy access to relevant information. Cross-referencing implemented in this way is termed "Hypertext cross-referencing" or "Hypertext linking". Systems providing such capabilities are called "Hypertext systems". In order for existing hypertext systems to carry out this type of navigation, codes and/or instructions need to be embedded in the text by the author using a given "authoring" program. When the text is displayed using a compatible "viewing" program the codes and instructions, as embedded by the author (but now hidden from view), are interpreted and carried out. A large amount of time and effort is usually expended by the author.
Typically the following steps, as shown in FIG. 1, are carried out during the authoring process:
(a) identify a word or phrase from which to cross-reference
(b) identify all occurrences of this word or phrase in the entire text
(c) determine the location of the referred-to text i.e. its page number or other positional or relative location or its identifying label
(d) mark each occurrence from step b) to show it is a cross-reference and also attach to it the result found in step c) to tell the system where to navigate to
(e) repeat steps a to d for all cross-references.
This procedure would usually involve the author in having to mark cross-reference words and phrases with special codes or with some form of computer language. A known standard for coding such links is Hypertext Markup Language (HTML).
Depending on the system used, software support can be found to assist in the above processes, but the author is still required to identify and code cross-references. The coded text is then compiled: which means codes and instructions are validated, navigation links are resolved, text may be compressed. Compilation can take many hours; authoring, in the mechanistic sense, can take many months.
When new text is added to the publication, occurrences of words and phrases are inevitably added which are the same as existing cross-references, the above steps have to be repeated for them. If text which is referred-to is deleted then all cross-references to that text have to be found and any code or instructions nullified. Conversely, if new text is added which might be referred-to by existing text, then the entire document must be taken through steps a to e in order to add codes and instructions to existing text wherever it is required to make reference to the new text. The result is that the Hypertext file is static, in that items cannot be added or deleted without recompiling the entire Hypertext file.
A representation of a prior art Hypertext system is shown in FIG. 2. Once the authoring process is complete, the text portions are interrelated to one another in the manner described. To add new text, the author must decide which existing text portions should have links to the new text within the body of their text, and which existing text portions should have links from the body of new text. It can be seen that this is a time consuming, labour intensive operation.
SUMMARY OF THE INVENTION
It is, therefore, an object of the invention to provide a method of arranging and retrieving data in a computer which does not require the authoring process previously described. It is a more particular object of the invention to provide a method of cross-referencing data in a computer which does not require an author to identify and code links within the data. It is also an object of the invention to provide an effective method of searching data items within a system operating the invention.
These and other objects are accomplished by providing a method of associating portions of data stored in an information retrieval system, the system including:
a display; and
a store for storing data as a plurality of data portions comprising data elements, each data portion having a unique reference name,
the method comprising:
(a) reading the data elements of a first data portion of said plurality of data portions;
(b) comparing said data elements of said first data portion with each of said reference names;
(c) determining where occurrences of said references correspond to data elements in said first data portion and determining a set of data portions for which such occurrences are found;
(d) associating said first data portion with each of said data portions in said set of data portions; and
(e) displaying said first data portion on said display.
The present invention may be implemented in a database in which each record comprises a data portion in the form of several pages of text relating to a particular topic, and a further field in the same record contains the unique reference in the form of a topic name. Other data is also contained in other fields of the same record. A data portion, such as text on a particular topic, is displayed for the user to read and digest. Just prior to displaying the topic text, the invention compares the text to references, such as topic names for text, pictures, video and sound, for other data portions containing information on other topics. Upon display of the text to the user, the invention indicates that other topic names have been found within the topic text being displayed and read by the user, and that an association has been created between the text being read and the other topics. The user may then request any one of the topics found in the comparison be displayed. If the requested topic is a text topic, the process is repeated for the new topic. If the requested topic is a picture, or video topic, it will be shown or played without moving from the current text topic. The invention thus provides a structure for cross-referencing text which does not require manual authoring of cross-reference links. This reduces the time and effort required to produce, and maintain hypertext documents, and eliminates the need for the author to identify a word or phrase from which to cross-reference. There is also, therefore, no need for the author to embed codes to indicate the existence of a cross-reference, or to specify instructions for navigation to the referred to text.
The comparison operation may be a string search; a preferred comparison method is described later. The association process provides links between data elements, such as words or phrases and data portions, such as passages of text, and other data portions. One may consider that, as a data element within a first data portion is associated with a further data portion, then that first data portion is effectively associated to the further data portion. The invention and drawings will, therefore, be described in terms of associating, by linking, portions of text to other text portions or pictures or sound.
Generally, the operating environment of the present invention includes a general purpose computer system having a processor, a memory, a display and associated peripheral equipment such as disk drive storage or other storage medium. In particular, the invention is embodied in an application operating in a Windows™ environment on an IBM™ compatible personal computer. The invention is, advantageously, operable in a computer network such as workgroups, local-area networks (LAN) and wide-area networks (WAN), remotely and internationally. When operating in a network, the store of data in the form of a database may be centrally located, with each network user having access to the information therein. As the text stored is only compared, and associated, with topic names at the moment of display, the links between text portions are always up to date. If a topic is added to the database, viewing users have immediate access to that text. Any existing text which happens to refer to the new topic will automatically be associated and show the new topic as a cross-reference link. Conversely, if the author deletes a topic, no links to it will appear on the system.
The invention is effective with respect to textual data stored as separate topics; each topic comprising a few pages of text. However, that the invention applies to other types of data, such as: images, sound, video, executable files or other data.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a flow diagram showing the prior art authoring process required to set up a hypertext system;
FIG. 2 shows the basic structure of links between text portions in prior art Hypertext systems;
FIG. 3 shows the basic structure of links between text portions in a system according to the invention;
FIG. 4 is a flow diagram showing the basic processes of the invention; and
FIG. 5 shows in detail a flow diagram of the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The basic structure of data organisation in a system using the invention is shown in FIG. 3. The data portions 700 and reference names 600 are stored in the form of a database; with a reference name stored as a first field in a record, and the data portion to which that reference refers stored as a second field in that record. A reference name 600 is a unique, meaningful name which indicates the subject matter of the data portion to which it refers. The name may be a word, a phrase or other string indicative of the topic of the data portion. A data portion comprises pages of text on a particular topic, as well as any images, sound, video or executables. We refer to a record in the database, comprising topic data such as text pages, pictures or sound, reference name and any further fields of data, as a HyperNODE™. The database itself containing the records is referred to as a HyperDB™, and the application of the invention is known as XGL Hypertext VOYAGER™. The process of creating associations between data is named Auto Hyperlinking™.
Information is input into a system using the invention in the following manner. Text for a topic is either typed into the database, input as an ASCII text file, or input from other applications such as wordprocessors and database applications. The text may then be manipulated by the user by "cutting and pasting" the text in the usual manner for Windows™ applications. Alternatively, text may be cut and pasted from other Windows™ applications, such as word-processors. Various wordprocessors and database applications provide suitable text formats, such as: WordPerfect™, Word™ and DBase™. The author may also import pictures or sound from other Windows applications. Using any of these techniques the author may easily input text and pictures to construct the database of topics, with each topic stored as a separate record. The user also defines the reference name for each topic at this stage. An embodiment uses the same standards as the Paradox™ database application produced by Borland™, with which a database produced for the present invention is compatible. The reader is referred to the package Paradox™ for further details on the codes and the manner in which data is stored for Paradox™ compatibility. Other platforms such as IBM VSAM™, DBase™ and Oracle™ are equally suitable, and the invention is not limited to any particular format.
Once a database has been constructed, as described above, the user may interrogate the database using the invention, the comparison process 200, and association process 400 are shown in relation to the database in FIG. 3. Referring now to FIG. 4, the first step 100 is to read a first topic selected by the user. This selection is made by positioning a cursor on the display, using a mouse, in the usual manner for Windows™. The selection of the topic may be from a list of available topics. On selection, the first page of topic text is compared 200 to the other topic names in the database and then displayed. The comparison is conducted by automatically searching for the occurrence of topic names in the body of text of the first page of the first topic. A preferred searching technique to conduct the comparison is described later. On finding a match 300, the matched topic name occurring within the text of the first topic is associated with the topic data of the topic to which the matched topic name refers.
Association 400 could involve simply indicating the existence of the related topic found in the search. However, the invention advantageously provides links, known as Auto -- Hyperlinks™, meaning that the word or phrase in the text found to be a match with a topic name is highlighted on the display, and linked to the topic to which the topic name refers. The user may then jump to the associated topic by selecting the highlighted word or phrase in the first topic text, as in prior art Hypertext systems, or if the associated topic is a picture it is displayed on selection. The link is made with reference to the database which stores the topic text, reference name and other identifiers. Such identifiers note the location of the data for each topic, and provide the navigational links for the hypertext jumps.
Prior to displaying the first page of a topic, the comparison with the topic names is conducted for that page. The comparison for subsequent pages of that topic is also undertaken, preemptively while the first page of text is displayed, until the entire text for that topic has been compared, or the user has moved to a new topic 500. Text is thus linked a page at a time for the topic the viewing user has requested. The invention thus assumes that the user is likely to display the next page of the topic and so preemptively links the next pages while the user is reading the first page. The sequence is then repeated for the newly displayed topic as shown by steps 100 and 500 in FIG. 4.
The invention is set out in the flow chart of the invention of FIG. 5. The first page of text is read 100, the first word 201 selected and the next word of text 202 is scanned. If the word overflows the user predefined topic name length 203, then the database of topic names is searched in comparison to the concatenation buffer contents 208. If the word does not overflow 203, then the word is added to the buffer 204, and the word count is incremented by one 205. If the word ends in punctuation 206, the contents of the buffer is searched against the topic names 208. If no punctuation is present, and the predefined buffer word limit is not reached 207, the next word 202 is scanned. In this way, steps 202 to 207 successively scan words and adds them to the concatenation buffer until the predefined word limit is reached. At this point the concatenated phrase is searched against the database. If a topic is found 209, a link is created 211 (providing that the name does not refer to the present topic 210) and the process moves m words along, where m is the word count in the buffer. At this point the buffer is cleared in preparation for the next set of steps 202 to 207.
If no match is found with the buffer search term having the user defined maximum number of words, and a near match is found 213, the steps 213 to 218 check for plurals and, if still no match is found, successively removes the last word added to the buffer and compares the buffer contents with the list of topic names until a match is found. If no match is found, the system moves to the next word along 219 and starts the comparison again at 202. Once sufficient text has been processed to fit the size of the display window of the display, the processed text is diplayed. Upon displaying the first page, the invention continues to repeat the above process for subsequent pages of the topic text.
A database has been created to cover the subject area: planets of our solar system. The database contains the following text and picture topics:
______________________________________Earth IoJupiter MarsMercury NeptuneOur moon PlanetPluto Rings of Saturn.Ring system Satellites of JupiterSaturn Solar SystemThe red spot (picture topic)Uranus Venus______________________________________
Topic being viewed by user: Planet
Text for topic planet:
There are ten major known planets in our solar system. Jupiter is the largest, with a diameter ten times that of the Earth. There are 12 satellites of Jupiter or moons, the most famous being Io. Jupiter which also has a faint ring system nowhere near as prominent as the rings of Saturn is famous for the red spot which is 3 times the diameter of the earth. Saturn is the second largest planet . . . .
The text for the topic planet is shown above. The words highlighted in bold and underlined have been automatically shown as hyperlinks. These words or phrases have been found to exist on the database as topics in their own right and the logical deduction from this is that there is more information available for them so they are automatically cross-referenced or Hyperlinked. If the user clicks the mouse on any of the hyperlinked words which refer to a text topic, they would automatically be taken to that topic and its associated topic text would be displayed with again any hyperlinks automatically found and highlighted as above. If the hyperlinked phrase "the red spot" is selected, the picture associated with the phrase is displayed without moving off the present text topic. In the above example the word planet is not hyperlinked because it relates to itself.
The following illustrates how concatenation and the finding of hyperlinks in the above text is achieved.
______________________________________Concatenated Key Operation performed______________________________________There are ten First group of 3 words are concatenated and then a lookup is done with the key "There are ten" to see if a topic of this name exists. As it does not, the search continues with the next words.are ten major Next group of 3 words are concatenatedten major known And so on . . .major known planetsknown planets inplanets in ourin our solarour solar systemsolar system. Full stop causes concatenation of only these two words. As a match has been found, these words are marked as an Auto hyperlink. The process now continues, with the word immediately following the word "system".Jupiter is the Near match found, so continue with these wordsJupiter isJupiter Match found, so search continues after "Jupiter".is the largestthe largest withetc . . . and so on until10 satellites ofsatellites of Jupiter Match found on this phraseetc . . . untilbeing are Io.are Io. Full stop causes concatenation of two words onlyIo. Match foundJupiter also has Near match found so continue to try these wordsJupiter alsoJupiter Match foundas the ringsthe rings ofrings of Saturn. Match foundthe red spot Match found, and end of text.______________________________________
In this example the user defined maximum number of words to be concatenated is three. The searching process described above is an effective way of comparing text for matching strings comprising several words.
It should be noted that, whilst the invention has been described with reference to textual data, it is clear that the invention is applicable to other types of data. In essence, the invention provides a dynamic structure for relating information in a store, and displaying the information, along with links between the data found by the invention. The data portions can be any suitable data, particularly alphanumeric data. For non-alphanumeric data, such as images, video or executables, the data has a reference name as with textual data portions. This reference name may be searched within text of other data portions and linked in the manner described. A phrase in a document may, therefore, refer to an image name which, when selected, automatically displays the image having that name. If the referred to data portion is an executable file, that executable will be executed on selection of its name from the highlighted text. Many applications other than simple cross-referencing may thus be envisaged. Executable management in this way provides a useful system for a user to perform operations such as copying or deleting data, or other disk and memory management functions.
In the embodiment described the invention is particularly effective as the association of data portions is undertaken just prior to display of the selected topic. This ensures that the system is always up to date unlike prior manually authored systems which are only updated when the author manually adds the links. This aspect allows multiple users to add topics to the database without the need to be aware of the topics already stored on the system. In the context of a news system, for example, individuals may add news from different parts of the world onto the system without the need of communicating with one another. Since the association of topics occurs just prior to display, the database thus formed is always instantly up to date requiring no manual authoring or compilation.
Further rules of topic association other than simply searching for identical and similar word strings or using the concatenation search previously decribed may also be used. For example linguistic rules may be incorporated so that the phrase "moons of jupiter" within a portion of text is associated with a topic having the topic name "jupiter's moons". Other linguistic rules may also be applied such as associating a topic with the topic name "people" with an occurence of the word "person". These and other linguistic rules are within the scope and spirit of the invention.
It should also be noted that the topic names and text portions do not have to be stored in a database, and could be stored as separate files, or otherwise. A list of topic names could also be stored as a single file, with the topic text stored as a single flat file. The invention may thus be implemented in a variety of environments and platforms other than the embodiment described. As well as implementing the invention to run on a computer to provide hypertext information to a user on a computer, the invention can be used to provide hypertext information on a television. Some examples of useful television applications are: a news service providing up to date hypertext pages of news, a TV programme information service or an educational/exploratory service.
Taking the news service as an example: with news coming in all the time, a set of news pages could be dynamically maintained by several authors using the invention, all updating the same HyperDB. On detecting that a topic text has been changed the invention would hyperlink the text pages of that topic in the same way as described earlier. But instead of displaying the pages, the invention would pass the newly hyperlinked topic text to a Text Transmission Control Unit (TTCU) or some such similar processor. The TTCU would store the said pages, which would include appropriate indicators to distinguish hypertext words and phrases and also a news page number associated with each such hypertext reference. The TTCU, when all pages for a topic have been stored, would broadcast the said topic text as a number of pages. In normal operation the TTCU would be broadcasting all news pages continually so that any TV user could be receiving any page at any time. If a new topic has been added or one deleted from the database, the invention on detecting such events (as is currently done when the invention is run on a network) would automatically hyperlink, as described before, all the topics on the news database and pass each page to the TTCU which would again store them. Specifically in this event (adding/deleting of entire topics) the TTCU would receive and store all pages of the news database before it started to broadcast any of the new pages. This is because the hypertext linking would now relate to the entire set of pages comprising the news database including added or deleted topics.
If a TV user were to select a particular hypertext link the news page associated with the selected link would simply be displayed on the TV. This "jump" technology already exists in that you can display different pages of teletext or similar at will. Such similar technology could be used to achieve the jump associated with the hypertext link within the news pages, but with the additional advantages provided by the association process of the invention. Alternatively, a small piece of software (an extension of the implementation of the invention) would reside in all TV's capable of receiving hypertext pages from the invention.
A third alternative is that the same or similar piece of jump software from the invention could be implemented on the newly emerging TV-PC technology. Such jump software could be made freely available as part of the normal software provided with the TV-PC technology. Selection of a conventional PC or similar is typically done using a mouse by pointing and clicking. Televisions do not have an equivalent device, though a mouse roller ball and a selection button could be incorporated into the remote control. The usage of these would be conventional; the user would manipulate the roller ball to position a cursor on the screen and then press the button to select the item where the cursor rests.
Taking the television programme service as a second example: A set of television programme pages could be dynamically maintained by a number of authors. The pages would be equivalent to published journals like the BBC Radio/TV Times. This example would work in the same way as the example on the news service with the addition of a further feature.
The additional feature requires the use of a TV-PC instead of just a TV. The invention will further enable the authors to include in the programme information a Unique Alphanumeric Code (UAC) associated with each television, radio and future multi-media/virtual-reality/cyber-space programmes. The invention would enforce uniqueness when authors assigned a UAC to a programme. The invention when hyperlinking would for every found hyperlink include, as well as the page number as before, the UAC if a UAC existed for the reference hyperlink. Such pages as before would not be displayed but passed to the TTCU. The TTCU would broadcast hypertext pages as normal but also include the UAC (where one exists) with every hypertext reference.
In this application, the TV-PC user will be able to not only jump to different pages of hypertext information, but also to indicate to the TV-PC to store any hypertext reference and its UAC in a Personal Programme Schedule (PPS). The PPS could then be reviewed by the TV-PC user and each programme entry could be marked by the user to indicate actions that the TV-PC is to take such as "get me to watch/hear" , "record on video or audio or CD or PC memory" , or "censor" (stopping children watching inappropriate programmes). Once in the system the software would allow the user to add/remove further items and would be able to warn of scheduling conflicts, amount of tape/memory required to record selected programmes, etc. This provides the user with far greater control over the watching and recording of programmes. It assumes the TV-PC technology will also be connected to a Hi-Fi system which includes a radio and tape recorder.
It should be understood that the foregoing description of the present invention is illustrative only. Thus, although only a few examples of the invention have been described in detail, it is clear that the features of the present invention may be adapted without departing from the spirit of the invention. | Topic objects are stored with textual data objects containing references to other topic objects. The textual data objects are string-correlated to the topic objects to determine which topic objects are referenced in each textual data object. Hypertext links are generated for each reference in the textual data objects. The string-correlation is performed in a buffer in which each portion of text relating to a particular topic, having a unique topic name embedded, is concatenated and matched with the topic names. In the case of no match, one word is removed from the concatenated string to form a new string and the string-correlation is repeated. | 8 |
FIELD OF INVENTION
[0001] Embodiments of the invention generally relate to the field of drag-and-drop functionality, and more particularly to enhancing drag-and-drop functionality for web content.
BACKGROUND
[0002] Drag-and-drop user interfaces are commonly employed to perform visual layout customization with screen objects and to create different associations between abstract objects. The drag-and-drop action typically involves selecting a virtual object by pressing a mouse button or pointing device button, “dragging” the object to a desired location or onto another object while holding the button, and “dropping” the object by releasing the button. Some disabled users (e.g. blind users, users lacking motor control, etc.) may have difficulties utilizing drag-and-drop environments, as they may have trouble using mice and other pointing devices. However, many of these users can effectively use keyboards.
SUMMARY
[0003] In some embodiments, a method includes presenting an activation element in association with a web page and detecting activation of the activation element, wherein the detection occurs following an activation event. The method can also include identifying draggable elements and drop zones in the web page and associating identifiers with the draggable elements and the drop zones, wherein the identifiers indicate one or more input events that will move a certain one of the draggable elements to a certain one of the drop zones. The method can also include modifying the web page to display the identifiers in association with the draggable elements and the drop zones, detecting the input events, and moving the certain one of the draggable elements to the certain one of the drop zones.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The present embodiments may be better understood, and numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
[0005] FIG. 1 illustrates a web content processing system that enhances drag-and-drop functionality for web content, according to some embodiments of the invention;
[0006] FIG. 2 is a flow diagram illustrating operations for augmenting drag-and-drop-capable web pages to work with other hot keys and other input types, according to some embodiments of the invention;
[0007] FIG. 3 is a flow diagram (continuing from FIG. 2 ) illustrating more operations for augmenting a web page's draggable elements and drop zones to work with hot keys and other input, according to some embodiments of the invention;
[0008] FIG. 4 is a diagram illustrating a web page including graphical objects that are drag-and-drop capable; and
[0009] FIG. 5 is a diagram illustrating a web page including drag-and-drop objects that respond to hot keys and other input.
DESCRIPTION OF EMBODIMENTS
[0010] An increasing number of web portals and pages are moving toward making their sites more “user friendly”. Although operating systems often support drag-and-drop functionality, web page environments rarely provide it for common internet users. Some embodiments of the invention allow users to use drag-and-drop functionality within a web page environment. Additionally, some embodiments provide increased accessibility and usability to people who are unable, for various reasons, to utilize drag-and-drop environments with mice or other pointing devices. Some embodiments accomplish this by modifying web pages to move draggable elements to drop zones via hot keys (i.e., keyboard keys), voice commands, or other suitable user input techniques.
[0011] The description that follows includes exemplary systems, methods, techniques, instruction sequences and computer program products that embody techniques of the invention. However, the described invention may be practiced without these specific details. For instance, well-known web-related components, protocols, structures and techniques have not been shown to avoid obfuscating the description.
[0012] FIG. 1 illustrates a computer system including a web content processing system that can enhance drag-and-drop functionality for web content, according to some embodiments of the invention. The computer system 100 includes a main memory 130 connected to a central processing unit (“CPU”) 120 . The CPU 120 is connected to a bus 122 , which is connected to a video controller 124 , audio controller 126 , and peripheral device interfaces 128 . The video controllers 124 can present video content on a display device (e.g., a liquid crystal display monitor), while the audio controller can present audio content on audio devices (e.g., speakers). The peripheral device interfaces 128 can process input/output (“I/O”) from various I/O devices, such as a mouse, keyboard, microphone, printer, scanners, etc.
[0013] The main memory 130 includes an operating system 118 , application programs 116 , and a web content processing system 132 . The web content processing system 130 includes a web page 102 , rendering unit 103 , transformation unit 106 , filtering unit 108 , parser unit 109 , selection unit 114 , and activation unit 110 .
[0014] The rendering unit 103 can render the web page 102 , which can include content from web portals, such as Yahoo!, Google, etc. In some embodiments, the selection unit 114 detects when a user has provided input to launch a process for enhancing drag-and-drop functionality in the web page 102 , input indicating a hot key press or voice command, etc.
[0015] The parser unit 109 can search through code of the web page 102 for characters and symbols that signify draggable elements and drop zones. The transformation unit 106 can match hot keys and voice commands with the draggable elements and drop zones identified by parser unit 109 . In some embodiments, the transformation unit 106 can add and/or modify the web page's code, so users can activate the draggable elements and drop zones using the hot keys and voice commands.
[0016] The filtering unit 108 can reduce the number of draggable elements, drop zones, and hot key options/voice command options in the web page 102 . This reduction can make the drag-and-drop interface more understandable for some uses (e.g., users who perceive the web page's drag-and-drop options though a voice reader in the rendering unit 103 ). After the reduction, the rendering unit 103 can present identifiers that indicate hot keys or voice commands uses for selecting draggable elements and drop zones within the web page 102 . The selection unit 114 detects hot key presses and voice commands that select draggable elements and drop zones.
[0017] Although not shown in FIG. 1 , the web content processing system 132 can include other components for acquiring, rendering, and storing web content. Those components can include any suitable code (e.g., Javascript) for processing web content. In some embodiments, one or more of the components the web processing system 132 can be included in a web browser. Furthermore, any of the components described herein can include hardware, firmware, and/or machine-readable media including instructions for performing the operations described herein. Machine-readable media includes any mechanism that provides (i.e., stores and/or transmits) information in a form readable by a machine (e.g., a game machine, computer, etc.). For example, tangible machine-readable media includes read only memory (ROM), random access memory (RAM), magnetic disk storage media, optical storage media, flash memory machines, etc. Machine-readable media also includes any media suitable for transmitting software over a network.
System Operations
[0018] This section describes operations performed by some embodiments of the systems described above. In certain embodiments, the operations can be performed by executing instructions residing on machine-readable media (e.g., software), while in other embodiments, the operations can be performed by a combination of software, hardware, and/or other logic (e.g., firmware). In some embodiments, the operations can be performed in series, while in other embodiments, one or more of the operations can be performed in parallel. Moreover, some embodiments can perform less than all the operations shown in the Figures.
[0019] FIG. 2 is a flow diagram illustrating operations for augmenting drag-and-drop-capable web pages to work with other hot keys and other input techniques, according to some embodiments of the invention. The flow 200 will be described with reference to the computer system in FIG. 1 . In FIG. 2 , flow 200 begins at block 202 .
[0020] At block 202 , the rendering unit 103 receives and renders web content. For example, the rendering unit 103 receives a web page 102 and presents it on a display device connected to the video controller 124 . The web page 102 can include code, such as the Hyper Text Markup Language (HTML) code or the Extensible Hyper Text Markup Language (XHTML) code. The code can identify graphical objects, text, photos, animations, audio, etc. for presentation by the rendering unit 103 . Some of the graphical objects are drag-and-drop capable, so users can drag and drop those objects using a mouse or other pointing device. FIG. 4 helps illustrate this concept. FIG. 4 is a diagram illustrating a web page including graphical objects that are drag-and-drop capable. In FIG. 4 , a web page 400 includes text 412 , draggable graphical objects 416 , 420 , & 424 , and drop zones 406 & 410 . The rendering unit 103 can render such a web page by performing the operations of block 202 of FIG. 2 . In FIG. 4 , a user can use a mouse to drag and drop the graphical object 416 in the drop zone 406 (see arrow 407 ). Similarly, a user can use a mouse to drag and drop the graphical objects 420 & 424 in the drop zone 410 (see arrows 408 ).
[0021] Referring back to FIG. 2 , the flow continues at block 204 .
[0022] At block 204 , the activation unit 110 inserts an activation element into the content. In some embodiments, the activation unit 110 adds code (e.g., HTML code) representing the activation element to the code representing the web page 102 . In other embodiments, the activation element is not part of the web page itself, but is part of the user interface containing the web page. The activation element can be a button, a window for receiving voice commands, or any other suitable variation of input components. The flow continues at block 206 .
[0023] At block 206 , the activation unit 110 presents the activation element. FIG. 5 helps illustrate this concept. FIG. 5 is a diagram illustrating a web page including drag-and-drop objects that respond to hot keys and other input. FIG. 5 shows the web page 400 . In FIG. 5 , the activation unit 110 has added an activation button 502 to the web page 400 . A user can activate the activation button 502 by pressing a keyboard key, such as keyboard key “D”, as shown. Alternatively, the activation element can include a voice reader that responds to a user's voice commands. Upon activation, the web content processing system 132 performs a process that adds hot key and other features to a web page's drag-and-drop objects. The flow continues at block 208 .
[0024] At block 208 , the selection unit 114 detects activation of the activation element. For example, the selection unit 114 can detect an activation event, such as a hot key press or voice command associated with the activation element. The flow continues at block 210 .
[0025] At block 210 , the parser unit 109 identifies draggable elements and drop zones in the web page 102 . In some embodiments, the parser unit 109 parses through the web page's code in search of certain characters or symbols that identify draggable elements and drop zones. The parser unit 109 can compile a list of all draggable elements and drop zones. The flow continues at FIG. 3 .
[0026] FIG. 3 is a flow diagram (continuing from FIG. 2 ) illustrating more operations for augmenting a web page's draggable elements and drop zones to work with hot keys and other input, according to some embodiments of the invention. The flow will be described with reference to the computer system of FIG. 1 . In FIG. 3 , the flow continues at block 302 .
[0027] At block 302 , the transformation unit 106 associates hot keys and/or voice commands with draggable elements and drop zones. The hot keys and/or voice commands identifiers are also associated with identifiers (see 514 , 518 , 522 , etc.) that identify the hot keys and/or voice commands that can select the draggable graphical objects. For example, in FIG. 5 , the transformation unit 106 can associate a hot key “A” with the draggable graphical object 416 , hot key “B” with the draggable graphical object 420 , etc. The flow continues at block 304 .
[0028] At block 304 , the transformation unit 106 transforms the web page 102 to function with the hot keys and/or voice commands. In some embodiments, the transformation unit 106 inserts, into the web page 102 , code (e.g., HTML code) that displays identifiers (e.g., see 514 , 518 , 522 , etc.) indicating a relationship between the hot keys and the draggable objects and drop zones. In addition, the transformation unit 106 can update the web page 102 to include code that audibly communicates relationships between voice commands and the draggable elements and drop zones. This changes the web page to a state in which users can use hotkeys and voice commands to illicit drag-and-drop functionality. For example, blind users or users without fine motor control can utilize the drag and drop functionality without using a mouse. The flow continues at block 306 .
[0029] At block 306 , the filtering unit 108 determines whether it will filter the identifiers and draggable elements. By filtering the draggable elements and identifiers, the filtering unit 108 can reduce the number of draggable element options to a more manageable number. Filtering can result in a modified arrangement of the objects in the drag-and-drop interface. Filtering may be particularly useful in embodiments in which the rendering unit 103 audibly presents draggable elements and their identifiers. Listening to long lists of draggable elements and identifiers may be tedious for some users. In some embodiments, filtering is automatically turned on, but may be turned off via user input. If filtering is not performed, the flow continues at block 314 . If filtering is performed, the flow continues at block 310 .
[0030] At block 310 , the filtering unit 108 groups identifier options to reduce the number of available identifier options. In some embodiments, the filtering unit 108 reduces the number of identifier options by showing only the most frequently used draggable elements and drop zones in the active section of the web page 102 . As a result, the filtering unit 108 reduces the number of hot key choices a user has in an interface, and it reduces the number of elements the rendering unit 103 audibly presents. The flow continues at block 312 .
[0031] At block 314 , the rendering unit 103 presents, in the web page 102 , the identifiers associated with the hot keys and/or voice commands. The rendering unit 103 can present each identifier near a draggable element, as shown in FIG. 5 (see 514 , 518 , & 522 ). The rendering unit 103 can also audibly. The flow continues at block 316 .
[0032] At block 316 , the selection unit 114 detects selection of a draggable element and/or drop zone within web page 102 . Users can select the draggable elements by activating the associated hot key or speaking a voice command. For example, as shown in FIG. 5 , the draggable graphical object 420 is juxtaposed to the “B” identifier 516 . A user can select the draggable graphical object 410 by pressing keyboard key “B” or by speaking the letter “B” into a microphone connected to the computer system 100 . The flow continues at block 318 .
[0033] At block 318 , after selection of a draggable element, the rendering unit 103 presents identifiers associated with the drop zones. In FIG. 5 , this operation would cause the rendering unit 103 to present the identifiers 508 & 512 . In some embodiments, the rendering unit 103 audibly presents the identifiers 508 & 512 . The flow continues at block 320 .
[0034] At block 320 , the selection unit 114 detects selection of a drop zone within the web page 102 . For example, in FIG. 5 , a user selects the drop zone 406 by pressing keyboard key “Z” or by speaking the letter “Z” into a microphone connected to the computer system 100 . Once a drop zone is selected, the system 100 moves the draggable graphical object 416 into the drop zone as if the user dragged-and-dropped the graphical object with a mouse. In some embodiments, the drag-and-drop operation causes addition operations specific to the web page (e.g., a file is deleted, money transferred between accounts, etc.). From block 320 , the flow ends.
[0035] Although FIG. 3 shows selecting draggable elements and drop zones as two separate operations, some embodiments enable users to select draggable elements and drop zones in a single operation. For example, a user may be working in an email box. If a draggable email message can be dropped in only one drop zone, the filtering unit 108 can associate both the email message and drop zone with a hot key. The user need only press one hot key to drop the email message in the drop zone.
Other Embodiments
[0036] While the invention(s) is (are) described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the invention(s) is not limited to them. In general, the techniques described herein may be implemented with facilities consistent with any hardware system or hardware systems. Many variations, modifications, additions, and improvements are possible.
[0037] Plural instances may be provided for components, operations or structures described herein as a single instance. Finally, boundaries between various components, operations and data stores are somewhat arbitrary, and particular operations are illustrated in the context of specific illustrative configurations. Other allocations of functionality are envisioned and may fall within the scope of the invention(s). In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the invention(s). | Techniques for enhancing accessibility to web content are described herein. In some embodiments, a method includes presenting an activation element in association with a web page and detecting activation of the activation element, wherein the detection occurs following an activation event. The method can also include identifying draggable elements and drop zones in the web page and associating identifiers with the draggable elements and the drop zones, wherein the identifiers indicate one or more input events that will move a certain one of the draggable elements to a certain one of the drop zones. The method can also include modifying the web page to display the identifiers in association with the draggable elements and the drop zones, detecting the input events, and moving the certain one of the draggable elements to the certain one of the drop zones. | 6 |
[0001] This application is a Divisional of co-pending application Ser. No.10/377,057, filed on Feb. 28, 2003, which is a divisional of application Ser. No. 10/092,752, filed on Mar. 5, 2002 and for which priority is claimed under 35 U.S.C. § 120; and this application claims priority of application Ser. No. SE 0100733.5 filed in SWEDEN on Mar. 5, 2001 under 35 U.S.C. § 119; the entire contents of all are hereby incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates to non-nucleoside reverse transcriptase inhibitors active against HIV-1 and having an improved resistance and pharmacokinetic profile. The invention further relates to novel intermediates in the synthesis of such compounds and the use of the compounds in antiviral methods and compositions.
BACKGROUND TO THE INVENTION
[0003] Non nucleoside reverse transcriptase inhibitors (NNRTI) bind to an allosteric site on reverse transcriptase and represent an important development in the arsenal of drugs against HIV, particularly HIV-1. International patent application WO 93/03022, discloses thiourea NNRTI which were later denoted “PETT” (phenyl ethyl thiazolyl thiourea) compounds in J Med Chem 39 6 1329-1335 (1995) and J Med Chem 39 21 4261-4274 (1996). International patent application nos. WO99/47501, WO/0039095, WO/0056736, WO00/78315 and WO00/78721 describe thiourea PETT derivatives which have allegedly been optimised against a composite RT binding pocket.
[0004] International patent application no WO95/06034 and J Med Chem 42 4150-4160 (1999) disclose urea isosteres of PETT NNRTIs. International patent application no WO99/36406 discloses urea NNRTI compounds with a freestanding cyclopropyl bridge, wherein the phenyl left hand wing bears an obligate 6-hydroxy function and international patent application no WO00/47561 discloses prodrugs of such compounds.
[0005] Although the urea and thiourea NNRTI disclosed in the above documents are active against reverse transcriptase, especially that of HIV-1, the nature of the HIV virus with its extreme lack of replicative fidelity and consequent tendency to rapid resistance development prompts a demand for further antiretroviral agents with enhanced antiviral performance against problematic drug escape mutants, notably at the RT 100, 103 and/or 181 positions.
[0006] Additionally, modern HIV therapy regimes, denoted HMRT, Highly Active Anti Retroviral Therapy, administer antivirals as combinations of three or more antivirals of various classes, which combinations are administered for prolonged periods, if not for life. HAART requires the patient to follow a complicated dosing schedule with sometimes dozens of tablets per day taken at various times of the day in some cases before and in other cases after the ingestion of food. There is thus a need for antiretroviral preparations allowing greater flexibility in dosing to facilitate patient compliance.
BRIEF DESCRIPTION OF THE INVENTION
[0007] In accordance with a first aspect of the invention there are provided compounds of the formula I:
where
R 1 is O, S; R 2 is an optionally substituted, nitrogen-containing heterocycle, wherein the nitrogen is located at the 2 position relative to the (thio)urea bond; R 3 is H, C 1 -C 3 alkyl, R 4 -R 7 are independently selected from H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkanoyl, haloC 1 -C 6 alkanoyl, C 1 -C 6 alkoxy, haloC 1 -C 6 alkoxy, C 1 -C 6 alkyloxy-C 1 -C 6 alkyl, haloC 1 -C 6 alkyloxy-C 1 -C 6 alkyl hydroxy-C 1 -C 6 alkyl, amino-C 1 -C 6 alkyl, carboxy-C 1 -C 6 alkyl, cyano-C 1 -C 6 alkyl, amino, carboxy, carbamoyl, cyano, halo, hydroxy, keto and the like; X is —(CH 2 ) n -D-(CH 2 ) m — D is —NR 8 —, —O—, —S—, —S(═O)— or —S(═O) 2 — R 8 is H, C 1 -C 3 alkyl n and m are independently 0 or 1;
and pharmaceutically acceptable salts and prodrugs thereof.
[0016] The currently preferred value for R 1 is O, that is a urea derivative, although R 1 as S (ie a thiourea derivative) is also highly potent.
[0017] Representative values for R 2 include thiazolyl, pyridyl, pyrimidyl, pyrazinyl, pyridazinyl, pyrrolyl, imidazolyl, indolyl, triazolyl, tetrazolyl, piperidyl, piperazinyl and fused rings such as benzothiazolyl, benzopyridyl, benzodiazolyl, benzimidazolyl, quinolyl, purinyl and the like, any of which can be optionally substituted.
[0018] Preferred R 2 values include pyrid-2-yl and thiazol-2-yl.
[0019] The optional substituents to R 2 can include up to three substituents such as C 1 -C 6 alkyl, C 1 -C6 alkoxy, C 2 -C 6 alkenyl, C 2 -C 8 alkynyl, C 2 .C 8 alkenoxy, C 1 -C 6 alkoxy C 1 -C 6 alkyl, C 1 -C 6 alkanoyl, haloC 1 -C 6 alkyl, C 1 -C 4 alkanoyloxy, C 1 -C 4 alkylthio, amino (including C 1 -C 3 alkyl-substituted amino), carboxy, carbamoyl, cyano, halo, hydroxy, aminomethyl, carboxymethyl, hydroxymethyl, nitro, aryl, (such as phenyl, pyrrol-1-yl, tetrazol-5-yl, triazol-4-yl, pyridyl, pyrimidyl, pyrazinyl, imidazolyl, indolyl, piperidyl, piperazinyl, and the like) substituted (as herein defined) aryl, or —SO 2 Q or —C(═O)Q, where Q is C 1 -C 6 alkyl, halosubstituted C 1 -C 6 alkyl, aryl (as herein defined), substituted (as herein defined) aryl or amino. Heteroatoms in R 2 can be derivatised, such as with C 1 -C 6 alkyl, oxo and the like. The optional R 2 substituent may be ortho or meta to the bond to the (thio)urea function but is preferably para.
[0020] Preferred optional substituents to R 2 include ethynyl, phenoxy, pyrrid-1-yl, cyclopropyl, phenyl, halo-substituted phenyl (especially para and meta chloro and fluorophenyl), and dimethylamino. Particularly preferred R 2 substituents include halo (F, Br, Cl and l) and cyano. Preferred halo groups include Cl.
[0021] The currently preferred value for R 3 is H.
[0022] Preferably R4 is hydrogen, halo or hydroxy, especially fluoro.
[0023] Preferably R 5 is halo, C 1-3 alkylcarbonyl, C1-3alkyloxy or H, especially fluoro and most preferably H.
[0024] Preferably R 6 is hydrogen, halo, C 1 -C 3 alkyloxy, C1-3alkylcarbonyl, cyano or ethynyl, especially methoxy or fluoro and most preferably H.
[0025] Preferably R 7 is hydrogen, halo, C 1-3 alkyloxy, or C 1-3 alkylcarbonyl, most preferably fluoro.
[0026] Preferably R 5 and R 6 are H and R4 and R 7 are halo, most preferably both are fluoro.
[0027] Preferably D is —O—, n is 0, m is 1, R 1 is O, R 2 is substituted pyrid-2-yl and R 3 is H. An alternative preferred embodiment embraces compounds wherein D is —O—, n is 0, m is 1, R 1 is S, R 2 is substituted pyrid-2-yl and R 3 is H.
[0028] The compounds of formula I may be administered as a racemic mixture, but preferably the cyclopropyl moiety intermediate the (thio)urea function, X and the phenyl ring (denoted Y below) is at least 75% such as around 90% enantiomerically pure with respect to the conformation:
[0029] Prefered optical isomers of the compounds of formula I show a negative
optical rotation value. Such isomers, for example when X is —O—CH 2 —, tend to elute less rapidly from a chiral chromatagram, for example chiral AGP 150×10 mm, 5 μm; Crom Tech LTD Colomn, flow rate 4 ml/min, mobile phase 89 vol % 10 mM HOAc/NH 4 OAc in acetonitrile. On the basis of preliminary x-ray crystallography analysis a presently favoured absolute configuration appears to be:
[0030] The currently preferred value for D is —O—. Convenient values for n and m include 1:0 and 1:1. Preferred values of n:m include 0:2 and especially 0:1, that is a chroman derivative. Particularly preferred compounds have 5 stereochemistry corresponding to (1S,1aR,7bR)-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl. For the sake of clarity, it is noted that the structure:
[0031] The expression C 1 -C n alkyl, where n is 3, 6, 7 etc or lower alkyl includes such groups as methyl, ethyl, n-propyl, isopropyl, n-butyl, s-butyl, t-butyl, n-pentyl, n-hexyl, 3-methyl pentyl and the like. The term halo refers to chloro, bromo, fluoro and iodo, especially fluoro. C 1 -C n alkoxy refers to groups such as methoxy, ethoxy, propoxy, t-butoxy and the like. C 2 -C n alkenyl, refers to groups such as vinyl, 1-propen-2-yl, 1-buten-4-yl, I-penten-5-yl, 1-buten-1-yl and the like. C 1 -C n alkylthio includes methylthio, ethylthio, t-butylthio and the like. C 1 -C n alkanoyloxy includes acetoxy, propionoxy, formyloxy, butyryloxy and the like. C 2 -C n alkenoxy includes ethenyloxy, propenyloxy, iso-butoxyethenyl and the like. HaloC 1 -C n alkyl (including complex substituents comprising this moiety such as haloC 1 -C n alkyloxy) includes alkyls as defined herein substituted 1 to 3 times by a halogen including trifluormethyl, 2-dichloroethyl, 3,3-difluoropropyl and the like. The term amine includes goups such as NH 2 , NHMe, N(Me) 2 which may optionally be substituted with halogen, C 1 -C 7 acyloxy, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, nitro, carboxy, carbamoyl, carbamoyloxy cyano, methylsulphonylamino and the like. Carboxy, carboxymethyl and carbamoyl include the corresponding pharmaceutically acceptable C 1 -C 6 alkyl and aryl esters.
[0032] Prodrugs of the compounds of formula I are those compounds which following administration to a patient release a compound of the formula I in vivo. Typical prodrugs are pharmaceutically acceptable ethers and especially esters (including phosphate esters) when any of R 4 -R 7 or the optional substituent to R 2 represent an hydroxy function, pharmaceutically acceptable amides or carbamates when any of the R 2 substituent or R 4 -R 7 represent an amine function or pharmaceutically acceptable esters when the R 2 substituent or R 4 -R 7 represent a carboxy function.
[0033] The compounds of formula I can form salts which form an additional aspect of the invention. Appropriate pharmaceutically acceptable salts of the compounds of formula I include salts of organic acids, especially carboxylic acids, including but not limited to acetate, trifluoroacetate, lactate, gluconate, citrate, tartrate, maleate, malate, pantothenate, isethionate, adipate, alginate, aspartate, benzoate, butyrate, digluconate, cyclopentanate, glucoheptanate, glycerophosphate, oxalate, heptanoate, hexanoate, fumarate, nicotinate, palmoate, pectinate, 3-phenylpropionate, picrate, pivalate, proprionate, tartrate, lactobionate, pivolate, camphorate, undecanoate and succinate, organic sulphonic acids such as methanesulphonate, ethanesulphonate, 2-hydroxyethane sulphonate, camphorsulphonate, 2-napthalenesulphonate, benzenesulphonate, p-chlorobenzenesulphonate and p-toluenesulphonate; and inorganic acids such as hydrochloride, hydrobromide, hydroiodide, sulphate, bisulphate, hemisulphate, thiocyanate, persulphate, phosphoric and sulphonic acids.
[0034] Hydroxy protecting group as used herein refers to a substituent which protects hydroxyl groups against undesirable reactions during synthetic procedures such as those O-protecting groups disclosed in Greene, “Protective Groups In Organic Synthesis,”(John Wiley & Sons, New York (1981)). Hydroxy protecting groups comprise substituted methyl ethers, for example, methoxymethyl, benzyloxymethyl, 2-methoxyethoxymethyl, 2-(trimethylsilyl)ethoxymethyl, t-butyl and other lower alkyl ethers, such as isopropyl, ethyl and especially methyl, benzyl and triphenylmethyl; tetrahydropyranyl ethers; substituted ethyl ethers, for example, 2,2,2-trichloroethyl; silyl ethers, for example, trimethylsilyl, t-butyldimethylsilyl and t-butyldiphenylsilyl; and esters prepared by reacting the hydroxyl group with a carboxylic acid, for example, acetate, propionate, benzoate and the like.
[0035] The invention further provides pharmaceutical compositions comprising the compounds of the invention and pharmaceutically acceptable carriers or diluents therefor. Additional aspects of the invention provide methods for the inhibition of HIV comprising administering a compound of the formula I to a subject afflicted with or exposed to HIV-1. The HIV-1 may comprise a drug escape mutant, such as HIV strain comprising the mutations at the 100, 103 and/or 181 mutations, especially K103N.
[0036] The invention also extends to the use of the compounds of formula I in therapy, such as in the preparation of a medicament for the treatment of HIV infections.
[0037] In treating conditions caused by HIV, the compounds of formula I are preferably administered in an amount to achieve a plasma level of around 100 to 5000 nM, such as 300 to 2000 nM. This corresponds to a dosage rate, depending on the bioavailability of the formulation, of the order 0.01 to 10 mg/kg/day, preferably 0.1 to 2 mg/kg/day. A typical dosage rate for a normal adult will be around 0.05 to 5 g per day, preferably 0.1 to 2 g such as 500-750 mg, in one to four dosage units per day. As with all pharmaceuticals, dosage rates will vary with the size and metabolic condition of the patient as well as the severity of the infection and may need to be adjusted for concomitant medications.
[0038] In keeping with the usual practice with HIV inhibitors it is advantageous to co-administer one to three additional antivirals to provide synergistic responses and to ensure complementary resistance patterns. Such additional antivirals may include AZT, ddI, ddC, D4T, 3TC, DAPD, alovudine, abacavir, adefovir, adefovir dipivoxil, bis-POC-PMPA, GW420 867X, foscarnet, hydroxyurea, Hoechst-Bayer HBY 097, efavirenz, trovirdine, capravirine, nevirapine, delaviridine, tipranavir, emtricitabine, PFA, H2G (omaciclovir), MIV-606 (valomaciclovir stearate), TMC-126, TMC-125, TMC-120, efavirenz, DMP-450, loviride, ritonavir, (including kaletra), lopinavir, saquinavir, lasinavir, indinavir, amprenavir, amprenavir phosphate, nelfinavir and the like, typically at molar ratios reflecting their respective activities and bioavailabilities. Generally such ratio will be of the order of 25:1 to 1:25, relative to the compound of formula I, but may be lower, for instance in the case of cytochrome antagonists such as ritonavir.
[0039] Compounds of the invention are typically prepared as follows:
[0040] Compounds of the general formula (I), wherein R 1 , is O (urea) or S (thiourea), R 2 is, for instance, a 5-substituted pyrid-2-yl, and R 3 is H, are prepared by methods shown in Scheme 1. The cyclopropanecarboxylic acid 1-Scheme-1 is converted to the acyl azide and heated to 120° C. to induce Curtius rearrangement and provide the isocyanate 2-Scheme-1. The urea 3-Scheme-1 is obtained by coupling of the isocyanate with the relevantly substituted 2-aminopyridine. Hydrolysis of the isocyanate as in step (c) which results in the cyclopropylamine 4-Scheme-1, followed by reaction with a 2-pyridyl isothiocyanate provides the thiourea 5-Scheme-1. The isothiocyanate may be prepared from the optionally ring substituted 2-aminopyridine by known methods, such as treatment with thiophosgene or thiocarbonyldiimidazole. R 3 variants of formula I are prepared correspondingly using the appropriately amine-substituted amino-R 2 , ie 2-(N-methylamino)pyridine for R 3 as methyl. Many 2-aminopyridines are commercially available and others are described in literature, for example those shown in Scheme 2. R 1 ═S compounds can alternatively be prepared from the isothiocyanate corresponding to 2-Scheme 2 or from amine 3-Scheme 2 and amino-R 2 in conjunction with an RC(═S)R′ both as described in WO 9303022. Although Scheme 1 has been illustrated with a substituted pyridyl it is readily apparent that corresponding couplings can be used for other R 2 variants such as optionally substituted thiazolyl, pyrazinyl, benzothiazolyl, pyrimidinyl etc.
[0041] Replacement of the bromine in 5-bromo-2-nitropyridine by a phenoxy group, followed by reduction of the nitro group affords the 2-amino-5-phenoxypyridine. The Sonogashira coupling of 2-amino-5-iodopyridine with the terminal alkyne SiMe 3 C≡CH in the presence of catalytic amounts of bis(triphenylphosphine)palladium dichloride and cuprous iodide as in step (c) provides the 2-amino-5-(2-trimethylsilylethynyl)pyridine. Removal of the silyl group by TBAF yields 2-amino-5-ethynylpyridine which can be coupled to the isocyanate as described in Scheme 1. Alternatively, treatment with TBAF may be performed on the urea 3-Scheme-1 or thiourea 5-Scheme-1 where R10 is —C≡CSiMe 3 to convert R10 to —C≡CH.
[0042] Compounds of the general formula (I), wherein R1 is O (urea) or S (thiourea), R2 is, for example, a 5-substituted pyrid-2-yl, R3 is H, X is -D-CH 2 , and wherein the cyclopropyl moiety has the relative configuration
are prepared by methods shown in Scheme 3. Cyclopropanation of the double bond in the chromene 1-Scheme-3 with ethyl diazoacetate is catalyzed by cuprous or rhodium(II) salts such as Cul, (CuOTf) 2 -benzene, and Rh 2 (OAc) 4 in solvents such as dichloromethane, 1,2-dichloroethane, or chloroform. The reaction provides a diastereomeric mixture of the cyclopropanecarboxylic acid ethyl esters 2-Scheme-3, with the all cis relative configuration, and its trans isomer 3-Scheme-3. Separation by column chromatography of the cis and trans diastereomers may be accomplished at this stage, followed by hydrolysis of the isolated 2-Scheme-3, such as by refluxing in aqueous methanolic LiOH, to yield a racemic mixture of the all cis cyclopropanecarboxylic acid 4-Scheme-3, as described in step (b). Alternatively, the diastereomeric mixture of ethyl esters may be subjected to hydrolysis, and separation conducted on the mixture of cyclopropanecarboxylic acids to provide the isolated all cis isomer, as in step (c). Step (d) involves isolation of the cis ethyl ester 2-Scheme-3 which may also be done by selective hydrolysis of the trans 3-Scheme-3 at lower temperatures, such as treatment with aqueous methanolic NaOH at ambient temperature. The isolated cis ethyl ester may then be hydrolyzed in the usual manner to the cyclopropanecarboxylic acid 4-Scheme-3. The cyclopropanecarboxylic acid is subjected to the methods outlined in Scheme 1 to obtain the urea or thiourea 5-Scheme-3. The chromenes 1-Scheme-3 are prepared by methods shown in Schemes 4, 5, and 6.
[0043] Although this scheme 3 has been illustrated with a D═O variant it will be apparent that corresponding manipulations will be available to the D═S, S═O; S(═O) 2 and D═NR8 variants. When R8 is H, the nitrogen is typically protected with a conventional secondary amine protecting group, such as those described in Greene & Wuts Protective Groups in Organic Synthesis 2 nd ed, Wiley N.Y. 1991).
[0044] Scheme 4 describes the preparation of chromenes, including many from commercially available disubstituted phenols, such as those wherein the substitution pattern in the benzene ring is as follows: R4 and R7 are halo; R4 and R6 are halo; R5 and R7 are halo; R4 is halo and R7 is C 1-3 alkylcarbonyl; and R4 is hydroxy while R5 is C 1-3 alkylcarbonyl. Reaction of the available disubstituted phenol 1-Scheme-4 with 3-bromopropyne in the presence of a base, such as K 2 CO 3 in acetone or NaH in DMF, results in nucleophilic substitution of the halide to provide the ether 2-Scheme-4. Ring closure may be accomplished by heating the ether in N,N-dimethylaniline or polyethylene glycol to yield the chromene 3-Scheme-4.
[0045] Scheme 5 describes the preparation of chromenes, used as starting material in Scheme 3, from the appropriately substituted chromanones, which are readily accessed from commercially available chromanones, for example those wherein one of the positions in R4 to R7 is substituted with halo or C 1-3 alkoxy. Conversion of the carbonyl group in 4-chromanone 1a-Scheme-5 and to the correponding alcohol by a suitable reducing agent such sodium borohydride in ethanol provides 2-Scheme-5. Refluxing the alcohol with small amounts of acid, such as p-TsOH in toluene, causes dehydration of 2-Scheme-5 to the desired chromene 1-Scheme-3. Corresponding manipulations will be available for other D variants. For example the corresponding 2H-1-benzothiopyran is readily prepared from commercially available (substituted) thiochroman-4-ones by reaction with a reductant such as a metal hydride for example lithium aluminium hydride in an organic solvent such as ether, followed by dehydration such as refluxing with an acid for example potassium acid sulphate or the like.
[0046] Chromenes, for use as starting material in Scheme 3, are prepared from substituted o-hydroxybenzaldehydes as shown by methods outlined in Scheme 6. Reaction of 1-Scheme-6 with allyl bromide in the presence of a base, such as K 2 CO 3 in acetone, results in nucleophilic substitution of the halide to provide the ether 2-Scheme-6. Witting reaction transforms the aldehydic group into the olefin and provides 3-Scheme-6. The pair of terminal double bonds may undergo metathesis intramolecularly by treatment with a catalyst such as the ruthenium complex Grubb's catalyst in step (c) to produce the chromene. Alternatively 1-Scheme-6 can be cyclised directly as shown in step d) in the legend above.
[0047] Pd(0) catalyzed coupling of the triflate 1-Scheme-7 leads to the replacement of the trifluoromethanesulfonyloxy group and the introduction of other substiutents at R6. Thus, Scheme 7 provides the preparation of synthesis intermediates for use in scheme 3 to give the urea or thiourea 5-Scheme-3 wherein R6 is cyano, ethynyl, or C 1-3 alkylcarbonyl.
[0048] Convenient routes to compounds wherein X is —CH 2 —O—are depicted in Scheme 8, where R a and R b are optional substituents R 4 -R 7 , which are suitably protected with conventional protecting groups as necessary and Rc is a lower alkyl ester. Optionally substituted phenol 1-Scheme-8 which is hydroxy-protected with a protecting group such as methyl, MOM and the like is reacted with a base such as BuLi or the like in a solvent such as THF or the like and transformed to zinc salt by adding zinc chloride or the like. A catalyst such as Pd(OAc) 2 or the like is added along with an activated acrylate such as lower alkyl-cis-3-haloacrylate, for example BrCH═CHCOOEt or the like. The reaction mixture is cooled and a reducing agent such as DIBAL or the like is added portionwise and quenched to yield 2-Scheme-8. A hydrazone such as the p-toluenesulfonylhydrazone of glyoxylic acid chloride or the like and a base such as N,N-dimethylaniline or the like is added in a solvent such as CH 2 Cl 2 or the like followed by the addition of another base such as Et 3 N or the like to yield 3-Scheme-8. The reaction product is dissolved in a solvent such as dichloromethane or the like which is preferably degassed. A chiral Doyle's catalyst such as Rh 2 (5-R-MEPy) 4 (U.S. Pat. No. 5,175,311, available from Aldrich or Johnson Matthey), or the like is added to yield 4-Scheme-8 in a high enantiomeric excess such as greater than 80, preferably greater than 90% ee. Preferably, this compound is first reacted with BBr 3 in dichloromethane followed by the addition of acetonitrile the reaction mixture and finally sodiumhydroxide is added to give 6-Scheme-8. Alternatively, this product (4-Scheme-8) is ring-opened with an electrophile preferably HBr or the like under in conjunction with an acid such as AcOH or the like. Under acid conditions a spontaneous ring closure takes place to form chromenone 5-Scheme-8. When subjected to basic conditions such as NaOH or the like, the chromenone rearranges to form the chromencyclopropylcarboxylic acid 6-Scheme-8. Alternatively, 4-Scheme-8, for instance when the phenolic protecting group is MOM, can be subjected to basic conditions such as NaOH, carbon dioxide and a lower alkyl halide such as iPrl in a solvent such as DMSO to open the lactone and yield the alkyl ester 7-Scheme-8. Displacement of the hydroxy protecting group and ring closure with the free hydroxymethyl moiety occurs in acidic conditions such as iPrOH/HCl or the like followed by DEAD; PPH 3 in an organic solvent such as THF or the like.
[0049] Alternatively, in a convergent approach, compound 1-Scheme-8 is reacted with BuLi and transformed to a zinc salt. This salt reacted with the cyclopropyliodide, 9-Scheme-8, in a palladium-catalyzed reaction to give after reaction with Jone's reagent compound 4-Scheme-8. This carboxylic acid is in turn converted to the isocyanate as shown in Scheme 1 and subsequently to the heteroarylurea or heteroarylthiourea of the Formula I.
[0050] A further aspect of the invention provides novel intermediates useful in the above described syntheses of the compound of formula I. A preferred group of intermediates include compounds of the formula II:
where X and R 4 -R 7 are as defined above and R 11 is —C(O)OR 12 , where R 12 is H or a carboxy protecting group such as a lower alkyl ester; —NCO, —NCS or an amine such as NH 2 . A favoured subset of the compounds of formula II have the formula III:
where R 4 and R 7 are independently halo, most preferably fluoro, and R 11 is —COOH, a lower alkyl ester thereof, isocyanate, isothiocyanate or amino.
[0051] A further group of preferred intermediates includes compounds of the formula IV
where R4 to R 7 are as defined above, PG is an hydroxy protecting group and PG* is an hydroxy protecting group or together with the adjacent O defines a keto function.
[0052] A preferred subset of compounds of formula IV are those of formula V:
where R 4 and R 7 are independently halo, most preferably fluoro, PG is lower alkyl, such as isopropyl, ethyl and most preferably methyl and PG* is lower alkyl such as isopropyl, ethyl and most preferably methyl or together with the adjacent O defines a keto group
[0053] A still further group of preferred intermediates includes compounds of the formula VI:
where R 4 -R 7 are as defined above, PG is an hydroxy protecting group and R 13 is H, an ester thereof or an hydroxy protecting group. A preferred subset within formula VI has the formula VII:
where R 4 and R 7 are independently halo, preferably fluoro, PG is lower alkyl, such as isopropyl, ethyl and most preferably methyl and R 12 is H or —C(═O)CH═N═N.
[0054] Favoured compounds of formula I include
cis-1-(5-Cyano-pyridin-2-yl)-3-(1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-yl)-urea, cis-1-(5-Cyano-pyridin-2-yl)-3-(1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]naphthalen-1-yl)-urea, cis-1-(5-Cyano-pyridin-2-yl)-3-(7-hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea, cis-1-(6-Acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea, cis-1-(5-Cyanopyridin-2-yl)-3-(7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea, cis-1-(5-Cyano-pyridin-2-yl)-3-(7-fluoro-4-methoxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea, cis-1-(5-Cyano-pyridin-2-yl)-3-(7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea, cis-1-(5-Chloro-pyridin-2-yl)-3-(4-chloro-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-yl)-urea, cis-1-(5-Bromo-pyridin-2-yl)-3-(4-chloro-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-yl)-urea, cis-1-(5-Cyano-pyridin-2-yl)-3-(5-cyano-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea, cis-1-(5-Cyano-pyridin-2-yl)-3-(5-ethynyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea, cis-1-(5-Acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea, cis-1-(5-Methoxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl )-3-(5-cyano-pyridin-2-yl)-urea, cis-1-(5-Cyano-pyridin-2-yl)-3-(N-acetyl-1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]quinoline-1-yl))-urea, cis-1-(5-Cyano-3-methyl-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea, cis-1-(4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl )-3-(5-ethynyl-pyridin-2-yl)-urea, cis-1-(5-Bromo-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea, cis-1-(4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-phenoxy-pyridin-2-yl)-urea, cis-1-(5-Cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-thiourea, 1-(6-Chloro-5-cyano-pyridin-2-yl)-3-(5,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)urea, 1-(5-Cyano-pyridin-2-yl )-3-(5,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)urea, cis-1-(4-Bromo-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea, cis-1-(4-Bromo-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(6-chloro-5-cyano-pyridin-2-yl)-urea, cis-1-(4-Bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea, cis-1-(4-Bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(6-cloro-5-cyano-pyridin-2-yl)-urea, cis-1-(5-Cyanopyridin-2-yl)-3-(6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)urea, cis N-[1a,6b-dihydro-1H-benzo[b]cyclopropa[d]thien-1-yl]-N′-(5-cyano-2-pyridinyl)-urea, N-[(1S,1aR,7bR) or (1R,1aS,7bS)-1,1a,2,7b-tetrahydrocyclopropa[c]-[1]benzothiopyran-1-yl]-N′-(5-cyano-2-pyridinyl)urea, cis-N-(5-bromo-2-pyridinyl)-N′-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea, cis-N-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)-N′-(5-chloro-2-pyridinyl)urea, cis-N-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)-N′-(5-cyano-2-pyridinyl)urea, cis-N-(5-phenoxy-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea, cis-N-(5-bromo-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea, cis-N-(5-chloro-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea, cis-N-(5-cyano-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea, N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(5-fluoro-2-pyridinyl)urea, N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(5-iodo-2-pyridinyl)urea, N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(3-isoxazolyl)urea, N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-[4-(4-chlorophenyl)-1,3-thiazol-2-yl]urea, N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(6-fluoro-1,3-benzothiazol-2-yl)urea, N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(4-pyrimidinyl)urea N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(2-pyrazinyl)urea, N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(5-cyclopropyl-1H-pyrazol-3-yl)urea
and pharmaceutically acceptable salts thereof, especially enantiomerically enriched, for example greater than 80% by weight, preferably >90%, such as >97% ee or pure preparations comprising the (−) enantiomer.
[0098] Particularly preferred compound thus include
(−)-cis-1-(5-Cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea, (−) cis-1-(5-Chloro-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea; or (−)-cis-1-(5-Cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-thiourea; (−)-cis-1-(5-Fluoropyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea, (−)-cis-1-(5-Fluoropyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-thiourea;
and pharmaceutically acceptable salts thereof.
[0104] While it is possible for the active agent to be administered alone, it is preferable to present it as part of a pharmaceutical formulation. Such a formulation will comprise the above defined active agent together with one or more acceptable carriers or excipients and optionally other therapeutic ingredients. The carrier(s) must be acceptable in the sense of being compatible with the other ingredients of the formulation and not deleterious to the recipient.
[0105] The formulations include those suitable for rectal, nasal, topical (including buccal and sublingual), vaginal or parenteral (including subcutaneous, intramuscular, intravenous and intradermal) administration, but preferably the formulation is an orally administered formulation. The formulations may conveniently be presented in unit dosage form, e.g. tablets and sustained release capsules, and may be prepared by any methods well known in the art of pharmacy.
[0106] Such methods include the step of bringing into association the above defined active agent with the carrier. In general, the formulations are prepared by uniformly and intimately bringing into association the active agent with liquid carriers or finely divided solid carriers or both, and then if necessary shaping the product. The invention extends to methods for preparing a pharmaceutical composition comprising bringing a compound of Formula I or its pharmaceutically acceptable salt in conjunction or association with a pharmaceutically acceptable carrier or vehicle. If the manufacture of pharmaceutical formulations involves intimate mixing of pharmaceutical excipients and the active ingredient in salt form, then it is often preferred to use excipients which are non-basic in nature, i.e. either acidic or neutral. Formulations for oral administration in the present invention may be presented as discrete units such as capsules, cachets or tablets each containing a predetermined amount of the active agent; as a powder or granules; as a solution or a suspension of the active agent in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid emulsion or a water in oil liquid emulsion and as a bolus etc.
[0107] With regard to compositions for oral administration (e.g. tablets and capsules), the term suitable carrier includes vehicles such as common excipients e.g. binding agents, for example syrup, acacia, gelatin, sorbitol, tragacanth, polyvinylpyrrolidone (Povidone), methylcellulose, ethylcellulose, sodium carboxymethylcellulose, hydroxypropylmethylcellulose, sucrose and starch; fillers and carriers, for example corn starch, gelatin, lactose, sucrose, microcrystalline cellulose, kaolin, mannitol, dicalcium phosphate, sodium chloride and alginic acid; and lubricants such as magnesium stearate, sodium stearate and other metallic stearates, stearic acid, glycerol stearate, silicone fluid, talc waxes, oils and colloidal silica. Flavouring agents such as peppermint, oil of wintergreen, cherry flavouring or the like can also be used. It may be desirable to add a colouring agent to make the dosage form readily identifiable. Tablets may also be coated by methods well known in the art. A tablet may be made by compression or moulding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active agent in a free flowing form such as a powder or granules, optionally mixed with a binder, lubricant, inert diluent, preservative, surface-active or dispersing agent. Moulded tablets may be made by moulding in a suitable machine a mixture of the powdered compound moistened with an inert liquid diluent. The tablets may be optionally be coated or scored and may be formulated so as to provide slow or controlled release of the active agent.
[0108] Other formulations suitable for oral administration include lozenges comprising the active agent in a flavoured base, usually sucrose and acacia or tragacanth; pastilles comprising the active agent in an inert base such as gelatin and glycerin, or sucrose and acacia; and mouthwashes comprising the active agent in a suitable liquid carrier.
DETAILED DESCRIPTION
[0109] Various aspects of the invention will now be illustrated by way of example only with reference to the following non-limiting examples.
EXAMPLE 1
(±) cis-1-(5-Cyano-pyridin-2-yl)-3-(1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-yl)-urea.
[0110] a) ±cis-1,1a,2,7b-Tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0111] To a mixture of 2H-chromene (4.89 g, 37 mmol) and (CuOTf) 2 -benzene (186 mg, 0.37 mmol) in 1,2-dichloroethane (80 mL) at 20° C., was added dropwise (3 h) a solution of ethyl diazoacetate (8.44 g, 74 mmol) in 1,2-dichloroethane (20 mL). After 15 min at 20° C., the reaction mixture was washed with H 2 O (100 mL). The H 2 O phase was washed with CH 2 Cl 2 (50 mL) and the solvent of the combined organic phases was removed under reduced pressure. The crude product was column chromatographed (silica gel, 20→50% EtOAc in hexane), to give 1.96 g (24%) of ±cis-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester and 3.87 g (48%) of ±-trans-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester as a byproduct.
[0112] 1 H-NMR (CDCl 3 ): 7.26 (d, 1H), 7.10 (dd, 1H), 6.90 (dd, 1H), 6.78 (d, 1H), 4.49 (dd, 1H), 4.20 (dd, 1H), 3.97 (q, 2H), 2.44 (dd, 1H), 2.14 (dd, 1H), 2.07-1.95 (m, 1H), 1.02 (t, 3H).
b) (±)-cis-1,1a,2,7b-Tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0113] A mixture of (±)-cis-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (1.96 g, 9.0 mmol), LiOH (539 mg, 22.5 mmol), H 2 O (10 mL) and MeOH (20 mL) was heated to reflux for 2 h. The reaction mixture was concentrated to about 10 mL, 4N HCl was added dropwise giving a white precipitate. The reaction mixture was extracted with CH 2 Cl 2 (3×15 mL) and the solvent of the combined organic phases was removed under reduced pressure. The crude product was crystallized from EtOAc/hexane, to give 435 mg (25%) of (±)-cis-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid as a white solid.
[0114] 1 H-NMR (CDCl 3 ): 9.80 (br s, 1H), 7.22 (d, 1H), 7.10 (dd, 1H), 6.89 (dd, 1H), 6.77 (d, 1H), 4.45 (dd, 1H), 4.22 (dd, 1H), 2.45 (dd, 1H), 2.14-1.98 (m, 2H).
c) (±)-cis-1-(5-Cyano-pyridin-2-yl)-3-(1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-yl)-urea.
[0115] To a solution of (±)-cis-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (285 mg, 1.5 mmol) and triethylamine (209 μL, 1.5 mmol) in toluene (1.5 mL) at 20° C., was added diphenylphosphoryl azide (413 mg, 1.5 mmol). After 30 min at 20° C., the reaction mixture was heated to 120° C. for 15 min, where after a solution of 2-amino-5-cyano-pyridine (197 mg, 1.65 mmol) in DMF (1 mL) was added. After 3 h at 120° C., the reaction mixture was allowed to assume room temperature. The reaction mixture was concentrated under reduced pressure, benzene (20 mL) was added and the reaction mixture was washed with 1 N HCl (30 mL), H 2 O (30 mL) and brine (30 mL). The solvent of the organic phases was removed under reduced pressure. The crude product was crystallized from EtOH/CH 2 Cl 2 , to give 133 mg (29%) of (±)-cis-1-(5-cyano-pyridin-2-yl)-3-(1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-yl)-urea.
[0116] 1 H-NMR (DMSO-d 6 ): 9.78 (s, 1H), 8.31 (d, 1H), 7.99 (dd, 1H), 7.83 (d, 1H), 7.43 (d, 1H), 7.27 (d, 1H), 7.09 (dd, 1H), 6.89 (dd, 1H), 6.80 (d, 1H), 4.25 (dd, 1H), 4.14 (dd, 1H), 3.43 (m, 1H), 2.35 (dd, 1H), 1.92 (m, 1H).
EXAMPLE 2
(±)-cis-1-(5-Cyano-pyridin-2-yl)-3-(1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]naphthalen-1-yl)-urea
[0117] a) (±)-cis-1,1a,3,7b-Tetrahydro-2-oxa-cyclopropa[a]naphthalene-1-carboxylic acid ethyl ester
[0118] (±)-cis-1,1a,3,7b-Tetrahydro-2-oxa-cyclopropa[a]naphthalene-1-carboxylic acid ethyl ester was synthesized analogously to Example 1a from 1H-isochromene (3.57 g, 27 mmol), to give 910 mg (15%) of (±)-cis-1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]naphthalene-1-carboxylic acid ethyl ester.
[0119] 1 H-NMR (CDCl 3 ): 7.34 (d, 1H), 7.25 (dd, 1H), 7.18 (dd, 1H), 7.03 (d, 1H), 4.81 (d, 1H), 4.51 (d, 1H), 4.28 (dd, 1H), 3.95 (q, 2H), 2.43 (dd, 1H), 2.05 (dd, 1H), 1.04 (t, 3H).
b) (±)-cis-1,1a,3,7b-Tetrahydro-2-oxa-cyclopropa[a]naphthalene-1-carboxylic acid
[0120] (±)-cis-1,1a,3,7b-Tetrahydro-2-oxa-cyclopropa[a]naphthalene-1-carboxylic acid was synthesized analogously to Example 1b from (±)-cis-1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]naphthalene-1-carboxylic acid ethyl ester (436 mg, 2 mmol), to give 86 mg (22%) of (±)-cis-1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]-naphthalene-1-carboxylic acid as a white solid. The crude product was column chromatographed (silica gel, 1→5% MeOH in CH 2 Cl 2 ).
[0121] 1 H-NMR (CDCl 3 ): 8.50 (br s, 1H), 7.39 (d, 1H), 7.30 (dd, 1H), 7.21 (dd, 1H), 7.07 (d, 1H), 4.87 (d, 1H), 4.57 (d, 1H), 4.38 (dd, 1H), 2.59 (dd, 1H), 2.15 (dd, 1H).
c) (±)-cis-1-(5-Cyano-pyridin-2-yl)-3-(1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]naphthalen-1-yl)-urea
[0122] (±)-cis-1-(5-Cyano-pyridin-2-yl)-3-(1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]naphthalen-1-yl)-urea was synthesized analogously to example 1c from (±)-cis-1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]naphthalene-1-carboxylic acid (86 mg, 0.45 mmol). The crude product was column chromatographed (silica gel, 1→5% MeOH in CH 2 Cl 2 ), to give 21 mg (15%) of (±)-cis-1-(5-cyano-pyridin-2-yl)-3-(1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]naphthalen-1-yl)-urea.
[0123] 1 H-NMR (DMSO-d 6 ): 9.62 (s, 1H), 8.29 (d, 1H), 7.98 (dd, 1H), 7.52-7.44 (m, 2H), 7.27-7.05 (m, 4H), 4.69 (d, 1H), 4.45 (d, 1H), 4.05 (dd, 1H), 3.25-3.10 (m, 1H), 2.22 (dd, 1H).
EXAMPLE 3
(±)-cis-1-(5-Cyano-pyridin-2-yl)-3-(7-hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0124] a) 1-(2-Hydroxy-4-prop-2-ynyloxy-phenyl)-propan-1-one
[0125] A mixture of 2′,4′-dihydroxy-propiophenone (24.9 g, 0.15 mol), 3-bromo-propyne (24.2 g, 0.20 mol) and K 2 CO 3 (20.7 g, 0.15 mol) in acetone (500 mL) was refluxed for 12 h. The reaction mixture was allowed assume room temperature and the precipitate was removed by filtration. The filtrate was concentrated under reduced pressure. The crude product was purified by column chromatography (silica gel, 0→2% MeOH in H 2 O), to give 26.2 g (85%) of 1-(2-hydroxy-4-prop-2-ynyloxy-phenyl)-propan-1-one.
[0126] 1 H-NMR (CDCl 3 ): 12.80 (s, 1H), 7.69 (d, 1H), 6.52 (m, 2H), 4.72 (d, 2H), 2.96 (q, 2H), 2.56 (t, 1H), 1.23 (t, 3H).
3b) 1-(5-Hydroxy-2H-chromen-6-yl)-propan-1-one.
[0127] A mixture of 1-(2-hydroxy-4-prop-2-ynyloxy-phenyl)-propan-1-one (19.8 g, 97 mmol) and N,N-diethylaniline (100 mL) was heated to reflux for 3 h. The reaction mixture was concentrated under reduced pressure. The crude product was purified by column chromatography (silica gel, 5→10% EtOAc in Hexane) and thereafter recrystallized from EtOAc/Hexane, to give 8.91 g (45%) of 1-(5-hydroxy-2H-chromen-6-yl)-propan-1-one. 1 H-NMR (CDCl 3 ): 13.00 (s, 1H), 7.49 (d, 1H), 6.75 (dt, 1H), 6.27 (d, 1H), 5.67 (dt, 1H), 4.86 (dd, 2H), 2.90 (q, 2H), 1.19 (t, 3H).
3c) 7-Hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0128] To a mixture of 1-(5-hydroxy-2H-chromen-6-yl)-propan-1-one (511 mg, 2.5 mmol) and (Rh(II)Ac 2 ) 2 (11 mg, 0.025 mmol) in 1,2-dichloroethane (8 mL) at 20° C., was added dropwise (3 h) a solution of ethyl diazoacetate (571 mg, 5 mmol) in 1,2-dichloroethane (2 mL). After 15 min at 20° C., the reaction mixture was washed with H 2 O (10 mL). The H 2 O phase was washed with CH 2 Cl 2 (10 mL) and the solvent of the combined organic phases was removed under reduced pressure. The crude product was purified by column chromatography (silica gel, 1→5% MeOH in CH 2 Cl 2 ), to give 300 mg (41%) of 7-hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (a 33/64 mixture of cis and trans isomers).
[0129] 1 H-NMR (CDCl 3 ): 13.13-13.07 (m, 1H), 7.57-7.49 (m, 1H), 6.41-6.38 (m, 1H), 4.65-3.92 (m, 4H), 3.01-1.95 (m, 5H), 1.29-1.08 (m, 6H).
3d) (±)-cis-7-Hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0130] ±cis-7-Hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid was synthesized analogously to Example 2b from 7-hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (299 mg, 1.03 mmol, a 33/64 mixture of cis and trans isomers), to give 39.3 mg (15%) of (±)-cis-7-hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid as a white solid and (±)-trans-7-hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid as a byproduct. The crude product was purified by column chromatography (silica gel, 1→5% MeOH in CH 2 Cl 2 ).
[0131] 1 H-NMR (DMSO-d 6 ): 7.67 (d, 1H), 6.35 (d, 1H), 4.57 (dd, 1H), 4.36 (dd, 1H), 2.98 (q, 2H), 2.55-2.46 (m, 1H), 2.18-2.00 (m, 2H), 1.10 (t, 3H).
3e) (±)-cis-1-(5-Cyano-pyridin-2-yl)-3-(7-hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0132] (±)-cis-1-(5-Cyano-pyridin-2-yl)-3-(7-hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea was synthesized analogously to Example 1c from ±cis-7-hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (39.3 mg, 0.15 mmol). The crude product was purified by HPLC (C 18 , 5→95% acetonitrile in H 2 O), to give 2.9 mg (5.1%) of (±)-cis-1-(5-cyano-pyridin-2-yl)-3-(7-hydroxy-6-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0133] 1 H-NMR (DMSO-d 6 ): 13.15 (s, 1H), 9.71 (s, 1H), 8.30 (d, 1H), 8.01 (dd, 1H), 7.73 (d, 1H), 7.57 (d, 1H), 7.50 (d, 1H), 6.43 (d, 1H), 4.42 (dd, 1H), 4.13 (dd, 1H), 3.45-3.32 (m, 1H), 3.01 (q, 2H), 2.49-2.42 (m, 1H), 1.97-1.86 (m, 1H), 1.12 (t, 3H).
EXAMPLE 4
±cis-1-(6-Acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea
[0134] 4a) 1-(2-Hydroxy-4-prop-2-ynyloxy-phenyl)-ethanone
[0135] 1-(2-Hydroxy-4-prop-2-ynyloxy-phenyl)-ethanone was synthesized analogously to Example 3a from 1-(2,4-dihydroxy-phenyl)-ethanone (20 g, 131 mmol), to give 22 g (88%) of 1-(2-hydroxy-4-prop-2-ynyloxy-phenyl)-ethanone.
[0136] 1 H-NMR (CDCl 3 ): 12.70 (s, 1H), 7.66 (d, 1H), 6.52 (m, 2H), 4.72 (d, 2H), 2.58-2.55 (m, 4H).
4b) 1-(5-Hydroxy-2H-chromen-6-yl)-ethanone
[0137] 1-(5-Hydroxy-2H-chromen-6-yl)-ethanone was synthesized analogously to Example 3b from 1-(2-hydroxy-4-prop-2-ynyloxy-phenyl)-ethanone (17 g, 89 mmol), to give 6.0 g (35%) of 1-(5-hydroxy-2H-chromen-6-yl)-ethanone.
[0138] 1 H-NMR (CDCl 3 ): 12.92 (s, 1H), 7.51 (d, 1H), 6.79 (dt, 1H), 6.32 (d, 1H), 5.71 (dt, 1H), 4.89 (dd, 2H), 2.55 (s, 3H).
4c) 6-Acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester
[0139] 6-Acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (a 40/60 mixture of cis and trans isomers) was synthesized analogously to Example 3c from 1-(5-hydroxy-2H-chromen-6-yl)-ethanone.
[0140] 1 H-NMR (CDCl 3 ): 13.05-12.97 (m, 1H), 7.54-7.47 (m, 1H), 6.43-6.33 (m, 1H), 4.63-3.94 (m, 4H), 3.02-1.96 (m, 6H), 1.31-1.08 (m, 3H).
4d) 6-Acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0141] 6-Acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid was synthesized analogously to Example 1b from 6-acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (2 g, 8.1 mmol, a 40/60 mixture of cis and trans isomers), to give 300 mg (17%) of 6-acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (a 40/60 mixture of cis and trans isomers). The crude product was purified by column chromatography (silica gel, 1→5% MeOH in CH 2 Cl 2 )
[0142] 1 H-NMR (CDCl 3 ): 7.55-7.45 (m, 1H), 6.45-6.30 (m, 1H), 4.65-4.00 (m, 2H), 3.05-1.95 (m, 6H).
4e) (±)-cis-1-(6-Acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea
[0143] (±)-cis-1-(6-Acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea was synthesized analogously to Example 1c from 6-acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (300 mg, 1.21 mmol, a 40/60 mixture of cis and trans isomers). The crude product was purified by HPLC (C 18 , 5→95% acetonitrile in H 2 O), to give 7.7 mg (17%) of (±)-cis-1-(6-acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea and 9.0 mg (20%) of (±)-trans-1-(6-acetyl-7-hydroxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea as a byproduct.
[0144] 1 H-NMR (CDCl 3 +CD 3 OD): 7.98 (d, 1H), 7.74 (dd, 1H), 7.60 (d, 1H), 7.01 (d, 1H), 6.40 (d, 1H), 4.43 (dd, 1H), 4.29 (dd, 1H), 3.57 (dd, 1H), 2.69 (m, 1H), 2.61 (s, 3H), 2.00-1.86 (m, 1H).
EXAMPLE 5
(±)-cis-1-(5-Cyanopyridin-2-yl)-3-(7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0145] 5a) 1-(4-Fluoro-2-prop-2-ynyloxy-phenyl)-propan-1-one.
[0146] To a mixture of NaH (95%, 278 mg, 11 mmol) in DMF (20 mL) at 0° C., was added 1-(4-fluoro-2-hydroxy-phenyl)-propan-1-one (1.68 g, 10 mmol) in DMF (5 mL). After 15 min at 0° C., was 3-bromo-propyne (3.02 g, 20 mmol) added to the reaction mixture. After 1 h at 0° C., was the reaction mixture allowed to assume room temperature. The reaction mixture was extracted with H 2 O (100 mL). The H 2 O phase was washed with Et 2 O (3×100 mL) and the solvent of the combined organic phases was removed under reduced pressure. The crude product was purified by column chromatography (silica gel, CH 2 Cl 2 ), to give 1.40 g (68%) of 1-(4-fluoro-2-prop-2-ynyloxy-phenyl)-propan-1-one.
[0147] 1 H-NMR (CDCl 3 ): 7.64 (dd, 1H), 6.69 (dd, 1H), 6.60 (ddd, 1H), 4.68 (d, 2H), 2.85 (q, 2H), 2.58 (t, 1H), 1.03 (t, 3H).
5b) 1-(5-Fluoro-2H-chromen-8-yl)-propan-1-one.
[0148] 1-(5-Fluoro-2H-chromen-8-yl)-propan-1-one was synthesized analagously to Example 3b from 1-(4-fluoro-2-prop-2-ynyloxy-phenyl)-propan-1-one (1.34 g, 6.5 mmol), to give 619 mg (46%) of 1-(5-fluoro-2H-chromen-8-yl)-propan-1-one.
[0149] 1 H-NMR (CDCl 3 ): 7.60 (dd, 1H), 6.67-6.58 (m, 2H), 5.86 (dt, 1H), 4.76 (dd, 2H), 2.93 (q, 2H), 1.23 (t, 3H).
5c) (±)-cis-7-Fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0150] (±)-cis-7-Fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester was synthesized according to method 3c) from 1-(5-fluoro-2H-chromen-8-yl)-propan-1-one (619 mg, 3 mmol), to give 142 mg (16%) of (±)-cis-7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester and (±)-trans-7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester as a byproduct.
[0151] 1 H-NMR (CDCl 3 ): 7.59 (dd, 1H), 6.65 (m, 1H), 4.50-4.46 (m, 2H), 3.95 (q, 2H); 2.89 (q, 2H), 2.57 (dd, 1H), 2.20 (dd, 1H), 1.13-1.03 (m, 1H), 1.12-1.01 (m, 6H).
5d) (±)-cis-7-Fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0152] (±)-cis-7-Fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid was synthesized analogously to Example 1b from (±)-cis-7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (140.3 mg, 0.48 mmol), to give 83 mg (65%) of (±)-cis-7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid as a white solid. The crude product was purified by column chromatography (silica gel, 1→5% MeOH in CH 2 Cl 2 ).
[0153] 1 H-NMR (DMSO-d 6 ): 12.15 (br s, 1H), 7.46 (dd, 1H), 6.78 (dd, 1H), 4.57 (dd, 1H), 4.43 (dd, 1H), 2.93-2.80 (m, 2H), 2.55 (dd, 1H), 2.24 (dd, 1H), 2.20-2.10 (m, 1H), 1.02 (t, 3H).
5e) (±)-cis-1-(5-Cyanopyridin-2-yl)-3-(7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0154] (±)-cis-1-(5-Cyanopyridin-2-yl)-3-(7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea was synthesized analagously to Example 1c from (±)-cis-7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (81.9 mg, 0.31 mmol). The crude product was purified by HPLC (C 18 , 5→95% acetonitrile in H 2 O), to give 12 mg (10%) of (±)-cis-1-(5-cyanopyridin-2-yl)-3-(7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0155] 1 H-NMR (DMSO-d 6 ): 9.81 (s, 1H), 8.33 (d, 1H), 8.04 (dd, 1H), 7.83 (br s, 1H), 7.49-7.40 (m, 2H), 6.89 (dd, 1H), 4.41 (dd, 1H), 4.34 (dd, 1H), 3.46-3.38 (m, 1H), 2.76 (q, 2H), 2.56-2.46 (m, 1H), 2.09-1.98 (m, 1H), 0.93 (t, 3H).
EXAMPLE 6
(±)cis-1-(5-Cyano-pyridin-2-yl)-3-(7-fluoro-4-methoxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0000] 6a) 6-Fluoro-2-hydroxy-3-methoxy-benzaldehyde.
[0156] 1 M boron trichloride in dichloromethane (25 ml; 25 mmol) was added to a solution of 6-fluoro-2,3-dimethoxy-benzaldehyde [Cantrell, Amanda S.; Engelhardt, Per; Hoegberg, Marita; Jaskunas, S. Richard; Johansson, Nils Gunnar; et al.; J.Med.Chem.; 39; 21; 1996; 4261-4274] (4.26 g; 23 mmol) in dichloromethane (30 ml) keeping the reaction temperature at −70 C. The reaction mixture stirred at room temperature overnight and hydrolyzed with water. The organic phase was separated, washed with water and evaporated in vacuo. The residue was chromatographed (silica gel, EA:Hex, 5:1) to give 3.72 g (94%) of 6-fluoro-2-hydroxy-3-methoxy-benzaldehyde as yellow crystals.
[0157] 1 H-NMR (CDCl 3 ): 11.61 (s, 1H), 10.23 (s, 1H), 7.02 (dd, 1H), 6.55 (app. t, 1H), 3.87 (s, 3H).
[0000] 6b) 5-Fluoro-8-methoxy-2H-chromene.
[0158] 6-Fluoro-2-hydroxy-3-methoxy-benzaldehyde (3.32 g, 19 mmol) was dissolved in acetonitrile (20 ml) and DBU (2.97 ml, 19 mmol) was added followed by vinyltriphenylphosphine bromide (7.2 g, 19 mmol). The reaction mixture was heated under reflux for 48 h, diluted with water and extracted with ether (3×50 ml). The organic phase was washed with water, 10% sodium hydroxide, water and brine and evaporated in vacuo. The residue was submitted to column chromatography (silica gel, EA:Hex, 1:20) yielding 1.2 g of 5-fluoro-8-methoxy-2H-chromene (34%).
[0159] 1 H-NMR (CDCl 3 ): 6.65 (m, 2H), 6.54 (t, 1H), 5.83 (dt, 1H), 4.88 (dd, 2H), 3.83 (s, 3H).
[0000] 6c) (±)-cis-7-Fluoro-4-methoxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0160] The title compound was synthesized analogously to example 3c from 5-fluoro-8-methoxy-2H-chromene.
[0161] 1 H-NMR (CDCl 3 ): 6.7-6.5 (m, 2H), 4.48 (m, 2H), 3.99 (m, 2H), 3.80 (s, 3H), 2.57 (app.t, 1H), 2.20 (app.t, 1H), 2.05 (m, 1H), 1.08 (t, 3H).
[0000] 6d) (±)-cis-7-Fluoro-4-methoxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0162] The title compound was synthesized analogously to example 1b from (±)-cis-7-fluoro-4-methoxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0163] 1 H-NMR (CDCl 3 ): 6.7-6.5 (m, 2H), 4.48 (m, 2H), 3.80 (s, 3H), 2.61 (app. t, 1H), 2.17 (app. t, 1H), 2.06 (m, 1H).
[0000] 6e) (±)-cis-1-(5-Cyano-pyridin-2-yl)-3-(7-fluoro-4-methoxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0164] The title compound was synthesized analogously to Example 1c from (±)-cis-7-fluoro-4-methoxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (62 mg, 0.17 mmol). Yield 38 mg (40%).
[0165] 1 H-NMR (CDCl 3 ): 10.06 (br. s, 1H), 9.40 (br. d, 1H), 8.11 (d, 1H), 7.70 (dd, 1H), 6.91 (d, 1H), 6.68 (m, 2H), 4.48 (dd, 1H), 4.28 (dd, 1H), 3.90-3.72 (m, 4H), 2.64 (app. T, 1H), 1.96 (m, 1H).
EXAMPLE 7
(±)-cis-1-(5-Cyano-pyridin-2-yl)-3-(7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0000] 7a) 1-Chloro-4-fluoro-2-prop-2-ynyloxy-benzene.
[0166] The title compound was synthesized analogously to example 15a) from 2-chloro-5-fluorophenol (2.5 g). Yield 2.8 g (90%).
[0167] 1 H-NMR (CDCl 3 ): 7.32 (dd, 1H), 6.85 (dd, 1H), 6.68 (m, 1H), 4.77 (d, 2H), 2.58 (t, 1H).
[0000] 7b) 5-Fluoro-8-chloro-2H-chromene.
[0168] The title compound was synthesized analogously to Example 15b) from 1-chloro-4-fluoro-2-prop-2-ynyloxy-benzene (2.8 g). Yield 0.97 g (35%).
[0169] 1 H-NMR (CDCl 3 ): 7.09 (dd, 1H), 6.63 (dt, 1H), 6.56 (t, 1H), 5.84 (dt, 1H), 4.95 (dd, 2H).
[0000] 7c) ±cis-7-Fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0170] The title compound was synthesized analogously to Example 15c) from 5-Fluoro-8-chloro-2H-chromene.
[0171] 1 H-NMR (CDCl 3 ): 7.14 (dd, 1H), 6.60 (t, 1H), 4.51 (m, 2H), 4.01 (m, 2H), 2.60 (app.t, 1H), 2.23 (t, 1H), 2.09 (m, 1H), 1.08 (t, 3H).
[0000] 7d) (±)-cis-7-Fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0172] The title compound was synthesized analogously to example 15d) from (±)-cis-7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester 850 mg). Yield 43 mg (96%).
[0173] 1 H-NMR (CDCl 3 ): 8.86 (br. s, 1H), 7.13 (dd, 1H), 6.59 (t, 1H), 4.50 (m, 2H), 2.63 (t, 1H), 2.23-2.05 (m, 2H).
[0000] 7e) ±cis-1-(5-Cyano-pyridin-2-yl)-3-(7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0174] The title compound was synthesized analogously to example 1c from (±)-cis-7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (63 mg). Yield 52 mg (56%).
[0175] 1 H-NMR (CDCl 3 ): 9.79 (br. s, 1H), 9.34 (br. s, 1H), 8.22 (d, 1H), 7.72 (dd, 1H), 7.17 (dd, 1H), 6.87 (d, 1H), 6.67 (t, 1H), 4.54 (dd, 1H), 4.33 (dd, 1H), 3.84 (app. q, 1H), 2.68 (dd, 1H), 2.00 (m, 1H).
EXAMPLE 8
±cis-1-(5-Chloro-pyridin-2-yl)-3-(4-chloro-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-yl)-urea.
[0176] ±cis-1-(5-Chloro-pyridin-2-yl)-3-(4-chloro-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-yl)-urea (15 mg, 24%) was prepared according to the procedure described in example 1c, from ±cis-(4-chloro-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene)-1-carboxylic acid (40 mg, 0.16 mmol) and 2-amino-5-chloropyridine (76 mg, 0.57 mmol).
[0177] 1 H NMR (400 MHz,CDCl 3 ) δ ppm: 9.29 (brs, 1H), 9.26 (brs 1H), 7.84 (d, 1H), 7.47 (dd, 1H), 7.16 (dd, 1H), 6.76 (d, 1H), 6.67 (dd, 1H), 4.65 (dd, 1H), 4.34 (dd, 1H), 3.82 (dd, 1H), 2.62 (dd, 1H), 1.96 (m, 1H)
EXAMPLE 9
±cis-1-(5-Bromo-pyridin-2-yl)-3-(4-chloro-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-yl)-urea.
[0178] ±cis-1-(5-Bromo-pyridin-2-yl)-3-(4-chloro-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-yl)-urea (13 mg, 19%) was prepared according to the procedure described in example 1c, from ±cis-(4-chloro-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene)-1-carboxylic acid (40 mg, 0.16 mmol) and 2-amino-5-bromopyridine (99 mg, 0.57 mmol).
[0179] 1 H NMR (400 MHz, CDC1 3 ) δ ppm: 9.27 (brs, 1H), 9.02 (brs, 1H), 7.95 (d, 1H), 7.60 (dd, 1H), 7.16 (dd, 1H), 6.70 (d, 1H), 6.67 (dd, 1H), 4.50 (dd, 1H), 4.35(dd, 1H), 3.81 (dd, 1H), 2.63 (dd, 1H), 1.97 (m, 1H)
EXAMPLE 10
±cis-1-(5-Cyano-pyridin-2-yl)-3-(5-cyano-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0000] 10a) Trifluoro-methanesulfonic acid 4-formyl-3-hydroxy-phenyl ester.
[0180] A solution of triflic anhydride (1.77 ml, 10.5 mmol) in dichloromethane 10 ml) was added to a mixture of 2,4-dihydroxybenzaldehyde (1.38 g, 10 mmol) and pyridine (0.85 ml, 10.5 mmol) in dichloromethane (30 ml) at −70 C. Dry ice bath was removed and the reaction mixture was stirred for 2 h at room temperature. The reaction mixture was diluted with dichloromethane, washed with water, brine and evaporated in vacuo. The crude product was purified by column chromatography (silica gel, EA:Hex, 1:6) to give 1.55 g of trifluoro-methanesulfonic acid 4-formyl-3-hydroxy-phenyl ester (57%).
[0181] 1 H-NMR (CDCl 3 ): 11.28 (s, 1H), 9.93 (s, 1H), 7.67 (d, 1H), 6.95 (m, 2H).
[0182] 10b) Trifluoro-methanesulfonic acid 3-allyloxy-4-formyl-phenyl ester. Potassium carbonate (1.6 g, 11.5 mmol) and allyl bromide (1 ml, 11.5 mmol) were added to a solution of trifluoro-methanesulfonic acid 4-formyl-3-hydroxy-phenyl ester (1.55 g, 5.7 mmol) in acetone (50 ml). The reaction mixture was stirred at 55 C for 2 h, filtered and evaporated in vacuo. The residue was chromatographed (silica gel, EA:Hex, 1:20) to give 1.3 g (73%) of trifluoro-methanesulfonic acid 3-allyloxy-4-formyl-phenyl ester.
[0183] 1 H-NMR (CDCl 3 ): 10.47 (s, 1H), 7.93 (d, 1H), 6.95 (d, 1H), 6.90 (s, 1H), 6.05 (m, 1H), 5.47 (d, 1H), 5.40 (d, 1H), 4.69 (d, 2H).
[0000] 10c) Trifluoro-methanesulfonic acid 3-allyloxy-4-vinyl-phenyl ester.
[0184] Methyltriphenylphosphonium bromide (1.95 g, 5.45 mmol) was added to a suspension of sodium hydride (60% in oil) (0.25 g, 6.3 mmol) in THF (35 ml) at 0 C and it was stirred for 30 min at room temperature. To the above solution was added solution of trifluoro-methanesulfonic acid 3-allyloxy-4-formyl-phenyl ester (1.3 g, 4.2 mmol) in THF (15 ml), and the reaction mixture was stirred for 2 h at room temperature. The reaction mixture was diluted with hexane and extracted with water. Organic phase was washed with brine and evaporated. Silica gel column chromatography (EA:Hex, 1:20) afforded trifluoro-methanesulfonic acid 3-allyloxy-4-vinyl-phenyl ester (0.68 g, 53%).
[0185] 1 H-NMR (CDCl 3 ): 7.51 (d, 1H), 7.02 (dd, 1H), 6.85 (dd, 1H), 6.77 (d, 1H), 6.05(m, 1H), 5.76 (dd, 1H), 5.43 (m, 1H), 5.32 (m, 2H), 4.58 (dt, 2H).
[0000] 10d) Trifluoro-methanesulfonic acid 2H-chromen-7-yl ester.
[0186] To a solution of trifluoro-methanesulfonic acid 3-allyloxy-4-vinyl-phenyl ester (0.68 g, 2.2 mmol) in dichloromethane (5 ml) was added Ru-catalyst (Grubb's catalyst) (36 mg, 2 mol %), and the reaction mixture was stirred for 2 h at room temperature. After that period the reaction was complete (GC) and the reaction mixture was used in the next step without any work-up. Analytical sample was obtained after removal of the solvent by silica gel column chromatography (EA:Hex, 1:20).
[0187] 1 H-NMR (CDCl 3 ): 6.97 (d, 1H), 6.76 (dd, 1H), 6.68 (d, 1H), 6.39 (dt, 1H), 5.81 (dt, 1H), 4.98 (dd, 2H).
[0000] 10e) ±cis-5-Trifluoromethanesulfonyloxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0188] Rh(OAc) 2 (19 mg, 2 mol %) was added to the above solution (10d) and the solution of EDA (0.44 ml, 4.4 mmol) in 1 ml of dichloromethane was added with a syringe pump over 5 h at room temperature. When the reaction was complete (GC) dichloromethane was evaporated, the residue was dissolved in ethyl acetate and washed with saturated ammonium chloride solution and brine. Organic phase was evaporated and crude mixture of cis- and trans-isomers (1:1.3) was separated by column chromatography (silica gel, EA:Hex, 1:6) to give 0.4 g (50%) of ±cis-5-trifluoromethanesulfonyloxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0189] 1 H-NMR (CDCl 3 ): 7.29 (d, 1H), 6.82 (dd, 1H), 6.73 (d, 1H), 4.51 (dd, 1H), 4.29 (dd, 1H), 3.98 (m, 2H), 2.45 (t, 1H), 2.19 (t, 1H), 2.05 (m, 1H), 1.03 (t, 3H).
[0000] 10f) ±cis-5-Cyano-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0190] ±cis-5-Trifluoromethanesulfonyloxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (154 mg, 0.42 mmol), Pd(OAC) 2 (9 mg, 10 mol %) and PPh 3 (44 mg, 40 mol %) were mixed in DMF (4 ml) and gentle stream of nitrogen passed through reaction mixture for 10 min. Zn(CN) 2 (74 mg, 0.63 mmol) was added, vial was sealed and the reaction mixture was stirred at 120 C overnight. The reaction mixture was diluted with ethyl acetate and extracted with saturated ammonium chloride. Organic phase was evaporated and residue chromatographed (silica gel, EA:Hex 1:5) to give 53 mg (52%) of ±cis-5-cyano-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0191] 1 H-NMR (CDCl 3 ): 7.33 (d, 1H), 7.19 (dd, 1H), 7.05 (d, 1H), 4.50 (dd, 1H), 4.25 (dd, 1H), 3.99 (q, 2H), 2.46 (t, 1H), 2.25 (t, 1H), 2.11 (m, 1H), 1.06 (t, 3H).
[0000] 10g) ±cis-5-Cyano-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0192] ±cis-5-Cyano-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (53 mg, 0.22 mmol) and NaOH (35 mg, 0.88 mmol) were dissolved in mixture methanol water (1:1) (5 ml). Reaction mixture was stirred at 60 C for 30 min. Methanol was evaporated in vacuo and 20 ml of water was added. Resulting solution was extracted with ether. Water phase was concentrated, acidified with 1 M HCl to pH-2 and extracted with ether. The organic phase was washed with brine and evaporated to give 42 mg (90%) of ±cis-5-cyano-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0193] 1 H-NMR (CDCl 3 ): 7.33 (d, 1H), 7.19 (dd, 1H), 7.06 (d, 1H), 4.51 (dd, 1H), 4.31 (dd, 1H), 2.53 (app. t, 1H), 2.27 (app. t, 1H), 2.16 (m, 1H).
[0000] 10h) ±cis-1-(5-Cyano-pyridin-2-yl)-3-(5-cyano-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0194] ±cis-5-Cyano-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (42 mg, 0.19 mmol) and TEA (0.032 ml, 0.21 mmol) were dissolved in 3 ml of toluene. DPPA (0.046 ml, 0.21 mmol) and 2-amino-5-cyano-pirydine (25 mg, 0.21 mmol) were added. The reaction mixture was heated under reflux with stirring for 3 h. The resulting precipitate was filtered and washed with hot ethanol (3 ml) yielding 41 mg (63%) of ±cis-1-(5-cyano-pyridin-2-yl)-3-(5-cyano-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0195] 1 H-NMR (DMSO-d 6 ): 9.86 (s, 1H), 8.48 (d, 1H), 8.07 (dd, 1H), 7.97 (br. s, 1H), 7.51 (d, 1H), 7.43 (d, 1H), 7.37 (d, 1H), 7.34 (dd, 1H), 4.39 (dd, 1H), 4.19 (dd, 1H), 3.57 (app. q, 1H), 2.54 (app. t, 1H), 2.09 (m, 1H).
EXAMPLE 11
±cis-1-(5-Cyano-pyridin-2-yl)-3-(5-ethynyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0000] 11a) ±cis-5-Trimethylsilanylethynyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0196] ±cis-5-Trifluoromethanesulfonyloxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (152 mg, 0.41 mmol), DPPP (38 mg, 20 mol %), Pd(dba) 2 (24 mg, 10 mol %), Cul (3 mg, 4 mol %) were mixed in 3 ml of triethylamine and gentle stream of nitrogen passed through reaction mixture for 10 min. Trimethylsilyl-acetylene (0.088 ml, 0.62 mmol) was added, vial was sealed and the reaction mixture was stirred at 120 C overnight. The reaction mixture was diluted with ethyl acetate, washed with water, brine and evaporated. The residue was purified by silica gel column chromatography (EA:Hex, 1:15) to give 0.1 g (77%) of ±cis-5-trimethylsilanylethynyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0197] 1 H-NMR (CDCl 3 ): 7.15 (d, 1H), 7.01 (dd, 1H), 6.88 (d, 1H), 4.47 (dd, 1H), 4.16 (dd, 1H), 3.96 (q, 2H), 2.38 (t, 1H), 2.13 (t, 1H), 2.01 (m, 1H), 1.04 (t, 3H), 0.22 (s, 9H).
[0000] 11b) ±cis-5-Ethynyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0198] ±cis-5-Trimethylsilanylethynyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (0.1 g, 0.32 mmol) and sodium hydroxide (0.076 g, 1.9 mmol) were dissolved in mixture of methanol:water (1:1) (5 ml). The reaction mixture was heated at 60 C for 5 h, then it was acidified with 1M HCl to pH˜2 and extracted with ether. The organic phase was washed with brine and evaporated to give 66 mg (97%) of ) ±cis-5-ethynyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0199] 1 H-NMR (CDCl 3 ): 7.17 (d, 1H), 7.03 (dd, 1H), 6.91 (d, 1H), 4.45 (dd, 1H), 4.23 (dd, 1H), 3.02 (s, 1H), 2.46 (t, 1H), 2.13 (t, 1H), 2.07 (m, 1H).
[0000] 11c) ±cis-1-(5-Cyano-pyridin-2-yl)-3-(5-ethynyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0200] The title compound was synthesized analogously to example 10h from ±cis-5-ethynyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (66 mg, 31 mmol).Yield 53 mg (52%).
[0201] 1 H-NMR (DMSO-d 6 ): 9.88 (s, 1H), 8.41 (d, 1H), 8.06 (dd, 1H), 7.86 (br. s, 1H), 7.46 (d, 1H), 7.32 (d, 1H), 7.02 (dd, 1H), 6.93 (d, 1H), 4.31 (dd, 1H), 4.16 (dd, 1H), 4.12 (s, 1H), 3.47 (q, 1H), 2.43 (app. t, 1H), 2.00 (m, 1H).
EXAMPLE 12
±cis-1-(5-Acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea
[0000] 12a) ±cis-5-Acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0202] ±cis-5-Trifluoromethanesulfonyloxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (117 mg, 0.32 mmol), DPPP (7.3 mg, 50 mol %), Pd(OAc) 2 (2 mg, 25 mol %) and triethyl amine (0.09 ml, 0.64 mmol) were mixed in DMF (3 ml) and gentle stream of nitrogen passed through reaction mixture for 10 min. Butyl vinyl ether (0.21 ml, 1.6 mmol) was added, vial was sealed and the reaction mixture was stirred at 100 C for 2 h. 5% HCl (5 ml) was added and the reaction mixture was stirred at room temperature for 30 min. Resulting mixture was extracted with ethyl acetate. The organic phase was washed with saturated ammonium chloride and evaporated. The residue was purified by silica gel column chromatography (EA:Hex, 1:5) to give 76 mg (91%) of ±cis-5-acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic
[0203] 1 H-NMR (CDCl 3 ):7.52 (dd, 1H), 7.36 (d, 1H), 7.34 (d, 1H), 4.51 (dd, 1H), 4.21 (dd, 1H), 3.98 (q, 2H), 2.53 (s, 3H), 2.47 (t, 1H), 2.23 (t, 1H), 2.08 (m, 1H), 1.05 (t, 3H).
[0000] 12b) ±cis-5-Acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0204] The title compound was synthesized analogously to example 10g from ±cis-5-acetyl-1,1 a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (76 mg, 29 mmol).Yield 66 mg (97%).
[0205] 1 H-NMR (CDCl 3 ): 7.52 (dd, 1H), 7.37 (d, 1H), 7.34 (d, 1H), 4.52 (dd, 1H), 4.26 (dd, 1H), 2.55 (s, 3H), 2.53 (t, 1H), 2.25 (t, 1H), 2.13 (m, 1H).
[0000] 12c) ±cis-1-(5-Cyano-pyridin-2-yl)-3-(5-acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0206] The title compound was synthesized analogously to example 1Oh from ±cis-5-acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (66 mg, 28 mmol).Yield 58 mg (59%).
[0207] 1 H-NMR (DMSO-d 6 ): 9.87 (s, 1H), 8.42 (d, 1H), 8.05 (dd, 1H), 7.88 (br. s, 1H), 7.52 (dd, 1H), 7.49-7.44 (m, 2H), 7.37 (d, 1H), 4.39 (dd, 1H), 4.18 (dd, 1H), 3.55 (q, 1H), 2.55-2.50 (m, 4H, superimposed on residual DMSO-d 6 peak), 2.07 (m, 1H).
EXAMPLE 13
±cis-1-(5-Methoxy-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea
[0208] The title compound was synthesized analogously to example 10 from 2-hydroxy-4-methoxybenzaldehyde.
[0209] 1 H-NMR (CDCl 3 ): 8.44 (br. s, 1H), 8.06 (d, 1H), 7.70 (dd, 1H), 7.18 (d, 1H), 6.82 (br. d, 1H), 6.55 (dd, 1H), 6.36 (d, 1H), 4.32 (dd, 1H), 4.24 (dd, 1H), 3.76 (s, 3H), 3.58 (q, 1H), 2.36 (dd, 1H), 1.86 (m, 1H).
EXAMPLE 14
±cis-1-(5-Cyano-pyridin-2-yl)-3-(N-acetyl-1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]quinoline-1-yl))-urea
[0000] a) N-Acetyl-1,2-dihydroquinoline.
[0210] Quinoline (19.37 g, 150 mmol) was dissolved in anhydrous diethyl ether (500 ml) and cooled to 0° C. under inert atmosphere. DIBAL, 1.5 M in toluene (100 ml, 150 mmol) was added dropwise over 2 hrs and the reaction mixture was stirred at 0° C. for 30 min. Acetic anhydride (500 ml) was added dropwise over 30 min and the reaction mixture was stirred at 0° C. for 30 min. H 2 O was added cautiously. The reaction mixture was extracted with diethyl ether and concentrated to give N-acetyl-1,2-dihydroquinoline (11.5 g, 44%).
[0000] b) ±cis-(N-acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]quinoline)-1-carboxylic acid ethyl ester.
[0211] ±cis-(N-acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]quinoline)-1-carboxylic acid ethyl ester was prepared according to the procedure described in example 1a, from N-acetyl-1,2-dihydroquinoline (10 g, 58 mmol) The product was purified by column chromatography on silica (EtOAc/hexane 5% 50%) to give ±cis-(N-acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]quinoline)-1-carboxylic acid ethyl ester (2.0 g, 13%).
[0000] c) ±cis-(N-Acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]quinoline)-1-carboxylic acid.
[0212] ±cis-(N-Acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]quinoline)-1-carboxylic acid (425 mg, 24%) was prepared according to the procedure described in example 1b, from ±cis-(N-acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]quinoline)-1-carboxylic acid ethyl ester (2.0 mg, 7.7 mmol).
[0000] d) ±cis-1-(5-Cyano-pyridin-2-yl)-3-(N-acetyl-1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]quinoline-1-yl))-urea.
[0213] ±cis-1-(5-Cyano-pyridin-2-yl)-3-(N-acetyl-1,1a,3,7b-tetrahydro-2-oxa-cyclopropa[a]quinoline-1-yl))-urea (250 mg, 40%) was prepared according to the procedure described in example 1c, from ±cis-(N-acetyl-1,1a,2,7b-tetrahydro-cyclopropa[c]quinoline)-1-carboxylic acid (416 mg, 1.8 mmol).
[0214] 1 H NMR (250 MHz, DMSO-d 6 ) δ ppm: 9.51 (brs, 1H), 8.30 (d 1H), 8.01 (dd, 1H), 7.54 (dd, 1H), 7.44, (dd, 1H), 7.36 (d, 1H), 7.23-7.18 (m, 3H), 4.10 (d, 1H), 3.60 (dd, 1H), 3.12-3.05 (m, 1H), 2.37 (tr, 1H), 2.0-1.92 (m, 4H)
EXAMPLE 15
+/−-cis-1-(5-Cyanopyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0215]
15a) 2,4-Difluoro-2-propynyloxybenzene.
[0216] Commercially available 2,5-difluorophenol (20 g , 0.15 mol), K 2 CO 3 (53 g, 0.38 mol) and commercially available 3-bromopropyne (45 g, 0.38 mol) were dissolved in acetone (300 ml), refluxed over night, cooled and filtrated. The solvent was removed and the crude product, dissolved in ether and washed with water and brine. The organic phase was evaporated and the crude product was re-dissolved in a small amount of ether and filtrated through a column of basic Al 2 O 3 . Evaporation and drying gave20 g (80%) of 2,4-difluoro-2-prop-ynyloxy-benzene
15b) 5,8-Difluoro-2H-chromene.
[0217] 2,4-Difluoro-2-propynyloxybenzene (20 g, 0.12 mol) was dissolved in N,N,-diethyl aniline (100 ml) and heated under argon atmosphere at 225 deg. Celcius with an oil-bath for 6-8 h. Ether (150 ml) was added and the aniline was removed by extraction using 2 M HCl (aq) . Purification by chromatography (silica gel, n-hexane) gave 5,8-difluoro-2H-chromene 5.8 g (29%)
15c) ±/−cis-4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0218] 5,8-Difluoro-2H-chromene (5 g, 0.03 mol), (Rh(II)Ac 2 ) 2 (0.39 g, 0.00089 mol) was dissolved in 1,2-dichloroethane (60 ml) or ethanol-free chloroform. Ethyl diazoacetate (9.4 ml, 0089 mol) in the same solvent was added dropwise over a period of approximately 5 h under N 2 atmosphere. The solvent was then removed under vacuum and the mixture was taken upp in ethyl acetate, washed with NaHCO 3 (aq), water and brine and the solvent removed. The product (33% cis, 66% trans) was purified by hromatography (0→10% ethyl acetate in n-hexane) to give 2.2 g of the title compound (30%).
15d) cis-4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
Cis-4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (2 g, 0.008 mol) was heated in 1M LiOH in methanol-water (25%) at 80 deg. for 2 h. The volume was reduced to half and acidified. Extraction with ether followed by chromatography (silica gel, ether) gave pure title compound (35%)
e) (/-)cis-1-(5-Cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0219] (+/−)-cis-1-(5-Cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea was prepared analogously to Example 1c but using cis-4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (0.2 g, 0.00088 mol) to give 0.130 g (42%) of pure title compound. The crude product was purified by extraction between 0.01 M HCl (aq) and ethyl acetate and chromatography (silica gel, 0→1% MeOH in Ether). The solvent was evaporated and the solid washed with a cold solution of 50% aceton in n-hexane.
[0220] 1 H-NMR (CDCl 3 -MeOD): 8.16 (d, 1H), 7.72 (dd, 1H), 6.97-6.86 (m, 2H), 6.69-6.61 (m, 1H), 4.47 (dd, 1H), 4.31 (dd, 1H), 3.75 (m, 1H), 2.65 (t, 1H), 2.05-1.96 (m, 1H).
EXAMPLE 16
(+/−)-cis-1-(5-Cyano-3-methyl-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0221]
[0222] (+/−)-cis-1-(5-Cyano-3-methyl-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea was prepared analogously to Example 1c but using cis-4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (168 mg, 0.74 mmol) and 6-amino-5-methyl-nicotinonitrile (109 mg, 0.82 mmol ) to give (+/−)-cis-1-(5-cyano-3-methyl-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea 52 mg of(20%). The crude product was purified by extraction between 0.01 M HCl (aq) and ethyl acetate and chromatography (silica gel, 0→25% MeOH in Ether). The solvent was evaporated and the solid washed with 25% aceton in n-hexane.
[0223] 1 H NMR (CDCl3-MeOD): 8.02 (d, 1H), 7.61 (dd, 1H), 6.97-6.87 (m, 1H, 6.70-6.62 (m, 1H), 4.48 (dd, 1H), 4.30 (dd, 1H), 3.78 (t, 1H), 3.37 (s, 3H), 2.66 (t, 1H), 2.03 (m, 1H).
EXAMPLE 17
+/−-cis-1-(5-Chloro-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0224]
[0225] +/−-cis-1-(5-Chloro-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea was prepared analogously to Example 1c but using cis-4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (90 mg, 0.4 mmol) and 6-amino-5-chloropyridine (51 mg, 0.44 mmol) to give +/−-cis-1-(5-chloro-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea (50 mg, 35%). The crude product was purified by extraction between 0.01 M HCl (aq) and ethyl acetate-ether (1:1) and chromatography (silica gel, ether).
[0226] 1 H NMR (CDCl 3 ): 9.2 (broad s, NH), 8.6 (broad s, NH), 7.81 (dd, 1H), 7.48 (dd, 1H), 6.89 (m, 1H), 6.75 (d, 1H), 6.69 (m, 1H), 4.45 (dd, 1H), 4.33 (dd, 1H), 3.75 (m, 1H), 2.61 (m, 1H), 1.97 (m, 1H).
EXAMPLE 18
(+/−)-cis-1-(4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-ethynyl-pyridin-2-yl)-urea
[0227]
[0228] +/−cis-1-(4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-ethynyl-pyridin-2-yl)-urea was prepared analogously to Example 1c) but using cis-4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (100 mg, 0.4 0.44 mmol) and 5-trimethylsilanylethynyl-pyridine-2-ylamine (93 mg, 0.49 mmol) to give (25 mg, 17%). The crude product was purified by extraction between 0.01 M HCl (aq) and ethyl acetat-ether (1:1) and chromatography (silica gel, ether). The mixture obtained (containing the title compound together with silylated compound) was stirred with Bu 4 N + F − in 25% water in THF for 30 min and the chromatography was repeated to obtain pure +/−cis-1-(4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-ethynyl-pyridin-2-yl)-urea.
[0229] 1 H NMR (CDCl 3 ): 9.2 ( broad s, NH), 7.95 (d, 1H), 7.59 (dd, 1H), 7.48 (broad s, 1H), 6.89 (td, 1H), 6.64 (td, 1H), 6.57 (d, 1H), 4.46 (dd, 1H), 4.33 (dd, 1H), 3.78 (q, 1H), 3.11 (s, 1H), 2.62 (t, 1H), 1.99-1.97 (m, 1H)
EXAMPLE 19
(+/−)-cis-1-(5-Bromo-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0230]
[0231] +/−-cis-1-(5-Bromo-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea was prepared analogously to Example 1c but using cis-4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (50 mg, 0.22 mmol) and 6-amino-5-bromopyridine (42 mg, 0.24 mmol ) to give +/−-cis-1-(5-bromo-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea (50 mg, 35%). The crude product was purified by extraction between 0.01 M HCl (aq) and ethyl acetate and chromatography (silica gel, ether.
[0232] 1 H NMR (CDCl 3 ): 9.2 (broad s, NH), 7.88 (d, 1H), 7.75 (broad s, 1H), 7.60 (dd, 1H), 6.89 (m, 1H), 6.63 (td,1H), 6.59 (d, 1H), 4.45 (dd, 1H), 4.33 (dd, 1H), 3.78 (q, 1H), 2.62 (t, 1H), 1.98 (m, 1H).
EXAMPLE 20
+/−cis-1-(4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-phenoxy-pyridin-2-yl)-urea.
[0233]
[0234] (+/−)-cis-1-(4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-phenoxy-pyridin-2-yl)-urea was prepared analogously to Example 1c) but using cis-4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (60 mg, 0.26 mmol) and 6-amino-5-phenoxypyridine ( 56 mg, 0.29 mmol) to give 32 mg (30%) of the title compound. The crude product was purified by extraction between 0.01 M HCl (aq) and ethyl acetate and chromatography (silica gel, 20% ether in n-hexane)
[0235] 1 H NMR (CDCl 3 ): 7.60 (d, 1H), 7.45 (broad s, 1H), 7.37-7.34 (m, 2H), 7.27-7.24 (m, 2H), 7.14-7.11 (m, 1H), 6.94-9.92 (m, 2H), 6.79-7.74 (m, 1H), 6.63 (d, 1H), 6.59-6.55 (m, 1H), 4.43 (dd, 1H), 4.36 (dd, 1H), 3.75 (q, 1H), 2.59 (t, 1H), 1.98-1.94 (m, 1H).
EXAMPLE 21
(+/−)-cis-1-(5-Cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-thiourea
[0236]
[0237] cis-4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (113 mg, 0.5 mmol), DPPA (118.6 μl, 0.55 mmol) and TEA (70.7 μl, 0.55 mmol) was refluxed in toluene (2 ml) for 1 h. Dioxane (3 ml) and HCl (aq) (1.5 ml, 6M) was then added and the reaction mixture was left for 1 h. at 50° C. Ether and water was then added and the layers separated. The water phase was washed with ether and then made alkaline with ammonia (aq) . Extraction with dichlorometane and drying gave the intermdiate 4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1ylamine, which was directly treated with 6-isothiocyanato-nicotinonitril (34 mg, 0.55 mmol) in acetonitrile (4 ml) at RT over-night. The precipitated crystals were filtrated off and washed with cold acetonitrile to give30 mg (17%) of pure (+/−)-cis-1-(5-Cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-thiourea LC-MS: m/z 358.9
EXAMPLE 22
1-(6-Chloro-5-cyano-pyridin-2-yl)-3-(5,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)urea
[0238]
[0239] 1-(6-Chloro-5-cyano-pyridin-2-yl)-3-(5,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)urea was prepared analogously to Example 1c) but using cis-5,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (280 mg, 1.21 mmol) and 6-amino-2-chloro-3-cyanopyridine (203 mg, 1.33 mmol) to give the title compound in small amount. The crude product was purified by extraction between 0.01 M HCl (aq) and ether and chromatography (silica gel, ether) and washed with acetone-ether.
[0240] 1 H NMR (DMSO-d 6 ): 10 (br s, NH), 8.20 (d, 1H), 7.70 (d, 1H), 6.9 (brs, NH), 6.8 (m, 1H), 6.6 (m, 1H), 4.4 (dd, 1H), 4.2 (dd, 1H), 3.2 (m, 1H), 2.4 (t, 1H), 1.9 (m, 1H).
EXAMPLE 23
1-(5-cyano-pyridin-2-yl)-3-(5,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)urea
[0241]
[0242] 1-(5-cyano-pyridin-2-yl)-3-(5,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)urea was prepared analogously to Example 1c) but using cis-5,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (390 mg, 1.72 mmol) and 2-amino-5-cyanopyridine (226 mg, 1.89 mmol). The crude product was purified by extraction between 0.01 M HCl (aq), recrystallization, several washings with aceton and acetonitrile and chromatography (silica gel, 1% EtOAc in ether) to give 28 mg of the title compound.
[0243] 1 H NMR (CDCl3-MeOD): 8.16 (t, 1H), 7.78 (dd, 1H), 7.09 (d, 1H), 6.56-6.34 (m, 2H), 4.34 (m, 2H), 3.54 (t, 1H), 2.57 (dd, 1H), 2.00-1.90 (m, 1H).
EXAMPLE 24
cis-1-(4-Bromo-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea
[0244]
[0245] cis-1-(4-Bromo-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea was prepared analogously to Example 1c) but using cis-4-bromo-7fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (178 mg, 0.62 mmol) and 2-amino-5-cyanopyridine (0.81 mg, 0.68 mmol) The crude product was chromatographed (silica, ether) and washed with acetone to give 40 mg (16%) of cis-1-(4-Bromo-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea.
[0246] 1 H NMR (CDCl 3 ): 9.85 (s, 1H), 9.3 (s, 1H), 7.75 (dd, 1H), 7.33 (dd, 1H), 6.95 (d, 1H), 6.65 (t, 1H), 4.05 (dd, 1H), 4.32 (dd, 1H), 3.35 (t, H), 2.65 (t, 1H), 2.05-1.95 (m, 1H).
EXAMPLE 25
cis-1-(4-Bromo-7-fluoro-1,1a,2,7b-tetrahydro-cycloprona[c]chromen-1-yl)-3-(6-chloro-5-cyano-pyridin-2-yl)-urea
[0247]
[0248] cis-1-(4-Bromo-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(6-chloro-5-cyano-pyridin-2-yl)-urea was prepared analogously to Example 1c but using cis-4-bromo-7fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (178 mg, 0.62 mmol) and 2-amino-6-chloro-5-cyanopyridine (105 mg, 0.68 mmol). The crude product was chromatographed (silica, 0→1% MeOH in ether) and washed with acetone-hexane to give 40 mg (13%) of cis-1-(4-bromo-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(6-chloro-5-cyano-pyridin-2-yl)-urea.
[0249] 1 H NMR (CDCl 3 ): 9.90 (s, 1H), 8.30 (s, 1H), 7.75 (d, 1H), 7.25 (d, 1H), 6.60 (t, 1H), 4,5 (dd, 1H), 4.35 (dd, 1H), 3.5 (m, 1H), 2.65 (m, 1H), 2.1-1.95 (m, 1H).
EXAMPLE 26
cis-1-(4-Bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea
[0250]
[0251] cis-1-(4-Bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea urea was prepared analogously to Example 1c but using cis-4-bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (177 mg, 0.62 mmol) and 2-amino-5-cyanopyridine ( 81 mg, 0.68 mmol). The crude product was extracted between ether and 0.02 M HCl (aq) , chromatographed (silica, 0→1% MeOH in ether) and washed with acetone-hexane to give 42 mg (17%) of cis-1-(4-Bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(5-cyano-pyridin-2-yl)-urea.
[0252] 1 H NMR (CDCl3-MeOD): 8.37 (m, 1H), 7.75 (dd, 1H), 7.14 (dd, 1H), 7.05 (dd, 1H), 6.93 (d, 1H), 4.56 (dd, 1H), 4.21 (dd, 1H), 3.77 (t, 1H), 2.42 (dd, 1H), 2.00 (m, 1H).
EXAMPLE 27
cis-1-(4-Bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(6-cloro-5-cyano-pyridin-2-yl)-urea
[0253]
[0254] cis-1-(4-Bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(6-chloro-5-cyano-pyridin-2-yl)-urea was prepared analogously to Example 1c) but using cis-4-bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (177 mg, 0.62 mmol) and 2-amino-6-chloro-5-cyanopyridine (105 mg, 0.68 mmol). The crude product was extracted between ether and 0.01 M HCl (aq) , chromatographed (silica, 0→1% MeOH in ether) and washed with acetone-hexane to give 46 mg (17%) of cis-1-(4-bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-3-(6-cloro-5-cyano-pyridin-2-yl)-urea.
[0255] 1 H NMR (CDCl3): 9.41 (s 1H,), 8.28 (dd, 1H), 7.04 (dd, 1H), 4.54 (dd, 1H), 4.25 (dd, 1H), 3.50 (m, 1H), 2.41 (dd, 1H), 2.06-1.98 (m, 1H).
EXAMPLE 28
Cis-1-(5-cyanopyridin-2-yl)-3-(6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)urea
[0256]
[0257] cis-1-(5-Cyano-pyridin-2-yl)-3-(6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)urea was prepared analogously to Example 1c) but using cis-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (168 mg, 0.8 mmol) and 2-amino-5-cyanopyridine ( 105 mg, 0.88 mmol). The crude product was extracted between ether and 0.01 M HCl (aq) chromatographed (silica, 0→1% MeOH in ether) and washed with aceton-hexane to give only 10 mg (4%) of cis-1-(5-cyano-pyridin-2-yl)-3-(6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)urea.
[0258] 1 H NMR (CDCl3-MeOD): 8.16 (d, 1H), 7.73 (dd, 1H), 7.05 (dd, 1H), 6.96 (d, 1H), 6.84 (td , 1H), 6.76 (dd, 1H), 4.39 (dd, 1H), 4.17 (dd, 1H), 3.67 (t, 1H), 2.39 (dd, 1H), 1.96-1.92 (m, 1H).
EXAMPLE 29
Intermediates
[0259] 29a) 6-Fluorochroman-4-ol
[0260] 6-Fluorochroman-4-one (10 g, 61 mmol) was dissolved in ethanol (100 ml). NaBH 4 (excess) was added and cooled on icebath. The mixture was then left in room temperature for 2 h, folowed by reflux for 4 h. Purification by chromatography (silica gel, ether-hexane, 1:5) gave 8. g (80%) pure 6-fluoro-chroman-4-ol.
29b) 6-Fluoro-2H-chromene
[0261] 6-Fluorochroman-4-ol (8 g, 48 mmol) and toluene-4-sulphonic acidn (1 g) were dissolved in toluene and refluxed over-night with subsequent water removal. The mixture was then cooled and washed with NaHCO 3 (aq) and purified by chromatography (silica gel, n-hexane) to give 4.2 g (52%) of pure 6-fluoro-2H-chromene.
29c) ±/−cis-6-Fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester
[0262] This Compound was prepared analogously to cis-4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester but using 6-fluoro-2H-chromene to give 1.9 (29%) of the title compound.
29d) Cis-6-Fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid
[0263] This compound was prepared analogously to cis-4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid but using cis-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (1.9 g, 8 mmol) to give 350 mg (21%) of pure cis-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid
29e) 1-Bromo4-fluoro-2-prop-2-ynyloxy-benzene
[0264] This compound was prepared analogously to 2,4-difluoro-2-prop-ynyloxy- benzene but using 2-bromo-5-fluorphenol (15 g, 78 mmol) to give 1-bromo-4-fluoro-2-prop-2-ynyloxy-benzene 15.6 g (87%)
29f) 2-Bromo4-fluoro-1-prop-2-ynyloxy-benzene
[0265] This compound was prepared analogously to 2,4-difluoro-2-prop-ynyloxy-benzene but using 2-bromo4-fluoro-phenol (15 g, 78 mmol) to give 2-bromo-4-fluoro-1-prop-2-ynyloxy-benzene 15. g (84%).
29g) 1,3-difluoro-5-prop-2-ynyloxy-benzene
[0266] This compound was prepared analogously to 2,4-difluoro-2-propynyloxybenzene but using 3,5-difluoro-phenol (14 g, 107 mmol) to give 1,3-difluoro-5-prop-2-ynyloxy-benzene 12 g (67%).
9h) 8-Bromo-6-fluoro-2H-chromene
[0267] This compound was prepared analogously to 5,8-difluoro-2H-chromene but using (15 g, 65 mmol ) of 2-bromo-4-fluoro-1-prop-2-ynyloxybenzeneto give the title compound (7 g, 46%)
29i) 8-Bromo-5-fluoro-2H-chromene
[0268] This compound was prepared analogously to 5,8-difluoro-2H-chromene but using (15 g, 65 mmol) of 1-bromo-4-fluoro-2-prop-2-ynyloxybenzene to give the title compound (3.7 g, 25
29 j) 5,7-Difluoro-2H-chromene
[0269] This compound was prepared analogously to 5,8-difluoro-2H-chromene but using (18 g, 107 mmol) of 1,3-difluoro-5-prop-2-ynyloxybenzene and PEG-200 as solvent to give the title compound (4 g, 23%).
29k) +/−cis-4-Bromo-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester
[0270] This compound was prepared analogously to +/−cis-4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester but using 5 g (22 mmol) of 8-bromo 6-fluoro-2H-chromene to give 1.9 g (30%) of cis-6-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
291) +/−cis-4-Bromo-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester
[0271] This compound was prepared analogously to +/−cis-4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester but using 3.5 g (15.3 mmol) of 8-bromo-5-fluoro-2H-chromene to give 1.6 g (33%) of +/−cis-4-bromo-7-fluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
29m) +/−cis-5,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0272] This compound was prepared analogously to +/−cis-4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester but using 2 g (12 mmol) of 5,7-difluoro-2H-chromene to give 0.9 g (29%) of +/−cis-5,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
EXAMPLE 30
Optical isomers of cis-1-(5-Cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0273] Racemic (+/−)-cis-1-(5-cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea (see Example 15) was separated into optically active compounds by using a chiral AGP 150×10 mm, 5 μm; Crom Tech LTD Colomn. The flow rate was set to 4 ml/min. The mobile phase was 89 vol % 10 mM HOAc/NH 4 OAc in acetonitrile. Two elution peaks are seen. The isomer eluting second, typically exhibiting negative rotation is particularly active.
[0274] Without in any way wishing to be bound by this observation, it is believed that the more slowly eluting isomer bears the absolute configuration depicted below, which has been established by reference to x-ray crystallographic coordinates of the unsubstituted analogue of Example 1 liganded within reverse transcriptase enzyme. The configuration depicted below is clearly seen in the solved structure, whereas the other enantiomer is not present.
EXAMPLE 31
(−) cis-1-(5-Chloro-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0275] Racemic (+/−)-cis-1-(5-chloropyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea (see Example 17) was separated into optically active compounds by using a chiral AGP 150×10 mm, 5 μm; Crom Tech LTD Colomn. The flow rate was set to 4 ml/min. The mobile phase was 89 vol % 10 mM HOAc/NH 4 OAc in acetonitrile. Two elution peaks at 27.7 min and 33.2 min are seen. The title isomer eluting at 33.2 min, typically exhibiting negative rotation, is particularly active.
EXAMPLE 32
(−)cis-1-(5-Cyano-pyridin-2-yl)-3-(7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropafclchromen-1-yl)-urea
[0000] a) Resolution of the racemic cis-7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0276] 0.32 g (1.32 mmol) of racemic cis-7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid was dissolved in hot acetonitrile (50 ml) and (1R,2R)-2-benzyloxycyclopentylamine (0.25 g, 1.32 mmol) was added. The resulting solution was left for crystallization. After few hours the mother liquor was decanted and crystals were washed with acetonitrile. The second crystallization from acetonitrile gave 92 mg of pure diastereomeric salt. The salt was treated with 1 M HCl and resulting mixture was extracted with ethyl acetate. The organic phase was washed with water, brine and evaporated to give 0.05 g of enantiomeric cis-7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0000] b) (−)cis-1-(5-Cyano-pyridin-2-yl)-3-(7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0277] The title compound was synthesized analogously to Example 1c) from enantiomeric cis-7-fluoro-4-chloro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (50 mg). Yield 60.2 mg (84%). [α] D =-0.388 (c=0.5, CHCl 3 ).
EXAMPLE 33
+/−cis-N-(5-cyano-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea
[0278] a) 1,4-dichloro-2-(2-propynyloxy)benzene
[0279] 2,5-Dichlorophenol (8 g, 49 mmol) was mixed with potassium carbonate (13.6 g, 98 mmol) and 80% solution of propargyl bromide in toluene (11 ml, 98 mmol) in acetone (100 ml) and stirred overnight at room temperature. The precipitate was removed by filtration and washed with acetone. The acetone solution obtaind was concentrated by rotary evaporation and kept under vacuum for 5 h. The product was obtained as yellow oil with quantitative yield. It was used for futher transformations without additional purification.
b) 5,8-dichloro-2H-chromene
[0280] 1,4-Dichloro-2-(2-propynyloxy)benzene was degassed and heated at stirring under argon for 4 h at 224° C. The reaction mixture was then distilled in Kugelrohr apparatus (150-175° C./4.1×10 −2 mbar) to give 3.58 g of desired product as white solid. Yield 36% from starting dichlorophenol.
c) +/−cis-ethyl 4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylate
[0281] 5,8-Dichloro-2H-chromene (3.15 g, 16 mmol), (Rh(ll)Ac 2 ) 2 (30 mg, 0.1 mol %) was dissolved in degassed dry methylene chloride (3 ml). Ethyl diazoacetate (3 ml, 2 eq.) in the same solvent was added by a syringe at the flow rate 0.4 ml/h over a period of approximately 5 h under N 2 atmosphere. The reaction mixture was then washed with NH 4 Cl (aq), water and brine and the solvent removed. The product (45% cis, 55% trans) was purified by chromatography on silica (200 g, ethyl acetate/n-hexane 1:15) to give 0.9 g of the pure cis product (racemate). Yield 20%. M + =287.
[0282] 1 H-NMR (CDCl 3 ): 7.15 (d, 1H, J=8.5Hz), 6.91 (d, 1H, J=8.8Hz), 4.59 (dd, 1H, J 1 =12.02, J 2 =7.03), 4.48 (dd, 1H, J=12.02, J 2 =4.10), 4.07-3.94 (m, 3H), 2.62 (t, 1H, J=8.8Hz), 2.27 (t, 1H, J=8.36Hz), 2.20-2.12 (m, 1H), 1.1 (t, 3H).
d) +/−cis-4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid
[0283] +/−cis-Ethyl 4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylate was mixed with methanol (3 ml) and water solution of NaOH (1.5 eq., 3 ml) and heated at stirring for 1.5 h at 60° C. The extraction of basic reaction mixture into hexane showed that no starting material present. The reaction mixture was acidified with excess of 3M HCl solution (pH=1). The precipitate formed was collected by suction and washed with water. White solid obtained was dried under high vacuum (yield 80%).
e) +/−cis-N-(5-cyano-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea
[0284] +/−cis-4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (100 mg, 0.39 mmol) was mixed with toluene (3 ml), triethylamine (1.1 eq), 5-cyano-2-aminopyridine (1.1 eq), DPPA (1.1 .eq) and bubbled with argon for about 5 min. The reaction mixture was then heated at stirring at 115° C. for 3 h under argon. The reaction mixture was concentrated by rotary evaporation and mixed with small amount of dry ethanol. The precipitate formed was collected by suction and washed with ethanol (2×2 ml) Desired product (+/−cis isomer) was obtained as beige-white powder (65 mg, yield 45%).
[0285] 1 H-NMR (DMSO-d 6 ): 9.83 (s, 1H), 8.34 (d, 1H), 8.03 (dd, 1H), 7.75 (br s, 1H), 7.44 (d, 1H), 7.30 (d, 1H), 7.10 (d, 1H), 4.43 (dd, 1H), 4.18 (dd, 1H), 3.55-3.45 (m, ˜1H overlapped with H 2 O signal), 2.54 (dd, 1H), 2.10-2.02 (m, 1H).
EXAMPLE 34
+/−cis-N-(5-chloro-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea
[0286]
[0287] +/−cis-N-(5-chloro-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa [c]chromen-1-yl)urea was synthesized analogously to Example 33 from +/−cis-4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (100 mg, 0.39 mmol) and 2-amino-5-chloropyridine (1.1 eq) to give 66 mg of product as white powder. Yield 44%.
[0288] 1 H-NMR (DMSO-d 6 ): 9.47 (s, 1H), 7.98 (d, 1H), 7.86 (br s, ˜1H), 7.83 (dd, 1H), 7.30 (d, 1H), 7.23 (d, 1H), 7.10 (d, 1H), 4.44 (dd, 1H), 4.18 (dd, 1H), 3.55-3.48 (m, 1H), 2.54 (dd, 1H), 2.10-2.02 (m, 1H).
EXAMPLE 35
+/−cis-N-(5-bromo-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea
[0289]
[0290] +/−cis-N-(5-bromo-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa [c]chromen-1-yl)urea was synthesized analogously to Example 33 from +/−cis-4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (100 mg, 0.39 mmol) and 2-amino-5-bromopyridine (1.1 eq) to give 35 mg of product as grey powder. Yield 21%.
[0291] 1 H-NMR (DMSO-d 6 ): 9.47 (s, 1H), 7.97 (d, 1H), 7.86 (br s, ˜1H), 7.83 (dd, 1H), 7.30 (d, 1H), 7.23 (d, 1H), 7.10 (d, 1H), 4.43 (dd, 1H), 4.18 (dd, 1H), 3.55-3.48 (m, 1H), 2.54 (dd, ˜1H overlapped with DMSO signal), 2.08-2.01 (m, 1H).
EXAMPLE 36
+/−cis-N-(5-phenoxy-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea
[0292]
[0293] +/−cis-N-(5-phenoxy-2-pyridinyl)-N′-(4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea was synthesized analogously to Example 33 from +/−cis-4,7-dichloro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (58 mg, 0.22 mmol) and 2-amino-5-phenoxypyridine (1.1 eq) to give 49 mg of product as slightly brownish powder. Yield 49%.
[0294] 1 H-NMR (CDCl 3 ): 9.30 (br s, 1H), 8.26 (s, 1H), 7.53 (d, 1H), 7.35 (m, 2H), 7.25 (dd, 1H), 7.16-7.10 (dd, ˜1H overlapped with CHCl 3 signal), 7.05 (d, 1H), 6.97-6.90 (m, 3H), 6.72 (d, 1H), 4.46 (dd, 1H), 4.30 (dd, 1H), 2.73 (m, 1H), 2.63 (dd, 1H), 2.05-1.95 (m, 1H).
EXAMPLE 37
+/−cis-N-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)-N′-(5-cyano-2-pyridinyl)urea
[0295] a) 5-chloro-2-fluorophenol
[0296] 5-Chloro-2-fluoroaniline (10 g, 68 mmol) was dissolved in 6M sulfuric acid and cooled in ice/brine bath to −5° C. The solution of NaNO 2 (5.2 g, 76 mmol) in minimum amount of water was added dropwise to the stirred suspension at the temperature not higher then −2° C. After the addition clear yellow solution formed was allowed to stir for additional 30 min at cooling. CuSO 4 was dissolved water (80 ml) and mixed with sulfuric acid (32 ml). The diazonium salt solution was added dropwise to the preheated (160° C.) cuprous sulfate solution and the product was removed from the reaction flask by steam distillation. The reaction took about 2 h to be complete. The water/phnol solution was extracted into ether, washed with brine and dried over Na 2 SO 4 . Concentration gave 4 g of crude phenol (40%).
b) 4-chloro-1-fluoro-2-(2-propynyloxy)benzene
[0297] 4-Chloro-1-fluoro-2-(2-propynyloxy)benzene was synthesized analogously to Example 33a from (4 g, 27 mmol) 4-chloro-1-fluorophenol to give 4.6 g of product (purified by column chromatography on silica, ethyl acetate/n-hexane 1:15) as yellow oil. Yield 90%.
c) 5-chloro-8-fluoro-2H-chromene
[0298] 5-Chloro-8-fluoro-2H-chromene was synthesized analogously to Example 33b) from 4-chloro-1-fluoro-2-(2-propynyloxy)benzene (4.6 g, 25 mmol) to give 1 g of product (purified by column chromatography on alumina, ethyl acetate/n-hexane 1 :15) as colourless oil. Yield 22%.
d) ethyl +/−cis-7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylate
[0299] Ethyl +/−cis-7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylate was synthesized analogously to Example 33c from 5-chloro-8-fluoro-2H-chromene (1 g, 5.4 mmol) to give 360 mg of +/−cis product (purified by column chromatography on silica, ethyl acetate/n-hexane 1:20) as white solid. Yield 25%.
e) +/−cis-7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid
[0300] +/−cis-7-Chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid was synthesized analogously to Example 33d from ethyl +/−cis-7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylate (360 mg, 1.3 mmol) to give 259 mg of +/−-cis acid (80%).
f) +/−cis-N-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)-N′-(5-cyano-2-pyridinyl)urea
[0301] +/−cis-N-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)-N′-(5-cyano-2-pyridinyl)urea was synthesized analogously to Example 33e from +/−cis-7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (60 mg, 0.25 mmol) and 2-amino-5-chloropyridine (1.1 eq) to give 59 mg of product as white powder. Yield 66%.
[0302] 1 H-NMR (DMSO-d 6 ): 9.47 (br s, 1H), 7.89 (d, 1H), 7.80 (br s, 1H), 7.74 (dd, 1H), 7.32 (d, 1H), 7.16-7.05 (m, 2H), 4.39 (dd, 1H), 4.16 (dd, 1H), 3.55-3.48 (m, 1H), 2.51 (dd, ˜1H overlapped with DMSO signal), 2.08-2.01 (m, 1H).
EXAMPLE 38
+/−cis-N-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)-N′-(5-chloro-2-pyridinyl)urea
[0303]
[0304] +/−cis-N-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)-N′-(5-chloro-2-pyridinyl)urea was synthesized analogously to Example 5 from +/−cis-7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (60 mg, 0.25 mmol) and 2-amino-5-chloropyridine (1.1 eq) to give 59 mg of product as white powder. Yield 65%.
[0305] 1 H-NMR (DMSO-d 6 ): 9.47 (br s, 1H), 7.89 (d, 1H), 7.80 (br s, 1H), 7.74 (dd, 1H), 7.32 (d, 1H), 7.16-7.04 (m, 2H), 4.39 (dd, 1H), 4.16 (dd, 1H), 3.55-3.48 (m, 1H), 2.51 (dd, ˜1H overlapped with DMSO signal), 2.06-2.01 (m, 1H).
EXAMPLE 39
+/−cis-N-(5-bromo-2-pyridinyl)-N′-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea
[0306]
[0307] +/−cis-N-(5-bromo-2-pyridinyl)-N′-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)urea was synthesized analogously to Example 32e from +/−cis-7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (60 mg, 0.25 mmol) and 2-amino-5-bromopyridine (1.1 eq) to give 56 mg of product as white powder. Yield 55%.
[0308] 1 H-NMR (DMSO-d 6 ): 9.46 (br s, 1H), 7.96 (d, 1H), 7.83 (dd, 1H), 7.81 (br s, 1H), 7.27 (d, 1H), 7.16-7.04 (m, 2H), 4.38 (dd, 1H), 4.17 (dd, 1H), 3.55-3.48 (m, 1H), 2.51 (dd, ˜1H overlapped with DMSO signal), 2.07-2.00 (m, 1H).
EXAMPLE 40
+/−cis-N-(7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)-N′-(5-phenoxy-2-pyridinyl)urea
[0309]
[0310] +/−cis-N-(7-Chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl)-N′-(5-phenoxy-2-pyridinyl)urea was synthesized analogously to Example 32e from +/−cis-7-chloro-4-fluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (60 mg, 0.25 mmol) and 2-amino-5-phenoxypyridine (1.1 eq) to give 76 mg of product as slightly brownish powder. Yield 73%.
[0311] 1 H-NMR (CDCl 3 ): 9.33 (brs, 1H), 7.93 (s, 1H), 7.51 (d, 1H), 7.38-7.32 (m, 2H), 7.25 (dd, ˜1H overlapped with CHCl 3 signal), 7.16-7.10 (m, 1H), 6.96-6.88 (m, 3H), 6.79 (dd, 1H), 6.68 (d, 1H), 4.45 (dd, 1H), 4.25 (dd, 1H), 3.75-3.70 (m, 1H), 2.61 (dd, 1H), 2.05-1.95 (m, 1H).
EXAMPLE 41
N-[( 1S,1aR,7bR) or (1R,1aS,7bS)-1,1a,2,7b-tetrahydrocyclopropa[c]-[1]benzothiopyran-1-yl]-N′-(5-cyano-2-pyridinyl)urea
[0312] a) 3,4-dihydro-2H-1-benzothiopyran-4-ol
[0313] A solution of thiochroman-4-one (9 g) in ether (27 ml) was added slowly to a mixture of lithium aluminium hydride (0.53 g) in ether (54 ml). After the end of the addition, the mixture was refluxed for 2 hours. The reaction mixture was cooled and ice was added, followed by water and by a solution of 20% H 2 SO 4 . The water phase was washed twice with ether. The ether phase was washed twice with NaOH 2N, and once with water, dried over MgSO 4 and evaporated. The clear oil (8.9 g) crystallised after few hours. Rdt=97%
b) 2H-1-benzothiopyran and 4H-1-benzothiopyran
[0314] 4-Thiochromanol (8.9 g) and potassium acid sulfate (0.89 g) were placed in a flask and evacuated to 1 mm. The flask was put in a bath heated at 90° C. until the alcohol melted. The magnetic stirrer was started and the bath slowly brought to 120° C. Dehydration was rapid and a mixture of the product and water distilled and was collected in a ice-cooled receiver. The product was taken up in ether and dried. The crude product (7 g, Rdt=88%) wasn't purified. The NMR showed the presence of 10% of the 4H-1-benzothiopyran.
c) Ethyl ester 1,1a,2,7b-tetrahydro-cyclopropa[c][1]benzothiopyran-1-carboxylic acid, (1S,1aR,7bR) or (1R,1aS,7bS)
[0315] Ethyl diazoacetate was added slowly to 500 mg of thiochromene at 140 C. The reaction was followed by Gas chromatography and stopped when all starting material was consumed (about 7 hours). The residue was purified by flash chromatography (5% ether in hexane). The cis isomer (46,5 mg, Rdt=6%) was identified by NMR spectroscopy.
d) 1,1a,2,7b, tetrahydro-cyclopropa[c][1]benzothiopyran-1-carboxylic acid, (1S,1aR,7bR) or (1R,1aS,7bS)
[0316] A mixture of the cis isomer (46,5 mg), LiOH (4 eq., 19 mg) in 5 ml of methanol/25% H 2 O was refluxed for 1 hour. After evaporation of the solvent under vacuum, the residue was dissolved in water and washed with ether. The water phase was acidified with concentrated HCl, and extracted twice with dichloromethane. After drying, the organic phase was evaporated and gave the desired acid (30 mg). Rdt=73%.
e) N-[(1S,1aR,7bR) or (1R,1aS,7bS)-1,1a,2,7b-tetrahydrocyclopropa[c][1]benzothiopyran-1-yl]-N′-(5-cyano-2-pyridinyl)urea
[0317] The cis acid (30 mg) was refluxed for 4 hours in toluene (2 ml) in presence of Et 3 N (0.02 ml), diphenyl phosphonic azide (0.03 ml) and 2-amino 6-cyanopyridine (19.5 mg). After cooling, the toluene phase was washed with water, followed by a solution of HCl (0.01 M). The organic phase was dried and evaporated. The residue was purified by flash chromatography (EtOAc 2/Hexane 1) and gave 10 mg of the desired compound. Rdt=22%.
[0318] 1 H (DMSO-d 6 ): 1.96 (1H, m); 2.30 (1H, t, 8.6); 2.71 (1H, ddt, 13.65, 6.24); 3.24 (2H, m); 7.19 (3H, m); 7.37 (1H, dd, 7.4, 1.56); 7.42 (1H, dd, 9.0, 3.1); 7.60 (1H, NH); 8.02 (1H, dd, 9.0, 2.3); 8.15 (1H, s); 9.89 (1H, NH) Mass: 322 (M + .), 321 (M−H)
EXAMPLE 42
(1S,1aR,7bS)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid
[0319] a) (2Z)-3-(3,6-difluoro-2-methoxyphenyl)-2-propen-1-ol.
[0320] A solution of BuLi (2.5M) in hexane (9.6 ml; 0.024 mol) was added to a stirred solution of 2,5-difluoroanisol (2.88 g, 0.02 mol) in dry THF (30 ml) at −70 C, followed after 2 h by solution of zinc chloride (3.6 g ; 0.026 mol) in dry THF (50 ml). The reaction temperature was allowed to raise to room temperature and then stirring was maintained at room temperature for 30 min. Pd(OAc) 2 (8 mg; 0.2 mol %) was added, followed by ethyl cis-3-bromoacrylate (3.58 g ; 0.02 mol). The reaction mixture was placed in preheated oil bath and heated under reflux for 1 h. The resulting reaction mixture was chilled to −78 C and 60 ml (0.06 mol) of DIBAL (1M solution in hexanes) was added dropwise. The stirring was continued at −78 C for 2 h and 1 h at room temperature. The reaction was quenched with water and all solids were dissolved by addition of HCl. The organic phase was diluted with ether, separated, washed with 5N HCl, brine and evaporated in vacuo. The residue was Kugelrohr distilled (1.5×10 −2 mbar, 150 C) to give 3.7 g (92%) of crude (2Z)-3-(3,6-difluoro-2-methoxyphenyl)-2-propen-1-ol, which contains ˜6% of other regioisomers. The crude product was used in the next step without further purification. 1 H-NMR (CDCl 3 ): 7.00 (m, 1H); 6.77 (m, 1H); 6.31 (app. d, 1H); 6.12 (app. dt, 1H); 4.08 (br. t, 2H); 3.89 (d, 3H); 1.80 (br. t, 1H).
b) (2Z)-3-(3,6-difluoro-2-methoxyphenyl)prop-2enyl diazoacetate
[0321] The p-toluenesulfonylhydrozone of glyoxylic acid chloride (5.16 g; 0.02 mol) was added to a solution of (2Z)-3-(3,6-difluoro-2-methoxyphenyl)-2-propen-1-ol (3.6 g; 0.018 mol) in dry CH 2 Cl 2 (50 ml) at −5 C, and N,N-dimethylaniline (2.5 ml; 0.02 mol) was added slowly. After stirring for 30 min at −5 C, Et 3 N (12 ml; 0.09 mol) was added slowly. The resulting mixture was stirred for 15 min at −5 C and then for 30 min at room temperature, whereupon water (˜50 ml) was added. The organic phase was separated washed with water, brine and concentrated in vacuo. Flash chromatography (silica, EA:Hex; 1:15) gave 3.86 g (80%) of product as a yellow solid.
[0322] 1 H-NMR (CDCl 3 ): 7.00 (m, 1H); 6.76 (m, 1H); 6.41 (app. d, J=12.2 Hz; 1H); 6.00 (app. dt, J=12.2; 6.10 Hz; 1H); 4.71 (br. s, 1H); 4.67 (dt, 2H); 3.89 (d, 3H).
c) (1S,5R,6S)-6-(3,6-difluoro-2-methoxyphenyl)-3-oxabicyclo[3.1.0]hexan-2-one.
[0323] (2Z)-3-(3,6-difluoro-2-methoxyphenyl)prop-2enyl diazoacetate (3.45 g, 0.013 mol) was dissolved in 100 ml of dried degassed dichloromethane and added dropwise to the solution of chiral Doyle catalyst (Aldrich, also available from Johnsson Matthey, 10 mg, 0.1 mol %) in 50 ml of dichloromethane under argon at ambient temperature over a period of ˜6 h. The initial blue color had turned to olive by the end of the addition. The reaction mixture was concentrated in vacuo and the crude product was purified by flash chromatography (silica, EA:Hex, 1:5→1:1) to give 2.72 g (88%) of (1S,5R,6S)-6-(3,6-difluoro-2-methoxyphenyl)-3-oxabicyclo[3.1.0]hexan-2-one as colorless solid. Enantiomeric purity could be checked on this stage using Chiracel OD column, 10% IPA in hexane —94% ee.
[0324] 1 H-NMR (CDCl 3 ): 7.00 (m, 1H); 6.72 (m, 1H); 4.33 (dd, 1H); 4.10 (d, 1H); 4.02 (d, 3H); 2.66 (m, 2H); 2.37 (t, 1H).
d) (1S,1aR,7bS)-1-(bromomethyl)-4,7-difluoro-1a,7b-dihydrocyclopropa[c]chromene-2 (1H)-one.
[0325] (1S,5R,6S)-6-(3,6-difluoro-2-methoxyphenyl)-3-oxabicyclo[3.1.0]hexan-2-one (130 mg, 0.55 mmol) was mixed with 1.2 ml of 30% HBr/AcOH (6 mmol) and heated in a sealed vessel at stirring for about 4 h at 90° C. The reaction mixture was then cooled down, mixed with water and extracted into diethyl ether (3×20 ml). Ether extract was washed with sat. sodium bicarbonate solution and brine. Dried over magnesium sulfate. Concentration gave 160 mg of white solid material. 98% yield.
[0326] 1 H-NMR (CDCl 3 ): 7.08 (m, 1H); 6.88 (m, 1H); 3.44 (dd, 1H); 3.06 (t, 1H); 2.96 (dd, 1H); 2.64 (dd, 1H); 2.46 (m, 1H).
e) (1S,1aR,7bS)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid.
[0327] (1S,1aR,7bS)-1-(bromomethyl)-4,7-difluoro-1a,7b-dihydrocyclopropa [c]chromen-2(1H)-one (360 mg, 1.2 mmol) was mixed with the solution of NaOH (0.1 g, 2.5 mmol) in 5 ml of water and heated at stirring for 1 h at 90° C. After completion the reaction mixture was cooled down and extracted into diethyl ether (2×20 ml). Water phase was acidified with conc. HCl. The precipitate formed was collected by filtration to give 180 mg of pure product. Mother liquor was extracted into ether and washed with brine, dried over magnesium sulfate. Concentration gave additional 70 mg of product (containing up to 15% of impurities). Overall yield about 92%.
[0328] 1 H-NMR (CDCl 3 ): 6.86 (m, 1H); 6.54 (m, 1H); 4.48 (m, 2H); 2.62 (t, 1H); 2.20 (t, 1H); 2.11 (m, 1H).
EXAMPLE 43
(+/−) cis N-[1a,6b-dihydro-1H-benzo[b]cyclopropa[d]thien-1-yl]-N′-(5-cyano-2-pyridinyl)-urea
[0329]
a) cis ethyl ester 1a,6b-dihydro-1H-benzo[b]cyclopropa[d]thiophene-1-carboxylic acid, (1S,1aS,6bR) or (1R,1aR,6bS)
[0330] Ethyl diazoacetate is added slowly to 10 g of thiophene at 140° C. The reaction was checked by gas chromatography and stopped after 7 hours. The residue is purified by flash chromatography (5% ether in hexane). The cis isomer (917 mg, Rdt=6%) was identified by NMR spectroscopy.
[0331] Reference: Badger G. M. et al, J. Chem. Soc ., 1958,1179-1184.
[0332] Badger G. M. et al, J. Chem. Soc ., 1958, 4777-4779.
b) cis 1a,6b-dihydro-1H-benzo[b]cyclopropa[d]thiophene-1-carboxylic acid, (1S,1aS,6bR) or (1R,1aR,6bS)
[0333] A mixture of the cis isomer (443 mg), LiOH (193 mg) in 15 ml of methanol/25% H 2 O is refluxed for 1 hour. After evaporation of the solvent under vacuum, the residue is dissolved in water and washed with ether. The water phase is acidified with concentrated HCl, and extracted twice with dichloromethane. After drying, the organic phase is evaporated and gave the desired acid (313.6 mg). Rdt=81%.
c) (+/−) cis N-[1a,6b-dihydro-1H-benzo[b]cyclopropa[d]thien-1-yl]-N′-(5-cyano-2-pyridinyl)-urea
[0334] The cis acid (313 mg) was refluxed for 4 hours in toluene (20 ml) in presence of Et 3 N (0.25 ml), diphenyl phosphoryl azide (0.3 ml) and 2-amino 6-cyanopyridine (220 mg). After cooling, the toluene phase was washed with water, followed by a solution of HCl (0.01 M). The organic phase was dried and evaporated. The residue was purified by flash chromatography (EtOAc 2/Hexane 1) and gave 10 mg of the desired compound. Rdt=2%.
[0335] 1 H (DMSO-d 6 ): 3.32 (1H, m); 3.39 (1H, td, 8.05, 7.69); 3.52 (1H, dd, 7.69, 6.22); 7.08 (1H, td, 7.32, 1.1); 7.15 (1H, td, 7.32, 1.1); 7.22 (1H, dd, 8.4, 0.8); 7.39 (2H, m); 7.50 (1H, NH); 8.00 (1H, dd, 8.79, 2.2); 8.23 (1H, d, 2.2); 9.76 (1H, NH)
[0336] 13 C (DMSO-d 6 ): 25.6 (CH), 29.5 (CH), 33.7 (CH), 101.5 (C), 112.1 (CH), 118.0 (C), 122.1 (CH), 124.9 (CH), 127.3 (CH), 128.0 (CH), 136.3 (C), 141.7 (CH), 143.7 (C), 151.6 (CH), 155.1 (C), 156.1 (C) Mass: 310 (M+2), 309 (M+H)
EXAMPLE 44
(−)-cis-1-(5-Chloro-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropac[c]chromen-1-yl)-urea
[0337]
[0338] This compound was prepared analogously to Example 1c but using chiral (+)−cis-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-carboxylic acid (see Example 42e) (1.3 g, 5.75 mmol). The silica gel purified product was recrystallized from acetonitrile to give 0.95 g (47%) of the title product. Absolute stereochemical configuration assigned as for Example 30.
[0339] 1 H-NMR (CDCl 3 ): 9.25 (broad s, 1H), 8.67 (s, 1H), 7.79 (d, 1H), 7.48 (dd, 1H), 6.92-6.86 (m, 1H), 6.71 (d, 1H), 6.65-6.60 (m, 1H), 4.45 (dd, 1H), 4.34 (dd, 1H), 3.80 (q, 1H), 2.61 (t, 1H), 2.00-1.98 (m, 1H).
EXAMPLE 45
(−)-cis-1-(5-Cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0340]
[0341] (+)-cis-4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (see example 42e) (1,18 g, 5.2 mmol), diphenylphosphorylazide [1340 μL, 6.3 mmol (d=1.277)], triethylamine (870 μL, 6.3 mmol) and 2-amino-5-cyanopyridine (740 mg, 6.3 mmol) were dissolved in toluene (15 mL) and refluxed for 4 h. The solvent was then removed in vacuo and the crude product was dissolved in ether and washed (3×100 mL 0.01 M HCl) and purified by chromatography (silica gel, 0O % MeOH in ether) to give pure (−)-cis-1-(5-cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea (1.1 g, 64%). ee 92% as determined by HPLC on a Chiral AGP column, eluent 11% acetonitrile in sodium phosphate buffer, flow 0.9 mL/min. Absolute stereochemical configuration assigned as for Example 30.
[0342] 1 H-NMR (CDCl 3 ): 9 (s, NH), 8.42 (s, NH), 8.16 (d, 1H), 7.72 (dd, 1H), 6.97-6.76 (m, 2H), 6.69-6.61 (m, 1H), 4.47 (dd, 1H), 4.31 (dd, 1H), 3.75 (m, 1H), 2.65 (t, 1H), 2.05-1.96 (m, 1H).
EXAMPLE 46
(−)-cis-1-(5-cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-thiourea
[0343]
[0344] (+)-cis-4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid (2.2 g, 9.7 mmol), DPPA [2380 μl, 10.7 mmol 97%( d=1.277)] and TEA (1510 μl, 11.7 mmol) was refluxed in toluene (20 ml) for 2 h. Dioxane (26 mL) and HCl (aq) (26 mL, 6M) was then added and the reaction mixture was left for 1-2 h. At 50° C. Water (50 mL) was added and the water phase was washed with Ether (2×25 mL) and then made alkaline with ammonia (aq) . Extraction with dichioromethane and drying gave the intermediate 4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1ylamine (1.37 g, 71%), which was directly treated with 6-isothiocyanato-nicotinonitrile (1.25 g, 7.7 mmol) in acetonitrile (2 mL) at RT over the weekend. The precipitated crystals were filtrated off and the solvent removed in vacuo and chromatographed (silica, 20% ether in pentane). The product obtained was combined with the crystals and the crude product (900 mg) was re-crystallised (ethanol-acetone) to give pure (−)-cis-1-(5-cyano-pyridin-2-yl)-3-(4,7-difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]-chromen-1-yl)-thiourea (590 mg 18%). Absolute stereochemical configuration assigned as for Example 30.
[0345] 1 H-NMR (CDCl 3 -MeOD): 8.1 (d, 1H), 7.77 (dd, 1H), 6.99-6.91 (m, 1H), 6.74 (dd, 1H) 6.73-6.66 (m, 1H), 4.48 (dd, 1H), 4.33 (dd, 1H), 4.20 ( dd, 1H), 2.78 (t, 1H), 2.16-2.1 (m, 1H).
EXAMPLE 47
(+)-cis-1-(5-bromopyridin-2-yl)-3-(7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea
[0346]
a) 1-(4-Fluoro-2-prop-2-ynyloxy-phenyl)-propan-1-one.
[0347] To a mixture of NaH (95%, 278 mg, 11 mmol) in DMF (20 mL) at 0° C., was added 1-(4-fluoro-2-hydroxy-phenyl)-propan-1-one (1.68 g, 10 mmol) in DMF (5 mL). After 15 min at 0° C., was 3-bromo-propyne (3.02 g, 20 mmol) added to the reaction mixture. After 1 h at 0° C., was the reaction mixture allowed to assume room temperature. The reaction mixture was extracted with H 2 O (100 mL). The H 2 O phase was washed with Et 2 O (3×100 mL) and the solvent of the combined organic phases was removed under reduced pressure. The crude product was purified by column chromatography (silica gel, CH 2 Cl 2 ), to give 1.40 g (68%) of 1-(4-fluoro-2-prop-2-ynyloxy-phenyl)-propan-1-one.
[0348] 1 H-NMR (CDCl 3 ): 7.64 (dd, 1H), 6.69 (dd, 1H), 6.60 (ddd, 1H), 4.68 (d, 2H), 2.85 (q, 2H), 2.58 (t, 1H), 1.03 (t, 3H).
[0000] b) 1-(5-Fluoro-2H-chromen-8-yl)-propan-1-one.
[0349] 1-(5-Fluoro-2H-chromen-8-yl)-propan-1-one was synthesized analagously to Example 3b from 1-(4-fluoro-2-prop-2-ynyloxy-phenyl)-propan-1-one (1.34 g, 6.5 mmol), to give 619 mg (46%) of 1-(5-fluoro-2H-chromen-8-yl)-propan-1-one.
[0350] 1 H-NMR (CDCl 3 ): 7.60 (dd, 1H), 6.67-6.58 (m, 2H), 5.86 (dt, 1H), 4.76 (dd, 2H), 2.93 (q, 2H), 1.23 (t, 3H).
[0000] c) (+)-cis-7-Fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester.
[0351] (±)-cis-7-Fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester was synthesized according to method 3c) from 1-(5-fluoro-2H-chromen-8-yl)-propan-1-one (619 mg, 3 mmol), to give 142 mg (16%) of (±)-cis-7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester and (+)-trans-7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester as a byproduct.
[0352] 1 H-NMR (CDCl 3 ): 7.59 (dd, 1H), 6.65 (m, 1H), 4.50-4.46 (m, 2H), 3.95 (q, 2H); 2.89 (q, 2H), 2.57 (dd, 1H), 2.20 (dd, 1H), 1.13-1.03 (m, 1H), 1.12-1.01 (m, 6H).
[0000] d) (±)-cis-7-Fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0353] (±)-cis-7-Fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid was synthesized analogously to Example 1b from (±)-cis-7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid ethyl ester (140.3 mg, 0.48 mmol), to give 83 mg (65%) of (±)-cis-7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid as a white solid. The crude product was purified by column chromatography (silica gel, 1→5% MeOH in CH 2 Cl 2 ).
[0354] 1 H-NMR (DMSO-d 6 ): 12.15 (brs, 1H), 7.46 (dd, 1H), 6.78 (dd, 1H), 4.57 (dd, 1H), 4.43 (dd, 1H), 2.93-2.80 (m, 2H), 2.55 (dd, 1H), 2.24 (dd, 1H), 2.20-2.10 (m, 1H), 1.02 (t, 3H).
[0000] e) (±)-cis-1-(5-bromopyridin-2-yl)-3-(7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromen-1-yl)-urea.
[0355] The title compound is synthesized analogously to example 1c) by reacting 1 equivalent of (±)-cis-7-fluoro-4-propionyl-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid and 1 eq of triethylamine in toluene with 1 eq of diphenylphosphoryl azide for 30 minutes at room temperature. The reaction mixture is heated to 120° C. and an approximately equimolar solution of 2-amino-5-bromopyridine is added. After 3 hours the solution is allowed to assume room temperature and the title compound extracted as shown above.
EXAMPLE 48
(1S,5R,6S)-6-(3,6-difluoro-2-methoxyphenyl)-2-methoxy-3-oxabicyclo[3.1.0]hexane
[0356]
a) Iodo-3-oxabicyclo[3.1.0]hexan-2-one
[0357] The title compound is synthesised in the depicted stereochemistry as described in Doyle J Amer Chem Soc 117 (21) 5763-5775 (1993)
b) Iodo-2-methoxy-3-oxabicyclo[3,1,0]hexane
[0358] The title compound is synthesised in the depicted stereochemistry as described in Martin et al Tett Lett 39 1521-1524 (1998).
c) (1S,5R,6S)-6-(3,6-difluoro-2-methoxyphenyl)-2-methoxy-3-oxabicyclo[3.1.0]hexane
2,4-diflouroanisol (90 mg, 0.62 mmol) was dissolved in anhydrous, degassed, THF (7 ml) and cooled to −78° C. under N 2 . nBuLi, 2,5 M in hexane, (0.30 ml, 0.77 mmol) was added and the reaction mixture was stirred at −78° C. for 2 hrs. ZnCl 2 (150 mg, 1.1 mmol), as a solution in anhydrous THF (7 ml), was added and the reaction mixture was allowed to warm to ambient temperature for 2 hrs. Iodo-2-methoxy-3-oxabicyclohexane (150 mg, 0.63 mmol), Pd (OAc) 2 (1.5 mg, 6.2 μmol), and ligand Tris(2,4-di-tert-butylphenyl)phosphite (40 mg, 62 μmol) were mixed in anhydrous THF (7 ml) and added to the reaction mixture. The reaction mixture was heated at reflux for 3 days and quenched with H 2 0. Diethyl ether was added and the layers were separated, the organic layer was washed with H 2 O and aq. sat. NaCl, dried over MgSO 4 , filtered and concentrated to give the title compound, otherwise denoted 2,4-di-fluoro-5-(cyclopropylacetal)anisol. Column chromatography on silica (EtOAc/Hexane 1:3) gave (4) 50 mg, 31%.
[0359] 1 H NMR (CDCl 3 ) δ (ppm): 6.88-6.94 (m, 1H, ArH), 6.68-6.73 (m, 1H, ArH), 4.82 (s, 1H, CHOCH 3 ), 3.97-3.98 (m, 1H, CHOCH) 3.94 (s, 3H, OCH 3 ), 3.79-3.81 (m, 1H, CHOCH) 3.30 (s, 3H, OCH 3 ), 2.13-2.19 (m, 2H, 2×CH-cyclopropyl), 1.89 (tr, J=7.81 Hz, 1H, CH cyclopropyl).
EXAMPLE 49
cis-4,7-Difluoro-1,1a,2,7b-tetrahydro-cyclopropa[c]chromene-1-carboxylic acid.
[0360]
[0361] BBr 3 1M solution in CH 2 Cl 2 (5.8 ml; 5.8 mmol 2.1 eq) was added to starting lactone, (1S,5R,6S)-6-(3,6-difluoro-2-methoxyphenyl)-3-oxabicyclo[3.1.0]hexan-2-one from example 42c) (0.66 g; 2.75 mmol) at 0° C. The reaction mixture was stirred at 0C for 1 h. Acetonitrile (5.8 ml) was added and stirring was continued for 3 h at 0° C. The reaction mixture was quenched by addition of water and the organic phase was separated. Water phase was extracted with CH 2 Cl 2 and combined organic phases were evaporated. NaOH (0.33 g; 8.25 mmol; 3 eq) in water (˜5 ml) was added to the resulted residue and stirred at 80° C. for 45 min. The reaction mixture was extracted with ether to remove none acidic impurities. The residual ether in water phase was evaporated in vacuo and conc. HCl was added to pH of ˜3. After ˜1 h the solid was filtered off yielding 0.497 g (80%) of crude final acid as brownish solid. The crude acid was dissolved in 6 ml of EtOH/H 2 O (40/60 v/v) and treated with activated carbon. The hot solution was filtered and left for crystallization. Yield 0.4 g (64%).
EXAMPLE 50
N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(5-fluoro-2-pyridinyl)urea
[0362]
[0363] (1S,1aR,7bS)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (50 mg, 0.22 mmol, ee ˜90%) was mixed with toluene (1 ml), triethylamine (0.034 ml, 1.1 eq), 2-amino-5-fluoropyridine (28 mg, 1.1 eq), DPPA (0.054 ml, 1.1 eq). The reaction mixture was then heated at stirring at 110° C. for 3 h. The reaction mixture was concentrated by rotary evaporation and purified by column chromatography on silica (50 g, ethylacetate/hexane 1:1) to give 30 mg of the product as white solid.
[0364] 1 H-NMR (DMSO-d 6 ): 9.34 (brs, ˜1H), 7.85 (brd, 2H), 7.6 (d t, 1H), 7.33 (dd, 1H), 7.06 (m, 1H), 6.77 (dt, 1H), 4.29 (m, 2H), 3.48 (m, 1H), 2.48 (m, 1H/overlapped with DMSO signal), 2.00 (m, 1H). LC-MS: M + 336
EXAMPLE 51
N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(5-iodo-2-pyridinyl)urea
[0365]
[0366] (1S,1aR,7bS)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (50 mg, 0.22 mmol, ee ˜90%) was mixed with toluene (1 ml), triethylamine (0.034 ml, 1.1 eq), 2-amino-5-iodopyridine (54 mg, 1.1 eq), DPPA (0.054 ml, 1.1 eq). The reaction mixture was then heated at stirring at 110° C. for 3 h. The reaction mixture was concentrated by rotary evaporation and purified by column chromatography on silica (50 g, ethylacetate/hexane 1:1) to give 35 mg of the product as white solid.
[0367] 1 H-NMR (DMSO-d 6 ): 9.4 (br s, ˜1H), 8.07 (d, 1H), 8.02 (br s, ˜1H), 7.91 (dd, 1H), 7.11 (d, 1H), 7.06 (m, 1H), 6.77 (dt, 1H), 4.29 (br d, 2H), 3.5 (m, 1H), 2.46 (m, 1H/overlapped with DMSO signal), 2.00 (m, 1H). LC-MS: M + 444.
EXAMPLE 52
N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(3-isoxazolyl)urea
[0368]
[0369] (1S,l aR,7bS)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (50 mg, 0.22 mmol, ee ˜90%) was mixed with toluene (1 ml), triethylamine (0.034 ml, 1.1 eq), 3-aminoisoxazole (0.018 ml, 1.1 eq), DPPA (0.054 ml, 1.1 eq). The reaction mixture was then heated at stirring at 110° C. for 3 h. The reaction mixture was concentrated by rotary evaporation and purified by column chromatography on silica (50 g, ethylacetate/hexane 1:1) to give 10 mg of the product as white solid.
[0370] 1 H-NMR (DMSO-d 6 ): 9.45 (br s, ˜1H), 8.6 (d, 1H), 7.06 (m, 1H), 6.75 (dt, 1H), 6.63 (d, 1H), 6.33 (br s, ˜1H), 4.29 (m, 2H), 3.37 (overlapped with water signal), 2.43 (m, 1H), 1.98 (m, 1H). LC-MS: M + 308.
EXAMPLE 53
N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-[4-(4-chlorophenyl)-1,3-thiazol-2-yl]urea
[0371]
[0372] (1S,1aR,7bS)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (50 mg, 0.22 mmol, ee ˜90%) was mixed with toluene (1 ml), triethylamine (0.034 ml, 1.1 eq), 2-amino-4-(4-chlorophenyl)-1,3-thiazole (52 mg, 1.1 eq), DPPA (0.054 ml, 1.1 eq). The reaction mixture was then heated at stirring at 110° C. for 3 h. The reaction mixture was concentrated by rotary evaporation and the product was crystallized from ethanol and collected by filtration to give 50 mg of the product as white solid.
[0373] 1 H-NMR (CDCl 3 ): 10.32 (br s, ˜1H), 7.68 (d, 2H), 7.37 ( s, 1H), 7.32 (d, 2H), 6.96 (s, 1H), 6.87 (m, 1H), 6.62 (dt, 1H), 4.44 (dd, 1H), 4.33 (dd, 1H), 3.53 (m, 1H), 2.56 (m, ˜1H), 1.96 (m, 1H). LC-MS: M + 434.
EXAMPLE 54
N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(6-fluoro-1,3-benzothiazol-2-yl)urea
[0374]
[0375] (1S,1aR,7bS)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (50 mg, 0.22 mmol, ee ˜90%) was mixed with toluene (1 ml), triethylamine (0.034 ml, 1.1 eq), 2-amino-6-fluoro-1,3-benzothiazole (41 mg, 1.1 eq), DPPA (0.054 ml, 1.1 eq). The reaction mixture was then heated at stirring at 110° C. for 3 h. The reaction mixture was concentrated by rotary evaporation and the product was crystallized from ethanol and collected by filtration to give 20 mg of the product as white solid.
[0376] 1 H-NMR (CDCl 3 ): 10.58 (br s, ˜1H), 7.78 (br d, 1H), 7.52 ( dd, 1H), 7.45 (dd, 1H), 7.05 (dt, 1H), 6.94 (m, 1H), 6.65 (dt, 1H), 4.44 (dd, 1H), 4.33 (dd, 1H), 3.53 (m, 1H), 2.58 (m, ˜1H), 2.03 (m, 1H). LC-MS: M + 434.
EXAMPLE 55N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(4-pyrimidinyl)urea
[0377]
[0378] (1S,1aR,7bS)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (50 mg, 0.22 mmol, ee ˜90%) was mixed with toluene (1 ml), triethylamine (0.034 ml, 1.1 eq), 4-aminopyrimidine (25 mg, 1.1 eq), DPPA (0.054 ml, 1.1 eq). The reaction mixture was then heated with stirring at 110° C. for 3 h. The reaction mixture was concentrated by rotary evaporation and the product was crystallized from ethanol and collected by filtration to give 20 mg of the product as white solid.
[0379] 1 H-NMR (DMSO-d 6 ): 9.71 (br s, 1H), 8.4 (br s, 1H), 8.39 (d, 1H), 7.86 (br s, 1H), 7.31 (d, 1H), 7.08 (m, 1H), 6.77 (dt, 1H), 4.31 (m, 2H), 3.48 (m, 1H), 2.48 (m, 1H, overlapped with DMSO signal), 2.02 (m, 1H).
EXAMPLE 56
N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(2-pyrazinyl)urea
[0380]
[0381] (1S,1aR,7bS)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (50 mg, 0.22 mmol, ee ˜90%) was mixed with toluene (1 ml), triethylamine (0.034 ml, 1.1 eq), 4-aminopyrazine (25 mg, 1.1 eq), DPPA (0.054 ml, 1.1 eq). The reaction mixture was then heated with stirring at 110° C. for 3 h. The reaction mixture was concentrated by rotary evaporation and the product was crystallized from ethanol and collected by filtration to give 5 mg of the product as white solid.
[0382] 1 H-NMR (DMSO-d 6 ): 9.57 (br s, 1H), 8.67 (br s, 1H), 8.10 (d, 1H), 7.95 (br s, 1H), 7.64 (br s, 1H), 7.05 (m, 1H), 6.77 (dt, 1H), 4.31 (m, 2H), 3.49 (m, 1H), 2.48 (m, ˜1H, overlapped with DMSO signal), 2.02 (m, 1H).
EXAMPLE 57
N-[(1S,1aR,7bR)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromen-1-yl]-N′-(5-cyclopropyl-1H-pyrazol-3-yl)urea
[0383]
[0384] (1S,1aR,7bS)-4,7-difluoro-1,1a,2,7b-tetrahydrocyclopropa[c]chromene-1-carboxylic acid (50 mg, 0.22 mmol, ee ˜90%) was mixed with toluene (1 ml), triethylamine (0.034 ml, 1.1 eq), 3-amino-5-cyclopropyl-1H-pyrazole (30 mg, 1.1 eq), DPPA (0.054 ml, 1.1 eq). The reaction mixture was then heated at stirring at 110° C. for 3 h. The reaction mixture was concentrated by rotary evaporation and two compounds were separated by column chromatography on silica (50 g, ethylacetate/hexane 1:3) to give 3 mg of the title product. The structure assignment was proved by 13 C, gHMBC, gHMQC and NOESY NMR experiments.
[0385] 1 H-NMR (CDCl 3 ): 7.05 (br d, ˜1H), 6.88 (m, 1H), 6.64 (dt, 1H), 5.24 (d, 1H), 4.49 (dd, 1H), 4.33 (dd, 1H), 3.63 (m, 1H), 2.61 (m, ˜2H), 1.99 (m, 1H), 0.99 (m, 2H), 0.58 (m, 2H).
Biological results
[0386] Extensive guidance on the assay of test compounds at the enzyme level and in cell culture, including the isolation and/or selection of mutant HIV strains and mutant RT are found in DAIDS Virology Manual for HIV Laboratories complied by Division of AIDS, NIAID USA 1997. Resistance studies, including rational for various drug escape mutants is described in the HIV Resistance Collaborative Group Data Analysis Plan for Resistance Studies, revised 31 Aug. 1999.
[0387] Compounds of the invention are assayed for HIV activity, for example using multiple determinations with XTT in MT-4 cells (Weislow et al, J Nat Cancer Inst 1989, vol 81 no 8, 577 et seq), preferably including determinations in the presence of 40-50% human serum to indicate the contribution of protein binding. In short the XTT assay uses human T cell line MT4 cells grown in RPMI 1640 medium supplemented with 10% fetal calf serum (or 40-50% human serum as appropriate), penicillin and streptomycin seeded into 96 well microplates (2·10 4 cells/well) infected with 10-20 TCID 50 per well of HIV-1 IIIB (wild type) or mutant virus, such as those bearing RT IIe 100, Cys 181 or Asn 103 mutations. Serially diluted test compounds are added to respective wells and the culture incubated at 37° C. in a CO 2 enriched atmosphere and the viability of cells is determined at day five or six with XTT vital dye. Results are typically presented as ED 50 μM.
[0388] Compounds of the invention were assayed in the above XTT assay using wild type HIV-1 IIIB as shown in Table I:
TABLE 1 Example ED 50 (nM) Example 7 7 Example 16 6 Example 18 6 Example 19 10 Example 20 7 Example 23 7 Example 24 20 Example 30 3 Example 31 2.5 Example 33 9 Example 43 2
[0389] Compounds are preferably potent against wild type virus and mutant HIV virus, especially virus comprising drug escape mutations. Drug escape mutations are those which arise in patients due to the selective pressure of a prior art antiviral and which confer enhanced resistance to that antiviral. The above cited Data Analysis Plan outlines relevant drug escape mutants for each of the antiviral classes currently on the market. Drug escape clones are readily isolated from HIV patients who are failing on a particular antiviral therapy. Alternatively the preparation of RT mutations on a known genetic background is shown in WO97/27319, WO99/61658 and WO00/73511 which also show the use of such mutants in sensitivity profiling.
[0390] K103 N is a particularly relevant drug escape mutant in the context of NNRTI therapy and compounds of the invention preferably have a low ED 50 against this mutant, especially in assays mimicking the presence of human serum. Compounds of the invention, such as those exemplified above show sub micromolar activities in such assays. | This invention relates to non-nucleoside reverse transcriptase inhibitors active against HIV-1 and having an improved resistance and pharmacokinetic profile. The invention further relates to novel intermediates in the synthesis of such compounds and the use of the compounds in antiviral methods and compositions. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of the U.S. national stage designation of International Application PCT/EP99/05333 filed Jul. 20, 1999, the content of which is expressly incorporated herein by reference thereto.
FIELD OF INVENTION
[0002] The invention relates to the refining of fatty substances, in particular of oils, in order to selectively free them from most of their free fatty acids.
BACKGROUND ART
[0003] In the treatment of fatty substances, the removal of free fatty acids is a major step, the aim of which is to lead to oxidation, products with good stability and good organoleptic qualities.
[0004] The following process for removal of free fatty acids from fatty substances are known in the art: alkaline refining, refining micelles, steam distillation, liquid/liquid extraction and membrane or chromatographic separation. Among these known methods, only alkaline refining and steam distillation are applied on an industrial scale.
[0005] These known methods have disadvantages. For example, some of the disadvantages of alkaline refining are loss of neutral oil by saponification, occlusion of soaps in the neutral oil, elimination of active phenolic compounds and the need to treat the soaps. By way of illustration, a process for refining oils containing fatty acids as impurities by neutralizing the crude oils with an aqueous alkaline solution containing a polyol and separating the purified oils from the soaps formed is known, for example, from FR-A-2321537.
[0006] One of the disadvantages of steam distillation is that it takes place at high temperature and under a high vacuum, which causes losses of volatile nutrients, for example tocopherols, undesirable chemical changes, for example formation of trans fatty acids, changes in color and polymerizations.
[0007] An object of this invention is to provide an industrially applicable process which selectively and quantitatively removes the fatty acids without exhibiting the above mentioned disadvantages.
SUMMARY OF THE INVENTION
[0008] The present invention provides a process for removal of free fatty acids from fatty substances or oils. In particular, this process comprises removal of free fatty acids by a controlled neutralization, at a temperature greater than the melting point of the fatty substances, in an aqueous medium containing an alcohol or a polyol. A base is gradually added to the reaction medium so as to maintain the pH at 9-11, which leads to partition of the free fatty acids between a lipid phase and an aqueous phase containing the alcohol or the polyol, that is nonmiscible with the lipid phase. The formation of soaps, which are solubilized progressively in the aqueous phase, produces a shift in the equilibrium and a gradual deacidification of the lipid phase until the pH has stabilized, in that the two phases are separated and in that the deacidified lipid phase is collected, from which the alcohol or the polyol is removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] In the text which follows, fatty substances will be called “oils” for the sake of simplicity.
[0010] According to a first embodiment of the process, the controlled neutralization of the fat containing free fatty acids is carried out in a reactor equipped with a pH electrode, with a stirrer and a pH-stat equipped with a burette delivering an aqueous alkaline solution. The pH-stat is connected to the pH electrode so as to provide the alkaline solution as required when a set pH value, for example 9.5, is reached.
[0011] The reaction is carried out in the presence of alcohol, in a homogeneous medium with slow stirring, at a temperature greater than the melting point of the fatty substance and less than the azeotropic boiling point of the aqueous-alcoholic mixture, preferably at room temperature. The stirring conditions chosen are such that the lipid phase and the aqueous-alcoholic phase remain separated during the neutralization, which makes it possible to avoid the formation of stable emulsions due to the presence of soaps. The pH electrode is in contact with the aqueous-alcoholic phase alone. In this embodiment, the neutralization lasts for 6 to 20 h depending on the pH chosen for the neutralization, depending on the characteristics of the equipment and depending on the nature of the initial fat. The fat:alcohol volume ratio used is 1:0.5 to 1:2.5.
[0012] It is possible to use, as alcohol, a C 1 -C 3 alcohol, preferably ethanol or 2-propanol.
[0013] In a preferred embodiment, allowing easier application on an industrial scale, the process according to the invention may be carried out in a heterogeneous medium, with vigorous stirring, in the presence of an alcohol or a polyol at a temperature of 40 to 80° C., with a pH of 9-11 and in a simple manner, without using a pH-stat. The quantity of alkali just required for the neutralization is calculated, without excess of alkali, relative to the quantity of free fatty acids present, determined for example by calorimetric titration. The neutralization may be carried out in about 60 min. As polyol, there may be used glycerol, propylene glycol, ethylene glycol or a polyalkylene glycol, in particular a polyethylene glycol, propylene glycol or a polyethylene glycol being preferred, anhydrous or diluted with water. The polyol:fat weight ratio may be, preferably, from 0.5:10 to 1:1.
[0014] The advantage of using a polyol is being able to work in conventional plants, that it is not necessary for the plant to be constructed in order to withstand explosions with a device for recovering the solvents.
[0015] Regardless of the variant of the process, it is possible to use, as alkali, an aqueous solution of KOH or of NaOH at concentrations of 1 to 40% by weight.
[0016] A decisive advantage of the process according to the invention is that, in contrast to conventional refining processes, it is not necessary to add alkali in excess for the neutralization. The weakly acidic phenolic substances are thus preserved and the alkaline hydrolysis of the triacylglycerols avoided.
[0017] Furthermore, it is not necessary to know precisely either the quantity of fatty acids present in the fat, or the weight of the fat to be neutralized.
EXAMPLES
[0018] The following examples illustrate, bud do not limit, this invention. . In these examples, the parts and proportions are by weight, unless otherwise stated.
Examples 1-3
[0019] [0019] 100 g of filtered coffee oil, that is to say degummed and dewaxed in a conventional manner, are introduced into a 400-ml beaker, provided with an anchor-shaped stirrer, containing an Inlab 420 (R) pH electrode (Mettler-Toledo, Greifensee, CH) connected to a pH-stat (Metrohm 620 (R), Impulsomat 614 (R), Dosimat 645 (R)) provided with a glass reactor, a 20-ml glass cylinder and a burette (Metrohm, Herisau, CH) combined with a pipette delivering an alkaline solution. The coffee oil contains 4.85% of free fatty acids as measured by calorimetric titration in methanol/hexane nonaqueous medium with an ethanolic solution of KOH using phenolphthalein as pH indicator (IUPAC 2.201 method).
[0020] 100 ml of 94% aqueous ethanol (Fluka, Buchs, CH) are added to the reaction mixture and the mixture is moderately stirred at 70 rpm at room temperature. The moderate stirring makes it possible to work in a homogeneous medium, avoiding the mixing of phases and the formation of an emulsion. The pH value is then set by means of the pH-stat. The pH electrode as well as the pipette delivering the alkaline solution are placed such that they are completely present in the aqueous-alcoholic phase. The system for delivering the aqueous KOH solution at 85% is switched on and controlled automatically during the reaction. When there is no longer consumption of alkali, the system is stopped manually. The two phases are then separated by settling out and the fatty phase is washed by stirring it moderately with 50 ml of aqueous ethanol. The aqueous phases are then removed. The fatty phase is dried under vacuum (80° C./25 mbar) and the loss of neutral lipids is determined by differential weighing. The deacidified oil is treated with 1% of adsorbent (Trisyl 300(R)) at 80° C./15 min so as to remove the residual soaps, and then it is dried under vacuum at 80° C./25 mbar for 15 min. After filtration, the quantity of residual free fatty acids is finally determined by potentiometric titration (IUPAC 2.201 method).
[0021] By way of comparison (Comparative Example 1), conventional neutralization of the preceding coffee oil is carried out in the following manner: 100 g of degummed and dewaxed coffee oil are treated at 70-80° C. in a 400-ml glass beaker provided with a stirrer. A quantity of 30% aqueous KOH solution, equivalent to the content of free fatty acid measured by calorimetric titration with phenolphthalein, plus an excess of 2 to 5%, are added thereto over 2 min. The mixture is then stirred for 5 min at 70-80° C. and it is centrifuged at 3000 rpm, at 60° C. for 10 min. The fatty phase is separated and the loss of neutral oil is determined by differential weighing. The deacidified oil is then treated with 1% of adsorbent (Trisyl(R)) at 80° C. for 15 min so as to remove the residual soaps therefrom, and finally the oil is dried under vacuum at 80° C./25 mbar for 15 min. After filtration, the quantity of residual free fatty acids is determined by potentiometric titration (IUPAC 2.201 method).
[0022] Table 1 shows neutralization conditions and results obtained by the processs of the present invention, compared to that of conventional neutralization. It is observed that the loss of free fat decreases by a factor greater than 3 when a process according to the invention is used compared with a conventional neutralization.
TABLE 1 Water Alkali, Free in Neutra- 5N Dur- fatty Losses of ethanol lization KOH ation acids neutral Example (%) pH (ml) (h) (%) lipids 1 10 11 3.32 17 0.2 2.8 2 15 9.5 3.28 20 0.29 2.5 3 15 11 3.34 20 0.22 2.7 Comparative 1 — — 3.5 — 0.23 9.5
Examples 4-9
[0023] A degummed and dewaxed rice bran oil is treated in a conventional manner, under conditions similar to those of Examples 1-3 . Thus, 100 g of oil containing 9.14% of free fatty acids and 1.57% of oryzanol are introduced into a beaker and brought into contact with 150 ml of aqueous ethanol (Fluka, Buchs, CH), with moderate stirring at 75 rpm, at room temperature. The pH is set at different set values by means of a pH stat and the system for delivering an aqueous solution of alkali is switched on as described above. At the end of the neutralization reaction, the contents of free fatty acids and of oryzanol are determined by potentiometric titration.
[0024] By way of comparison (Comparative Example 2), a conventional neutralization of the rice bran oil is carried out as described above for the Comparative Example 1.
[0025] Table 2, below, shows neutralization conditions and the results obtained by the process according to the invention as compared to conventional neutralization. It is observed that the losses of neutral lipids and of oryzanol decrease considerably when the process according to the invention is used as compared with conventional neutralization.
TABLE 2 Water in Alkali 5N Free fatty Losses Losses of ethanol Neutralization KOH Duration acids Oryzanol of oryzanol neutral lipids Example (%) pH (ml) (h) (%) (%) (%) (%) 4 6 9.5 6.25 16 0.14 1.5 4.5 2.4 5 10 9.5 6.25 18 0.18 1.5 4.5 1.5 6 15 9.5 6.25 20 0.2 1.5 4.5 1 7 20 9.5 6.25 22 0.22 1.5 4.5 <1 8 10 10 6.25 16 0.1 1.5 4.5 1.6 9 10 11 6.25 16 0.07 1.41 10 2.6 Comparative — — 8.5 — 0.07 0.16 90 13 2
Examples 10-12
[0026] A synthetic mixture composed of palm fat containing 51.82% of free fatty acids of the following composition is treated:
% Caprylic acid C 8:0 9.27 Capric acid C 10:0 14.83 Lauric acid C 12:0 9.27 Oleic acid C 18:1 66.62
[0027] To carry out the neutralization, the procedure is carried out in a heterogeneous medium, with vigorous stirring, in the presence of 94% ethanol or of propylene glycol in a simple manner, without using a pH-stat. To control the reaction, the quantity of alkali just necessary for the neutralization, without excess of alkali, is calculated relative to the quantity of free fatty acids present, determined by colorimetric titration (IUPAC 2.201 method). 100 g of fat are introduced into a 400-ml beaker equipped with an anchor-type stirrer; the solvent is added thereto and the mixture is stirred at 125 rpm. An Inlab 424-type pH-measuring electrode (Mettler), connected to a pH-meter 632 (Metrohm), is plunged into the mixture. The mixture is then heated with the aid of an oil bath. When the temperature of the mixture reaches 60-65° C., a 10% aqueous NaOH solution is added dropwise thereto with the aid of a dropping funnel. The pH increases slowly from the initial value of about 3, until the value of 10 is reached, after which the addition of the alkali is stopped. The mixture is further stirred for 30 min while the pH is kept at 10 by addition of a few drops of alkali. The quantity of alkali used corresponds to 0.227 mol, that is to say 101.3%. After that, the stirring is stopped and the mixture is allowed to settle out for 2 h. The light phase, consisting of the neutralized fat, is washed with 50 ml of water, it is dried under vacuum at 70° C./30 mbar, it is weighed and it is analysed.
[0028] The heavy phase, composed of the soaps, the solvent and the water, is separated so as to treat it with an acid in order to recover the fatty acids. It is acidified to pH 2.5 with an aqueous solution of 31.6 g of H 3 PO 4 at 85%. After 2 h of settling out, two phases are formed:
[0029] the top phase containing the fatty acids is dried at 70° C./30 mbar and 53.1 g of a fraction containing about 90% of fatty acids are obtained,
[0030] the bottom phase which contains partially crystallized sodium phosphate in suspension in a mixture of solvent and water. After removing the water by vacuum distillation and filtration of the sodium phosphate, the solvent can be reused for a subsequent operation.
Example 13
[0031] A rice bran oil which has been subjected to partial degumming is treated with water in the same manner as in Examples 10-12 above. The quantity of alkali used for the neutralization is 0.03 mol, that is to say 93.4%.
[0032] Table 3 shows the neutralization conditions and the results obtained by treating 100 g of fat are indicated in Examples 10-13. In Examples 10-12, the content of residual fatty acids is equal to or less than 0.1%. In Examples 10 and 12, the use of propylene glycol does not generate a loss of neutral lipids greater than 5%. In Example 12, when the rice bran oil is treated, the loss of oryzanol is about 9.1%.
TABLE 3 NaOH Initial free Final free Initial Final Losses of Solvent 10% fatty acids fatty acids oryzanol oryzanol Final yield neutral lipids* Example (g) (g) (%) (%) (%) (%) (g) (%) 10 100 90.8 51.82 0.1 — — 45.8 5 propylene glycol 11 100 91 51.82 0.08 — — 44.6 7.5 EtOH 12 100 91.5 51.82 0.09 — — 45.5 5.6 polyethylene glycol 200 13 10 13.3 9.87 0.06 1.7 1.55 87.5 3.4 propylene glycol
Example 14
[0033] By carrying out the procedure as in Example 10, with 100 g of degummed and dewaxed millet oil, the settling out of the two phases is complete after 2 h. The quantity of alkali just required for the neutralization used is determined by calorimetric titration and corresponds to 0.047 mol, that is to say 101%. The operating conditions and the results obtained are indicated in Table 4 below.
Example 15
[0034] By carrying out the procedure as in Example 10, with 100 g of an interesterified fat prepared according to the process described in European patent application No. 97202289 (EP-A 0893064) and which has not been subjected to the last neutralization step, this fat contains about 50-55% of free fatty acids. It was not possible to carry out the exact determination of the content of free fatty acids by acidimetric assay because of the fact that the average molecular weight of the fatty acids is not known. The analysis makes it possible, however, to determine the number of acid equivalents to be neutralized. The quantity of alkali just required for the neutralization used is determined by colorimetric titration and corresponds to 0.225 mol, that is to say 102.8%. The operating conditions and the results obtained are indicated in Table 4 below.
Example 16
[0035] Using the procedure of Example 10 with isopropyl alcohol, 2-PrOH, as solvent, 100 g of sunflower oil containing 15% of oleic acid are neutralized. The quantity of alkali just required for the neutralization corresponds to 0.0538 mol, that is to say 101.1%. The operating conditions and the results obtained are indicated in Table 4 below.
TABLE 4 Initial Final Losses NaOH free free Final of Solvent 10% fatty acids fatty acids yield neutral Example (g) (g) (%) (%) (g) lipids (%) 14 100 18.8 13.1 0.1 83 3.9 propy- lene glycol 15 100 90.1 0.219** 0.1 42.5 7.5*** propy- lene glycol 16 100 21.5 15 0.1 83 2 2-PrOH
[0036] **: This figure relates to the number of fatty acid equivalents to be neutralized.
[0037] ***: In this example, the loss of neutral lipids is determined by extracting the phase containing the soaps with hexane. | A process for refining fatty substances in order to selectively and quantitatively separate therefrom the free fatty acids. The process combines the extraction with an alcohol or a polyol and a neutralization is conducted with an alkali at a controlled pH of 9 to 11. | 2 |
[0001] This research described in this patent application was partially funded by the National Institutes of Health (AI053138), and therefore the U.S. Government may have certain rights in the invention.
BACKGROUND
[0002] Aminoglycoside antibiotics have long been used as bactericidal drugs. 1 Unlike many antibiotics that are active only against gram positive bacteria, aminoglycosides have broad spectrum activity against both gram positive and negative bacteria. However, their clinical usage has often been limited only to serious infections due to the prevalence of aminoglycoside resistant bacteria 1c,2 and the high cytotoxicity of aminoglycosides. 3 In an effort to revive the effectiveness of aminoglycoside antibiotics against resistant bacteria, we have been working on modification and synthesis of novel aminoglycosides.
[0003] Over expression of aminoglycoside modifying enzymes from resistant bacteria is the most commonly encountered mode of resistance. 2 Various aminoglycoside modifying enzymes have been identified that catalyze a wide range of modifications including acetylation, phosphorylation, and adenylation.
[0004] Aminoglycosides with deoxygenation at 3′-OH have been demonstrated to be effective against APH(3′) as reported by Umezawa 1b,6 and others. 7 The concept has led to the syntheses and discovery of tobramycin, 8 arbekacin, 9 and other similar aminoglycosides. 1b Despite the fruitful results from these studies, there are several shortcomings. First, most of the research uses carbamate-type protecting groups for the protection of amino groups on the aminoglycoside, resulting in the formation of polycarbamate compounds with low solubility in organic media. The poor solubility of these compounds poses difficulties in their purification and characterization. Second, most of the syntheses begin with the kanamycin scaffold. There are very few examples of deoxygenation on neomycin class antibiotics. 7d Third, the reported syntheses of both classes of antibiotics usually derive from kanamycin or neomycin, which limits the options for introducing novel structural motifs at other desirable places of aminoglycosides. Therefore, we have invented novel pyranmycin compounds with activity against resistant strains equipped with aminoglycoside modifying enzymes.
SUMMARY OF THE INVENTION
[0005] The invention relates to novel compounds that have activity against gram positive and gram negative bacteria, preferably bacteria that are resistant to other antibiotics. The compounds are derivatives of paranmycins.
[0006] Another aspect of the invention is the treatment of bacterial infections using the compounds of the invention.
DESCRIPTION OF THE CHARTS AND SCHEMES
[0007] The present invention contains no figures. However, Charts showing compounds and compound constituents and Schemes showing synthesis pathways are provided as summarized and described below.
[0008] Chart 1 shows a preferred group of pyranmycins with dideoxygenation.
[0009] Chart 2 shows a group of pyranmycins with N-1 modifications.
[0010] Chart 3 shows a group of pyranmycins with both dideoxygenation and N-1 modification.
[0011] Scheme 1 shows the synthesis of neamine acceptor.
[0012] Scheme 2 shows the synthesis of 3′-4′-Dideoxy Pyranmycin.
[0013] Scheme 3 shows synthesis of 3′,4′-di-O-benzylneamine.
[0014] Scheme 4 shows One-pot synthesis of N−1 Modified Neamine.
[0015] Scheme 5 shows glycosylation of the hydroxyl group.
[0016] Scheme 6 shows current synthesis for pyranmycin with O-6 modification.
[0017] Scheme 7 shows synthesis of pyranmycin with n-1 and O-6 modifications.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention relates to antibacterial compound comprising a compound having Formula 1
wherein
[0019] R1 and R2 are both either H or OH
[0020] R3 is selected from the group consisting of
[0021] And R4 is either H or
[0022] AHB: (S)-4-amino-2-hydroxybutyryl
[0023] More specifically, the compounds are of three different groups as shown in Charts 1, 2, and 3.
CHART 1 Pyranmycin with dideoxygenation pyranmycin (TC005) AHB: (S)-4-amino-2-hydroxybutyryl R 1 R 2 R 3 R 4 H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H
[0024]
CHART 2
Pyranmycin with N-1 Modification
pyranmycin (TC005)
AHB: (S)-4-amino-2-hydroxybutyryl
R 1
R 2
R 3
R 4
OH
OH
H
AHB
OH
OH
AHB
OH
OH
AHB
OH
OH
AHB
OH
OH
AHB
OH
OH
AHB
OH
OH
AHB
OH
OH
AHB
OH
OH
AHB
OH
OH
AHB
[0025]
CHART 3
Pyranmycin with combined deoxygenation and N-1 Modification
pyranmycin (TC005)
AHB: (S)-4-amino-2-hydroxybutyryl
R 1
R 2
R 3
R 4
H
H
H
AHB
H
H
AHB
H
H
AHB
H
H
AHB
H
H
AHB
H
H
AHB
H
H
AHB
H
H
AHB
H
H
AHB
H
H
AHB
[0026] Preferably the compounds are selected from the group consisting of
[0027] Generally, the compounds of the invention can be made using the starting materials of neomycin (Research Organics). The known reactions described in references 4 can be used to make the basic pyranmycin structure. Pyranmycin with hydroxyl groups at the 3′ and 4′ positions can by made using an elimination reaction. Substitution of the AHB on the amine position can be accomplished by using a selective Staudinger reaction followed by typical peptide coupling reaction. Substitution of any of the R3 substituents can result from selective alkylation reactions. Detailed synthesis of the compounds of the invention are provided in the examples, which are not meant to limit the scope of the present invention in any way.
[0028] Once made, the compounds of the present invention show anti bacterial activity in a standard dilution and diffusion assay. As such, the compounds of the present invention either alone or formulated into a pharmaceutically acceptable formulation, are useful as anti bacterial compounds to prevent, alleviate or eliminate the symptoms and/or organisms associated with a bacterial or viral infection. Preferably, the compounds are used for treating a bacterial infection.
[0000] Methods of Administration (Amts, Regimes)
[0029] The pharmaceutical compositions according to the invention are those for enteral (including oral or rectal) and parenteral (including intravenous, transdermal or intraarterial biodegradable stent) administration to a mammal, i.e. a warm-blooded animal or human. The daily dose of the active ingredients depends on the age and the individual condition and also on the manner of administration.
[0030] The pharmaceutical compositions contain, for example, from about 10% to about 80%, preferably from about 20% to about 60%, of the active ingredient. Pharmaceutical compositions according to the invention for enteral or parenteral administration are, for example, those in unit dose forms, such as sugar-coated tablets, tablets, capsules, gel caps, caplets, or suppositories, and furthermore ampoules. The compositions may also be in sublingual dosages, sustained release formulations and elixirs. These are prepared in a manner known per se, for example by means of conventional mixing, granulating, sugar-coating, dissolving or lyophilizing processes. Thus, pharmaceutical preparations for oral use can be obtained by combining the active ingredient with solid carriers, if desired granulating a mixture obtained, and processing the mixture or granules, if desired or necessary, after addition of suitable excipients to give tablets or sugar-coated tablet cores.
[0031] Suitable pharmaceutical carriers are, in particular, fillers, such as sugars, for example lactose, sucrose, mannitol or sorbitol, cellulose preparations and/or calcium phosphates, for example tricalcium phosphate or calcium hydrogen phosphate, furthermore binders, such as starch paste, using, for example, corn, wheat, rice or potato starch, gelatin, tragacanth, methylcellulose and/or polyvinylpyrrolidone, if desired, disintegrants, such as the abovementioned starches, furthermore carboxymethyl starch, crosslinked polyvinylpyrrolidone, agar, alginic acid or a salt thereof, such as sodium alginate; auxiliaries are primarily glidants, flow-regulators and lubricants, for example silicic acid, talc, stearic acid or salts thereof, such as magnesium or calcium stearate, and/or polyethylene glycol. Sugar-coated tablet cores are provided with suitable coatings which, if desired, are resistant to gastric juice, using, inter alia, concentrated sugar solutions which, if desired, contain gum arabic, talc, polyvinylpyrrolidone, polyethylene glycol and/or titanium dioxide, coating solutions in suitable organic solvents or solvent mixtures or, for the preparation of gastric juice-resistant coatings, solutions of suitable cellulose preparations, such as acetylcellulose phthalate or hydroxypropylmethylcellulose phthalate. Colorants or pigments, for example, to identify or to indicate different doses of active ingredient, may be added to the tablets or sugar-coated tablet coatings.
[0032] Other orally utilizable pharmaceutical preparations are hard gelatin capsules, and also soft closed capsules made of gelatin and a plasticizer, such as glycerol or sorbitol. The hard gelatin capsules may contain the active ingredient in the form of granules, for example in a mixture with fillers, such as lactose, binders, such as starches, and/or lubricants, such as talc or magnesium stearate, and, if desired, stabilizers. In soft capsules, the active ingredient is preferably dissolved or suspended in suitable liquids, such as fatty oils, paraffin oil or liquid polyethylene glycols, it also being possible to add stabilizers.
[0033] Suitable rectally utilizable pharmaceutical preparations are, for example, suppositories, which consist of a combination of the active ingredient with a suppository base. Suitable suppository bases are, for example, natural or synthetic triglycerides, paraffin hydrocarbons, polyethylene glycols or higher alkanols. Furthermore, gelatin rectal capsules which contain a combination of the active ingredient with a base substance may also be used. Suitable base substances are, for example, liquid triglycerides, polyethylene glycols or paraffin hydrocarbons.
[0034] Suitable preparations for parenteral administration are primarily aqueous solutions of an active ingredient in water-soluble form, for example a water-soluble salt, and furthermore suspensions of the active ingredient, such as appropriate oily injection suspensions, using suitable lipophilic solvents or vehicles, such as fatty oils, for example sesame oil, or synthetic fatty acid esters, for example ethyl oleate or triglycerides, or aqueous injection suspensions which contain viscosity-increasing substances, for example sodium carboxymethylcellulose, sorbitol and/or dextran, and, if necessary, also stabilizers.
[0035] The dose of the active ingredient depends on the mammal species, the age and the individual condition and on the manner of administration. Typically, for an adult mammal of approximately 75 kg, the dosage of the benzodiazepines of the invention or a pharmaceutically acceptable salt is from about 0.75 to about 7500 mg, preferably about 1 to about 1000 mg. Modified dosage ranges for mammals of other sizes and stages of development will be apparent to those of ordinary skill.
[0036] All references cited in this patent are hereby incorporated by reference for their relevant teachings. The following Examples illustrate specific embodiments of the inventions, but are not intended to limit the scope of the invention in any way.
EXAMPLES
Example 1
Synthesis of 3′,4′-Dideoxy Pyranmycin (RR501)
[0037] To avoid the solubility problem, we used azido groups as the surrogate for amino groups. The synthesis of a key intermediate, 3′,4′-dideoxyneamine, began from neamine. Neamine was obtained from acid-hydrolysis of neomycin (purchased from Research Organics Inc.), then converted to tetraazidoneamine, 2, using TfN 3 and CuSO 4 (Scheme 1). 5 The selective protection of the diol was achieved using cyclohexanone dimethylketal. The key transformation is the elimination of diol to alkene. To our surprise, we were unable to locate didexoygenation methods that are compatible with the presence of azido group and the acid-labile glycoside bond despite numerous documentations. In general, the reported methods for dideoxygenation often require reductive or harsh conditions, for example, the presence of Zn, NaI, and heating from dimesylated compound (Tipson-Cohen method), 10 acid-catalyzed elimination from a diol using ethyl orthoformate (Crank-Eastwood method), 11 LiAlH 4 /TiCl 4 (McMurry-Fleming method), 12 diphosphorous tetraiodide from diol (Kuhn-Winterstein reaction), 13 SnCl 2 /HCl, 14 and PPh 3 and I 2 . 15
[0038] Among these reported methods, the method involving mesylated compound and Zn-mediated elimination appeared to be the most applicable one of being modified to meet our needs. Since a triflated hydroxyl group is more reactive than a mesylated hydroxyl group, we expected that the ditriflate can be replaced with a trans diiodide in which, the two iodides are in an anti-parallel configuration. Such a configuration can induce a facile elimination under the catalysis of I − producing the desired alkene and I 2 . To avoid complication from the possible addition reaction between the alkene and I 2 , Na 2 S 2 O 3 was added to reduce I 2 into I − allowing I 2 /I − to function as catalyst. We are pleased to discover that the elimination occurred smoothly as expected providing compounds 4 and 5. Compound 5 was converted to 4 giving an overall yield of ˜80%.
[0039] Regioselective protection of C-6 hydoxyl group using benzoyl chloride furnished compound 6 in excellent yield (Scheme 2). Compound 6 was glycosylated with the corresponding trichloroacetimidate donor, 7, from the lead structure of our previous work generating the 3′,4′-dideoxy pyranmycin adduct RR501.
Example 2
Synthesis of Pyranmycin Compounds (with 3′,4′ hydroxyl) and
[0040] Compounds of Example 1 with hydroxyl substitutions at both the R 1 and R 2 positions are made as described in Reference 4.
Example 3
Synthesis of Pyranmycin, 3′,4′-Dideoxy Pyranmycin Compounds with (S)-4-amino-2-hydroxybutyryl in the R 4 Position
[0041] Compounds of Examples 1 and 2 with (S)-4-amino-2-hydroxybutyryl in the R 4 position are made as follows (Scheme 3). Compound 10 was obtained from 3 (see Scheme 1) via acetylation of the O-3′ and O-4′ diols, followed by deprotection of the cyclohexylidene group. Diacylation of O-5 and O-6 diols afforded 11.
A one-pot azido reduction/amine protection was employed to selectively modify the N-1 azido group of 11 (Scheme 4). After hydrolysis of the acyl groups, the desired 1-N-tBoc protected neamine, 15, was synthesized in an overall of 33% along with 3-N-tBoc protected neamine (5%) and 1,3-N-di-tBoc protected neamine (22%) as the minor products. Selective benzoylation of O-6 of 15 yielded 17.
Glycosylation of 17 using 7 as the glycosyl donor followed by NaOMe-mediated hydrolysis afforded 18 (Scheme 5). Deprotection of the tBoc exposed the N-1 amino group, which was coupled with desired side chain, 25, yielded 19. Global deprotection using Staudinger reaction and hydrogenation, followed by ion-exchange offered the final product, JT005, as a chloride sale.
Example 4
Synthesis of 3′,4′-Dideoxy Pyranmycin Substituted in the R 3 Position
[0042] Compounds of Formula 1, including those of Examples 1-3, with additional substitutions at the R3 position are made using commercially available reagents and utilizing known chemical reactions. Any of the following can be substituted at the R3 position:
[0043] These compounds are made utilizing known alkylation methods. For example, compound 15 can be mono-alkylated using allyl bromide generating 20 (Scheme 6). Ozonlysis of 20 followed by reductive workup afforded 22. Azido substitution of the primary hydroxyl group of 22 provided 23, which can be glycosylated with 7 yealding 24. Global deprotection using hydrolysis, Staudinger reaction, and hydrogenation, followed by ion-exchange offered the final product, JT050, as chloride sale.
II. Synthesis of Pyranmycin with O-6 and N-1 Modifications
[0044]
[0045] The incorporation of functional groups at O-6 position can begin from compound 20 (Scheme 7). The designed epoxides, 23 and 24 can be obtained from treatment of 20 with mCPBA. Both 23 and 24 can be utilized for the introduction of more functionalities via know procedures, leading to the synthesis of JT054, JT055, JT056, and JT057. Alternatively, using different but known chemical reagents, compound 20 can be converted into 22 and 29. Compound 22 can be employed for the synthesis of JT051 and JT058 while 29 can be used for the synthesis of JT052 and JT053. Similar strategy can be applied for the synthesis of pyranmycin in other two designs.
Pyranmycin with N-1 and O-6 Modifications Compound R JT051 JT052 JT053 JT054 JT055 JT056 JT057 JT058 TC050 TC005
Example 5
Anti Bacterial Activity
[0046] After the synthesis was completed, both representative aminoglycosides were assayed in standard dilution and diffusion assay against aminoglycoside susceptible and resistant strains of Escherichia coli using amikacin, kanamycin, ribostamycin, and butirosin as the controls. One resistant strain is equipped with the pTZ19-3 plasmid encoded for APH(3′)-I, which renders resistance to kanamycin, neomycin, lividomycin, paromomycin, and ribostamycin. The other resistant strain is equipped with the pSF815 plasmid encoded for AAC(6′) and APH(2″), which produces a bifunctional enzyme that catalyzes acetylation of amino group at C-6′ and phosphorylation of hydroxyl group at C-2″ position. This bifunctional enzyme enables bacteria to acquire resistance against gentamycin, amikacin, tobramycin, netilmicin, and kanamycin.
[0047] The minimum inhibitory concentration (MIC) results are summarized in Table 1. As expected, both kanamycin and ribostamycin are either inactive or much less active against aminoglycoside resistant bacteria. Both kanamycin and amikacin are more active than their neomycin counterparts, ribostamycin and butirosin, against aminoglycoside susceptible strain. Kanamycin class antibiotics are, however, less effective than neomycin-class antibiotics against bacteria equipped with AAC6′/APH2″. Incorporation of an (S)-4-amino-2-hydroxybutyryl (AHB) group at the N-1 position appears to be the superior design against resistant bacteria equipped with APH(3′). Although both RR501 and RT501 contain no AHB group at N-1, they are both active against resistant bacteria equipped with APH(3′). They are, however, less active against bacteria equipped with AAC6′/APH2″. RR501 is slightly more active than RT501 against both resistant strains which is consistent with the results obtained from commercially available aminoglycosides. By summarizing the information from MIC values, we believe a better design should be a neomycin class with the AHB group at N-1 and 3′,4′-dideoxygenation (or 3′-deoxygenation). Nevertheless, the problem of the acid-labile glycosidic bond between rings II and III will be an obstacle remained to be overcome. Therefore, our design of RR501 that has better stability in acidic media could be valuable for designing new aminoglycosides against a broad spectrum of aminoglycoside resistant bacteria.
TABLE 1 Minimum Inhibitory Concentration of Synthesized Aminoglycosides a Strains E. coli (TG1) E. coli (TG1) Compounds E. coli (TG1) (pSF815) b (pTZ19U-3) c Amikacin 1 1 0.5 Kanamycin B 4 Inactive 32 Ribostamycin 2 16 Inactive Butirosin 0.5 0.5 0.5 RR501 8 4 4 RT501 8 Inactive 4 TC005 8 Inactive 8 JT005 4 4 4 TC050 8 Inactive 8 JT050 8 2 4 a Unit: μg/mL b plasmid encoded for AAC6′/APH2″ c plasmid encoded for APH(3′)-I
Example 6
Synthesis of Pyrankacin
[0048] The synthesis of pyrankacin started from the chlorobenzoylation of 2 (16) to yield 3 in Scheme 1 below (entitled “Synthesis of Pyrankacin”), which was then subjected to a selective Staudinger reaction to yield the N-1 Boc-protected compound 4 (Scheme 1 below). Interestingly, the obtained selectivity was even better than when 5,6-di-O-acyl-3′,4′-di-O-benzyltetraazidoneamine was employed (17). Hydrolysis of the ester protecting groups followed by selective benzoylation at the O-6 position gave 6. Glycosylation of 6 with 7 (18) followed by the hydrolysis of the acyl groups offered the corresponding trisaccharide, 10. Deprotection of the Boc group and coupling with the (S)-N-carbobenzyloxy-4-amino-2-hydroxybutyric acid yielded 10. Global deprotection and ion-exchange provided the desired final product, which we named, pyrankacin.
Example 7
Anti Bacterial Activity of Pyrankacin
[0049] Pyrankacin was assayed against various strains of bacteria and the minimum inhibitory concentration (MIC) was determined using amikacin, neomycin, butirosin, gentamicin, kanamycin as the controls. (Table 2). Aminoglycoside susceptible Escherichia coli (ATCC 25922), Staphylococcus aureus (ATCC 25923), and Klebsiella pneumoniae (ATCC 13883, resistant to ampicillin, susceptible to aminoglycosides) were used as standard reference strains. E. coli (pSF815) and E. coli (pTZ19U-3) are laboratory resistant strains using E. coli (TG1) as the host. K. pneumoniae (ATCC 700603)(19) is a clinical isolate that is resistant to ceftazidime, other β-lactams, and several aminoglycosides (ANT(2″)). Pseudomonas aeruginosa (ATCC 27853) that expresses APH(3′)-IIb manifests modest resistance toward aminoglycosides (20). Methicillin-resistant S. aureus (ATCC 33591) (MRSA) is the leading cause of bacterial infections and a global scourge. Many MRSA strains contain genes encoded for APH(3′), ANT(4′), and AAC(6′)/APH(2″), which render the bacteria resistant to many aminoglycosides (21).
[0050] From the MIC values, pyrankacin appears to be one with the most prominent broad spectrum antibacterial activity against all the examined strains. For example, for the clinically used gentamicin and amikacin, the former is ineffective against bacteria with the bifunctional enzyme, AAC(6′)/APH(2″) and K. pneumoniae (ATCC 700603) (entries 3 and 5) while the latter is less active against MRSA (entry 7). Pyrankacin is more active than gentamicin against E. coli (pSF815) and K. pneumoniae (ATCC 700603) (entries 3 and 5). While being less active than gentamicin against MRSA, pyrankacin is more active than amikacin against the same strain. More interestingly, even pyrankacin can be viewed as a neomycin class aminoglycoside, it is the only active compound against P. aeruginosa among JT005 (17), neomycin, butirosin and ribostamycin. The attachment of AHB group at N−1 of kanamycin class aminoglycoside as in the case of amikacin revives the antibacterial activity, while the same modification on butirosin and JT005 does not produce the same effect. This result suggests that a combination of 3′,4′-dideoxygenation and N-1 AHB group is essential for neomycin class aminoglycoside to be active against P. aeruginosa .
TABLE 2 Minimum Inhibitory Concentrations (MIC) a entry strains amikacin butirosin gentamicin neomycin ribostamycin kanamycin B pyrankacin RR501 JT005 1 E. coli b 1 2 2 4 8 2 4 ND ND 2 E. coli (TG1) c 1 1 2 8 2 4 4 8 4 3 E. coli (pSF815) d 1 0.25 Inactive k 2 16 Inactive 1 4 4 4 E. coli (pTZ19U-3) e 0.5 0.5 1 Inactive 32 Inactive 1 4 4 5 K. pneumoniae f 0.5-1 0.5 8-16 Inactive Inactive Inactive 1 2-4 1-2 6 K. pneumoniae g 1 0.5-1 1 2 4 1 2 2-4 2 7 S. aureus h 16 Inactive 4 Inactive Inactive Inactive 8 4 Inactive 8 S. aureus i 1 2 0.5 1 8 1-2 2 ND ND 9 P. aeruginosa j 0.5-1 Inactive 0.5-1 Inactive Inactive Inactive 2 Inactive Inactive a Unit: μg/mL, ND: Not Determined, b Escherichia coli (ATCC 25922), c E. coli (TG1) (aminoglycoside susceptible strain), d E. coli (TG1) (pSF815 plasmid encoded for (AAC(6′)/APH(2″)), e E. coli (TG1) (pTZ19U-3 plasmid encoded for APH(3′)-I), f Klebsiella pneumoniae (ATCC 700603), g K. pneumoniae (ATCC 13883), h Staphylococcus aureus (ATCC 33591) (MRSA), i S. aureus (ATCC 25923), j Pseudomonas aeruginosa (ATCC 27853), k Inactive is defined as MIC ≧ 32 μg/mL.
REFERENCES
[0000]
1. For reviewing: (a) Haddad, J; Kotra, L. P.; Mobashery, S. in Glycochemistry Principles, Synthesis, and Applications , Wang, P. G. and Bertozzi, C. R. Ed. Marcel Dekker, Inc. 2001; p307-424. (b) Umezawa, H. Jpn. J. Antibiotics, 1994, 47, 561-574. (c) Vakulenko, S. B.; Mobashery, S. Clinical Microbiol. Rev. 2003, 16, 430-450. (d) Hooper, I. R. Aminoglycoside Antibiotics Springer-Verlag 1982, New York.
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3. Mingeot-Leclercq, M.-P.; Tulkens, P. M. “Aminoglycosides: nephrotoxicity.” Antimicrob. Agents Chemother. 1999, 43, 1003-1012.
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21. Ida et al, (2001) J. Clin. Microbiol. 39:3155-3121 | The invention relates to novel paranmycin compounds that have activity against gram positive and gram negative bacteria, preferably bacteria that are resistant to other antibiotics. Paranmycins are of the general formula | 0 |
BACKGROUND
[0001] The subject matter of the invention is a device and a method for connecting housing sections for soot particle filters, as well as a clamping U-bolt.
[0002] In the case of vehicles with combustion engines, filters and catalytic converters are being used to an increasing degree for treating exhaust gases. In this way, the environmental load due to pollutants such as soot particles, hydrocarbons, carbon monoxide, or nitrogen oxides can be greatly reduced. For treating diesel exhaust gases, catalytically active soot particle filters are also known in which soot particles are first held on the filter surface and then—when the temperature is sufficiently high—converted catalytically. As a rule, filters and catalytic converters comprise a ceramic carrier or monolith that is provided with a so-called wash coat making the surface larger. This monolith is held in a metallic housing or the so-called canning that is installed rigidly in the exhaust-gas line.
[0003] In the case of diesel particle filters, as a rule the combustion of the particles does not take place completely without residue. Over time, additives contained in motor oil and in diesel fuel can lead to ash deposits in the filter. Metal wear debris in the engine likewise leads to the formation of ash. This increases the exhaust gas back pressure of the filter and thus the fuel consumption. Soot particle filters therefore must be regularly serviced or cleaned, e.g., annually or after reaching a predetermined number of miles traveled. For this purpose, soot particle filters must be separated from the exhaust-gas line and can be reattached after cleaning.
[0004] From DE 20012812 U1, an exhaust-gas cleaning device is known with a housing constructed from several cylindrical modules in which a filter unit is installed in at least one of these modules. The individual modules can be placed one in the other or joined to each other by flange-like fastening elements. In the case of metallic housings, the modules are welded for mutual attachment. Because the housing modules are welded to each other, the filter unit can be removed only when the housing is separated. Even without welding, flanges that project outward on the housing take up a lot of space. In the case of housing modules pushed one inside the other, space and play for movements are likewise required in the direction of the housing axis, so that the individual modules can be separated from each other.
SUMMARY
[0005] The objective of the present invention is to create a device and a method for the production of a detachable connection for housing sections of soot particle filters. Another objective of the invention is for allowing a simple removal and re-insertion of a filter unit for an exhaust-gas line, even when the spatial relationships are dimensioned narrowly. Another objective of the invention is for forming the fastening device that is insensitive relative to vibrations and exhaust-gas back pressures.
[0006] These objectives are met by a device and a method for connecting housing sections in the case of soot particle filters as well as a clamping U-bolt according to the features of Claims 1 , 6 , and 7 .
[0007] The device according to the invention comprises a multiple-part cylindrical housing, wherein the individual housing sections have peripheral beads or seams impressed from the inside on the lateral surface in the region of the end faces. Every two adjacent housing sections are held together by a yoke-like clamping U-bolt with a bracket-like shoulder along each of the two longitudinal sides. When the clamping U-bolt is tightened, its shoulders press elastically from the outside against the outward-projecting bead rings on the housing sections. The housing sections are therefore aligned coaxially and pressed against each other. One or both ends or end faces of the tube-like housing sections could have an inward-projecting step that increases the mutual contact surface area and improves the sealing properties of the connection. Alternatively, the housing sections could also be constructed without such collars reducing the inner diameter. Between the shoulders, a temperature-resistant sealing tape is formed on the inside of the clamping U-bolts made from sheet metal or stainless steel. In the assembled state, this sealing tape covers the gap between the joined-together housing sections and is pressed by the clamping force of the U-bolt from the outside tightly against the end regions of the housing sections.
[0008] In the case of a three-part housing, its middle part could be constructed for housing the soot particle filter. After detachment and shifting or removal of the two clamping U-bolts, this middle part can be pulled out without a problem laterally or in a plane vertical to the housing axis and thus separated from the two end parts of the housing connected to the feed or discharge lines. Here, movement of the middle housing section in the direction of the housing axis is not required. After cleaning or regeneration of the filter, it can be reinstalled in an analogous way. With the fastening device according to the invention, housings for soot particle filters could feature maintenance-friendly installation and construction even in the case of narrow spatial relationships.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention will be described in greater detail below with reference to a few figures. Shown here are:
[0010] FIG. 1 a front view of a filter unit with a cylindrical housing comprising three housing sections,
[0011] FIG. 2 a side view of the filter unit from FIG. 1 ,
[0012] FIG. 3 a detail of the housing from FIG. 1 in the region of two adjacent housing sections without a clamping U-bolt,
[0013] FIG. 4 a cross section of the housing from FIG. 1 in the region of the connecting point of two housing sections,
[0014] FIG. 5 a side view of the clamping U-bolt in the region of a turnbuckle,
[0015] FIG. 6 a top view of the clamping U-bolt in the region of the turnbuckle, and
[0016] FIG. 7 a cross section of the clamping U-bolt along the line A-A in FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] FIG. 1 shows a front view of a filter unit 1 with a housing 3 that comprises three housing sections 5 a , 5 b , 5 c with essentially cylindrical lateral surfaces 7 a , 7 b , 7 c with the outer diameters D 1 , D 2 , and D 3 .
[0018] Typically, the outer diameters D 1 , D 2 , D 3 each lie, according to the application, on the order of magnitude of approximately 100 mm to approximately 400 mm. The end faces of the housing 5 or the inlet-side housing section 5 a and the outlet-side housing section 5 c are formed by annular plates 9 a , 9 b , each having a cylindrical connection port 11 a , 11 b with the diameters D 4 and D 5 arranged coaxial to the housing axis H. These diameters typically lie on the order of magnitude of approximately 40 mm to approximately 150 mm. Alternatively, connection ports 13 a , 13 b projecting radially on the corresponding lateral surfaces 7 a , 7 c are also formed on the housing sections 5 a and 5 c , as is shown in FIGS. 1 and 2 by dashed lines. Obviously, in this variant, passage openings in the lateral surfaces 7 a , 7 c would be formed in the region of the connection ports 13 a , 13 b and the plates 9 a , 9 b closing the housing 5 laterally would be closed. The shape, arrangement, and size of the connection ports 11 a , 11 b are aligned according to the conditions of the corresponding exhaust-gas line in which the filter unit 1 is to be installed (as a rule by welding).
[0019] The invention comprises an arbitrary number of additional constructions of housings 5 , wherein these comprise at least two adjacent housing sections 5 a , 5 b or 5 b , 5 c and in which these housing sections 5 a , 5 b , 5 c have an essentially cylindrical shape at least in the adjacent regions. In the embodiment shown in FIGS. 1 to 4 , all of the housing sections 5 a , 5 b , 5 c comprise a cylindrical casing-like steel sheet with the thickness 1.25 mm. The wall thickness of the closing plates 9 a , 9 b equals 3 mm. Obviously, other wall thicknesses or wall thickness combinations are also possible. In particular, the wall thicknesses of the individual housing sections 5 a , 5 b , 5 c could be equal or different. The outer diameters D 1 , D 2 , D 3 of the three cylindrical housing sections 5 a , 5 b , 5 c are all of equal size in the shown example. Passage openings 15 that can be closed and that are provided, e.g., with threading on the lateral surface 7 a and on the closing plate 9 a are formed on the first housing section 5 a . There, e.g., connection cables for sensors can be guided into the interior of the housing 3 .
[0020] Every two adjacent housing sections 5 a , 5 b or 5 b , 5 c are connected detachably to each other by a clamping U-bolt 17 . The clamping U-bolt 17 comprises a band 19 with a yoke-like cross section with metallic band loops 21 welded on both ends each for holding a cylindrical insert 24 . These inserts 24 belong to the turnbuckle 22 ( FIGS. 5 , 6 , and 7 ).
[0021] FIG. 3 shows a partial diagram of the housing 3 with two adjacent housing sections 5 a and 5 b without the clamping U-bolt 17 . The arrows marked with “P” in the connection ports 11 a , 13 a indicate the direction of flow of the exhaust gases. FIG. 4 shows a region of the housing 3 marked in FIG. 3 by the dash-dot line G as a section diagram, but this time including the clamping U-bolt 17 .
[0022] Alternatively, the outer diameters D 1 , D 2 , D 3 of the housing sections 5 a , 5 b , 5 c or the adjacent regions of the housing sections 5 a , 5 b , 5 c could also be different. At axial distances S 1 and S 2 from adjacent end faces 20 a , 20 b of two housing sections 5 a , 5 b , respectively, peripheral seams 23 could be formed on the insides or peripheral beads 25 could be formed on the outsides of the lateral surfaces 7 a , 7 b . Adjacent to a middle region 27 of the clamping U-bolt 17 , wherein this middle region has an approximately straight-line cross section, there are bracket-like or gripper-like bulges 29 or shoulders that contact the outsides of the bead 25 elastically when the clamping U-bolt 17 is tightened and thus press together the two housing sections 5 a , 5 b in the direction of the housing axis H and simultaneously also align these sections relative to each other. In an analogous way, other deformations arranged at a distance to the housing section ends 20 a , 20 b or joints and projecting to the lateral surfaces 7 a , 7 b and/or set in these surfaces could be used as stops for corresponding structures or deformations on the clamping U-bolt 17 for the overlap-free connection of the housing sections 5 a , 5 b . Instead of deformations of the lateral surfaces 7 a , 7 b , e.g., rings or other structures could also be fused with the lateral surfaces 7 a , 7 b and used as stop elements for the bracket-like edges of the clamping U-bolt 17 .
[0023] The abutting ends 20 a , 20 b of the housing sections 5 a , 5 b are provided in the example of FIG. 4 with inward projecting steps 33 a , 33 b , wherein a larger contact surface is produced for the two housing sections 5 a , 5 b . The joint or the gap 35 between the two housing parts 5 a , 5 b can also be sealed by a sealing tape 31 made from ceramic, glass fibers, or a different, thermally resistant material. As shown in FIG. 4 , this sealing tape 31 is clamped tight between the clamping U-bolt 17 and the hoop-shaped end regions of the housing sections 5 a , 5 b when the clamping U-bolt 17 is tightened. The sealing tape 31 can be fixed, e.g., on the inside of the band 19 by a temperature-resistant adhesive. The attachment points for the seams 23 or beads 25 are arranged at an axial distance h 1 (advantageously 1 mm<h 1 <50 mm, e.g., h 1 =12 mm) from the corresponding ends 20 a , 20 b of the housing sections 5 a , 5 b . The seams 23 or beads 25 have a width h 2 , wherein the position with the maximum height h 3 of the bead 25 or the maximum depth h 3 of the depression of the seams 23 is arranged, as a rule, approximately in the middle. As a rule, a height h 3 on the order of magnitude of a few millimeters, for example, 3 mm, is sufficient. The geometry of the clamping U-bolt 17 is aligned to the mass and shape of the adjacent housing sections 5 a , 5 b , so that—in the case of beads 25 projecting outward on the lateral surfaces 7 a , 7 b —the bulges 29 surround the beads 25 and the housing section ends 20 a , 20 b and optionally the steps 33 a , 33 b are aligned relative to each other or coaxially and are pressed against each other. Outside of the tightening device of the clamping U-bolt 17 , the connection device thus has a very small projection h 4 of, e.g., 5 mm to 10 mm, advantageously less than 7.5 mm, past the outer diameter D 1 , D 2 , D 3 of the housing sections 5 a , 5 b , 5 c . Therefore, assembly and disassembly are possible even under narrow spatial relationships. This applies analogously also in the case of holding structures in the shape of seams 23 that are set from the outside into the lateral surfaces 7 a , 7 b , 7 c of the housing sections 5 a , 5 b , 5 c . In this case, the bulges 29 are adapted along the longitudinal sides of the band 19 to the shape of the lateral surfaces 7 a , 7 b , so that they engage in the seams 23 of adjacent housing sections 5 a , 5 b when the clamping U-bolt 17 is tightened. Therefore, the housing sections 5 a , 5 b are aligned coaxially and pressed against each other (not shown). The clamping U-bolt 17 thus must have regions engaging only in the seams 23 . An overlap or surrounding of the seams 23 in the axial direction is not absolutely necessary.
[0024] The band length of the clamping U-bolt 17 is directed according to the outer diameter D 1 , D 2 , D 3 of the housing sections 5 a , 5 b , 5 c to be connected. It is advantageously dimensioned so that, for a tightened clamping U-bolt 17 , a distance of a few millimeters up to a few centimeters—according to the extent of the lateral surfaces ( 7 a , 7 b ) to be enclosed—remains between the two end faces of the band 19 . FIG. 5 shows a side view of the clamping U-bolt 17 in the region of the turnbuckle 22 , FIG. 6 shows a top view of this clamping U-bolt 17 , and FIG. 7 shows a cross section of the clamping U-bolt 17 along the line A-A in FIG. 5 .
[0025] The first insert 24 comprises a radial through hole for guiding a screw 26 . The second insert 24 is formed as a nut with an inner thread for the screw 26 . When the screw 26 is tightened, the diameter of the band 19 bent into a ring shape is reduced. In the region of one band end, a tab 28 overlapping this band end is connected to the band 19 by weld points 30 on the bottom side of the band 19 (the weld points 30 between the band 19 and the band loops 21 on the top side of the band 19 are also visible). The tab 28 overlaps the band end and grips under the opposing other band end, without, however, being connected rigidly to this end. The tab 28 is used as a stop for the sealing tape 31 .
[0026] In the case of alternative constructions, the length of the band 19 could be dimensioned so that its two end faces just touch for a correctly tightened clamping U-bolt 17 or leave only a small intermediate space in the range of millimeters. In the case of another alternative construction, the two ends of the band 19 could also overlap.
[0027] Soot particle filters that are installed in a housing 3 with several housing sections 5 a , 5 b , 5 c that can be connected according to the invention and can be disassembled, cleaned, and then reassembled in a simple way. After the clamping U-bolts 17 are loosened, these can be shifted axially, so that they no longer overlap the connection points. Alternatively, the clamping U-bolts 17 could also be opened completely and then removed. Because adjacent housing sections 5 a , 5 b , 5 c do not overlap, the middle housing section 5 b that is not connected rigidly to the exhaust-gas line could be pushed forward laterally or radially without axial displacement and then separated from the rest of the housing 3 . After the cleaning or maintenance of the filter element that is arranged in the middle housing section 5 b , this housing section 5 b could be integrated back into the housing 3 in the reverse sequence. | A device and a method for connecting housing sections ( 5 a, 5 b, 5 c ) of soot particle filters uses a yoke-like clamping U-bolt ( 17 ) which has, disposed along the two longitudinal sides thereof, gripper-like bulges ( 29 ), for the mutual alignment and pressing against one another of end regions of adjacent housing sections ( 5 a, 5 b, 5 c ), which end regions are joined together without overlapping. A sealing tape ( 31 ), disposed at the inside of the clamping U-bolt ( 17 ), seals the gap between mutually adjoining housing sections ( 5 a, 5 b 5 c ) when the clamping U-bolt ( 17 ) is tightened. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from U.S. Provisional Application Ser. No. 61/599,946, filed on 17 Feb. 2012.
FIELD OF THE INVENTION
[0002] The present invention relates to magnetic resonance imaging (MRI) systems and, in particular, to the radio-frequency (RF) coils used in such systems.
BACKGROUND OF THE INVENTION
[0003] Magnetic Resonance Imaging (MRI) provides one of the best imaging technologies for distinguishing soft tissue. This is extremely important for diagnosis and treatment of breast cancer. Since the breast is comprised of soft tissue, it is difficult to distinguish various masses using diagnostic x-ray equipment. Traditional mammography equipment uses very low energy x-rays but these are not available on CT scanners and Radiation Therapy (RT) simulators.
[0004] MRI has not traditionally been used for RT simulation since the spatial accuracy of MRI has not been high enough to use it for planning and aiming the treatment beam. However, new MRI machines from manufacturers such as GE, Philips and Siemens have made significant advances in spatial accuracy, opening the way for RT simulation through MRI. This in turn drives the need for Radiation Therapy positioning devices that are MRI compatible and incorporate innovative MRI coils that allow MRI imaging with the patient in position on the treatment devices that will be employed during treatment.
[0005] The most common position for Breast Cancer treatment by RT is supine on a device commonly called a supine breast board. Supine breast boards typically contain an angling patient surface that acts somewhat like the back of a lawn chair. The patient's back is placed at an angle so that the breast drops in a repeatable manner from simulation to treatment and during each treatment fraction. In order to accomplish MRI simulation with a supine breast board, it is desirable to have an MRI coil to enhance the imaging of the breast.
SUMMARY OF THE INVENTION
[0006] The present invention solves the aforementioned problems and provides a device for supporting and imaging a patient in an MRI machine in preparation for radiation therapy treatment
[0007] The MRI coil configuration described herein can be used for breast imaging and treatment performed with an angling breast board. The present invention accommodates a wide variety of patient sizes and anatomy as well as being able to work with the angling feature of the breast board. Since the patient's anatomy during treatment must be in the same position during simulation imaging, it is preferable that the MRI coils do not touch the patient.
[0008] Generally, it is preferred to perform MRI imaging with both an anterior and posterior coil set to enhance the quality of the images. For flat surface devices (for example, Stereotactic Body Radiation Therapy (SBRT) positioning devices), the coil that is built into the table of the MRI machine can often be used. However, the quality of the image is greatly enhanced by being able to get the coils as close to the patients' anatomy as possible. Therefore, it is advantageous to mount a coil to either the top or bottom surface or both the top and bottom surfaces of the patient support surface. Coils used can either be rigid coils, flexible coils or a combination of the two. In the case of a breast board with angling backrest, it can be critical to mount a coil on the posterior side of the patient. In a preferred embodiment of the angling breast treatment device, the posterior coil is mounted to the underside of the angling section of the device by various attachment similar to the anterior coil.
[0009] The coil placed above the patient can be attached to a rigid attachment, a telescoping cylinder, a rotatable member, or an articulating coil support mechanism. This attachment mechanism is releasably attached to the device (platform) on either side of the patient's head or neck superior to the shoulder. The coil support mechanism may be attached either to the left side of the patient, the right side, or both sides. By attaching to either the left or right side of the patient a coil may be brought as close as possible to the breast of interest. The coil support mechanism can also be integrated into the coil set itself. In a preferred embodiment, the attachment comprises a quick disconnect. This can be accomplished by a variety of methods well known methods. The coil support structure is then cantilevered over the patient's thoracic region. Since it is not attached at the sides of the patient's thorax, a large variety of patient widths and girths can be accommodated without the coil or support mechanism touching the patient. In the case of the angling breast device, the coil set can be placed anterior to the patient. Another advantage of this configuration for breast imaging is that the coil set can be ideally placed for imaging of the supraclavicular region which contains the lymph nodes. It is often important during breast cancer treatment to treat the lymph nodes.
[0010] Specifically, the present invention provides a device for supporting and imaging a patient in an MRI machine in preparation for radiation therapy treatment comprising; a platform with a top and bottom surface for supporting the patient; at least one removable anterior coil set support mechanism attached to the platform; and at least one anterior MRI coil attached to the coil set support mechanism and suspended above or below the patient; wherein the MRI coil does not contact the patient, and wherein the MRI coil support attaches to the platform around the patient head or neck on at least one side of the patient head or neck.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an isometric view of a patient positioned for supine breast treatment and imaging. An MRI Coil is attached to the positioning device and is positioned above the patient's breasts.
[0012] FIG. 2 is an isometric view of a patient positioned for supine breast treatment and imaging. An MRI Coil is attached to the positioning device and is positioned above the patient's left breast.
[0013] FIG. 3 is a side view of a patient positioned for supine breast treatment and imaging with an MRI Coil positioned above her left breast. A posterior coil is mounted below the patient support platform.
[0014] FIG. 4 is a top view of a patient positioned for supine breast treatment and imaging demonstrating an electrical connection to the MRI Coil. The coil is positioned above the patient's breasts.
[0015] FIG. 5 is a top view showing a patient positioned for supine breast treatment and imaging demonstrating an electrical connection to the MRI Coil. The coil is positioned above the patient's breasts using two supports one on either side of the patient's head.
[0016] FIG. 6 is a top view of a patient positioned for supine breast treatment and imaging demonstrating an electrical connection to the MRI Coil. The coil is positioned above the patient's left breast.
[0017] FIG. 7 is an isometric view showing a flexible MRI coil positioned above the patient's breasts.
[0018] FIG. 8 is an isometric view of an MRI Coil attached to a patient support platform designed for positioning patients for Stereotactic Body Radiation Therapy.
[0019] FIG. 9 is a side view of MRI Coils attached to a patient support platform designed for positioning patients for Stereotactic Body Radiation Therapy. The anterior coil is attached with a rigid arm and a posterior coil attached to the underside of the patient support platform.
[0020] FIG. 10 is an isometric view showing the MRI Coil attached to the patient support platform using a rigid arm.
[0021] FIG. 11 is an isometric view showing the MRI Coil attached to the patient support platform using a telescoping arm.
[0022] FIG. 12 is an isometric view showing the MRI Coil attached to the patient support platform using an articulating arm.
[0023] FIG. 13 shows a variation of the anterior MRI coil ( 130 ) in which the support mechanism is integrated into the coil itself. This can be a rigid or articulating configuration. In this figure, the coil takes the form of a bib.
[0024] FIG. 14 shows the anterior coil with posterior coil.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention provides_a platform with a top and bottom surface for supporting the patient; at least one removable anterior coil set support mechanism attached to the platform; and at least one anterior MRI coil attached to the coil set support mechanism and suspended above or below the patient. It is critical to the present invention that the MRI coil does not contact the patient. This is accomplished with the MRI coil support attaching to the platform around the patient head or neck on at least one side of the patient head or neck. In this configuration, the MRI coil does not attach around the torso and therefore, the torso does not obstruct the imaging and treatment field laterally. Furthermore, by attaching the coil around the patient's head or neck you do not limit the size of the patient that can be accommodated.
[0026] A preferred embodiment of the invention is shown in FIG. 1 . A patient 8 is positioned on a patient support platform 2 in preparation for imaging in a MR imaging device. An MRI coil 4 is positioned above the patient's breasts by a support mechanism 6 . In this image the coil extends across the patient's chest. In FIG. 2 it is shown that a one-breast coil 12 can be placed such that it only covers the patient's breast that is to be treated.
[0027] In FIG. 3 it is shown that in addition to the anterior coil 12 a posterior coil 32 can be removably attached to the patient support platform 2 . In FIG. 4 an electrical connection 42 is connected to the MRI coil which can interface with the MRI machine. As shown in FIG. 5 the anterior coil can be positioned by two supports 6 one on either side of the patient.
[0028] In another preferred embodiment, shown in FIG. 7 , the support 6 is used to position a flexible coil 62 above the patient's chest. This allows for a more conformed coil to the patient's anatomy and can increase the quality of the images.
[0029] In yet another preferred embodiment, shown in FIG. 8 , involves attaching a support 74 to a patient support platform 72 which is used for Stereotactic Body Radiation Therapy. In addition, support bridges 76 can be attached to the platform. A compression paddle 78 can be attached to the bridges 76 . This paddle allows the diaphragm to be compressed during treatment which reduces tumor motion and contributes to more accurate treatment delivery. In this configuration the device can be used for imaging of the lung, liver, and pancreas.
[0030] FIG. 9 shows a side view of patient 80 on a patient support platform 72 . In this view the posterior coil 82 can be seen attached to the bottom of the patient support platform. This posterior coil is removably attached and can be positioned in multiple locations depending on tumor location and patient anatomy.
[0031] There are a number of ways the coil support can be configured. FIG. 10 shows one configuration in which the support 112 does not contain any adjustable pieces. The support can be mounted on the left or right of the patient platform 2 . It can also have multiple attachment points to the platform such that the coil 4 can be adjusted superior or inferior with respect to the patient.
[0032] Alternatively, adjustment can be provided within the support. FIG. 11 illustrates an adjustable support. The platform mount 106 can be located at multiple locations on the platform 2 . It can be mounted in such a way that it can be quickly connected and disconnected. The first member 102 is telescoping, allowing the coil 4 to be adjusted anteriorly and posteriorly. The telescoping configuration is preferred as this allow the overall height of the support to be kept to a minimum, allowing the coil to pass through the bore of the MRI without collision. The joint 104 is adjustable and can be locked into multiple locations allowing the angle of the coil to be adjusted. The second member 105 can also be configured to be telescoping to allow the coil to be adjusted superior or inferior with respect to the patient.
[0033] As shown in FIG. 12 the coil support 122 can also be an articulating arm. This allows for increased flexibility in positioning the coil. The arm can provide multiple degrees of freedom at the first knuckle 124 and the second knuckle 126 . It can also rotate about the joint 128 .
[0034] An important feature of any of these configurations is that the overall width of the patient and support structure is not increased. This allows the most versatility in fitting the device and patient through the bore of an MRI machine.
[0035] If the device is configured such that the patient is in the prone position the coil support positions the posterior coil and the inferior coil is attached to the bottom of the patient support platform.
[0036] The present invention is further defined by the following claims. | The present invention provides a novel MRI coil configuration for breast cancer imaging in preparation for radiation therapy planning and treatment. Both an adjustable anterior and posterior coil sets are described. The coil sets are supported and configured so as not to affect the accurate and repeatable positioning of the patient and breasts. The coil sets are removable so that they can be extracted before radiation therapy treatment commences. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to organic light-emitting devices.
BACKGROUND ART
[0002] An organic light-emitting device is a device that includes an anode, a cathode, and an organic compound layer interposed between the anode and the cathode. Holes and electrons injected from the respective electrodes of the organic light-emitting device are recombined in the organic compound layer to generate excitons and light is emitted as the excitons return to their ground state. The organic light-emitting device is also called an organic electroluminescent device or organic EL device. Recent years have seen remarkable advances in the field of organic light-emitting devices. Organic light-emitting devices offer low driving voltage, various emission wavelengths, rapid response, and small thickness and are light-weight.
[0003] Phosphorescence-emitting devices are a type of device that includes an organic compound layer containing a phosphorescence-emitting material, with triplet excitons contributing to emission. Creation of novel organic compounds has been actively pursued to provide high-performance phosphorescence-emitting devices.
[0004] PTL 1 discloses a compound 1 used as a host material of a phosphorescence-emitting device. The compound 1 is a xanthone derivative having carbazolyl groups.
[0000]
[0005] Since the excited triplet (T 1 ) energy of this compound is low, this material is not suitable as a host material of an emission layer of a blue or green phosphorescence-emitting device or as a material for forming a carrier transport layer.
CITATION LIST
Patent Literature
[0000]
PTL 1: International Publication No. 2006/114966
SUMMARY OF INVENTION
[0007] The present invention provides an organic light-emitting device that uses a xanthone derivative having a high T 1 energy and good electron injectability so that an organic light-emitting device having high emission efficiency and low driving voltage is provided and used as a blue or green phosphorescence-emitting device.
[0008] According to an aspect of the present invention, an organic light-emitting device includes an anode, a cathode, and an emission layer composed of an organic compound and interposed between the anode and the cathode. The emission layer contains a phosphorescence-emitting material. The organic light-emitting device contains a xanthone compound represented by general formula [1]:
[0000]
[0009] In general formula [1], R 1 to R 8 are each independently selected from a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, a substituted or unsubstituted phenyl group, a substituted or unsubstituted naphthyl group, a substituted or unsubstituted phenanthryl group, a substituted or unsubstituted fluorenyl group, a substituted or unsubstituted triphenylenyl group, a substituted or unsubstituted chrysenyl group, a substituted or unsubstituted dibenzofuranyl group, and a substituted or unsubstituted dibenzothienyl group.
[0010] According to the present invention, an organic light-emitting device having high emission efficiency and low driving voltage can be provided by using a xanthone derivative having high T 1 energy and good electron injectability.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a schematic cross-sectional view of an organic light-emitting device and a switching element connected to the organic light-emitting device.
DESCRIPTION OF EMBODIMENTS
[0012] An organic light-emitting device according to an embodiment of the present invention includes an anode, a cathode, and an emission layer composed of an organic compound and interposed between the anode and the cathode. The emission layer contains a phosphorescence-emitting material. The organic light-emitting device contains a xanthone compound represented by general formula [1]:
[0000]
[0013] In formula [1], R 1 to R 8 are each independently selected from a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, a substituted or unsubstituted phenyl group, a substituted or unsubstituted naphthyl group, a substituted or unsubstituted phenanthryl group, a substituted or unsubstituted fluorenyl group, a substituted or unsubstituted triphenylenyl group, a substituted or unsubstituted chrysenyl group, a substituted or unsubstituted dibenzofuranyl group, and a substituted or unsubstituted dibenzothienyl group.
[0014] Examples of the alkyl group having 1 to 4 carbon atoms include a methyl group, an ethyl group, a normal propyl group, an isopropyl group, a normal butyl group, a secondary butyl group, an isobutyl group, and a tertiary butyl group.
[0015] Examples of the substituents that may be included in the phenyl group, the naphthyl group, the phenanthryl group, the fluorenyl group, the triphenylenyl group, the chrysenyl group, the dibenzofuranyl group, and the dibenzothienyl group are as follows.
[0016] Examples of the substituents are a methyl group, an ethyl group, a normal propyl group, an isopropyl group, a normal butyl group, a secondary butyl group, an isobutyl group, and a tertiary butyl group; a phenyl group, a methylphenyl group, a dimethylphenyl group, a trimethylphenyl group, a pentamethylphenyl group, a triisopropylphenyl group, a tertiary butylphenyl group, a di-tertiary butyl phenyl group, a naphthylphenyl group, a phenanthrylphenyl group, a fluorenylphenyl group, a triphenylenylphenyl group, a chrysenylphenyl group, a dibenzofuranylphenyl group, a dibenzothienylphenyl group, and a 9,9′-spirobi[fluoren]-ylphenyl group; a biphenyl group, a di-tertiary butyl biphenyl group, a naphthylbiphenyl group, a phenanthrylbiphenyl group, a fluorenylbiphenyl group, a triphenylenylbiphenyl group, a chrysenylbiphenyl group, a dibenzofuranylbiphenyl group, and a dibenzothienylbiphenyl group; a naphthyl group, a di-tertiary butylnaphthyl group, a phenylnaphthyl group, and a biphenylnaphthyl group; a phenanthryl group, a phenylphenanthryl group, and a biphenylphenanthryl group; a fluorenyl group, a phenylfluorenyl group, a biphenylfluorenyl group, and a 9,9′-spirobi[fluoren]-yl group; a chrysenyl group, a phenylchrysenyl group, and a biphenylchrysenyl group; a triphenylenyl group, a phenyltriphenylenyl group, and a biphenyltriphenylenyl group; a dibenzofuranyl group, a tertiary butyldibenzofuranyl group, a di-tertiary butyldibenzofuranyl group; a phenyldibenzofuranyl group, a biphenyldibenzofuranyl group, a naphthyldibenzofuranyl group, a phenanthryldibenzofuranyl group, a fluorenyldibenzofuranyl group, a chrysenylbenzofuranyl group, and a triphenylenyldibenzofuranyl group; and a dibenzothienyl group, a tertiary butyldibenzothienyl group, a di-tertiary butyldibenzothienyl group, a phenyldibenzothienyl group, a biphenyldibenzothienyl group, a naphthyldibenzothienyl group, a phenanthryldibenzothienyl group, a fluorenyldibenzothienyl group, a chrysenyldibenzothienyl group, and a triphenylenyldibenzothienyl group.
Properties of Xanthone Compound
[0017] Since a xanthone skeleton contains a carbonyl group, it has high electron affinity. Since a xanthone skeleton is a planar skeleton, molecular overlap easily occurs and intermolecular electron migration occurs highly efficiently in a solid state. The xanthone compound having such properties is suited to carrying out injection and transport of electrons from the cathode or the adjacent organic layer when it is used in an organic light-emitting device. In other words, a xanthone compound is suited for use in an electron injection/transport layer and as a host in an emission layer.
[0018] Another feature of the xanthone skeleton is its high T 1 energy. A phosphorescent spectrum of a diluted toluene solution of unsubstituted xanthone (compound represented by formula [1] above with R 1 to R 8 each representing a hydrogen atom) was taken at 77 K, and the T 1 energy was determined from a 0-0 band. The T 1 energy was 3.02 eV (410 nm), which is sufficiently higher than that of blue (maximum peak wavelength in an emission spectrum is 440 nm to 480 nm). Accordingly, the xanthone compound may be used as a host of an emission layer or in a carrier transport layer adjacent to the emission layer in a phosphorescence-emitting device using a blue to red (600 nm to 620 nm) phosphorescence-emitting material.
[0019] In sum, a xanthone compound is suitable for use as a host of an emission layer and/or in an electron transport layer adjacent to the emission layer in a phosphorescence-emitting device.
[0020] When the xanthone compound is used as a host material of an emission layer of a phosphorescence-emitting device, the xanthone compound easily receives electrons from an electron transport layer and efficiently transports the electrons within the host (low voltage). Thus, the xanthone compound can give high T 1 energy generated by recombination of electrons and holes to the phosphorescence-emitting material without loss (high efficiency).
[0021] When the xanthone compound is used in an electron transport layer adjacent to the emission layer, the xanthone compound easily receives electrons from the cathode or an electron injection layer and transports the electrons to the emission layer (low voltage). Since the T 1 energy of the phosphorescence-emitting material in an excited state does not migrate to the xanthone compound in the electron transport layer adjacent to the emission layer, the T 1 energy is confined in the emission layer, thereby increasing the efficiency of the phosphorescence-emitting device. When the xanthone compound is used as a host of an emission layer and in an electron transport layer adjacent to the emission layer in a phosphorescence-emitting device, the lowest unoccupied molecular orbital (LUMO) energy barrier between the emission layer and the electron transport layer disappears and the effect of decreasing the voltage can be enhanced.
[0000] Regarding Substituents to be Introduced into Xanthone Compound
[0022] Introducing an alkyl group or an aromatic ring group into a highly planar compound such as a xanthone skeleton improves the solubility in a solvent, the sublimation property during vacuum deposition, and the amorphous property in a thin film state. However, since the sublimation property is degraded when an alkyl group has too many carbon atoms, the number of carbon atoms in the alkyl group may be 1 to 4.
[0023] In order to use the xanthone compound as a host of an emission layer and/or in an electron transport layer adjacent to the emission layer in a phosphorescence-emitting device, the xanthone compound desirably has a T 1 energy higher than that of the phosphorescence-emitting material. In other words, when the emission color of the phosphorescence-emitting material is blue to red (440 nm to 620 nm), it is important that the T 1 energy of the xanthone compound be decided according to the emission color of the phosphorescence-emitting material. In general, alkyl substituents little affect the T 1 energy but aromatic ring substituents greatly affect the T 1 energy of the compound as a whole. Thus, in deciding the T 1 energy of the xanthone compound, the T 1 energy of the aromatic ring substituent bonded to one of R 1 to R 8 in general formula [1] is extensively studied.
[0024] Table 1 shows the T 1 energy (on a wavelength basis) of each of major aromatic rings. Of these, preferred structures of the aromatic ring are benzene, naphthalene, phenanthrene, fluorene, triphenylene, chrysene, dibenzofuran, dibenzothiophene, and pyrene.
[0025] When the phosphorescence-emitting material has a blue to green range (440 nm to 530 nm) by utilizing the high T 1 energy property of the xanthone skeleton, preferable aromatic ring structures bonded to one of R 1 to R 8 of the xanthone compound are benzene, naphthalene, phenanthrene, fluorene, triphenylene, chrysene, dibenzofuran, and dibenzothiophene.
[0026] The substituents of the aromatic ring structures described above may further contain substituents as long as the T 1 energy of the xanthone compound is not significantly lowered.
[0000]
TABLE 1
T 1 energy
on a
wavelength
Structural formula
basis
Benzene
339 nm
Naphthalene
472 nm
Phenanthrene
459 nm
Fluorene
422 nm
Triphenylene
427 nm
Chrysene
500 nm
Dibenzofuran
417 nm
Dibenzothiophene
415 nm
Anthracene
672 nm
Pyrene
589 nm
[0027] Note that the compound 1 described above is a compound having a xanthone skeleton into which an N-carbazolyl group is introduced. In order to predict the T 1 energy of the compound 1, a molecular orbital calculation of the B3LYP/6-31G* level was performed based on a density functional theory. The calculation was also conducted on the xanthone compound represented by general formula [1] above, and the results are compared with the phosphorescent spectrum measurement results of a diluted toluene solution. Table 2 shows the results.
[0000]
TABLE 2
T 1 energy
T 1 energy
on a
on a
wavelength
wavelength
basis
basis
Structure
(calculated)
(observed)
Example Compound A-4
423 nm
439 nm
Example Compound A-15
444 nm
487 nm
Example Compound A-12
467 nm
502 nm
Compound 1
486 nm
—
[0028] The difference between the calculated value and the observed value of the T 1 energy of the three xanthone compounds of embodiments of the present invention was from 16 to 35 nm. Example Compound A-12 exhibited a T 1 energy observed value equal to the limitation value at which the compound can be used as a host in an emission layer or in an electron transport layer adjacent to the emission layer in a green phosphorescence-emitting device. In contrast, the compound 1 exhibited a calculated value 19 nm longer than that of Example Compound A-12; therefore, the observed value is assumed to be about 520 to 530 nm. The host of the emission layer or the material used in a carrier transport layer adjacent to the emission layer may have an energy about 20 nm higher than that of the emission material in terms of wavelength. However, since the compound 1 has a T 1 energy about the same as the emission wavelength (500 to 530 nm) of a green phosphorescence-emitting material, the energy of the green phosphorescence-emitting material may migrate to the compound 1 and the emission efficiency of the phosphorescence-emitting device may be lowered. Accordingly, the compound 1 is not suited for use as a host in an emission layer or in a carrier transport layer adjacent to the emission layer of a phosphorescence-emitting device for a wavelength shorter than green, and is thus not favored due to its narrow application range.
[0029] The reasons therefor is investigated by focusing on the electron distribution determined by a molecular orbital calculation. In the compound 1, the highest occupied molecular orbital (HOMO) is localized on the N-carbazolyl group and the LUMO is localized on the xanthone skeleton. This causes the compound 1 to enter a charge-transfer (CT) excited state and significantly decreases the excited singlet (S 1 ) and T 1 energies. In order for the xanthone skeleton to maintain a high T 1 energy, introduction of substituents, such as a carbazolyl group, that have a high HOMO energy level is avoided.
[0030] It is not desirable to introduce an electron-donating substituent such as an amino group since the electron acceptability of the xanthone skeleton may be degraded.
[0031] The position into which the substituent is to be introduced is at least one selected from R 1 to R 8 in general formula [1] to obtain desired physical property values.
[0032] The chemical stability of the compound can be further enhanced by introducing a substituent into a high-electron-density carbon atom on an aromatic ring. In the xanthone skeleton, the para position from the position at which an ether oxygen atom is bonded is susceptible to electrophilic reaction and has a high electron density. Thus, an alkyl group or an aromatic ring group is preferably introduced to at least one of R 2 and R 7 and more preferably to both R 2 and R 7 with the rest of Rs, i.e., R 1 , R 3 to R 6 , and R 8 , being hydrogen atoms. Most preferably, the R 2 and R 7 are the same substituents.
Examples of the Xanthone Compound
[0033] Examples of the xanthone compound are described below in Groups A to C.
[0000]
Properties of Example Compounds
[0034] Of the example compounds, those of Group A have an axis of symmetry within a molecule and two substituents of the same kind are respectively introduced into two benzene rings in a symmetrical manner. Thus, the electron distribution in the xanthone skeleton is unbiased and is thus stable.
[0035] Example compounds of Group B each have two or more substituents introduced into the xanthone skeleton and no axis of symmetry. These compounds achieve higher stability in an amorphous state. The physical property values can be finely adjusted by changing the position and type of the substituents.
[0036] Example compounds of Group C each have one substituent introduced therein. Since the high T 1 energy of the xanthone skeleton remains relatively undegraded, these compounds are particularly suited for use in blue or green phosphorescence-emitting devices.
Description of Synthetic Route
[0037] An example of a synthetic route for an organic compound is described. The reaction scheme therefor is presented below.
[0038] First, a halide, a triflate, and a boronic acid ester can be synthesized by using widely commercially available xanthone and its derivatives.
[0000]
[0039] The halide, triflate, and boronic acid ester is used in a Suzuki coupling reaction. As a result, an alkyl group or an aromatic ring group can be introduced into the xanthone skeleton.
[0000]
[0040] A Friedel-Crafts reaction may be employed to introduce an alkyl group into a xanthone skeleton.
[0000]
[0041] Alternatively, a dehydration condensation reaction may be conducted using a dihydroxybenzophenone derivative already having a reactive functional group or an aromatic ring group and the xanthone skeleton is formed later.
[0000]
[0042] Desired substituents can be introduced into desired positions selected from among R 1 to R 8 in general formula [1] by freely combining the above-described basic reactions.
Regarding the Properties of Organic Light-Emitting Device
[0043] Next, the organic light-emitting device is described.
[0044] The organic light-emitting device according to an embodiment of the present invention includes a pair of opposing electrodes, namely, an anode and a cathode, and an organic compound layer interposed between the electrodes. A layer containing a phosphorescence-emitting material in the organic compound layer is the emission layer. The organic compound layer of the organic light-emitting device contains a xanthone compound represented by general formula [1].
[0045] An example of the structure of the organic light-emitting device is an anode/emission layer/cathode structure on a substrate. Another example is an anode/hole transport layer/electron transport layer/cathode structure. Still other examples include an anode/hole transport layer/emission layer/electron transport layer/cathode structure, an anode/hole injection layer/hole transport layer/emission layer/electron transport layer/cathode structure, and an anode/hole transport layer/emission layer/hole-exciton blocking layer/electron transport layer/cathode structure. These five structures of the multilayer organic light-emitting device are basic device structures and the structure of the organic light-emitting device containing a xanthone compound is not limited to these. Various other layer configurations may be employed, e.g., an insulating layer may be provided at the interface between an electrode and an organic compound layer, an adhesive layer or an interference layer may be provided, and the electron transport layer or the hole transport layer may be constituted by two layers having different ionization potentials.
[0046] The device may be of a top emission type that emits light from the substrate-side electrode or of a bottom emission type that emits light from the side opposite the substrate. The device may be of a type that emits light from both sides.
[0047] The xanthone compound can be used in an organic compound layer of an organic light-emitting device having any layer structure. Preferably, the xanthone compound is used in an electron transport layer, a hole-exciton blocking layer, or an emission layer. More preferably, the xanthone compound is used in at least one of the host material of an emission layer, a hole blocking layer, an electron transport layer, and an electron injection layer.
[0048] In general, a “hole blocking layer” is a layer that blocks holes. In the present invention, a layer adjacent to the cathode-side of the emission layer is referred to as a “hole blocking layer”. The reason for this is as follows. The main purpose of using the xanthone compound is not to block holes but to use the xanthone compound in an electron transport layer. However, the xanthone compound is used in a layer located at the same position as a general hole blocking layer. Thus, in order to avoid confusion as to the position with the electron transport layer, the layer is referred to as a “hole blocking layer” from the position of the layer.
[0049] The emission layer of the organic light-emitting device may be constituted by two or more organic compounds, namely, a host material and a guest material. A guest material is an organic compound that emits light. One or more host materials may be used. In other words, the emission layer may contain two or more host materials in addition to the phosphorescence-emitting material. When only one host material is used, the xanthone compound may be used as this host material. When two or more host materials are used, the xanthone compound may be a host material having a smaller weight ratio than other host materials. In such a case, other host materials may have a hole transport property. This is because the xanthone compound has high electron transport property. When a material having a high hole transport property and a material having a high electron transport property are used together, the host material exhibits a substantial bipolar property in the emission layer.
[0050] The hole transport property of the emission layer may be enhanced by a guest material having a high hole transport property even when the hole transport property of the host material other than the xanthone compound is low. In such a case also, the xanthone compound may be used as a host material to adjust the carrier balance of the emission layer. Of the organic light-emitting devices shown in Table 3 below, the emission layer of the organic light-emitting device that has a host material 2 exhibits a high hole transport property due to properties of the host material 1 and the guest. The term “weight ratio” is a ratio relative to the total weight of the compounds constituting the emission layer.
[0051] The hole transport property and the electron transport property are regarded as “high” when the mobility is 10 −4 cm 2 /(V·s) or higher. The mobility can be measured by a time-of-flight (TOF) technique.
[0052] When two or more host materials are used, the xanthone compound having a smaller weight ratio than other host materials is referred to as a “host material” or, in some cases, an “assisting material”.
[0053] The concentration of the guest material relative to the host material is 0.01 to 50 wt % and preferably 0.1 to 20 wt % relative to the total amount of the constituent materials of the emission layer. The concentration of the guest material is most preferably 10 wt % or less to prevent concentration quenching. The guest material may be homogeneously distributed in the entire layer composed of a host material, may be contained in the layer by having a concentration gradient, or may be contained in particular parts of the layer, thereby creating parts only the host material is contained. The emission color of the phosphorescence-emitting material is not particularly limited but may be blue to green with the maximum emission peak wavelength in the range of 440 to 530 nm.
[0054] In general, in order to prevent a decrease in emission efficiency caused by radiationless deactivation from T 1 of the host material of a phosphorescence-emitting device, the T 1 energy of the host material needs to be higher than the T 1 energy of the phosphorescence-emitting material which is a guest material.
[0055] The T 1 energy of the xanthone skeleton that functions as the center of the xanthone compound is 410 nm, which is higher than the T 1 energy of a blue phosphorescence-emitting material. Thus, when the xanthone compound is used in an emission layer or a nearby layer of a blue to green phosphorescence-emitting device, a phosphorescence-emitting device having a high emission efficiency can be obtained.
[0056] The xanthone compound has a low LUMO level. When the xanthone compound is used not only as an electron injection material or an electron transport material, or in a hole blocking layer but also as a host material of the emission layer, the driving voltage of the device can be lowered. This is because a low LUMO level decreases the electron injection barrier from the hole blocking layer or the electron transport layer adjacent to the cathode-side of the emission layer.
[0057] When a xanthone compound is used as an assisting material of the emission layer, the lifetime of the device can be extended when the xanthone compound has a LUMO level lower than that of the host material having a larger weight ratio. This is because electrons are trapped in the xanthone compound, thereby creating delocalized electronic distribution and delocalized recombination regions in the emission layer and thereby avoiding deterioration of the material occurring intensely in one portion of the emission layer.
[0058] When the xanthone compound is used as an electron transport material, an assisting material, or a host material in a phosphorescent light-emitting layer, a phosphorescence-emitting material used as a guest material is a metal complex such as an iridium complex, a platinum complex, a rhenium complex, a copper complex, an europium complex, or a ruthenium complex. Among these, an iridium complex having a high phosphorescent property is preferred. Two or more phosphorescence-emitting materials may be contained in the emission layer to assist transmission of excitons and carriers.
[0059] Examples of the iridium complex used as the phosphorescence-emitting material and examples of the host material are presented below. These examples do not limit the scope of the present invention.
[0000]
[0060] If needed, a low-molecular-weight or high-molecular-weight compound may be used in addition to the xanthone compound. For example, a hole injection or transport compound, a host material, a light-emitting compound, or an electron injection or transport compound may be used in combination.
[0061] Examples of these compounds are presented below.
[0062] The hole injection/transport material can be a material having a high hole mobility so that holes can be easily injected from the anode and the injected holes can be easily transported to the emission layer. Examples of the low- and high-molecular-weight materials having hole injection/transport property include triarylamine derivatives, phenylenediamine derivatives, stilbene derivatives, phthalocyanine derivatives, porphyrin derivatives, poly(vinyl carbazole), poly(thiophene), and other conductive polymers.
[0063] Examples of the light-emitting material mainly contributing to the light-emitting function include the phosphorescent light-emitting guest materials described above, derivative thereof, fused compounds (e.g., fluorene derivatives, naphthalene derivatives, pyrene derivatives, perylene derivatives, tetracene derivatives, anthracene derivatives, and rubrene), quinacridone derivatives, coumarin derivatives, stilbene derivatives, organic aluminum complexes such as tris(8-quinolinolato)aluminum, organic beryllium complexes, and polymer derivatives such as poly(phenylenevinylene) derivatives, poly(fluorene) derivatives, and poly(phenylene) derivatives.
[0064] The electron injection/transport material may be selected from materials to which electrons can be easily injected from the cathode and which can transport the injected electrons to the emission layer. The selection may be made by considering the balance with the hole mobility of the hole injection/transport material. Examples of the electron injection/transport material include oxadiazole derivatives, oxazole derivatives, pyrazine derivatives, triazole derivatives, triazine derivatives, quinoline derivatives, quinoxaline derivatives, phenanthroline derivatives, and organic aluminum complexes.
[0065] The anode material may have a large work function. Examples of the anode material include single metals such as gold, platinum, silver, copper, nickel, palladium, cobalt, selenium, vanadium, and tungsten or alloys thereof, and metal oxides such as tin oxide, zinc oxide, indium oxide, indium tin oxide (ITO), and indium zinc oxide. Conductive polymers such as polyaniline, polypyrrole, and polythiophene may also be used. These anode materials may be used alone or in combination. The anode may be constituted by one layer or two or more layers.
[0066] The cathode material may have a small work function. Examples of the cathode material include alkali metals such as lithium, alkaline earth metals such as calcium, and single metals such as aluminum, titanium, manganese, silver, lead, and chromium. The single metals may be combined and used as alloys. For example, magnesium-silver, aluminum-lithium, and aluminum-magnesium alloys and the like can be used. Metal oxides such as indium tin oxide (ITO) can also be used. These cathode materials may be used alone or in combination. The cathode may be constituted by one layer or two or more layers.
[0067] Layers containing the xanthone compound and other organic compounds in the organic light-emitting device are formed by the following processes. Typically, thin films are formed by vacuum vapor deposition, ionization deposition, sputtering, plasma, and coating using an adequate solvent (spin-coating, dipping, casting, a Langmuir Blodgett method, and an ink jet method). When layers are formed by vacuum vapor deposition or a solution coating method, crystallization is suppressed and stability over time can be improved. When a coating method is employed, an adequate binder resin may be additionally used to form a film.
[0068] Examples of the binder resin include, but are not limited to, polyvinylcarbazole resins, polycarbonate resins, polyester resins, ABS resins, acrylic resins, polyimide resins, phenolic resins, epoxy resins, silicone resins, and urea resins. These binder resins may be used alone as a homopolymer or in combination of two or more as a copolymer. If needed, known additives such as a plasticizer, an antioxidant, and an ultraviolet absorber may be used in combination.
Usage of Organic Light-Emitting Device
[0069] The organic light-emitting device of the embodiment may be used in a display apparatus or a lighting apparatus. The organic light-emitting device can also be used as exposure light sources of image-forming apparatuses and backlights of liquid crystal display apparatuses.
[0070] A display apparatus includes a display unit that includes the organic light-emitting device of this embodiment. The display unit has pixels and each pixel includes the organic light-emitting device of this embodiment. The display apparatus may be used as an image display apparatus of a personal computer, etc.
[0071] The display apparatus may be used in a display unit of an imaging apparatus such as digital cameras and digital video cameras. An imaging apparatus includes the display unit and an imaging unit having an imaging optical system for capturing images.
[0072] FIG. 1 is a schematic cross-sectional view of an image display apparatus having an organic light-emitting device in a pixel unit. In the drawing, two organic light-emitting devices and two thin film transistors (TFTs) are illustrated. One organic light-emitting device is connected to one TFT.
[0073] Referring to FIG. 1 , in an image display apparatus 3 , a moisture proof film 32 is disposed on a substrate 31 composed of glass or the like to protect components (TFT or organic layer) formed thereon. The moisture proof film 32 is composed of silicon oxide or a composite of silicon oxide and silicon nitride. A gate electrode 33 is provided on the moisture proof film 32 . The gate electrode 33 is formed by depositing a metal such as Cr by sputtering.
[0074] A gate insulating film 34 covers the gate electrode 33 . The gate insulating film 34 is obtained by forming a layer of silicon oxide or the like by a plasma chemical vapor deposition (CVD) method or a catalytic chemical vapor deposition (cat-CVD) method and patterning the film. A semiconductor layer 35 is formed over the gate insulating film 34 in each region that forms a TFT by patterning. The semiconductor layer 35 is obtained by forming a silicon film by a plasma CVD method or the like (optionally annealing at a temperature 290° C. or higher, for example) and patterning the resulting film according to the circuit layout.
[0075] A drain electrode 36 and a source electrode 37 are formed on each semiconductor layer 35 . In sum, a TFT 38 includes a gate electrode 33 , a gate insulating layer 34 , a semiconductor layer 35 , a drain electrode 36 , and a source electrode 37 . An insulating film 39 is formed over the TFT 38 . A contact hole (through hole) 310 is formed in the insulating film 39 to connect between a metal anode 311 of the organic light-emitting device and the source electrode 37 . A single-layer or a multilayer organic layer 312 that includes an emission layer and a cathode 313 are stacked on the anode 311 in that order to constitute an organic light-emitting device that functions as a pixel.
[0076] First and second protective layers 314 and 315 may be provided to prevent deterioration of the organic light-emitting device.
[0077] The switching element is not particularly limited and a metal-insulator-metal (MIM) element may be used instead of the TFT described above.
EXAMPLES
[0078] The present invention will now be described by using Examples which do not limit the scope of the invention.
Example 1
Synthesis of Example Compound A-4
[0079]
[0080] The following reagents and solvents were placed in a 100 mL round-bottomed flask.
Xanthone (Tokyo Chemical Industry Co., Ltd.): 5.0 g (26 mmol) Bromine: 16 g (102 mmol) Iodine: 50 mg (0.20 mmol) Acetic acid: 20 mL
[0085] The reaction solution was refluxed for 5 hours at 100° C. under heating and stirring in a nitrogen atmosphere. Upon completion of the reaction, chloroform and a saturated aqueous sodium sulfite solution were added to the reaction solution and stirring was continued until the color of bromine was lost. The organic layer was separated, washed with a saturated aqueous sodium carbonate solution, dried with magnesium sulfate, and filtered. The solvent in the filtrate was distilled away at a reduced pressure. The precipitated solid was purified with a silica gel column (toluene: 100%). As a result, 2.9 g (yield: 41%) of 2-bromoxanthone and 2.2 (yield: 25%) g of 2,7-dibromoxanthone were obtained.
[0086] The following reagents and solvents were placed in a 100 mL round-bottomed flask.
2,7-Dibromoxanthone: 0.70 g (2.0 mmol) 4,4,5,5-Tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane: 1.9 g (4.8 mmol) Tetrakis(triphenylphosphine) palladium(0): 0.23 g (0.20 mmol) Toluene: 10 mL Ethanol: 2 mL 2M Aqueous sodium carbonate solution: 5 mL
[0093] The reaction solution was refluxed for 5 hours under heating and stirring in a nitrogen atmosphere. Upon completion of the reaction, the organic layer was separated, dried with magnesium sulfate, and filtered. The solvent in the filtrate was distilled away at a reduced pressure. The precipitated solid was purified with a silica gel column (chloroform:heptane=1:1). The resulting crystals was vacuum dried at 150° C. and purified by sublimation at 10 −1 Pa and 300° C. As a result, 0.90 g (yield: 63%) of high-purity Example Compound A-4 was obtained.
[0094] The compound was subjected to matrix-assisted laser desorption ionization-time-of-flight mass spectroscopy (MALDI-TOF-MS), and 724.4 which was M + of this compound was confirmed.
[0095] The structure of the compound was confirmed by proton nuclear magnetic resonance spectroscopy ( 1 H-NMR).
[0096] 1 H-NMR ((CD 3 ) 2 NCDO, 500 MHz) δ (ppm): 8.13 (2H, d), 7.63-7.44 (10H, m), 7.32 (4H, d), 7.15 (4H, d), 1.43 (18H, s), 1.25 (18H, s)
[0097] The T 1 energy of Example Compound A-4 was measured by the following process.
[0098] A phosphorescence spectrum of a diluted toluene solution (1×10 −5 M) of Example Compound A-4 was measured in an Ar atmosphere at 77K and an excitation wavelength of 350 nm. The T 1 energy was calculated from the peak wavelength of the 0-0-band (first emission peak) of the obtained phosphorescence spectrum. The T 1 energy was 439 nm on a wavelength basis.
Example 2
Synthesis of Example Compound A-5
[0099]
[0100] Example Compound A-5 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 3-biphenylboronic acid.
[0101] M + of this compound, 500.2, was confirmed by MALDI-TOF MS.
[0102] The structure of the compound was confirmed by 1 H-NMR.
[0103] 1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.66 (2H, d), 8.06 (2H, dd), 7.91 (2H, bs), 7.72-7.66 (6H, m), 7.66-7.60 (4H, m), 7.57 (2H, t), 7.49 (4H, t), 7.39 (2H, t)
[0104] The T 1 energy of Example Compound A-5 was measured as in Example 1. The T 1 energy was 446 nm on a wavelength basis.
Example 3
Synthesis of Example Compound A-7
[0105]
[0106] Example Compound A-7 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 3,5-diphenylphenylboronic acid.
[0107] M + of this compound, 652.2, was confirmed by MALDI-TOF MS.
[0108] The structure of the compound was confirmed by 1 H-NMR.
[0109] 1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.72 (2H, d), 8.13 (2H, dd), 7.90 (4H, d), 7.84 (2H, dd), 7.74 (8H, d), 7.68 (2H, d), 7.51 (8H, t), 7.42 (4H, t)
[0110] The T 1 energy of Example Compound A-7 was measured as in Example 1. The T 1 energy was 447 nm on a wavelength basis.
Example 4
Synthesis of Example Compound A-12
[0111]
[0112] Example Compound A-12 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 4,4,5,5-tetramethyl-2-(phenanthren-9-yl)-1,3,2-dioxaborolane.
[0113] M + of this compound, 548.2, was confirmed by MALDI-TOF MS.
[0114] The structure of the compound was confirmed by 1 H-NMR.
[0115] 1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.82 (2H, d), 8.76 (2H, d), 8.60 (2H, d), 7.98 (2H, dd), 7.96-7.90 (4H, m), 7.79 (2H, s), 7.76-7.68 (6H, m), 7.65 (2H, dd), 7.58 (2H, dd)
[0116] The T 1 energy of Example Compound A-12 was measured as in Example 1. The T 1 energy was 502 nm on a wavelength basis.
Example 5
Synthesis of Example Compound A-15
[0117]
[0118] Example Compound A-15 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 4,4,5,5-tetramethyl-2-(9,9-dimethylfluoren-2-yl)-1,3,2-dioxaborolane.
[0119] M + of this compound, 580.2, was confirmed by MALDI-TOF MS.
[0120] The structure of the compound was confirmed by 1 H-NMR.
[0121] 1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.68 (2H, d), 8.09 (2H, dd), 7.84 (2H, d), 7.80-7.76 (4H, m), 7.69 (2H, dd), 7.65 (2H, d), 7.48 (2H, dd), 7.40-7.33 (4H, m), 1.58 (12H, s)
[0122] The T 1 energy of Example Compound A-15 was measured as in Example 1. The T 1 energy was 487 nm on a wavelength basis.
Example 6
Synthesis of Example Compound A-16
[0123]
[0124] Example Compound A-16 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 4,4,5,5-tetramethyl-2-(9,9-dimethylfluoren-3-yl)-1,3,2-dioxaborolane.
[0125] M + of this compound, 580.2, was confirmed by MALDI-TOF MS.
[0126] The structure of the compound was confirmed by 1 H-NMR.
[0127] 1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.69 (2H, d), 8.10 (2H, dd), 8.06 (2H, d), 7.85 (2H, d), 7.66 (4H, d), 7.56 (2H, d), 7.48 (2H, d), 7.42-7.34 (4H, m), 1.55 (12H, s)
[0128] The T 1 energy of Example Compound A-16 was measured as in Example 1. The T 1 energy was 450 nm on a wavelength basis.
Example 7
Synthesis of Example Compound A-22
[0129]
[0130] Example Compound A-22 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 4-dibenzothienylboronic acid.
[0131] M + of this compound, 560.1, was confirmed by MALDI-TOF MS.
[0132] The structure of the compound was confirmed by 1 H-NMR.
[0133] 1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.76 (2H, d), 8.24-8.18 (6H, m), 7.88-7.84 (2H, m), 7.73 (2H, d), 7.64-7.58 (4H, m), 7.52-7.46 (4H, m)
[0134] The T 1 energy of Example Compound A-22 was measured as in Example 1. The T 1 energy was 450 nm on a wavelength basis.
Example 8
Synthesis of Example Compound A-32
[0135]
[0136] Example Compound A-32 was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by 4,4,5,5-tetramethyl-2-(9,9′-spirobi[fluoren]-3-yl)-1,3,2-dioxaborolane.
[0137] M + of this compound, 824.3, was confirmed by MALDI-TOF MS.
[0138] The structure of the compound was confirmed by 1 H-NMR.
[0139] 1 H-NMR (CDCl 3 , 500 MHz) δ (ppm): 8.70 (2H, d), 8.18 (2H, d), 8.08 (2H, dd), 7.97 (2H, d), 7.88 (4H, d), 7.65 (2H, d), 7.46-7.38 (8H, m), 7.18-7.12 (6H, m), 6.86 (2H, d), 6.80 (4H, d), 6.77 (2H, d)
[0140] The T 1 energy of Example Compound A-32 was measured as in Example 1. The T 1 energy was 452 nm on a wavelength basis.
Examples 9 and 10
Synthesis of Example Compounds A-23 and A-31
[0141] Each Example Compound was obtained as in Example 1 except that 4,4,5,5-tetramethyl-2-(4,4′-di-tert-butylbiphenyl-2-yl)-1,3,2-dioxaborolane used in Example 1 was replaced by a boronic acid derivative shown in Table 3.
[0142] Each Example Compound was identified by MALDI-TOF MS.
[0000]
TABLE 3
Example
MALDI-T OF MS
compound
Boronic acid derivative
(M + )
Example 9
A-23
560.1
Example 10
A-31
824.3
Example 11
Synthesis of Example Compound B-1
[0143]
[0144] The following reagents and solvents were placed in a 100 mL round-bottomed flask.
2,7-Dibromoxanthone: 0.70 g (2.0 mmol) 3-Biphenylboronic acid: 0.40 g (2.0 mmol) Tetrakis(triphenylphosphine) palladium(0): 0.23 g (0.20 mmol) Toluene: 10 mL Ethanol: 2 mL 2M Aqueous sodium carbonate solution: 3 mL
[0151] The reaction solution was refluxed for 3 hours under heating and stirring in a nitrogen atmosphere. Upon completion of the reaction, the organic layer was separated, dried with magnesium sulfate, and filtered. The solvent in the filtrate was distilled away at a reduced pressure. The precipitated solid was purified with a silica gel column (chloroform:heptane=1:1). As a result, 0.62 g (yield: 72%) of intermediate 1 was obtained.
[0152] The following reagents and solvents were placed in a 100 mL round-bottomed flask.
Intermediate 1: 0.62 g (1.5 mmol) 4,4,5,5-Tetramethyl-2-(triphenylen-2-yl)-1,3,2-dioxaborolane: 0.64 g (1.8 mmol) Tetrakis(triphenylphosphine) palladium(0): 0.17 g (0.15 mmol) Toluene: 10 mL Ethanol: 2 mL 2M Aqueous sodium carbonate solution: 3 mL
[0159] The reaction solution was refluxed for 3 hours under heating and stirring in a nitrogen atmosphere. Upon completion of the reaction, the precipitated solid was filtered and washed with water, methanol, and acetone. The obtained solid was dissolved in chlorobenzene under heating and insolubles were removed by hot filtration. The solvent in the filtrate was distilled away under a reduced pressure and the precipitated solid was recrystallized in a chlorobenzene/heptane system. The resulting crystals were vacuum dried at 150° C. and purified by sublimation at 10 −1 Pa and 360° C. As a result, 0.67 g (yield: 78%) of high-purity Example Compound B-1 was obtained.
[0160] M + of this compound, 574.2, was confirmed by MALDI-TOF MS.
Example 12
Synthesis of Example Compound B-4
[0161]
[0162] Example Compound B-4 was obtained as in Example 11 except that 4,4,5,5-tetramethyl-2-(triphenylen-2-yl)-1,3,2-dioxaborolane used in Example 11 was replaced by 4-biphenylboronic acid.
[0163] M + of this compound, 500.2, was confirmed by MALDI-TOF MS.
Example 13
Synthesis of Example Compound C-2
[0164]
[0165] The following reagents and solvents were placed in a 100 mL round-bottomed flask.
2-Bromoxanthone: 0.55 g (2.0 mmol) Boronic acid ester derivative 1: 1.2 g (2.4 mmol) Tetrakis(triphenylphosphine) palladium(0): 0.23 g (0.20 mmol) Toluene: 15 mL Ethanol: 3 mL 2M Aqueous sodium carbonate solution: 5 mL
[0172] The reaction solution was refluxed for 3 hours under heating and stirring in a nitrogen atmosphere. Upon completion of the reaction, the precipitated solid was filtered and washed with water, methanol, and acetone. The obtained solid was dissolved in chlorobenzene under heating and insolubles were removed by hot filtration. The solvent in the filtrate was distilled away under a reduced pressure and the precipitated solid was recrystallized in a chlorobenzene/heptane system. The resulting crystals were vacuum dried at 150° C. and purified by sublimation at 10 −1 Pa and 370° C. As a result, 0.93 g (yield: 81%) of high-purity Example Compound C-2 was obtained.
[0173] M + of this compound, 574.2, was confirmed by MALDI-TOF MS.
Examples 14 to 17
Synthesis of Example Compounds C-5, C-7, C-14, and C-16
[0174] Each Example Compound was obtained as in Example 13 except that the boronic acid ester derivative 1 used in Example 13 was replaced by a boronic acid ester derivative shown in Table 4.
[0175] Each Example Compound was identified by MALDI-TOF MS.
[0000]
TABLE 4
Example
MALDI-T OF MS
compound
Boronic acid derivative
(M + )
Example 14
C-5
540.2
Example 15
C-7
530.1
Example 16
C-14
540.2
Example 17
C-16
662.2
Example 18
Production of Organic Light-Emitting Device
[0176] In Example 18, an organic light-emitting device having an anode/hole transport layer/emission layer/hole blocking layer/electron transport layer/cathode structure on a substrate was produced by the following process.
[0177] Indium tin oxide (ITO) was sputter-deposited on a glass substrate to form a film 120 nm in thickness functioning as an anode. This substrate was used as a transparent conductive support substrate (ITO substrate). Organic compound layers and electrode layers below were continuously formed on the ITO substrate by vacuum vapor deposition under resistive heating in a 10 −5 Pavacuum chamber. The process was conducted so that the area of the opposing electrodes was 3 mm 2 .
[0178] Hole transport layer (40 nm) HTL-1
[0000] Emission layer (30 nm), host material 1: I-1, host material 2: none, guest material: Ir-1 (10 wt %)
Hole blocking (HB) layer (10 nm) A-4
Electron transport layer (30 nm) ETL-1
Metal electrode layer 1 (0.5 nm) LiF
Metal electrode layer 2 (100 nm) Al
[0000]
[0179] A protective glass plate was placed over the organic light-emitting device in dry air to prevent deterioration caused by adsorption of moisture and sealed with an acrylic resin adhesive. Thus, an organic light-emitting device was produced.
[0180] The current-voltage characteristic of the organic light-emitting device was measured with 2700 series ammeter produced by Keithley Instruments Inc., and the emission luminance was measured with BM7-fast produced by TOPCON CORPORATION. A voltage of 5.0 V was applied to the ITO electrode functioning as a positive electrode and an aluminum electrode functioning as a negative electrode. The emission efficiency was 55 cd/A and emission of green light with a luminance of 2000 cd/m 2 was observed. The CIE color coordinate of the device was (x, y)=(0.31, 0.63).
[0181] The lifetime (length of time the luminance decreased 20% from the initial value) of the device when a current was passed at 40 mA/cm 2 was 65 hours.
Examples 19 to 37
[0182] Devices were produced as in Example 18 except that the HB material, the host material 1, the host material 2 (15 wt %), and the guest material (10 wt %) were changed. The devices were evaluated as in Example 18. Emission of green light was observed from all devices. The emission efficiency at 2000 cd/m 2 , the applied voltage, and the lifetime (length of time the luminance decreased 20% from the initial value) when a current is passed at 40 mA/cm 2 are presented in Table 5.
Comparative Examples 1 and 2
[0183] Devices were produced as in Example 18 except that ETL-1 was used as the HB material and the host material 1 and the guest material (10 wt %) were changed. The devices were evaluated as in Example 18. Emission of green light was observed from both devices. The emission efficiency at 2000 cd/m 2 , the applied voltage, and the lifetime (length of time the luminance decreased 20% from the initial value) when a current is passed at 40 mA/cm 2 are presented in Table 5.
[0000]
TABLE 5
HB
Host
Host
Guest
Emission
Volt-
Life-
Example
mate-
mate-
mate-
mate-
efficiency
age
time
No.
rial
rial 1
rial 2
rial
(cd/A)
(V)
(h)
19
A-4
I-1
A-4
Ir-1
63
5.1
70
20
A-5
I-8
None
Ir-23
56
5.4
95
21
A-5
I-3
A-5
Ir-3
61
5.6
115
22
A-7
I-7
None
Ir-24
55
5.3
85
23
A-7
I-8
A-7
Ir-27
58
5.8
120
24
A-12
I-1
None
Ir-1
55
5.0
70
25
A-12
I-2
A-12
Ir-1
57
5.2
80
26
A-15
I-2
None
Ir-1
55
5.4
75
27
A-15
I-1
A-15
Ir-3
60
5.6
100
28
A-16
I-1
None
Ir-1
58
5.5
95
29
A-16
I-3
A-15
Ir-4
62
5.7
80
30
A-22
I-8
A-22
Ir-27
58
5.6
105
31
ETL-1
I-9
A-4
Ir-26
55
5.3
100
32
ETL-1
I-8
A-7
Ir-23
54
5.6
95
33
ETL-1
I-7
A-32
Ir-25
54
5.2
95
34
B-1
I-9
None
Ir-2
51
4.9
115
35
ETL-1
I-7
B-4
Ir-4
54
5.5
105
36
C-7
I-9
C-7
Ir-7
57
5.1
115
37
ETL-1
I-8
C-16
Ir-6
55
5.3
85
Comparative
ETL-1
I-1
None
Ir-1
36
5.8
20
Example 1
Comparative
ETL-1
I-2
None
Ir-5
42
5.6
35
Example 2
Examples 38 to 44
[0184] Devices were produced as in Example 18 except that the HB material, the host material 1, the host material 2 (15 wt %), and the guest material (10 wt %) were changed. The devices were evaluated as in Example 18. The emission efficiency at 2000 cd/m 2 , the applied voltage, and the color of emission are presented in Table 6.
[0000]
TABLE 6
HB
Host
Host
Guest
Emission
Volt-
Example
mate-
mate-
mate-
mate-
efficiency
age
Emission
No.
rial
rial 1
rial 2
rial
(cd/A)
(V)
color
38
A-4
I-5
None
Ir-13
11
6.4
Blue
39
A-5
I-5
A-5
Ir-13
10
6.6
Blue
40
A-32
I-5
A-16
Ir-15
16
6.2
Blue-green
41
B-4
I-4
None
Ir-15
14
6.3
Blue-green
42
B-4
I-5
A-22
Ir-15
16
6.2
Blue-green
43
C-5
I-6
C-5
Ir-13
10
6.7
Blue
44
C-16
I-5
C-16
Ir-13
12
6.6
Blue
[0185] The results show that when the xanthone compound is used as an electron transport material or an emission layer material in a phosphorescence-emitting device, good emission efficiency and long device lifetime can be achieved.
[0186] While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
[0187] This application claims the benefit of Japanese Patent Application No. 2010-101299, filed Apr. 26, 2010 and Japanese Patent Application No. 2010-228893, filed Oct. 8, 2010, which are hereby incorporated by reference herein in their entirety. | An organic light-emitting device that achieves highly efficient emission and low-voltage operation is provided. The organic light-emitting device contains a 9H-xanthen-9-one derivative. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a preassembled refrigerant subcooling unit adapted to be universally installable into existing air conditioning and refrigeration systems, and having the capability to increase the efficiency thereof, resulting in a reduction of operating time, and to improvements in such subcooling units.
This invention is an improvement over my U.S. Pat. No. 3,177,929 entitled "Refrigeration Subcooling Unit" that teaches a preassembled refrigerant subcooling unit with a primary object of increasing the cooling capacity of an existing refrigerating unit. During the period subsequent to the issuance of this patent, the United States has experienced severe shortages of energy with subsequent significant increases in costs of electrical power. My prior invention, as may be recognized by those skilled in the art, can reduce the operating costs of a refrigeration system into which it is installed when the system is operated at its original design capacity. Therefore, my earlier invention is advantageous and applicable for systems having adequate cooling capacity for the purpose of saving energy, as well as for its original purpose.
My original subcooling unit, while eminently suited and economical for its primary purpose, has several disadvantages for installation in small air conditioning systems of the home type. For example, it is most desirable to mount a subcooling unit for a building air conditioner adjacent to the condensing unit. For air-cooled condensing units, the usual mounting is outside of the building, allowing the heat to be rejected to the outside atmosphere. The design and bulk of my original unit makes an outside mounting difficult. Also, the high ambient air temperatures encountered in summer weather can reduce the degree of subcooling possible with my prior design. Another problem is that the preferred embodiment of my prior invention causes the water flow utilized for subcooling to be controlled by the refrigerant pressure as the compressor of the system is cycled, and in many cases, more water flow than is necessary will occur and possible savings will be reduced by such wastage.
In the present invention, I have disclosed newly-discovered means for overcoming the problems inherent in my earlier invention when it is desired to use a subcooling unit for reducing the energy used for cooling purposes, and in particular for small, home-type air conditioners that have the condensing unit mounted outside a building.
SUMMARY OF THE INVENTION
As is well known in the art, the refrigerant in the condenser of an air conditioner or refrigerating unit will condense to a liquid at the temperature determined from its pressure and type of refrigerant. Most air-cooled condensers do not have sufficient capacity to cause the temperature of the condensed fluid to drop below this value. However, it is also well known that subcooling the liquid will increase the cooling efficiency of the system, due to the increased capacity of the subcooled refrigerant for absorbing heat and the reduction or elimination of flash gas in the evaporator. It has been determined that the increase in efficiency obtainable by this means is approximately one percent for each 2°F of subcooling of conventional halogenated refrigerants. My invention utilizes a coaxial double-tube heat exchanger arranged for flow of a refrigerant between the outer and inner tubes, and for the flow of a coolant such as water through the inner tube. Liquid refrigerant leaving an air-cooled condenser, which may be in the temperature range of 105°F, to 125°F, is introduced into the heat exchanger. Cooling water is allowed to flow through the inner tube and absorb heat from the refrigerant by conduction through the inner tube wall, thereby accomplishing subcooling. For water supplies with temperatures in the 70°to 85°F range, significant gains in efficiency will result in accordance with my invention.
A novel temperature-controlled water flow valve is provided at the refrigerant outlet end of the heat exchanger. The valve controls the flow of cooling water into the heat exchanger in response to the outlet temperature of the refrigerant, in a counter flow arrangement. This control action advantageously provides a modulation of the water flow to the exact average amount needed for the desired subcooling, thereby preventing waste of water. The heat exchanger and water control assembly is embedded in a block of plastic foam material that serves the dual purpose of: (1) preventing high ambient air temperatures and solar heat from reducing the efficiency of the heat exchanger by flow of such heat through the outer tube wall, and (2) providing mechanical protection for the components of the heat exchanger. My improved preassembled subcooler unit design is further configured to use readily-available and low-cost components; thus, the initial cost of installing my invention in existing refrigeration systems is minimized, and such cost can be amortized in a reasonable time with the savings therefrom.
An alternative embodiment of my invention provides a novel method of using the water flow from the heat exchanger to further improve the overall system efficiency of an existing refrigeration or air conditioning system, and to reduce the average water consumption of my subcooling unit. In this embodiment, the output or drain line from the heat exchanger has attached thereto a nozzle device. This nozzle device is adjusted and positioned to spray the output water onto the cooling fins of the air-cooled condenser of the system. As may be understood, the nozzle may be configured to suit the particular condenser design with which it is used. The water is caused to be incident on the condenser fins in the direction of the cooling air flow. The result of this water spray is to significantly increase the efficiency of the condenser by removing refrigerant vapor super heat and additional refrigerant liquid heat by both evaporation and conduction. This action results in a reduction of the compressor load and the current drain of the compressor from the power line. For example, tests have shown a 20 percent reduction in line current. The lower condenser exit refrigerant temperature resulting also will reduce the required water flow for subcooling. Thus, in accordance with this facit of my invention, additional energy savings will be obtained.
It is therefore an object of my invention to provide a refrigerant subcooling unit that is preassembled in the form of a convenient package for installation in existing air conditioning and refrigeration systems.
It is a further object of my imvention to provide a preassembled refrigerant subcooling unit that is capable of increasing the operating efficiency of the cooling system into which it is installed, thereby reducing the energy consumption thereof and the operating costs of the system.
It is yet another object of my invention to provide a preassembled refrigerant subcooling unit that can be marketed at a low cost, whereby the original cost can be amortized over a reasonable period through the savings therefrom.
It is still another object of my invention to provide a preassembled refrigerant subcooling unit wherein water is utilized as a coolant for subcooling the liquid refrigerant, and temperature-sensitive automatic control means is provided for limiting the flow of water to the minimum amount required and usable for such subcooling of the refrigerant.
It is yet a further object of my invention to provide a preassembled refrigerant subcooling unit in which the heat exchanger is physically protected from damage and insulated from high ambient air temperatures.
It is still a further object of my invention to provide a preassembled refrigerant subcooling unit to be installed in an air conditioning system that has an air-cooled condenser, wherein water is used for subcooling and discharged as a spray so as to cause evaporative cooling of the air-type condenser to desuperheat the vapor and remove additional condenser heat, thereby further increasing the system efficiency.
These and other objects, features, and advantages of my invention will be more clearly seen by reference to the detailed description of my invention hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preassembled refrigerant subcooling unit in accordance with my invention in which the protective and insulating plastic foam-encapsulating material is partially cut away to expose the heat exchanger and the relationship of the unit components,
FIG. 2 is a cross-sectional view of the temperature-operated water coolant flow control valve,
FIG. 3 is an exploded view of the thermostatic valve mechanism used in the flow control valve,
FIG. 4 is a schematic diagram of the heat exchanger used in my invention, including the means used to modulate the coolant flow,
FIG. 5 is a graph showing the outlet temperature of the refrigerant as a function of time for a typical application of my invention, showing the manner in which the flow of coolant water is advantageously modulated during the "Compressor ON" phase, and
FIG. 6 illustrates my preassembled refrigerant subcooler installed adjacent to an air-cooled condensing unit having a spray device that utilizes the waste water from the heat exchanger to further increase the efficiency of the system through evaporation of the water by the condenser.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a partially cut away view is shown of the preferred embodiment of my invention. The components visible in this view are: the heat exchanger unit 12 having a coiled outer tube 20, an inlet line 22 for the refrigerant, an outlet tube 28 for the refrigerant, a water inlet fitting 26, a water outlet tube 24, a control valve housing 30, and a plastic foam protective and insulating coating 10. As may be recognized, the plastic foam coating has been partially cut away to expose the components, and actually has the form of a rectangular block. The components enumerated above will be described in more detail hereinafter.
Heat exchanger 12 comprises an external steel tube 20 which may have an outside diameter of five-eighths-inch and an internal copper tube 32 disposed coaxially within tube 20 as seen in FIG. 2. Inner tube 32 may be three-eighths-inch OD. The coaxial heat exchanger tubing is preferable coiled as shown in FIG. 1 to conserve space. The length of the heat exchange tubing is determined by the air conditioning system size and the subcooling capacity desired. In an exemplary design suitable for a home air conditioner, the outside diameter of the coil is 6 inches and contains 6 loops. It is to be understood that the size of the heat exchanger is determined by the capacity of the air conditioner and the amount of subcooling desired. In use, the refrigerant to be subcooled enters heat exchanger 12 via tube 22 (R in ) and flows through the annular space defined by tubes 20 and 32. Cooling water enters the device through fitting 26 (W in ), flows through inner tube 32, and exits heat exchanger 12 via tube 24 (W out ). Thus, the water flow is counter to the refrigerant flow. The copper tube 32 efficiently transmits heat from the liquid refrigerant into the cooling water, thereby lowering the temperature of the refrigerant. The flow of water from inlet fitting 26 to tube 32 is controlled by a valve located within control valve housing 30, as will be described below. The subcooled refrigerant flowing from tube 20 into valve housing 30 exits heat exchanger 12 via tube 28 (R out ).
FIG. 2 is a cross-section of control valve housing 30 showing the details of the control valve contained therein. Housing 30 has its inner end brazed or welded to the end of heat exchanger outer tube 20. Valve body 34 is inserted through the outer end of housing 30 and welded thereto. As may be noted, coaxial inner tube 32 projects from the end of outer tube 20 into the inner end of valve body 34 and is welded thereto. Tube 28 is welded through the wall of housing 30 to provide an outlet for the refrigerant. As may now be recognized, tube 20, housing 30, valve body 34, and inner tube 32 form a hermetically-sealed outer space 31 to contain liquid refrigerant surrounding valve 60, and an inner space 35 through which water can flow to inner tube 32.
Referring to FIG. 3, a thermostatic valve assembly 50 is shown in exploded view. The assembly 50 is disposed within valve body 34 as illustrated in FIG. 2. Water entering cap 52 through opening 54 impinges on ring 47 and flows through annular passages 48 located around the periphery of ring 47. Tubular inner valve body 46, concentric with ring 47 and attached thereto at one end as shown, has seal ring 42 and seal 44 disposed at its other end, and a set of holes 56 through its tubular wall. As may now be seen, water incoming through passages 48 cannot pass seal 44, and therefore is constrained to flow through holes 56. Assuming that the system conditions require subcooling, in accordance with my invention the water is permitted to flow thence into valve body 34 and therethrough to inner tube 32. To control the flow of water, I have provided thermostatic control means utilizing a thermostatic power device 49 as the sensing and motive element. Power device 49 is disposed in the outer end of ring 47, as best seen in FIG. 2.
Thermostatic power device 49 is preferably a readily-obtainable device used as the temperature-sensitive element in the majority of automobile radiator thermostats in the United States. This key element of my invention is available in a wide range of operating temperatures and at very low cost due to the high production rate thereof. A typical unit that is well-suited for use in my invention is the Model 98067-H manufactured by the Robertshaw Controls Company, which may be built to operate in the 80° to 90°F range. As seen in FIG. 3, power device 49 consists of a heat sink 57, body 59, and thermally-expansive medium 51 (FIG. 2). In operation, rod 40 is inserted in a hole 41 concentric with body 59 contacting therein medium 51. When heat sink 57 reaches the selected operating temperature, expansion of medium 51 forces rod 40 outward for a distance of appeoximately three-eighths inch.
Rod 40 has attached at its other end a valve washer 38 utilized to control the water flow through valve assembly 50. In the assembled view of control valve 60 in FIG. 2, rod 40 is shown in its extended position characteristic of heat sink 57 being above its operating temperature. In this position, water flows essentially unrestricted into heat exchanger inner tube 32. When the heat sink 57 temperature drops below the selected operating temperature, medium 51 contracts and compression spring 36 disposed between valve washer 38 and end of housing 34 forces rod 40 into its retracted position. As shown by the dotted lines in FIG. 2, valve washer 38 seats on the end of inner valve body 46, completely blocking the water flow into tube 32. Thermostatic valve assembly 50 has been designed to be readily removable from body 34 for repair or for changing the operating temperature. To this end, power unit 49 is fastened within ring 47 with epoxy cement or other suitable means, forming an integral unit. The unit is a press fit within body 34 by virtue of the diameter of ring 47 and seal 44. The unit may be withdrawn when necessary with a suitable tool. During assembly and after assembly 50 is pressed into place, spacer 55 is inserted, and cap 52 with washer 53 is screwed onto the threaded end of body 34. To remove assembly 50, cap 52 and spacer 55 are removed. A special tool is used to grasp heat sink 57 and to apply a pulling force, thereby extracting the assembly.
Having now described in detail the construction of the preferred embodiment of my invention, I will explain the specific operation by use of the schematic diagram of FIG. 4 and the temperature graph of FIG. 5. In FIG. 4, heat exchanger 12 is indicated diagrammatically as outer tube 20 and inner tube 32. It is to be understood that these tubes are concentric and FIG. 4 represents a cross-section thereof. The enlarged portion at end B represents control valve housing 30 and contains a schematic representation of control valve 60. Consider liquid refrigerant entering the tube 22 at end A, thence into heat exchanger outer tube 20. The refrigerant flows therethrough and exits at end B via tube 28. Assume for illustration that the system compressor has just turned ON and that water control valve 60 is in its closed or OFF position due to thermostatic power valve unit 49 being below its operating temperature. Valve washer 38 is in this condition closed against seat 64 and water entering via inlet 54 is prevented from entering inner tube 32.
The liquified refrigerant flowing in tube 20 will initially be at its condensing temperature. For illustrative purposes, I will use a fluid temperature of 115°F. An important feature of my invention as seen from FIG. 2 is that the liquid refrigerant completely surrounds temperature control valve 60. This advantageous construction ensures rapid heat transfer to heat sink 57 of power unit 49. Returning to FIG. 4, the heat from the refrigerant causes power unit 49, assumed to have an operating temperature of 80°F, to move washer 38 away from seat 64, admitting a flow of cooling water into tube 32. Heat will then flow from the liquid refrigerant through the walls of tube 32 and will be absorbed by the cooling water flowing therethrough and carried out via exit tube 24 at end A.
It may be noted that I specify that the cooling water flow counter to the refrigerant flow. As will be explained, this feature of my invention is used to control the volume of water flow to the minimum essential for maximum subcooling, advantageously preventing waste of water. This operation may be more easily understood with reference to FIG. 4 and FIG. 5. FIG. 5 is an exemplary time plot of the refrigerant temperature during a compressor ON-OFF cycle and indicates periods during which the water flow is ON and OFF, respectively. Starting at time T 0 to time T 1 , the compressor is shown to be OFF. The refrigerant in the heat exchanger will be at a low pressure and at a relatively low temperature, for example 60°F. Assuming that thermostatic power device is selected to open valve 60 at temperatures above 80°F, valve 60 will be closed and no water will flow during the period T 0 to T 1 .
At time T 1 , the compressor turns ON in response to the system requirement for cooling. The gas pressure is greatly increased to the point that the refrigerant in the condenser is at its saturated vaporization temperature and therefore becomes liquid as additional heat is removed by the condenser. The liquid refrigerant as it leaves the condenser may be, for example, at 115°F. The flow of refrigerant will quickly fill heat exchanger 12 and outer control valve housing 30 with liquid refrigerant. Due to the unique construction of my control valve 60, inner control valve housing 34 is surrounded by the 115°F liquid. Heat flow to power device 49 by conduction is then very rapid, causing it to open valve 60 allowing cooling water to flow and exit by tube 24. Assuming the cooling water is at 70°F as it enters at end B of heat exchanger 12, the cooling action therefrom will cause the entering liquid refrigerant to become progressively cooler as it flows toward end B, and to be a minimum at exit tube 28. The desired temperature for the refrigerant at exit tube 28 is 80°F in this example, in accordance with the selected calibration of power unit 49.
In accordance with my invention and assuming a sufficient volume of cooling water, I automatically maintain the average refrigerant outlet temperature at the selected 80°F. As shown in FIG. 5, as the outlet temperature drops from 115° to 80°F between times T 1 and T 2 , the thermostatic control turns the water flow OFF. While the figure indicates a sharp cutoff for simplicity, it is to be understood that it is actually a gradual on-off action. Due to the normal thermal lags, the refrigerant will then cool slightly below 80°F and thereafter begin to warm up as the water flow ceases. As shown at time T 3 , the liquid approaches 80°F, causing the water valve to turn ON again. This water flow modulation will continue in accordance with my invention until time T 4 , when the compressor is turned OFF in response to the system cooling requirements. At this time, the refrigerant reverts to its low temperature condition and the water flow stops completely. As readily seen, the ON-OFF modulation of the water flow thus obtained controls the average flow to the exact volume required to achieve the desired subcooling without regard to the cooling system environmental parameters within the range of control provided. As may be understood, if control valve 60 were at the refrigerant inlet end A, continuous input of high-temperature refrigerant would prevent the desired water modulation control, and the water flow would not be dependent on the refrigerant exit temperature as desired. As is evident, the temperatures used for illustration may be varied without departing from the scope of my invention.
The advantageous action of the water volume control just described is one key to achieving an object of my invention to increase the operating efficiency of a cooling system into which it is installed. It is emphasized that this action is obtained by the features of surrounding control valve 60 with refrigerant and providing high thermal conductivity to thermal power element 49; and by locating valve 60 at the refrigerant outlet end of heat exchanger 12.
Another feature of my invention that contributes to its efficiency of subcooling is the means provided to prevent flow of ambient heat into the outer wall of tube 20. As may be recognized, when my preassembled refrigerant subcooler is installed near the outside condenser of an air conditioner, the air surrounding the subcooler unit can reach 100°F and higher during hot weather. Heat from this source and from incident solar heat that is transferred to the refrigerant through the outer wall of tube 20 could significantly negate part of the subcooling action. Therefore, I advantageously cover heat exchanger 12, control valve 30, and portions of tubes 22, 24, and 28 with a rigid plastic foam material, which may be, for example, polystyrene foam, which has a low heat conductivity. A typical form for this plastic coating is shown partially cut away in FIG. 1. The preferred form as shown is a rectangular block that is easily handled. A secondary purpose of the foam coating is to protect the elements of my preassembled subcooler from physical damage. In this form, the unit can be easily mounted by means of sheet metal straps if used in an enclosure. Where installation open to the weather is desired, it is preferred to enclose the plastic foam block in a lightweight sheet metal case.
While not pertinent to the internal operation of my preassembled subcooler, it is of interest to mention disposal of the water used for subcooling. This water may be disposed of in an available drain system or, in case of a residential application, a hose bib may be supplied in connection with water outlet tube 24 and a lawn sprinkler attached thereto. The waste water can then be used for watering of lawns or other plant life and therefore serve a useful purpose.
An alternative embodiment of my invention advantageously combines a means for disposing of the subcooling water with a means for further improving the operating efficiency of the air conditioning systems into which my preassembled subcooling unit is connected. Referring to FIG. 6, one version of this alternative design will be described. Plastic foam block 10 enclosing heat exchanger 12 is secure to the base of a condenser unit 70 by means of straps 11. Attached to water outlet tube 24 is spray tube 80, to be considered part of this version of my invention. Condenser unit 70 is part of the air conditioning system into which my invention is installed. Spray tube 80 has a series of nozzle holes 84 drilled along its lower length. Holes 84 are arranged to produce a fine spray of water 90 over the condenser tubes and fins during periods for which water is flowing through heat exchanger 12 in accordance with my invention. Spray tube 80 is mounted to condenser 70 by brackets 86 on the side of the condenser 70 upon which air from its blower (not shown) is incident. As water spray 90 strikes the surfaces of condenser 70, evaporation occurs, removing significant amounts of super heat from the refrigerant vapor and liquid refrigerant in condenser 70. As is well known, the evaporative principle is the most efficient approach to design of a condenser, since one pound of water will extract nearly 1000 BTU evaporation. The extraction of these significant amounts of heat from the refrigerant will reduce the load on the system compressor due to a lower highside pressure. The power drain of the compressor motor is consequently reduced, resulting in lower operating costs. The lower condenser pressure also results in a lower saturated liquid temperature, and the work required by the subcooler is reduced. While I have shown a particular type of spray tube 80, alternative spray head arrangements may be tailored to the particular configuration of the condenser to be accommodated.
As may now be understood, my preassembled refrigerant subcooling unit can be installed into an existing air conditioning or refrigeration system. FIG. 6 may be considered to illustrate a typical installation. Refrigerant inlet 22 is connected to the condenser refrigerant outlet, and refrigerant outlet 28 is connected to the line running to the expansion valve and evaporator. If the unit is installed at a time the system is to be recharged, the lines may be brazed or soldered following normal practices; alternatively, standard fittings may be used. For installation into operating systems, special saddle-type connectors can be utilized that obviate the necessity of recharging the system with refrigerant. These connectors are brazed at the desired points along the condenser outlet line and to the subcooler connections. Special cutter bolts are then tightened externally, shearing the line internally to make the connections with the subcooler. The system line between the connectors is then crimped, causing the refrigerant to flow through the subcooler heat exchanger. A water line is installed and connected to a suitable cold-water source, and the desired waste water connection made, completing the installation. Other types and forms of installation will be obvious to those skilled in the art.
The embodiments of my invention herein described are not to be considered limiting, and many variations in design may be made without departing from the scope of my invention. | A preassembled unit for subcooling the refrigerant in existing air conditioning and refrigeration systems to a temperature less than its saturated vaporization temperature. The unit is installable in existing refrigeration systems and has the capability to increase the efficiency of such systems. A coaxial tube heat exchanger includes a refrigerant tube to be connected between the system condenser and expansion valve, and a cooling medium tube through which a flow of cooling water is provided. A thermostatically-operated control valve is utilized to adjust the flow of water in response to the refrigerant outlet temperature. The control valve ensures that only the minimum quantity of water necessary to reduce the refrigerant temperature to a selected value is used. The heat exchanger and control valve are completely enclosed in a block of plastic foam to prevent a high ambient temperature from affecting these elements. An alternative embodiment of the invention includes a spray head to be attached to an air-cooled condenser and arranged to discharge the outlet cooling water so as to impinge on the condenser heat exchange surfaces. The resultant evaporation of the water removes additional heat from the condenser and contributes to an additional increase in system efficiency. | 5 |
The present application is a 371 of International application PCT/EP2010/003652, filed Jun. 17, 2010, which claims priority of DE 10 2009 031 527.6, filed Jul. 2, 2009, the priority of these applications is hereby claimed and these applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention concerns a method for the open-loop and closed-loop control of an internal combustion engine.
In an internal combustion engine with a common rail system, the quality of combustion is critically determined by the pressure level in the rail. Therefore, in order to stay within legally prescribed emission limits, the rail pressure is automatically controlled. A closed-loop rail pressure control system typically comprises a comparison point for determining a control deviation, a pressure controller for computing a control signal, the controlled system, and a software filter for computing the actual rail pressure in the feedback path. The control deviation is computed as the difference between a set rail pressure and an actual rail pressure. The controlled system comprises the pressure regulator, the rail, and the injectors for injecting the fuel into the combustion chambers of the internal combustion engine.
DE 197 31 995 A1 discloses a common rail system with closed-loop pressure control, in which the pressure controller is equipped with various controller parameters. The various controller parameters are intended to make the automatic pressure control more stable. The pressure controller then uses the controller parameters to compute the control signal for a pressure control valve, by which the fuel drain-off from the rail into the fuel tank is set. Consequently, the pressure control valve is arranged on the high-pressure side of the common rail system. This source also discloses an electric pre-feed pump or a controllable high-pressure pump as alternative measures for automatic pressure control.
DE 103 30 466 B3 also describes a common rail system with closed-loop pressure control, in which, however, the pressure controller acts on a suction throttle by means of a control signal. The suction throttle in turn sets the admission cross section to the high-pressure pump. Consequently, the suction throttle is arranged on the low-pressure side of the common rail system. This common rail system can be supplemented by a passive pressure control valve as a protective measure against an excessively high rail pressure. The fuel is then redirected from the rail into the fuel tank via the opened pressure control valve. A similar common rail system with a passive pressure control valve is known from DE 10 2006 040 441 B3.
Control leakage and constant leakage occurs in a common rail system as a result of design factors. Control leakage occurs when the injector is being electrically activated, i.e., for the duration of the injection. Therefore, the control leakage decreases with decreasing injection time. Constant leakage is always present, i.e., even when the injector is not activated. This is also caused by part tolerances. Since the constant leakage increases with increasing rail pressure and decreases with falling rail pressure, the pressure fluctuations in the rail are damped. In the case of control leakage, on the other hand, the opposite behavior is seen. If the rail pressure rises, the injection time is shortened to produce a constant injection quantity, which leads to decreasing control leakage. If the rail pressure drops, the injection time is correspondingly increased, which leads to increasing control leakage. Consequently, control leakage leads to intensification of the pressure fluctuations in the rail. Control leakage and constant leakage represent a loss volume flow, which is pumped and compressed by the high-pressure pump.
However, this loss volume flow means that the high-pressure pump must be designed larger than necessary. In addition, some of the motive energy of the high-pressure pump is converted to heat, which in turn causes heating of the fuel and reduced efficiency of the internal combustion energy.
In present practice, to reduce the constant leakage, the parts are cast together. However, a reduction of the constant leakage has the disadvantages that the stability behavior of the common rail system deteriorates and that automatic pressure control becomes more difficult. This becomes clear in the low-load range, because here the injection quantity, i.e., the removed fuel volume, is very small. This also becomes clear in a load reduction from 100% to 0%, since here the injection quantity is reduced to zero, and therefore the rail pressure is only slowly reduced again. This in turn results in a long correction time.
SUMMARY OF THE INVENTION
This objective is achieved by a method for the open-loop and closed-loop control of an internal combustion engine with the features of claim 1 . Refinements are described in the dependent claims.
The method consists not only in providing closed-loop rail pressure control by means of the suction throttle on the low-pressure side as the first pressure regulator, but also in generating a rail pressure disturbance variable for influencing the rail pressure by means of a pressure control valve on the high-pressure side as a second pressure regulator. Fuel is redirected from the rail into a fuel tank by the pressure control valve on the high-pressure side. An essential element of the invention is that a constant leakage is reproduced by the control of the pressure control valve. The rail disturbance variable is computed on the basis of a corrected set volume flow of the pressure control valve, which in turn is computed from a static set volume flow and a dynamic set volume flow.
The static set volume flow is computed as a function of a set injection quantity, alternatively, a set torque, and an engine speed by means of a set volume flow input-output map. The set volume flow input-output map is realized in such a form that in a low-load range a set volume flow with a positive value, for example, 2 liters/minute, is computed and in a normal operating range a set volume flow of zero is computed. In accordance with the invention, the low-load range is understood to mean the range of small injection quantities and thus low engine output.
The dynamic set volume flow of the pressure control valve is computed by a dynamic correction unit as a function of the set rail pressure and the actual rail pressure by computing a resultant control deviation and setting the dynamic set volume flow to a value of zero when the resulting control deviation is less than zero. If, on the other hand, the resulting control deviation is greater than or equal to zero, then the dynamic set volume flow is set to the value of the product of the resulting control deviation and a factor. In other words, the dynamic set volume flow is determined to a great extent by the control deviation of the rail pressure. If the control deviation is negative and falls below a limit, i.e., for example, in the case of a load reduction, the static set volume flow is corrected by means of the dynamic set volume flow. Otherwise, no change is made in the static set volume flow.
Since during steady operation the fuel is redirected from the rail only in the low-load range and in small quantities, there is no significant increase in the fuel temperature and also no significant reduction of the efficiency of the internal combustion engine. The increased stability of the closed-loop rail pressure control system in the low-load range can be recognized from the fact that the rail pressure in the coasting range remains more or less constant, and in a load reduction the rail pressure peak value is clearly lower. The pressure increase of the rail pressure is counteracted by means of the dynamic set volume flow, with the advantage that the correction time of the system can be improved once again.
The drawings illustrate a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a system diagram.
FIG. 2 is a closed-loop rail pressure control system.
FIG. 3 is a block diagram of the closed-loop rail pressure control system with an open-loop control unit.
FIG. 4 is a block diagram of the dynamic correction unit.
FIG. 5 is a closed-loop current control system.
FIG. 6 is a closed-loop current control system with input control.
FIG. 7 is a set volume flow input-output map.
FIG. 8 is a time chart.
FIG. 9 is a program flowchart.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a system diagram of an electronically controlled internal combustion engine 1 with a common rail system.
The common rail system comprises the following mechanical components: a low-pressure pump 3 for pumping fuel from a fuel tank 2 , a variable suction throttle 4 on the low-pressure side for controlling the fuel volume flow flowing through the lines, a high-pressure pump 5 for pumping the fuel at increased pressure, a rail 6 for storing the fuel, and injectors 7 for injecting the fuel into the combustion chambers of the internal combustion engine 1 . The common rail system can also be realized with individual accumulators, in which case an individual accumulator 8 is integrated, for example, in the injector 7 as an additional buffer volume. To protect against an impermissibly high pressure level in the rail 6 , a passive pressure control valve 11 is provided, which, in its open state, redirects the fuel from the rail 6 . An electrically controllable pressure control valve 12 also connects the rail 6 with the fuel tank 2 . A fuel volume flow redirected from the rail 6 into the fuel tank 2 is defined by the position of the pressure control valve 12 . In the remainder of the text, this fuel volume flow is denoted. the rail pressure disturbance variable VDRV.
The operating mode of the internal combustion engine 1 is determined by an electronic control unit (ECU) 10 . The electronic control unit 10 contains the usual components of a microcomputer system, for example, a microprocessor, interface adapters, buffers, and memory components (EEPROM, RAM). Operating characteristics that are relevant to the operation of the internal combustion engine 1 are applied in the memory components in the form of input-output maps/characteristic curves. The electronic control unit 10 uses these to compute the output variables from the input variables. FIG. 1 shows the following input variables as examples: the rail pressure pCR, which is measured by means of a rail pressure sensor 9 , an engine speed nMOT, a signal FP, which represents an engine power output desired by the operator, and an input variable INPUT, which represents additional sensor signals, for example, the charge air pressure of an exhaust gas turbocharger. In a common rail system with individual accumulators 8 , the individual accumulator pressure pE is an additional input variable of the electronic control unit 10 .
FIG. 1 also shows the following as output variables of the electronic control unit 10 : a signal PWMSD for controlling the suction throttle 4 as the first pressure regulator, a signal ve for controlling the injectors 7 (injection start/injection end), a signal PWMDV for controlling the pressure control valve 12 as the second pressure regulator, and an output variable OUTPUT. The signal PWMDV defines the position of the pressure control valve 12 and thus the rail pressure disturbance variable VDRV. The output variable OUTPUT is representative of additional control signals for the open-loop and closed-loop control of the internal combustion engine 1 , for example, a control signal for activating a second exhaust gas turbocharger during a register supercharging.
FIG. 2 shows a closed-loop rail pressure control system 13 for automatically controlling the rail pressure pCR. The input variables of the closed-loop rail pressure control system 13 are: a set rail pressure pCR(SL), a volume flow that characterizes the set consumption VVb, the engine speed nMOT, the PWM base frequency fPWM, and a variable E 1 . The variable E 1 combines, for example, the battery voltage and the ohmic resistance of the suction throttle coil with lead-in wire, which enter into the computation of the PWM signal. The output variables of the closed-loop rail pressure control system 13 are the raw value of the rail pressure pCR, an actual rail pressure pCR(IST), and a dynamic rail pressure pCR(DYN). The actual rail pressure pCR(IST) and the dynamic rail pressure pCR(DYN) are further processed in the open-loop control system shown in FIG. 3 .
The actual rail pressure pCR(IST) is computed from the raw value of the rail pressure pCR by means of a first filter 19 . This value, is then compared with the set value pCR(SL) at a summation point A, and a control deviation ep is obtained from this comparison. A correcting variable. is computed from the control deviation ep by means of a pressure controller 14 . The correcting variable represents a volume flow VR with the physical unit of liters/minute. The computed set consumption VVb is added to the volume flow VR at a summation point B. The set consumption VVb is computed by a computing unit 23 , which is shown in FIG. 3 and will be explained in connection with the description of FIG. 3 . The result of the addition at summation point B represents an unlimited set volume flow VSDu(SL). The unlimited set volume flow VSDu(SL) is then limited by a limiter 15 as a function of the engine speed nMOT. The output variable of the limiter 15 is a set volume flow VSD(SL) of the suction throttle. A set electric current iSD(SL) of the suction throttle is then assigned to the set volume flow VSD(SL) by the pump characteristic curve 16 . The set current iSD(SL) is converted to a PWM signal PWMSD in a computing unit 17 . The PWM signal PWMSD represents the duty cycle, and the frequency fPWM corresponds to the base frequency. The magnetic coil of the suction throttle is then acted upon by the PWM signal PWMSD. This changes the displacement of the magnetic core, and the output of the high-pressure pump is freely controlled in this way. For safety reasons, the suction throttle is open in the absence of current and is acted upon by current via PWM activation to move in the direction of the closed position. A closed-loop current control system can be subordinate to the PWM signal computing unit 17 , as described in DE 10 2004 061 474 A1. The high-pressure pump, the suction throttle, the rail, and possibly the individual accumulators represent a controlled system 18 . The closed-loop control system is thus closed. A dynamic rail pressure pCR(DYN) is computed from the raw value of the rail pressure pCR by means of a second filter 20 . The dynamic rail pressure pCR(DYN) is one of the input variables of the block diagram of FIG. 3 . In this regard, the second filter 20 has a smaller time constant and smaller phase distortion than the first filter 19 in the feedback path.
FIG. 3 in the form of a block diagram shows the greatly simplified closed-loop rail pressure control system 13 and an open-loop control unit 21 . The open-loop control system 21 generates the rail pressure disturbance variable VDRV, i.e., that volume flow which the pressure control valve redirects into the fuel tank from the rail. The input variables of the open-loop control unit 21 are: the set rail pressure pCR(SL), the actual rail pressure pCR(IST), the dynamic rail pressure pCR(DYN), the engine speed nMOT, and the set injection quantity QSL. The set injection quantity QSL is either computed by an input-output map as a function of the power desired by the operator or represents the correcting variable of a speed controller. The physical unit of the set injection quantity is mm 3 /stroke. In a torque-based structure, a set torque MSL is used instead of the set injection quantity QSL. The output variable of the open-loop control system 21 is the rail pressure disturbance variable VDRV.
The static set volume flow Vs(SL) for the pressure control valve is computed from the engine speed nMOT and the set injection quantity QSL by a set volume flow input-output map 22 (3D input-output map). The set volume flow input-output map 22 is realized in such a form that in the low-load range, for example, at idle, a positive value of the static set volume flow Vs(SL) is computed, while in the normal operating range a static set volume flow Vs(SL) of zero is computed. A possible embodiment of the set volume flow input-output map 22 is shown in FIG. 7 and will be explained in detail in the description of FIG. 7 . A computing unit 23 also uses the engine speed nMOT and the set injection quantity QSL to compute the set consumption VVb, which is one of the input variables of the closed-loop rail pressure control system 13 . In accordance with the invention, the static set volume flow Vs(SL) is corrected by adding a dynamic set volume flow Vd(SL). The dynamic set volume flow Vd(SL) is computed by a dynamic correction unit 24 . The input variables of the dynamic correction unit 24 are the set rail pressure pCR(SL), the actual rail pressure pCR(IST), and the dynamic rail pressure pCR(DYN). The dynamic correction unit 24 is shown in FIG. 4 and will be described in connection with FIG. 4 . The sum of the static volume flow Vs(SL) and the dynamic set volume flow Vd(SL) is a corrected set volume flow Vk(SL), which is limited above to a maximum volume flow VMAX and below to a value of zero by a limiter 25 . The maximum volume flow VMAX is computed by a (2D) characteristic curve 26 as a function of the actual rail pressure pCR(IST). The output variable of the limiter 25 is a resultant set volume flow Vres(SL), which is one of the input variables of a pressure control valve input-output map 27 . The second input variable is the actual rail pressure pCR(IST). A set current iDV(SL) of the pressure control valve is assigned to the resultant set volume flow Vres(SL) and to the actual rail pressure pCR(IST) by the pressure control valve input-output map 27 . A PWM computing unit 28 converts the set current iDV(SL) to the duty cycle PWMDV, with which the pressure control valve 12 is controlled. A current controller, closed-loop current control system 29 , or a current controller with input control can be subordinate to the conversion. The current controller is shown in FIG. 5 and will be explained in the description of FIG. 5 . The current controller with input control is shown in FIG. 6 and will be explained in the description of FIG. 6 . The pressure control valve 12 is controlled with the PWM signal PWMDV. The electric current iDV that occurs at the pressure control valve 12 is converted for current control to an actual current iDV(IST) by a filter 30 and fed back to the computing unit 28 for the PWM signal. The output signal of the pressure control valve 12 is the rail pressure disturbance variable VDRV, i.e., the fuel volume flow that is redirected from the rail into the fuel tank.
FIG. 4 shows the dynamic correction unit 24 from FIG. 3 .
The input variables are the set rail pressure pCR(SL), the actual rail pressure pCR(IST), the dynamic rail pressure pCR(DYN), a constant control deviation epKON, and a constant factor fKON. The output variable is the dynamic set volume flow Vd(SL). A limited control deviation epLIM is assigned to the set rail pressure pCR(SL) by a characteristic curve 31 . The value of the limited control deviation epLIM is negative. For example, a limited control deviation epLIM=−100 bars is assigned to the set rail pressure pCR(SL)=2150 bars by the characteristic curve 31 . A first switch S 1 serves to determine whether its output variable AG 1 corresponds to the limited control deviation epLIM or to the constant control deviation epKON. In the switch position S 1 =1, AG 1 epLIM, while in switch position S 1 =2, AG 1 =epKON. The constant control deviation can be set, for example, to the value epKON=−50 bars. At a summation point A, the output variable AG 1 is compared with the control deviation ep. The control deviation ep is computed at a summation point B from the set rail pressure pCR(SL) and the actual rail pressure pCR(IST) or, alternatively, the dynamic rail pressure pCR(DYN), The selection is made by a second switch S 2 . In the first switch position S 2 =1, the actual rail pressure pCR(IST) determines the computation of the control deviation ep. In the second switch. position S 2 =2, on the other hand, the dynamic rail pressure pCR(DYN) determines the computation of the control deviation. The difference computed at summation point A represents a resultant control deviation epRES.
A comparator 32 compares the resultant control deviation epRES with the value zero. If the resultant control deviation epRES is less than zero (epRES<0), then a third switch S 3 is set to the position S 3 =2. In this case, the dynamic set volume flow Vd(SL) is equal to zero (Vd(SL)=0). On the other hand, if the resultant control deviation epRES is greater than or equal to zero (epRES≧0), then the third switch is set to the position S 3 =1.
In this position S 3 =1, the dynamic set volume flow Vd(SL) is computed by multiplying the resultant control deviation epRES by a factor f. The factor f in turn is determined by a fourth switch S 4 . If the fourth switch is in the position S 4 =1, then the factor f is computed as a value fKL by a characteristic curve 33 as a function of the actual rail pressure pCR(IST) (switch S 2 =1) or as a function of the dynamic rail pressure pCR(DYN) (switch S 2 =2), On the other hand, if the fourth switch is in the position S 4 =2, then the factor f is set to a constant value fKON, for example, fKON=0.01 liters/(min-bars).
The function of the dynamic correction unit 24 will now be explained by an example, which is based on the following parameters:
first switch S 1 =2 with epKON=−50 bars, second switch S 2 =1 with ep=pCR(SL)−pCR(IST), and fourth switch S 4 =2 with f=fKON=0.01 liters/(min·bars).
If the control deviation is greater than −50 bars (ep>(−50 bars)), then the resultant control deviation epRES is less than zero (epRES<0). The third switch is thus moved into the position S 3 =2 by the comparator 32 , so that the dynamic set volume flow Vd(SL)=0. On the other hand, if the control deviation is less than or equal to −50 bars (ep≦(−50 bars)), then the resultant control deviation epRES>0. The comparator 32 thus moves the third switch into the position S 3 =1. The dynamic set volume flow is now computed as Vd(SL)=(−50 bars−ep)·0.01 liters/(min·bars).
A correction by means of the dynamic set volume flow Vd(SL) thus occurs when the control deviation ep falls below the value ep=−50 bars. If the control deviation ep becomes even smaller (more negative), i.e., if the actual rail pressure overshoots even more strongly, then the dynamic set volume flow Vd(SL) causes the fuel volume flow that is redirected by the pressure control valve, i.e., the rail pressure disturbance variable, to be increased. Finally, this causes the rail pressure to level off.
FIG. 5 shows a pure current controller, which corresponds to the closed-loop current control system 29 in FIG. 3 . The input variables are the set current iDV(SL) for the pressure control valve, the actual current iDV(IST) of the pressure control valve, the battery voltage UBAT, and controller parameters (kp, Tn). The output variable is the PWM signal PWMDV, with which the pressure control valve is controlled. First, the current control deviation ei is computed from the set current iDV(SL) and the actual current iDV(IST) (see FIG. 3 ). The current control deviation ei is the input variable of the current controller 34 . The current controller 34 can be realized as a PI or PI(DT1) algorithm. The controller parameters are processed in the algorithm. They are characterized, for example, by the proportional coefficient kp and the integral-action time Tn. The output variable of the current controller 34 is a set voltage UDV(SL) of the pressure control valve. This is divided by the battery voltage UBAT and then multiplied by 100. The result is the duty cycle of the pressure control valve in percent.
FIG. 6 shows a current controller with combined input control as an alternative to FIG. 5 . The input variables are the set current iDV(SL), the actual current iDV(IST), the controller parameters (kp, Tn), the ohmic resistance RDV of the pressure control valve, and the battery voltage UBAT. The output variable is again the PWM signal PWMDV, with which the pressure control valve is controlled. First, the set current iDV(SL) is multiplied by the ohmic resistance RDV. The result is a pilot voltage UDV(VS). The set current iDV(SL) and the actual current iDV(IST) are used to compute the current control deviation ei. The current controller 34 then uses the current control deviation ei to compute the set voltage UDV(SL) of the pressure control valve as a correcting variable. Here again, the current controller 34 can be realized either as a PI controller or as a PI(DT1) controller. The set voltage UDV(SL) and the pilot voltage are then added, and the sum is divided by the battery voltage UBAT and then multiplied by 100.
FIG. 7 shows the set volume flow input-output map 22 , with which the static set volume flow Vs(SL) for the pressure control valve is determined. The input variables are the engine speed nMOT and the set injection quantity QSL. Engine speed values of 0 to 2000 rpm are plotted in the horizontal direction, and set injection quantity values of 0 to 270 mm 3 /stroke are plotted in the vertical direction. The values inside the input-output map then represent the assigned static set volume flow Vs(SL) in liters/minute. A portion of the fuel volume flow to be redirected is determined by the set volume flow input-output map 22 . The set volume flow input-output map 22 is realized in such a form that in the normal operating range a static set volume flow of Vs(SL)=0 liters/minute is computed. The normal operating range is outlined by a double line in FIG. 7 . The region outlined by a single line corresponds to the low-load range. In the low-load range, a positive value of the static set volume flow Vs(SL) is computed. For example, at nMOT=1000 rpm and QSL=30 mm 3 /stroke, a static set volume flow of Vs(SL)=1.5 liters/minute is determined.
FIG. 8 is a time chart showing a load rejection from 100% to 0% load in an internal combustion engine which is being used to power an emergency power generating unit (60-Hz generator). FIG. 8 comprises four separate graphs 8 A to 8 D, which show the following as a function of time: the generator output P in kilowatts in FIG. 8A , the engine speed nMOT in FIG. 8B , the actual rail pressure pCR(IST) in FIG. 8C , and the dynamic set volume flow Vd(SL) in FIG. 8D . The broken line in FIG. 8C shows the behavior of the actual rail pressure pCR(IST) without dynamic correction. The time chart in FIG. 8 was based on the same parameters as in the example described above in connection with FIG. 4 . It was also based on a constant set rail pressure of pCR(SL)=2200 bars.
At time t 1 the load on the generator was suddenly reduced from an output of P=2000 kW to 0 kW. The absence of a load at the power take-off of the internal combustion engine causes an increasing engine speed at time t 1 . At time t 4 the engine speed reaches its maximum value of nMOT=1950 rpm. Since the engine speed is automatically controlled in its own closed-loop control system, it settles back to its original initial value. Due to the increasing engine speed nMOT and the resulting reduction of the injection quantity starting at time t 1 , the high-pressure pump builds up a higher pressure level in the rail, so that the actual rail pressure pCR(IST) increases with a time lag relative to the engine speed nMOT. At time t 2 the actual rail pressure pCR(IST) reaches the value pCR(IST)=2250 bars. The control deviation ep is thus ep=−50 bars. The dynamic set volume flow Vd(SL), which is computed by the dynamic correction unit 24 ( FIG. 3 ), is therefore Vd(SL)=0 liters/min. Since the actual rail pressure pCR(IST) continues to rise after time t 2 , the control deviation ep drops, i.e., it falls below the value −50 bars, so that now a positive dynamic set volume flow Vd(SL) is computed (see FIG. 8D ). At time t 3 the actual rail pressure reaches the value pCR(IST)=2300 bars. This results in a control deviation of ep=−100 bars. The dynamic set volume flow computed from this is now Vd(SL)=0.5 liters/min. An increasing dynamic set volume flow Vd(SL) corresponds to an increasing actual rail pressure pCR(IST). A decreasing dynamic set volume flow Vd(SL) corresponds to a decreasing actual rail pressure pCR(IST). At time t 7 the actual rail pressure pCR(IST) falls back below the value pCR(IST)=2250 bars, which results in a dynamic set volume flow of Vd(SL)=0 liters/min (see FIG. 8D ).
A comparison of the two curves of the actual rail pressure pCR(IST) in FIG. 8C with dynamic correction (solid-line curve) and without dynamic correction (broken-line curve) shows a reduction of the overshoot, which then also results in a shorter correction time.
FIG. 9 is a program flowchart of the method for determining the rail pressure disturbance variable with correction. It was based on the following parameters:
the first switch S 1 =1, so that the computation of the limited control deviation epLIM is activated, the second switch S 2 =1, so that the control deviation is computed from the set rail pressure pCR(SL) and the actual rail pressure pCR(IST), and the fourth switch S 4 =2, so that the factor f is equal to fKON.
At S 1 the set injection quantity QSL, the engine speed nMOT, the actual rail pressure pCR(IST), the battery voltage UBAT, and the actual current iDV(IST) of the pressure control valve are read in. At S 2 the static set volume flow Vs(SL) is then computed by the set volume flow input-output map as a function of the set injection quantity QSL and the engine speed nMOT. At S 3 the control deviation ep is computed from the set rail pressure pCR(SL) and the actual rail pressure pCR(IST). In step S 4 the limited control deviation epLIM, which is negative, is computed from the set rail pressure by a characteristic curve 31 ( FIG. 4 ). The resultant control deviation epRES is then computed at S 5 . The resultant control deviation epRES is determined from the control deviation ep and the limited control deviation epLIM. At S 6 an interrogation is made to determine whether the resultant control deviation epRES is negative. If this is the case, then the dynamic set volume flow Vd(SL) is set to a value of zero at S 7 . If the resultant control deviation epRES is not negative, then at S 8 the dynamic set volume flow Vd(SL) is computed as the product of the constant factor fKON and the resultant control deviation epRES. At S 9 the corrected set volume flow Vk(SL) is computed as the sum of the static set volume flow Vs(SL) and the dynamic set volume flow Vd(SL). At S 10 the maximum volume flow VMAX is computed from the actual rail pressure pCR(IST) by a characteristic curve 26 ( FIG. 3 ). At S 11 VMAX is then set as the upper limit to the corrected set volume flow Vk(SL). The result is the resultant set volume flow Vres(SL). At S 12 the set current iDV(SL) is computed as a function of the resultant set volume flow Vres(SL) and the actual rail pressure pCR(IST). Finally, at S 13 the PWM signal for controlling the pressure control valve is computed as a function of the set current iDV(SL). The program is then ended.
LIST OF REFERENCE NUMBERS
1 internal combustion engine
2 fuel tank
3 low-pressure pump
4 suction throttle
5 high-pressure pump
6 rail
7 injector
8 individual accumulator (optional)
9 rail pressure sensor
10 electronic control unit (ECU)
11 pressure control valve, passive
12 pressure control valve, electrically controllable
13 closed-loop rail pressure control system
14 pressure controller
15 limiter
16 pump characteristic curve
17 computing unit for PWM signal
18 controlled system
19 first filter
20 second filter
21 open-loop control unit
22 set volume flow input-output map
23 computing unit
24 dynamic correction unit
25 limiter
26 characteristic curve
27 pressure control valve input-output map
28 computing unit for PWM signal
29 closed-loop current control system (pressure control valve)
30 filter
31 characteristic curve
32 comparator
33 characteristic curve
34 current controller | Proposed is a method for controlling and regulating an internal combustion engine ( 1 ), in which the rail pressure (pCR) is controlled via a suction throttle ( 4 ) on the low pressure side as a first pressure-adjusting element in a rail pressure control loop. The invention is characterized in that a rail pressure disturbance variable (VDRV) is generated in order to influence the rail pressure (pCR) via a pressure control valve ( 12 ) on the high pressure side as a second pressure-adjusting element, by means of which fuel is redirected in a controlled manner from the rail ( 6 ) into a fuel tank ( 2 ), the rail pressure disturbance variable (VDRV) being calculated using a corrected target volume flow (Vk(SL)) of the pressure control valve ( 12 ). | 5 |
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 09/900,595 filed on Jul. 6, 2001, which is a continuation of U.S. patent application Ser. No. 09/453,358 filed on Dec. 1, 1999, now issued as U.S. Pat. No. 6,283,985, the specifications of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention concerns capacitors used in medical devices, such as implantable defibrillators, cardioverters, pacemakers, and more particularly methods of maintaining capacitors in these devices.
Since the early 1980s, thousands of patients prone to irregular and sometimes life threatening heart rhythms have had miniature defibrillators and cardioverters implanted in their bodies. These devices detect onset of abnormal heart rhythms and automatically apply corrective electrical therapy, specifically one or more bursts of electric current, to hearts. When the bursts of electric current are properly sized and timed, they restore normal heart function without human intervention, sparing patients considerable discomfort and often saving their lives.
The typical defibrillator or cardioverter includes a set of electrical leads, which extend from a sealed housing into the walls of a heart after implantation. Within the housing are a battery for supplying power, a capacitor for delivering bursts of electric current through the leads to the heart, and monitoring circuitry for monitoring the heart and determining when, where, and what electrical therapy to apply. The monitoring circuitry generally includes a microprocessor and a memory that stores instructions not only dictating how the microprocessor answers therapy questions, but also controlling certain device maintenance functions, such as maintenance of the capacitors in the device.
The capacitors are typically aluminum electrolytic capacitors. This type of capacitor usually includes strips of aluminum foil and electrolyte-impregnated paper. Each strip of aluminum foil is covered with an aluminum oxide which insulates the foils from the electrolyte in the paper. One maintenance issue with aluminum electrolytic capacitors concerns the degradation of their charging efficiency after long periods of inactivity. The degraded charging efficiency, which stems from instability of the aluminum oxide in the liquid electrolyte, ultimately requires the battery to progressively expend more and more energy to charge the capacitors for providing therapy.
Thus, to repair this degradation, microprocessors are typically programmed to regularly charge and hold aluminum electrolytic capacitors at or near a maximum-energy voltage (the voltage corresponding to maximum energy) for a time period less than one minute, before discharging them internally through a non-therapeutic load. (In some cases, the maximum-energy voltage is allowed to leak off slowly rather than being maintained; in others, it is allowed to leak off (or droop) for 60 seconds and discharged through a non-therapeutic load; and in still other cases, the voltage is alternately held for five seconds and drooped for 10 seconds over a total period of 30 seconds, before being discharged through a non-therapeutic load.) These periodic charge-hold-discharge (or charge-hold-droop-discharge) cycles for maintenance are called “reforms.” Unfortunately, reforming aluminum electrolytic capacitors tends to reduce battery life.
To eliminate the need to reform, manufacturers developed wet-tantalum capacitors. Wet-tantalum capacitors use tantalum and tantalum oxide instead of the aluminum and aluminum oxide of aluminum electrolytic capacitors. Unlike aluminum oxide, tantalum oxide is reported to be stable in liquid electrolytes, and thus to require no energy-consuming reforms. Moreover, conventional wisdom teaches that holding wet-tantalum capacitors at high voltages, like those used in conventional reform procedures, decreases capacitor life. So, not only is reform thought unnecessary, it is also thought to be harmful to wet-tantalum capacitors.
However, the present inventors discovered through extensive study that wet-tantalum capacitors exhibit progressively worse charging efficiency over time. Accordingly, there is a previously unidentified need to preserve the charging efficiency of wet-tantalum capacitors.
SUMMARY OF THE INVENTION
To address this and other needs, the inventors devised methods of maintaining wet-tantalum capacitors in implantable medical devices. One exemplary method entails reforming this type of capacitor. More particularly, the exemplary method entails charging wet-tantalum capacitors to a high voltage and keeping the capacitors at a high voltage for about five minutes, before discharging them through a non-therapeutic load. In contrast to conventional thinking, reforming wet-tantalum capacitors at least partially restores and preserves their charging efficiency.
Another facet of the invention includes an implantable medical device, such as defibrillator, cardioverter, cardioverter-defibrillator, or pacemaker, having one or more wet-tantalum or other type capacitors and means for reforming the capacitors. Yet another facet includes a computer-readable medium bearing instructions for reforming capacitors according to one or more unique methods.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an exemplary implantable heart monitor incorporating teachings of the present invention.
FIG. 2 is a flow chart illustrating exemplary operation of the heart monitor of FIG. 1 .
FIG. 3 is a state flow diagram illustrating an alternative operation of the heart monitor of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description, which references and incorporates FIGS. 1-3, describes and illustrates one or more specific embodiments of the invention. These embodiments, offered not to limit but only to exemplify and teach the invention, are shown and described in sufficient detail to enable those skilled in the art to practice the invention. Thus, where appropriate to avoid obscuring the invention, the description may omit certain information known to those of skill in the art.
FIG. 1 shows an exemplary implantable heart-monitoring device (or pulse generator) 100 incorporating teachings of the present invention. Device 100 includes a monitoring system 110 , a lead system 120 , a therapy system 130 , a power system 140 , and an interconnective bus 150 . Monitoring system 110 includes a processor or microcontroller 112 and a memory 114 . Memory 114 includes one or more software modules 116 which store one or more computer instructions in accord with the present invention. Some embodiments of the invention replace software modules 116 with one or more hardware or firmware modules. In the exemplary embodiment, processor 112 is similar to a ZiLOG™ Z80 microprocessor (with a math coprocessor), and memory 114 is a random-access memory. However, the invention is not limited to any particular microprocessor, microcontroller, or memory.
Lead system 120 , in the exemplary embodiment, includes one or more electrically conductive leads—for example, atrial, ventricular, or defibrillation leads—suitable for insertion into a heart. One or more of these are suitable for sensing electrical signals from a portion of the heart and one or more are suitable for transmitting therapeutic doses of electrical energy. Lead system 120 also includes associated sensing and signal-conditioning electronics, such as atrial or ventricular sense amplifiers and/or analog-to-digital converters, as known or will be known in the art.
In some embodiments, lead system 120 supports ventricular epicardial rate sensing, atrial endocardial bipolar pacing and sensing, ventricular endocardial bipolar pacing and sensing, epicardial patches, and Endotak® Series and ancillary leads. In some embodiments, lead system 120 also supports two or more pacing regimens, including DDD pacing. Also, some embodiments use at least a portion of a housing of device 100 as an optional defibrillation electrode. The invention, however, is not limited in terms of lead or electrode types, lead or electrode configurations, pacing modes, sensing electronics, or signal-conditioning electronics.
Therapy system 130 includes a capacitor system 132 and other circuitry (not shown) for delivering or transmitting electrical energy in measured doses through lead system 120 to a heart or other living tissue. Additionally, therapy system 130 includes one or more timers, analog-to-digital converters, and other conventional circuitry (not shown) for measuring various electrical properties related to performance, use, and maintenance of the therapy system.
In the exemplary embodiment, capacitor system 132 include three or four, flat or cylindrical wet-tantalum and/or other type capacitors. The exemplary wet-tantalum capacitors comprise a tantalum metal anode, Ta 2 O 5 dielectric, a liquid electrolyte, and a cathode of material other than tantalum, for example, RuO 2 . Capacitors of this description are known in the trade as hybrid capacitors, with some versions having tantalum cases and others having polypropylene cases. See also U.S. Pat. Nos. 5,982,609; 5,469,325; 5,737,181; and 5,754,394, which are incorporated herein by reference.
Exemplary specifications for the wet-tantalum capacitors are 185 volts surge, 60 microamp leakage current at 175 volts, 90 microamp leakage current at 185 volts, an AC capacitance of 490 microfarads, and equivalent series resistance (ESR) of 1.2 ohms. Capacitors meeting these or specifications or having similar construction are manufactured by Wilson Greatbatch Ltd. of Clarence, N.Y. or Evans Capacitor Company of East Providence, R.I.
In general operation, lead system 120 senses atrial or ventricular electrical activity and provides data representative of this activity to monitoring system 110 . Monitoring system 110 , specifically processor 112 , processes this data according to instructions of software module 116 of memory 114 . If appropriate, processor 112 then directs or causes therapy system 130 to deliver one or more measured doses of electrical energy or other therapeutic agents through lead system 120 to a heart. Additionally, software module 116 includes one or more instructions or code segments which manage and maintain capacitors 132 in accord with teachings of the inventions.
FIG. 2, which shows an exemplary flow chart 200 , illustrates an exemplary capacitor-management method embodied within software module 116 and executed by processor 112 and other relevant portions of device 100 . Flow chart 200 includes blocks 202 - 220 , which are arranged serially in the exemplary embodiment. However, other embodiments of the invention may execute two or more blocks in parallel using multiple processors or a single processor organized as two or more virtual machines or subprocessors. Moreover, still other embodiments implement the blocks as two or more specific interconnected hardware modules with related control and data signals communicated between and through the modules. Thus, the exemplary process flow applies to software, firmware, and hardware implementations.
In process block 202 , processor 112 of device 100 , determines whether to initiate reform of the wet-tantalum capacitors. The exemplary embodiment makes this determination based on whether a predetermined amount of time, for example 30, 60, 90, or 120 days, has elapsed since the last reform or the last therapeutic use, that is, charge and discharge, of the capacitor. Some embodiments use a timer to support this determination, with the timer in some embodiments being reset with every therapeutic use or certain therapeutic uses of the capacitors and other embodiments ignoring therapeutic use of the capacitor as a factor influencing reform timing. Other embodiments trigger or schedule reform based on thresholding of certain average or instantaneous performance aspects of the capacitors, such as actual or estimated full-energy charge time. And still other embodiments initiate reform as part of an overall storage mode. See also U.S. Pat. No. 5,899,923 which is entitled Automatic Capacitor Maintenance System for an Implantable Cardioverter Defibrillator and which is incorporated herein by reference.
If the processor determines that reform is presently undesirable, execution proceeds to block 206 , where the reform procedure is aborted. In the exemplary embodiment, aborting the reform procedure entails rescheduling it for some programmable amount of time in the future, for example 23-25 hours later. However, if the processor determines that reform is presently desirable, execution proceeds to block 204 .
In block 204 , the processor assesses whether the battery is in condition to execute the exemplary capacitor reform procedure. In the exemplary embodiment, this entails measuring the open-circuit battery voltage and determining whether the battery has reached the end of its life or whether the battery has reached an elective-replacement state. The system deems the battery to have an end-of-life status when the last recorded capacitor charge time exceeds a predetermined charge time, such as 30 seconds, or it has an open-circuit voltage less than 2.1 volts. The system deems the battery to be in an elective-replacement state when its last recorded charge time exceeds 20 seconds or its open-circuit voltage is less than or equal to a specific voltage, such as 2.45 volts. If the battery cannot execute the reform procedure, execution of the capacitor reform procedure is aborted at block 206 to conserve energy. On the other hand, if it can execute reform, execution continues at block 208 .
In block 208 , the processor discharges the capacitors to allow an accurate measurement of charge time during subsequent procedures. In the exemplary embodiment, the discharge begins on the first cardiac cycle after initiation of the reform procedure and may require as much as two seconds to complete. The exemplary embodiment discharges the capacitors through a 1000-ohm load resistor. However, the invention is not limited to any particular discharge load or rate.
Block 212 entails charging the capacitors to a high voltage. (Some embodiments include enter a tachy-off mode prior to charging the capacitors.) The exemplary embodiment charges the capacitors to a high voltage about 5-15% less than their maximum-energy voltage to avoid or reduce the risk of accelerating aging of the capacitors; however, other embodiments charge the capacitors to their full rated voltage. In addition, charging begins 90-110 milliseconds after the next cardiac cycle and ends when the capacitor voltage reaches the maximum-energy voltage. (In devices that use blanking intervals, the initiation of charging should fall within a blanking interval to reduce the risk of false arrhythmia detections.) When charging is completed, the exemplary embodiment records the elapsed charge time in memory.
In block 214 , the processor further charges, or tops off, the capacitors to maintain the capacitors at a sufficiently high voltage for reform. In the exemplary embodiment implements an N-second top-off procedure which entails changing the sensed refractory period to 250 milliseconds and charging for an M-millisecond period on each cardiac cycle that occurs during the N-second period. N and M are programmable to any desired value; exemplary values for N and M are 5 and 200, respectively.
In some other embodiments, execution of the top-off procedure is contingent on whether the measured capacitor voltage is within a specific voltage range. In one embodiment, this entails determining whether the capacitor voltage is greater than the maximum-energy voltage less 10 volts per capacitor in the capacitor system. For example, in a one-capacitor system having a maximum-energy voltage of 185 volts, this embodiment tops off the capacitor when its voltage falls below 175 volts.
After topping off the capacitors, execution proceeds to block 216 , to begin an L-second monitoring period. On the first cardiac cycle of this period, the system changes the sensed refractory back to its normal (pre-reform) setting, enabling detection of abnormal rhythms. If an abnormal rhythm is detected, the system aborts the reform procedure and addresses the abnormal rhythm. The exemplary embodiment sets L to 10; however, in general, this value is programmable. If an abnormal heart rhythm or heart condition requiring device therapy is detected, execution branches to block 206 to abort the reform procedure. However, if no condition requiring therapy is detected during the L-second period, execution proceeds to block 218 .
In block 218 , the processor determines whether the capacitors have been at the high voltage for a sufficiently long time period to effect reform of their tantalum oxide or other reformable portion. The exemplary embodiment uses a default period in the range of about five minutes as a sufficiently long time period. If sufficient time has not elapsed, execution branches back to block 214 . Other embodiments use periods in the range of 15 seconds to 10 minutes. (In conventional therapeutic use, capacitors typically hold their charge for a period in the range of 20 milliseconds to 10 seconds, before initiating a therapeutic discharge.) In other embodiments, the sufficient amount of time is based on measured electrical properties of the capacitor system. For example, one embodiment bases the determination on whether the capacitor leakage current has fallen below a certain threshold. To determine a value or proxy for the capacitor leakage current, this embodiment monitors an actual or average time between successive top-offs, with each top-off initiated when the capacitor voltage falls below a certain voltage level. In any event, if the processors determines that a sufficient amount of time has elapsed, the processor executes block 220 .
Block 220 entails initiating or allowing discharge of the one or more capacitors through a non-therapeutic load. (As used herein, discharge through a non-therapeutic load includes any discharge internal to the device as well as potential discharges at non-therapeutic levels or rates through the lead system.) The exemplary embodiment discharges the one or more capacitors through a 1000-ohm resistor; however, other embodiments allow the charge to dissipate through system leakage. Still other embodiments allow the one or more capacitors to float for some time, for example, 60 seconds, before initiating discharge through a load resistor. Also, one embodiment allows the one or more capacitors to decay through system leakage for a period of time, for example, 60, 90, or 120 seconds or even one or more hours, before initiating discharge through a load resistor or other non-therapeutic load. Still other embodiments, skip or omit blocks 214 , 216 , and 218 and initiate discharge of wet-tantalum capacitors through a non-therapeutic load immediately upon sensing or otherwise determining that the one or more capacitors are at the sufficiently high reform voltage. Thus, the invention is not limited to any particular mode, method, or technique of non-therapeutic discharge.
FIG. 3, which shows an exemplary state flow diagram 300 , illustrates an alternate exemplary capacitor-management method embodied within software module 116 and executed by processor 112 and other relevant portions of device 100 . Diagram 300 includes states or blocks 302 - 322 . The exemplary diagram, drawn using commercially available simulation software with a state-diagram capability, uses the following definitions:
CFM_START denotes a request to start the capacitor reformation. The request is made with CFM_TOP_OFF set either true or false, depending on the number of elapsed days since the last successful capacitor reformation conducted with the top-off of the capacitors to ensure effective reform.
CFM_TOP_OFF denotes a parameter set the requester of the reform and determines if the reform will involve use of top off cycles or not.
SAVE_CHRG, which is normally set to false, controls whether any charge in the capacitor system is retained to treat a detected arrhythmia. If an episode results in an abort of the capacitor reform, an abort function sets it true.
SCHEDULE_CAPFORM, which effects the abort functions, requests that a capacitor reform be run again within 24 hours or other specified time. The rescheduled reform will be same type as the aborted reform. For example, if the aborted reform used or was intended to use top off, the rescheduled reform will also use top off.
CAPFORMTOPOFFDETECTIONTIME denotes the desired value of the DETECTIONTIME when the reform uses top-off. In the exemplary embodiment, this value defaults to five minutes; however, in general, it lies in the range of 15 seconds to 10 minutes or 61 seconds to 10 minutes.
CAPFORMDETECTIONTIME denotes the desired value of reform conducted without use of top-off. The default value in the exemplary embodiment is zero.
CAPFORMTOPOFFINTERVAL denotes the top-off cycle time.
CHG_ABORT denotes the function of stopping the charging process.
CHG_DONE is a hardware signal indicating completion of a charging operation.
DETECTION_TIME equals CAPFORMTOPOFFDETECTIONTIME or CAPFORMDETECTIONTIME depending on the value of CFM_TOP_OFF.
V_EVENT denotes a detection of a ventricular sense, pace or no-sense timeout. However, more generally it denotes a detection of a cardiac event.
SW_CP_DUMP_DONE is a hardware signal denoting completion of a charge dump.
The exemplary state diagram also makes use of the following nomenclature: tm=timeout; en=enter; ex=exit. Thus, for example,
tm(ex(CHARGING), DETECTION_TIME)
means that when the DETECTION_TIME elapses after exiting the CHARGING state a timeout will occur, triggering the associated path to be traversed and the state to change.
The alternate exemplary method begins at idle state block 302 . During this state, the processor checks every 24 hours to see if it is time to reform. This entails determining whether it is time to perform a scheduled reform. For example, one can schedule a reform every 90 days. Depending on the value of CFM_TOP_OFF, the reform may or may not involve use of top offs of the capacitor to maintain capacitor voltage at a high voltage. Reforms with top off are done every 90 days in some embodiments.
At state 304 , charge in the capacitor system is dumped. Dumping the charge facilitates accurate measurement of charging times. The hardware signal SW_CAP_DUMP_DONE signals completion of the dump and initiates transition to decision state (or block) 306 .
At block 306 , the processor determines if an abort signal or a fault, such as a failed dump, has occurred. If so, the RESCHEDULE_CAPFORM function is invoked. If not, a transition to charging state 308 occurs. In this state, the capacitors are initially charged to their maximum-energy voltage. The hardware signal SW_CHARGE_DONE indicates completion of the charging and initiates transition to decision block 310 .
In decision block 310 , the processor checks for a charge-time-fault or high-voltage on leads indicating leak. The charge-time fault indicates that too much time has elapsed without bringing the capacitors to full charge, indicating or suggesting a leak in the system. If there is not fault, a transition to decision block 312 occurs. In block 312 , the processor checks for an external abort signal. One example of an activity that would result in the external abort signal is the use of telemetry to reprogram the device.
A fault at block 310 or an abort signal at block 312 forces a transition to decision block 322 . At block 322 , the processor decides whether to save the charge in the capacitors or to dump their charge, based on the value of SAVE_CHRG. With no fault at blocks 310 and 312 , a transition to monitor state 313 occurs. Monitor state 313 , which represents a parent state, includes three child states: wait state 314 , sync state 316 , and top-off state 318 . The processor essentially stays at monitor state 313 until the reform is completed or aborted.
More specifically, the transition to monitor state 313 enters wait, or delay, state 314 . Wait state 314 waits for a period of time, such as 10 seconds. This time is denoted CAPFORMTOPOFFINTERVAL. During this time, the device essentially looks for arrhythmia episodes. In an episode occurs, the reform is aborted and rescheduled and there is a transition to decision block 322 . If no episode occurs, expiration of the time period (CAPFORMTOPOFFINTERVAL) results in a transition to sync state 316 . Sync state 316 waits for the ventricular event, for example, a V-pace, V-sense, or no-sense timeout, before transitioning to top-off state 318 , during which the capacitors are topped off.
In one version of this alternate implementation, the top off voltage level is 38 volts less than the voltage for maximum energy for a four-capacitor system. This is to ensure the capacitors are never over charged. Top off cycles are performed every CAPFORMTOPOFFINTERVAL seconds (2-65535 sec) for a duration determined by CAPFORMTOPOFFDETECTIONTIME (0-65535 sec). No top off cycle is allowed to charge for more than CAPFORMTOPOFFTIMELIMIT (2200-65535 ms). Each top off charge cycle is started synchronous to a ventricular event to ensure the charge circuit is activated during a refractory period.
After the preset DETECTION TIME has expired, there is a transition from monitor state 313 to decision block 320 . Decision block 320 transitions to dump block 304 to dump the charge on the if no arrhythmia episode is in progress.
Conclusion
In furtherance of the art, the inventors have not only discovered the need to reform wet-tantalum capacitors in implantable medical devices, but also devised suitable reform methods and software. The exemplary method conducts reform every 90 days regardless of intervening therapeutic events, with reform entailing holding one or more wet-tantalum capacitors at a high voltage (within 10 percent of the rated capacitor voltage) for about five minutes. Other embodiments reform hybrid capacitors in medical devices generally and hold high-voltage charges on capacitors for times greater than one minute. Other applications for the invention include non-medical devices that require or would benefit from long-term stability of the charging efficiency of wet-tantalum capacitors.
The embodiments described above are intended only to illustrate and teach one or more ways of practicing or implementing the present invention, not to restrict its breadth or scope. The actual scope of the invention, which embraces all ways of practicing or implementing the teachings of the invention, is defined only by the following claims and their equivalents. | Miniature defibrillators and cardioverters detect abnormal heart rhythms and automatically apply electrical therapy to restore normal heart function. Critical to this function, aluminum-electrolytic capacitors store and deliver life-saving bursts of electric charge to the heart. This type of capacitor requires regular “reform” to preserve its charging efficiency over time. Because reform expends valuable battery energy, manufacturers developed wet-tantalum capacitors, which are generally understood not to require reform. Yet, the present inventors discovered through extensive study that wet-tantalum capacitors exhibit progressively worse charging efficiency over time. Accordingly, to address this problem, the inventors devised unique reform techniques for wet-tantalum capacitors. One exemplary technique entails charging wet-tantalum capacitors to a voltage equal to about 90% of their rated voltage and allowing the charge to dissipate through system leakage for a period of time, before discharging through a non-therapeutic load. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention is directed to data storage data processing systems. More specifically, the present invention is directed to a method, apparatus, and computer program product for automatically selecting and migrating data and then responding to requests to access the migrated data transparently to applications that access the data.
[0003] 2. Description of Related Art
[0004] A data storage data processing system typically includes one or more applications that access one or more databases. The applications are directly connected to each one of the databases. Thus, when an application needs to access a database, the application sends requests, such as Create, Retrieve, Update, or Delete requests, to the database using a vendor specific protocol.
[0005] When an application needs to access a database, the application will issue a request. The request is in a format, also referred to herein as a vendor specific protocol, which is required by the database that the application is attempting to access. For example, an application might issue a request to access an Oracle database. This request is in an Oracle format. The application expects to receive a result set back from the Oracle database in response to the request in that same Oracle format. The result set the application expects to receive back from the Oracle database will include all of the data requested by application. Thus, the application issues a request directly to a database in a database-specific format. The application then expects to receive a response from the database that includes a complete result set of all of the data requested by the application. The application expects the response to also be in the database-specific format.
[0006] It may be desirable to migrate data from one database to another. When data is migrated, the applications must be made aware of the new location of the data. When an application needs to access data where some of that data has been migrated, the application itself must retrieve the data from each location by issuing a request for data from each database in each database's database-specific format. For example, if the data is located in two different databases, the application must issue a first request for data from the first database in the first database's specific format and also issue a second request for data from the second database in the second database's specific format. The application will then receive a partial result set from each source that the application must assemble to form a complete result set. The data to satisfy the application's needs comes from two sources. The application must assemble the data responses from each database.
[0007] Therefore, a need exists for a method, apparatus, and computer program product for automatically selecting and migrating data and then responding to requests to access the migrated data transparently to applications that access the data.
SUMMARY OF THE INVENTION
[0008] A method, apparatus, and computer program product are disclosed for managing and migrating data. A request is received from an application for data. The request is in a database-specific format that adheres to a database-specific protocol. A determination is made regarding whether the data is located in a first database that utilizes the database-specific format. In response to determining that at least part of the data has been migrated from the first database, each current location of each part of the data is identified. A first request is generated for a first location of a first part of the data. The first request is in a database-specific format of the first location. A second request is generated for a second location of a second part of said data. The second request is in a database-specific format of the second location. The first and second parts of the data are combined into a complete result set that includes all of the originally requested data. A response to the request is generated for the application that includes the complete result set in the same database-specific format used in the original request from the application.
[0009] The above as well as additional objectives, features, and advantages of the present invention will become apparent in the following detailed written description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0011] FIG. 1 is a block diagram of a data storage data processing system in accordance with the present invention;
[0012] FIG. 2 depicts a high level flow chart that illustrates the creation of a migration policy in accordance with the present invention;
[0013] FIG. 3 illustrates a high level flow chart that depicts a gateway implementing a migration policy in accordance with the present invention;
[0014] FIG. 4 depicts a high level flow chart that illustrates a gateway retrieving data from multiple databases and combining the retrieved data into a response that includes a complete result set in accordance with the present invention;
[0015] FIG. 5 is a block diagram of a computer system that includes the present invention in accordance with the present invention;
[0016] FIG. 6A depicts a block diagram of a primary database that stores all data in accordance with the present invention; and
[0017] FIG. 6B illustrates a primary database and a secondary database after some data has been migrated from the primary database to the secondary database in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] A preferred embodiment of the present invention and its advantages are better understood by referring to the figures, like numerals being used for like and corresponding parts of the accompanying figures.
[0019] The present invention is a method, apparatus, and computer program product for automatically selecting and migrating data and then responding to requests to access the migrated data transparently to applications that request to access the data. The invention exists in an environment that includes multiple different databases that are accessed by multiple different applications. The present invention is a method, system, and computer program product that provides a gateway between primary databases and applications that need to access the databases. The gateway is located between the applications and the databases.
[0020] The applications and the databases send, receive, and respond to requests in the typical manner consistent with the prior art. Thus, an application will send a request assuming that all of the data it is requesting will be found in the primary database that it believes it is accessing. Each database also responds to requests in a manner that is known in the prior art. Thus, a particular database will respond to a request in that database's particular database-specific format.
[0021] According to the present invention, portions of the data that would ordinarily be stored in one of the primary database are migrated from that primary database to either a secondary database or an archive database. When an application sends a request for data to one of the multiple different databases, the gateway intercepts the request and determines whether the request requests data that has been migrated out of its primary database to a secondary database, an archive database, or both. If the request does not request data that has been migrated, the request is passed through to the primary database to be processed according to normal known procedures. According to the present invention, if the request does request data that has been migrated, the gateway accesses a metadata structure that includes information about where the migrated data can be found. The metadata structure maintains the keys or other information that are necessary in order to find where various parts of the data are now located.
[0022] The gateway converts the single request from the application into several different requests. Thus, for example, the application may be attempting to retrieve data from a particular primary database. One part of this data may have been migrated to a secondary database and a second part of the data may have been migrated to the archive database. A third part of the data may remain in the primary database. Thus, when the gateway receives the request from the application in the primary database's format, the gateway will generate three different requests. One request will be in the primary database's format and will request just that data that is stored in the primary database. A second request will be in the secondary database's format and will request just that data that is stored in the secondary database. A third request will be in the archive database's format and will request just that data that is stored in the archive database.
[0023] The gateway then transmits these requests to the primary, secondary, and archive databases which will then access the data as requested. Each database will response to the request from the gateway by accessing the data as requested and providing back to the gateway a response that includes the data that was stored in that particular database. Each database will respond back to the gateway using the database's database-specific format. The gateway will then combine all of the retrieved data from the responses from each database into one single response. The gateway will put the response in the database-specific format that the application is expecting and then send that one response back to the requesting application. Thus, the single response sent back to the application contains a complete result set of all requested data and is in the format expected by the application. In this manner, the application is unaware that the data had been found in multiple databases.
[0024] The present invention provides for setting policies that define what type of data is to be migrated, what event or events trigger the migration, and where to store the migrated data. The migration then takes place dynamically and automatically as the trigger events occur. This requires updating of the metadata structure in order to be able to continually locate data that may have been migrated in response to a trigger event.
[0025] Thus, the present invention acts as a virtual primary database to each application. An application transmits requests to the gateway which then executes the requests in the manner expected by the application. The actions of the gateway are completely hidden from the applications and from the databases themselves.
[0026] FIG. 1 is a block diagram of a data storage data processing system 100 in accordance with the present invention. System 100 includes a plurality of applications 102 that store and retrieve data from a primary database 104 . Applications 102 issue requests to access one of the primary databases 104 . An application issues a request in a particular database format for the particular primary database that the application is intending to access.
[0027] According to the present invention, a gateway 106 is provided between applications 102 and primary databases 104 . Gateway 106 will receive a request from an application in a particular database-specific format. Gateway 106 then either forwards that request to the appropriate primary database if none of the data has been migrated, or generates several requests in different formats for multiple databases in order to retrieve the partial result set that is stored in each database. Gateway 106 then receives the partial result set(s) from these databases, forms a response that includes a complete result set, and then sends that response back to the requesting application in the same particular database-specific format that is expected by the application.
[0028] Applications 102 may include, for example, a PeopleSoft application 108 , an Oracle Finance application 110 , a custom application 112 , and an SAP application 114 . Other vendor's applications may be included.
[0029] Primary databases 104 include, for example, an Oracle database 116 , and an Informix database 118 . Other vendor's databases or a custom database may be included.
[0030] When one of the applications needs to access a primary database, the application will issue a request. That request is in a format that is required by the primary database that the application is attempting to access. For example, custom application 112 may issue a request to access the Oracle database 116 . Thus, application 112 issues a request in an Oracle format. Application 112 expects to receive a single response that includes the complete result set back from Oracle database 116 in that same Oracle format. The result set that application 112 expects to receive back from Oracle database 116 includes all of the data requested by application 112 .
[0031] Data storage database system 100 also includes a secondary database 120 . Secondary database 120 stores data that will likely be accessed less frequently than the data that is stored in primary databases 104 . In addition, an archive database 122 may also be included. Archive database 122 stores data that will likely be accessed less frequently than the data that is stored in either secondary database 120 or primary databases 104 .
[0032] A metadata table 124 is included. Metadata table 124 includes information that identifies where data that has been migrated is currently located. For example, once data has been migrated from primary database 104 to either secondary database 120 or archive database 122 , primary and secondary keys or other information will be stored in metadata table 124 that can be used by gateway 106 to locate where that data is currently stored.
[0033] According to the present invention, when gateway 106 receives a request, such as request 130 which is in a primary database-specific format, from an application, gateway 106 will access metadata table 124 using key lookup 132 to determine whether the request 130 is requesting data that has been migrated from a primary database 104 to another location. Key lookup 132 will provide the current location of the data if that data has been migrated. If gateway 106 determines that none of the requested data has been migrated, gateway 106 passes the request 130 straight through gateway 106 to the appropriate primary database 104 which then executes the request and provides a complete result set. This complete result set 146 is in the primary database-specific format. This complete result set 146 is then received by gateway 106 and passed straight through gateway 106 and back to the requesting application. Gateway 106 does not modify the application's request or the primary database's response in this case.
[0034] If gateway 106 determines that some or all of the requested data has been migrated, gateway 106 uses key lookup information 132 to determine where that data is currently located. Gateway 106 then generates a request for each location that requests the data that is stored in that location. A location's request from gateway 106 is in the location-specific format. For example, if some of the data requested by the application is located in a particular one of the primary databases 104 , some of the data is located in secondary database 120 , and some of the requested data is located in archive database 122 , gateway 106 will generate a request 134 for a partial result set from the particular one of the primary databases 104 . Gateway 106 will also generate a request 136 for a partial result set from secondary database 120 and a request 138 for another partial result set from archive database 122 . Request 134 is in the particular primary database's format. Request 136 is in the secondary database's format. Request 138 is in the archive database's format.
[0035] The particular one of primary databases 104 will respond to request 134 by transmitting a partial result set 140 back to gateway 106 . Partial result set 140 is in the primary database's database-specific format. Secondary database 120 will respond to request 136 by transmitting a partial result set 142 back to gateway 106 . Partial result set 142 is in the secondary database's database-specific format. Archive database 122 will respond to request 138 by transmitting a partial result set 144 back to gateway 106 . Partial result set 144 is in the archive database's database-specific format.
[0036] Gateway 106 will then take the data from each one of the partial result sets 140 , 142 , and 144 to form a complete result set. Gateway 106 then generates a response 146 to the requesting application that includes the complete result set. This response is in the same database-specific format of the application's request. Gateway 106 then transmits the complete result set response 146 back to the requesting application. In this manner, the application is completely unaware that the requested data was located in more than one storage location. The gateway's actions are completely transparent to the application. The application generates a request in a particular database-specific format and receives a complete result set response in that same database-specific format regardless of where the data was actually located.
[0037] FIG. 2 depicts a high level flow chart that illustrates the creation of a migration policy in accordance with the present invention. The process starts as depicted by block 200 and thereafter passes to block 202 which illustrates creating one or more migration policies by specifying for each policy what data is to be migrated, one or more triggers for migrating this data, and the desired destination of the migrated data. Next, block 204 illustrates sending these one or more policies to the gateway system. The process then passes to block 206 which depicts a determination of whether or not a change to one of the policies has been received. If a determination is made that no change to any policy has been received, the process passes back to block 206 .
[0038] Referring again to block 206 , if a determination is made that a change to a policy has been received, the process passes to block 208 . Block 208 illustrates updating a policy by adding, deleting, and/or changing one or more aspects of that policy, such as by specifying different trigger events, specifying different data, and/or specifying different migration destinations. Next, block 210 depicts sending the updated policy information to the gateway. The process then passes back to block 206 .
[0039] FIG. 3 illustrates a high level flow chart that depicts a gateway implementing a migration policy in accordance with the present invention. The process starts as depicted by block 300 and thereafter passes to block 302 which illustrates a determination of whether or not the gateway determines that a policy's trigger event has occurred. If a determination is made that a policy's trigger event has not occurred, the process passes back to block 302 . Referring again to block 302 , if a determination is made that a policy's trigger event has occurred, the process passes to block 304 which depicts the gateway searching for data to be migrated as defined by the policy in response to the trigger event.
[0040] The process then passes to block 306 which illustrates the gateway migrating data to a secondary database and/or an archive database in accordance with the policy's requirements. The policy may specify that all of the data is migrated, that only part of the data is migrated to one location, or that different parts of the data are migrated to different locations. Block 308 , then, depicts the gateway updating the metadata table to indicate a new location for all of the migrated data. The process then passes back to block 302 .
[0041] FIG. 4 depicts a high level flow chart that illustrates a gateway retrieving data from multiple databases and combining the retrieved data into a response that includes a complete result set in accordance with the present invention. The process starts as depicted by block 400 and thereafter passes to block 402 which illustrates the gateway receiving a database request from an application. This database request is in a primary database-specific format. The gateway is capable of processing requests in any of multiple different formats.
[0042] Next, block 404 depicts the gateway searching the metadata table to determine where the requested data is currently located. The process then passes to block 406 which illustrates a determination of whether all of the data is located in a primary database. If a determination is made that all of the data is located in a primary database, the process passes to block 408 which depicts the gateway passing the request through the gateway directly on to the requested primary database without modification. Thus, in this case the gateway acts as a pass-through device that receives and then forwards the application's request without modifying the request.
[0043] Thereafter, block 410 illustrates the gateway receiving a response from the primary database that includes the complete result set that satisfies the application's request. The complete result set is received from the primary database in the primary database-specific format. Next, block 412 depicts the gateway passing the response directly to the requesting application without modification. The gateway again acts as a pass-through device that passes the complete result set from the primary database to the requesting application. The process then passes to block 414 .
[0044] Referring again to block 406 , if a determination is made that not all of the data is located in a primary database, the process passes to block 416 which illustrates the gateway generating a separate request for each database in which part of the requested data is stored. Each database request is in that database's database-specific format. Next, block 418 depicts the gateway transmitting each database request to that database.
[0045] The process then passes to block 420 which illustrates the gateway receiving a response from each database that includes a partial result set. The partial result set includes the data that is stored in that database. The response from a database is in that database's format. Block 422 , then, depicts the gateway combining the data from the partial result sets received from the various databases into a complete result set. The gateway creates a complete response to send to the requesting application. The complete response is in the primary database-specific format that is expected by the application. Next, block 424 illustrates the gateway transmitting the complete response that includes the complete result set to the requesting application. The process then passes to block 414 .
[0046] FIG. 5 is an illustration of a computer system that may be used to implement the present invention in accordance with the present invention. Data processing system 500 may be a multiprocessor system including a plurality of processors 502 and 504 connected to system bus 506 . Alternatively, a single processor system may be employed.
[0047] Also connected to system bus 506 is memory controller/cache 508 , which provides an interface to local memory 509 . I/O bus bridge 510 is connected to system bus 506 and provides an interface to I/O bus 512 . Memory controller/cache 508 and I/O bus bridge 510 may be integrated as depicted.
[0048] Peripheral component interconnect (PCI) bus bridge 514 connected to I/O bus 512 provides an interface to PCI local bus 516 . A number of modems may be connected to PCI bus 516 . Typical PCI bus implementations will support four PCI expansion slots or add-in connectors. Communications links to other computers may be provided through modem 518 and network adapter 520 connected to PCI local bus 516 through add-in boards.
[0049] Network adapter 520 includes a physical layer 582 which conditions analog signals to go out to the network, such as for example an Ethernet network over an R45 connector. A media access controller (MAC) 580 is included within network adapter 520 . Media access controller (MAC) 580 is coupled to bus 516 and processes digital network signals. MAC 580 serves as an interface between bus 516 and physical layer 582 . MAC 580 performs a number of functions involved in the transmission and reception of data packets. For example, during the transmission of data, MAC 580 assembles the data to be transmitted into a packet with address and error detection fields. Conversely, during the reception of a packet, MAC 580 disassembles the packet and performs address checking and error detection. In addition, MAC 580 typically performs encoding/decoding of digital signals transmitted and performs preamble generation/removal as well as bit transmission/reception.
[0050] Additional PCI bus bridges 522 and 524 provide interfaces for additional PCI buses 526 and 528 , from which additional modems or network adapters may be supported. In this manner, data processing system 500 allows connections to multiple network computers. A memory-mapped graphics adapter 530 and hard disk 532 may also be connected to I/O bus 512 as depicted, either directly or indirectly.
[0051] Those of ordinary skill in the art will appreciate that the hardware depicted in FIG. 5 may vary. For example, other peripheral devices, such as optical disk drives and the like, also may be used in addition to or in place of the hardware depicted. The depicted example is not meant to imply architectural limitations with respect to the present invention.
[0052] The following is an example of one application of the present invention. A business practice might suggest that settled vehicle insurance claims which are one year or older do not need to have the picture(s) of the vehicle damage maintained in the primary database. These pictures should be kept for five years, however. Claim information, without the pictures, should be kept for twenty years.
[0053] The following three policies are then created in order to implement the business practice. (1) On a daily basis, all claims that are stored on a primary database are checked to determine whether the claim was settled more than two years ago. Any pictures that are stored with claims that were settled more than two years ago are migrated from the primary database to the secondary database. (2) On a weekly basis, the secondary database is checked to determine whether there are any stored pictures that are associated with claims that are more than five years old. Any pictures that are associated with claims that are more than five years old are migrated from the secondary storage to the archive database. (3) On a monthly basis, the archived database is checked to determine whether there are any stored pictures that are associated with claims that are more than 20 years old. Any pictures that are associated with claims that are more than 20 years old that have not been accessed in the last 180 days are then deleted.
[0054] FIG. 6A depicts a block diagram of a primary database that stores all data in accordance with the present invention. Primary database 600 includes a table 602 of data. Table 602 includes three entries, each one of an insurance claim. Each entry contains an insurance policy number, a claim number, a settlement date, and a picture or collection of pictures of a vehicle associated with the claim.
[0055] For example, table 602 includes an entry for claim Xyz for policy Abc that was settled on Jun. 1, 1999. There are pictures 603 that are stored in primary database 600 for this claim. There is an entry for claim Qrs for policy Abc that was settled on Sep. 10, 2003. There are pictures stored for this claim. And, there is an entry for claim Ghi for policy Abc that does not have a settlement date. There are pictures stored for this claim. If the current date is Sep. 10, 2004, a determination will be made that the pictures 603 for claim Xyz are associated with a claim that is more than two years old and that the pictures for claims Qrs and Ghi are not associated with claims that are more than two years old. Therefore, the pictures data 603 should be migrated from primary database 600 to a secondary database.
[0056] FIG. 6B illustrates a primary database and a secondary database after data has been migrated from the primary database to the secondary database in accordance with the present invention. Primary database 604 includes a table 606 having three entries. The data in table 606 is the same as the data in table 602 with one difference. The pictures data 603 for claim Xrz has been migrated from primary database 604 to secondary database 608 . Secondary database 608 now includes a table 610 which includes the pictures 603 themselves as well as the key information regarding the claim and policy that are needed to properly identify the pictures 603 .
[0057] It is important to note that while the present invention has been described in the context of a fully functioning data processing system. Those of ordinary skill in the art will appreciate that the processes of the present invention are capable of being distributed in the form of a computer readable medium of instructions and a variety of forms and that the present invention applies equally regardless of the particular type of signal bearing media actually used to carry out the distribution. Examples of computer readable media include recordable-type media, such as a floppy disk, a hard disk drive, a RAM, CD-ROMs, DVD-ROMs, and transmission-type media, such as digital and analog communications links, wired or wireless communications links using transmission forms, such as, for example, radio frequency and light wave transmissions. The computer readable media may take the form of coded formats that are decoded for actual use in a particular data processing system.
[0058] The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | A method, apparatus, and computer program product are disclosed for managing and migrating data. A request is received from an application for data. The request is in a database-specific format. A determination is made regarding whether the data is located in a first database that utilizes the database-specific format. In response to determining that at least part of the data has been migrated from the first database, each current location of each part of the data is identified. A first request is generated for a first location of a first part of the data. The first request is in a database-specific format of the first location. A second request is generated for a second location of a second part of said data. The second request is in a database-specific format of the second location. The first and second parts of the data are combined into a complete result set that includes all of the originally requested data. A response to the request is generated for the application that includes the complete result set in the database-specific format. | 8 |
BACKGROUND
This invention relates to a process for selectively desulfurizing gases produced by reacting fuels with oxygen containing gases and water vapor under pressure. More particularly, this invention relates to a process for desulfurizing gases utilizing an alkali salt concentrated scrubbing solution at a certain temperature while maintaining a certain exchange of volume ratio.
Fuel gases which are produced by a gasification of solid or liquid fuels with oxygen, air or mixtures thereof and/or with steam and which are subsequently purified, particularly to remove sulfur compounds and, if desired, carbon dioxide, must be cooled before such purification from the high temperature of the gasifying reaction, which exceeds 500°C., to a temperature which is suitable for the purification and is below 150°C., preferably to the ambient temperature or below the same, e.g., down to -70°C. This cooling may result in a removal of certain components of the gas and such removal may constitute a loss as far as the subsequent stages are concerned in which the gas is utilized. Such components are, e.g., water vapor, which could be used for a shift conversion of carbon monoxide to form carbon dioxide and hydrogen, or hydrocarbons which are still vaporous at higher temperatures and which would contribute to the caloric value of the purified gas, particularly if the gas which has been produced is utilized as a fuel gas in a gas turbine. A gas for this purpose should be combustible, free of sulfur and as hot as possible. The value of the gas depends more on its volume than on its caloric value. For this reason, the fuel which is available is preferably gasified with air. Such gas may contain water vapor and carbon dioxide as components which are useful because they increase the volume.
Known processes of desulfurizing hot gases are compositions which absorb sulfur compounds and which consist, e.g., of iron oxide or zinc oxide and combine with sulfur to form sulfide. Their use is expensive and requires a gas which has been prepurified to a large extent and particularly is free of water vapor. For this reason, these processes are mainly used for a fine purification of pretreated gases or as a safety measure.
Gases are conventionally purified in scrubbing processes in which the substances to be removed from the gas are taken up by physically or chemically acting absorbent solutions.
In physically acting absorbent solutions, the gas components are dissolved in dependence on their absorption coefficient and their partial pressure. In accordance therewith, the aborption capacity of the physically acting scrubbing solution increases with increasing pressure and decreasing temperature. For this reason, scrubbing processes using physically acting absorbents are carried out under elevated pressures above about 10 kilograms per square centimeter and with high-boiling organic solvents, such as ethylene glycol, diglycol ether, propylene carbonate, N-methylpyrrolidone, at ambient temperature or with low-boiling organic solvents, particularly methanol, at temperatures below -10°C. down to about 70°C.
In chemically acting absorbent solutions, several gas components, particularly those having an acid function, specifically sulfur compounds and carbon dioxide, are chemically combined. Chemical absorbent solutions are generally required to lend themselves to easy regeneration, i.e., to a reversal of the absorption reaction under simple conditions.
Scrubbing processes using chemically acting absorbents are less dependent on pressure. They may be carried out under ambient pressure and at ambient temperature. The laden absorbent solution may be regenerated by boiling and stripping with steam or with the aid of air.
Suitable absorbent solutions are aqueous solutions of strong organic bases or of alkali salts of inorganic or organic acids. The aqueous solutions of weak acids may be used also at higher absorption temperatures, although an elevated pressure must then be applied. In this case, the regeneration is effected by a pressure relief to a lower pressure, preferably to ambient pressure, with boiling and stripping with steam.
U.S. Pat. No. 2,886,405 discloses a process of scrubbing fuel gases and synthesis gases to remove acid components, particularly carbon dioxide. In that process, the absorption is effected in a hot concentrated solution of potassium carbonate at a temperature near the atmospheric-pressure boiling point of the solution, and the laden solution is regenerated by a pressure relief and by boiling and stripping with the steam which is produced in the boiling solution or which is additionally introduced.
That known scrubbing process is particularly suitable for a removal of the large amounts of carbon dioxide which have been formed by shift conversion of carbon monoxide with water vapor to form carbon dioxide and hydrogen in the production of synthesis gases or hydrogen.
That process know as the hot potash scrubbing process may be used to remove sulfur compounds, particularly H 2 S together with the carbon dioxide, from the gas to be purified. So far, it has not been possible to accomplish a selective absorption of the sulfur compounds before the absorption of carbon dioxide under the conditions of the hot potash scrubbing process.
SUMMARY
It has been found that such selective absorption of sulfur compounds is possible by maintaining an exchange volume of from about 0.2 to about 2.0 cubic meters of absorbent solution per standard cubic meter of the sulfur compounds to be removed from the gas in the absorption column. This requirement is applicable not only to solutions of potassium carbonate but generally to aqueous solutions of alkali salts of weak inorganic acids, particularly of phosphoric acid, vanadium acid, boric acid, and the like, and particularly to aqueous solutions of mixtures of such salts. It is known that such mixtures of absorbent solutions may be used to increase the exchange rate or to inhibit corrosion (German Pat. No. 1,074,201).
The invention relates to a process of selectively desulfurizing gases which have been produced by a reaction of liquid or solid carbonaceous fuels with oxygen-containing gases and water vapor under pressure, which process comprises scrubbing with aqueous solutions of alkali salts of weak inorganic acids to remove the sulfur compounds and regenerating the laden solution by a pressure relief, heating, and stripping with water vapor.
The process according to the invention is characterized in that the gas is scrubbed with a concentrated solution of one or more alkali salts of weak inorganic acids at a temperature which is near the atmospheric-pressure boiling point of the solution in packed or plate columns while maintaining an exchange volume ratio of from about 0.20 to about 2.0 cubic meters of the solution per standard cubic meter hydrogen sulfide in the gas to be purified.
DESCRIPTION OF THE DRAWING
The present invention will be more fully understood from the following description taken in conjunction with the accompanying drawing which is a flow diagram of a suitable plant for carrying out the process of the invention.
DESCRIPTION
The raw gas is discharged from the gas producer at a temprature above 550°C. and is cooled in the usual manner in waste-heat boilers, scrubber-collers, soot-removing scrubbers and the like to about 150° - 200°C. and subsequently subjected to an indirect cooling to a temperature which is a few degrees below the operating temperature of the absorption tower of the desulfurizing plant. When the resulting condensate has been removed from the gas which has thus been precooled, the gas is heated to the operating temperature of the absorption tower by a direct heat exchange, e.g., in a counterflow column, with a small amount of a hot salt solution, which is additionally heated, and the gas is thus saturated with water vapor at the temperature to which it is heated. In this state the gas can flow through the absorption tower without entraining substantial amounts of water from the absorbent solution and without condensing substantial amounts of water vapor into the absorbent solution.
The substantially desulfurized gas, which is hot and saturated with water vapor, then flows off the top of the absorption column and may be supplied directly into a succeeding hot potash scrubber, in which carbon dioxide is absorbed, and/or into a carbon monoxide shift conversion unit.
In a special embodiment of the invention, the gas may be further heated and enriched with water vapor with utilization of the heat extracted before the desulfurization. The resulting gas is an excellent fuel for a gas turbine.
In accordance with the invention, the gas which has been directly cooled to a temperature between 200° and 150°C. in the conventional manner in a scrubber-cooler or a soot-removing scrubber is indirectly cooled in a plurality of stages to the operating temperature of the desulfurizing plant. The first, hottest cooling stage is an indirect-contact pressure cooler supplied with water. In this cooler, the water is heated to a temperature above that of the desulfurized gas exhausted from the absorption tower. In a trickling tower, the water is then contacted with that gas so that the latter is heated and further enriched with water vapor whereas the water is cooled and partly evaporated. When fresh water has been added to compensate the water which has evaporated, the water is returned into the indirect-contact pressure cooler. The further indirect cooling may be effected in the reboiler of the desorption column. The gas is then cooled to a temperature which is a few degrees below the temperature of the absorption tower in a final cooler, which is supplied, e.g., with fresh water. The condensate formed in all these indirect cooling stages is collected and discharged. Behind the final cooler, a condensate trap is suitably included to minimize the condensate content of the gas which enters the direct heat exchanger which directly precedes the absorption tower. The salt solution which is circulated through this heat exchanger and a reheater heats the gas to the temperature of the absorption column and saturates it with water vapor is suitably a concentrated solution of alkali, alkali carbonate or alkali bicarbonate. This salt solution may absorb from the gas any acid components thereof, such as phenols, fatty acids and the like, which are not expelled during the regeneration of the laden absorbent solution, so that such components do not enter the succeeding hot potash scrubber. The water which is lost in this heat exchanger may be compensated by means of a pressure pump. To prevent an enriching of the non-volatile acids in the salt solution to an upper limit, a small amount of salt solution may be removed from the heat exchanger from time to time or continuously and may be discarded. If the solution has taken up fatty acids or phenols from the raw gas, as is often the case when solid fuels are gasified, this comparatively small amount of salt solution may be introduced into the pressure gasifier together with the coal and may thus be eliminated.
The gas which has thus been pretreated now enters the absorption tower proper. Because the gas is saturated with water vapor and at the temperature of the absorbent solution, the sulfur compounds preferentially are removed by scrubbing under the existing conditions, particularly at the existing exchange volume ratio, whereas substantial amounts of water do not evaporate from or condense into the solution.
The exchange volume ratio (cubic meters of absorbent solution per standard cubic meter of sulfur compounds) is critical because it must ensure a substantial removal of the sulfur compounds from the gas and restrict the removal of CO 2 . On the other hand, the amount of CO 2 which is removed must not be too small so that the solution can be regenerated in such a manner that the residual H 2 S content of the regenerated solution is sufficiently low in view of the permissible H 2 S content in the scrubbed gas. This ratio should be as low as possible, but still sufficiently high. In view of this requirement, the range of 0.20 - 2.0 cubic meters of solution per standard cubic meter of sulfur compounds is selected. The low value of 0.20 will be used if the gas has a high content of sulfur compounds, approximately 1.5% by volume H 2 S. If the H 2 S content is low, e.g., about 0.12% by volume, the volume ratio should be 2.0.
The desulfurized, hot gas can then be further heated and enriched with water vapor by being contacted with the trickling hot water from the indirect-contact pressure cooler.
The drawing shows by way of example a flow scheme of a plant for carrying out the process according to the invention. The plant consists substantially of an indirect-contact pressure cooler 1, an absorption tower 2, a regenerating tower 3, a saturator 4 and a direct-contact heat exchanger 5.
The hot raw gas flows through a conduit 19 into the indirect-contact pressure cooler 1, in which part of the heat of the gas is delivered to water. Condensate formed by this indirect cooling is discharged through a conduit 21. The next indirect cooling stage for the raw gas is a reboiler 6 at the regenerating tower 2. In that reboiler, another part of the heat content of the gas is used to reboil the laden absorbent solution used in the regnerating tower 2.
Through a conduit 24, the gas flows into another indirect-contact cooler 7, which is supplied with fresh water and in which the gas is cooled to a temperature which is a few degrees below the operating temperature of the absorption tower 3. In an immediately succeeding condensate trap 12, as much as possible of the condensate is removed from the gas. The saturated gas, which is now free of condensate, flows from the condensate trap in a conduit 26 to the direct-contact heat exchanger 5. A hot salt solution is circulated by a pump 14 in a conduit 27 through the heat exchanger 5 and a reheater 8 and is maintained at a temperature which ensures that the gas in the heat exchanger 5 is heated to the operating temperature of the absorbent tower 3 and is saturated with water vapor. In this state, the gas flows in a conduit 30 to the absorption tower 3, in which it is scrubbed with the hot absorbent solution fed via conduit 35. The scrubbed gas which leaves the absorbent tower 3 has been desulfurized but in other respect has not changed in state as it flows in a conduit 31 to the saturator 4, which consists of a trickling tower, in which the gas is contacted with the hotter water from the indirect-contact pressure cooler 1, which is supplied. The water which has been cooled and partly evaporated in the saturator 4 is recycled by a pump 16 through a conduit 20 to the indirect-contact pressure cooler 1. The purified gas which is withdrawn from the saturator 4 through a conduit 32 is at a temperature above the operating temperature of the absorbent solution and correspondingly saturated with water vapor and is supplied to a further use, e.g., to the combustion chamber of a gas turbine or to a carbon monoxide shift conversion unit.
The absorbent solution laden with sulfur compounds is passed from the sump of the absorption tower 3 through a conduit 33 provided with a pressure relief valve 34 to the top of the regenerating tower 2. A reheater 10 may be provided in the conduit 33 to compensate the temperature loss which is due to the pressure relief. The pressure-relieved solution flows in the regenerating tower 2 over plates or packing down to the sump of the column, in which the regeneration temperature is maintained by means of the reboiler 6.
The regenerated solution is recycled from the sump of the tower 2 by means of a pump 13 through a conduit 35 to the top of the absorption tower 3.
Exhaust gas is withdrawn from the top of the regenerating tower 2 through a conduit 37, which includes a pressure-regulating valve 36, and is passed through a cooler 9 and a succeeding condensate trap 11. The collected condensate is water which has evaporated from the absorbent solution and which is recycled to the top of the regenerating tower by means of a pump 17 through the conduit 39 to maintain the concentration of the absorbent constant. Water which has been lost from the absorbent solution may be compensated by an addition of fresh water at this point. An exhaust gas which is rich in sulfur compounds and may be used in the Claus process is obtained from conduit 38.
The invention will be explained more fully in the subsequent examples.
EXAMPLE 1
A gas produced by a gasification of coal under pressure is passed through a scrubber-cooler and discharged from the same at a rate of 180,000 standard cubic meters per hour and a temperature of 161°C. and under a pressure of 21 kilograms per square centimeter (absolute prssure) and is saturated with water vapor. On a dry basis, the gas contains 13.0 % by volume CO 2 , 1.0% by volume H 2 S, 0.2% C n H m (unsaturated hydrocarbons), 15.8% CO, 25.0% H 2 , 5% CH 4 , and 40.0% N 2 . This gas is to be desulfurized in the plant shown in the drawing. The plant consists of the cooler 1, the regenerator 2, the absorber 3, the saturator 4, the prescrubber 5, the reboilers, reheaters and coolers 6 - 10, the traps 11 and 12 and the pumps 13 - 17.
The raw gas supplied in conduit 19 is cooled in the indirect-contact cooler 1 from 161° to 137°C. under a pressure of 20.6 kilograms per square centimeter (absolute pressure) with recirculated water at a rate of 760 metric tons per hour. The water is thus heated from 115°C. to 151°C. The residual heat is removed with condensate which is at a temperature of 140°C. and discharged in conduit 21 at a rate of 38.7 metric tons per hour.
The circulating water which has been heated is supplied through the conduit 22 to the saturator 4. The gas is supplied through a conduit 23 to the reboiler 6 at the regenerator 2 and in this reboiler delivers heat to the desulfurizing absorbent solution which is to be regenerated.
The gas leaving the reboiler 6 is at 110°C., under a pressure of 20.2 kilograms per square centimeter (absolute pressure), and saturated with water vapor so that 12.5 million kilocalories per hour are available for the regeneration. Condensate, which contains also tar components, is obtained at a rate of 12.5 metric tons per hour. For this reason, the gas together with the condensate is supplied in the conduit 24 first to an indirect-contact gas cooler 7 and thereafter to the trap 12, in which the gas is cooled to 103°C. and all condensate and tar components are removed therefrom. The condensate and tar components leave the trap 12 through a conduit 25. The gas then flows through conduit 26 into the counterflow column 5, where all chlorides, fatty acids, thiocyanic acid and other deleterious impurities are removed by a contact with a suitably alkaline salt solution, which is circulated by the pump 14 through the conduit 27 and consists, e.g., of a sodium carbonate solution. This prescubber contains 40 cubic meters of packing and is operated at 105°C., which is slightly above the condensing temperature of the tar components still contained in the gas. This operating temperature is adjusted by means of the steam-heated reheater 8. The small amount of water which is thus evaporated and the alkali which is consumed are compensated by a supply of an about 2% Na 2 CO 3 solution by a pump 18 through a conduit 28. Partly spent prescrubbing solution may be withdrawn through a conduit 29 when this is required and may be used further in the gas-producing plant.
The thus pretreated gas enters at 105°C. the absorber 3 through conduit 30, where the gas is desulfurized approximately at the same temperaure by a contact with the hot, regenerated, alkaline scrubbing solution. The gas flows to the saturator 4 through conduit 31 contains 300 ppm H 2 S. In the saturator 4, the gas is reheated to 149°C. by hot circulating water, which is at 151°C. and supplied from conduit 22 and flows in a countercurrent to the gas. By this treatment, the gas is correspondingly saturated with water vapor, and the circulated water is recooled to 115°C. At this temperature, the circulated water flows back through the conduit 20 to the cooler 1, whereas the water-vapor containing gas which has been desulfurized but is still hot is supplied through the conduit 32 to the gas turbine process.
The scrubbing solution drained from the absorber 3 is supplied through the conduit 33 and the valve 34 with a pressure relief into the regenerator 2, which is operated under a pressure of 1.1 kilograms per square centimeter (at the top) and at a sump temperature of 106°C. The regenerator is filled with 190 cubic meters of packing. The rising steam formed in the reboiler 6 from the solution regenerates the solution to such a degree that it can desulfurize the gas in the absorber 3 to a residual H 2 S content of 300 ppm. This will be possible if the solution has a residual content of 0.8 standard cubic meter H 2 S per cubic meter of the solution, provided that the bicarbonate content is at least 1.25 kilogram-molecules per cubic meter. This regenerated solution also contains 1.02 kilogram-molecules K 2 CO 3 per cubic meter and 0.25 kilogram-molecule borax (Na 2 B 4 O 7 .1 OH 2 O) per cubic meter. The solution at 107°C. is supplied at 500 cubic meters per hour by the pump 13 through the conduit 35 to the absorber 3, which contains 110 cubic meters of packing and in which the solution flows in a counter-current to the gas, from which it absorbs H 2 S at a rate of 1750 standard cubic meters per hour and CO 2 at a rate of 9450 standard cubic meters per hour. The solution leaves the tower at 115°C. through conduit 33 and returns to the regenerator 2. Before the pressure relief, the solution now contains 4.3 standard cubic meters H 2 S per cubic meter as 0.19 kilogram-molecule KHS per cubic meter, also 2.95 Kilogram-molecules KHCO 3 per cubic meter, 0.08 kilogram-molecles K 2 CO 3 per cubic meter and 0.25 kilogram-molecule borax per cubic meter. The pressure relief in the valve 34 results in a cooling so that part of the combined H 2 S and CO 2 are released. To assist the stripping of H 2 S, the reheater 10 in the conduit 33 may be used to reheat the pressure-relieved solution. H 2 S, CO 2 and water vapor escape from the top of the regenerator 2 through the valve 36 and the conduit 37. The stripping gas is cooled in the cooler 9 and condensate is removed from the gas in the trap 11. The H 2 S-containing gas is supplied in conduit 38 to a plant for utilization, e.g., to a Claus plant for a recovery of sulfur. The condensate from the trap 11 is recycled by the pump 17 through the conduit 39 to the regenerator.
Under certain circumstances it may be suitable to operate the regenerator 2 under a slight superatmospheric pressure, e.g., of 2 kilograms per square centimeter (absolute pressure) so that the temperature of the regenerated solution and also the temperature in the scrubbbing tower 3 are increased, e.g., to 115°C. This may be accomplished by a suitable setting of the valve 36.
EXAMPLE 2
A gas is produced by the gasification of residue oil with oxygen and steam at a rate of 18,000 standard cubic meters per hour and in a plant as shown in the drawing is pretreated as described in Example 1. At a temperature of 105°C. and under a pressure of 20 kilograms per square centimeter (absolute pressure) the gas which is saturated with water vapor enters the absorber 3 through the conduit 30. On a dry basis, the gas has the following composition under standard conditions:
CO 46.6% volumeH.sub.2 46.6% volumeCO.sub.2 5.0% volumeH.sub.2 S 0.15% volumeCOS 0.001% volumeCH.sub.4 +N.sub.2 +Ar 1.88% volume.
The gas is to be deslfurized to a sulfur content not in excess of 100 ppm by volume. For this purpose, the gas is scrubbed in the absorber 3 with 1.85 cubic meters of scrubbing solution per standard cubic meter of H 2 S, which corresponds to a rate of 50 cubic meters of solution per hour. The regenerated solution enters the absorber at 107°C. through conduit 35 and contains 1.00 kilogram-molecule K 2 CO 3 per cubic meter, 1.25 kilogram-molecules KHCO 3 per cubic meter, 0.25 kilogram-molecule borax per cubic meter, and 0.3 standard cubic meter H 2 S per cubic meter as KHS. Under these conditions, a scrubbed gas is obtained which contains 80 ppm H 2 S and 2 ppm COS whereas the solution takes up 25.6 standard cubic meters H 2 S per hour and 700 standard cubic meters CO 2 per hour, which are stripped off in the regenerator 2. | Gases produced by reacting fuels with oxygen containing gases and water vapor under pressure are desulfurized by scrubbing with a concentrated solution of one or more alkali salts of weak inorganic acids at a temperature near the atmospheric-pressure boiling point of the solution in a column while maintaining an exchange ratio of from 0.2 to 2.0 cubic meters of the concentrated solution per standard cubic meter hydrogen sulfide in the gas to be purified. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to a device intended for the analysis and for the reading of an optical signal of the type which can be analysed as at least one fundamental wave train associated with a set of secondary wave trains, which emanate from said fundamental train and which exhibit a set of corresponding delays in relation to said fundamental wave train.
The general principle of reading information comprises delaying a reference signal, namely, for example, the fundamental wave train, in order to cause an interference of said reference signal with the signals containing the information to be analysed, namely, for example, each one of said secondary wave trains.
Said information to be analysed may be, for example, the distance between the wave trains or alternatively the amplitude of the secondary wave trains.
This type of signal is, for example, obtained at the exit of a monomode fiber with maintenance of polarization, which is associated with a linearly polarized source 11 of broad spectrum (or a source emitting a beam which is linearly polarized outside the source), the fiber comprising points of coupling 12 between the two birefringent axes (FIG. 1). The optical sensor per se is constituted by the fiber section comprising the points of coupling 12, and may be either intrinsic (that is to say the fiber itself) or extrinsic (in the form of an external element).
The points of coupling 12 are, for example, constituted by the introduction of a slight shift in rotation of the axes of birefringence within the fibre, at each point c 1 , c 2 , . . . c n . Each one of these shifts, which are, in general, small in order to avoid multiple couplings, introduces a perturbation of the polarized fundamental wave train 13 emitted by the source 11. Each perturbation thus generates a secondary wave train 15 in polarization orthogonal in relation to the fundamental wave train 13-14. In other words, assuming the entrance wave train 13 coupled in the fast mode, there is recovered at the exit:
a fundamental wave train TO f 13, which has remained in the fast mode, and of amplitude e f -; and
a series of secondary wave trains TO i 15, which are coupled in the slow mode, and of amplitude e i .
It is then possible to project all the wave trains 14-15 in the same state of polarization, by means, for example, of a polarizer at 45° on the axes of birefringence.
Such a sensor with multiple points of coupling 12 may, for example, be used as continuous temperature probe, by utilizing the heat-sensitive properties of the propagation velocity differential between the two axes of birefringence of the optical fiber. In this case, the analysis and the reading of the signal received from the sensor consists in measuring the effective delay of each secondary wave train 15 in relation to the exit fundamental wave train 14. In a known manner, such a reading is undertaken by retarding the fundamental signal in the reading device, until detection of its interference with each one of the secondary wave trains. The value of the delay which is read permits the calculation of the temperature, after calibration of the device.
In a known manner, the means which is simplest (at least conceptually) for performing such a reading consists in using a Michelson interferometer which can be scanned, in order to induce the delay which is necessary in order that the fundamental wave train should be able to interfere with the wave trains TO i .
However, if consideration is given to a sensor comprising 100 points of coupling which are distributed with an interval of 10 m between each coupling and a fiber the birefringence of which is 5·10 -4 , the scanning of the interferometer must be 50 cm. Having regard to the necessary mechanical precision, such a scanning range involves a relatively low reading frequency and a limited flexibility of use: the reading can be only with sequential access (wave train N1, then N2, then N3 etc . . . ).
A second method which is suitable for this type of device would consist in processing the various wave trains in parallel (FIG. 2a). However, in this case, the number of detectors must be of the order of the number of couplings. In order to alleviate this disadvantage, it is possible to use active couplers. In this case again, the number of couplers must be of the order of the number of points of couplings (typically approximately 100), irrespective of the parallel or series structure adopted.
Furthermore, the series structure (FIG. 2b) exhibits the disadvantage of attenuating (on account of the repeated passages within the couplers which are switchable if, for example, they are of integrated-optics type) the secondary wave trains TO i ; this accordingly degrades the signal-to-noise ratio.
SUMMARY OF THE INVENTION
The object of the device according to the invention is to alleviate these various disadvantages.
More specifically, a first object of the invention is to provide a device for reading by optical sensor coherence, which performs a processing of the signal to be analysed without degrading the signal-to-noise ratio.
Reading by coherence is taken to refer essentially to the principle consisting in causing the interference of the fundamental and secondary wave trains.
A second object of the invention is to provide such a reading device which ensures, on the one hand, a fast scanning of the entire admissible delay range, while still permitting a supplementary fine scanning ensuring an accurate placing in interference and thus an accurate reading of the delays.
Another object of the invention, in a specific embodiment, is to provide a reading device permitting a simultaneous and parallel reading of the various delays of all the secondary wave trains originating from the optical sensor.
These objects, as well as others which will become evident hereinbelow, are achieved by means of a device for reading by optical sensor coherence, of the type supplying a signal to be processed which can be analysed as at least one fundamental wave train associated with a set of secondary wave trains which emanate from said fundamental wave train and exhibiting a set of corresponding delays in relation to said fundamental wave train, said device being intended to bring said fundamental wave train into interference with each one of said secondary wave trains,
characterized in that it comprises an interferometer, a first branch of which is traversed by at least said fundamental wave train, and a second branch of which is traversed by at least said secondary wave train,
and in that said first branch with a delay is equipped, on the one hand, with means for the generation of quantified delays of said fundamental wave train, and, on the other hand, with means for the generation of a delay which is continuously variable over a range about each quantified delay value.
The interferometer may be a Mach Zehnder or Michelson interferometer, or any other type of interferometer.
Such a device exhibits the advantage that the signal-to-noise ratio is only very slightly degraded on account of the fact that the asymmetric structure of the interferometer, for example a Mach Zehnder interferometer, involves the attenuation of only the amplitude of the fundamental wave train, which alone constitutes the useful signal traversing the delay branch of the interferometer. The "useful" secondary wave trains, which come into interference with the delayed fundamental wave train, do themselves traverse the branch of the interferometer which includes no optical elements.
In an advantageous embodiment of the invention, the means for the generation of quantified delays are constituted by a set of elementary delay lines, which are placed in series on said delay branch of the interferometer, each one of said means for the generation of quantified delays being selectively switchable into said branch in such a manner as to supply a combination of quantified values of delays by combination of the elementary lines which are simultaneously and selectively switched.
In another embodiment, said means for the generation of quantified delays are associated with means for the frequency shifting of the delayed signal, in such a manner that each delay value corresponds to a specific frequency shift. Said means for the generation of quantified delays are preferably constituted by a set of elementary delay lines which are consecutive and each coupled in parallel to said delay branch of the interferometer, in such a manner as to supply simultaneously a combination of quantified values of delays, which values are each associated with a specific frequency shift, by linear combination of the optical paths followed by the delayed signal.
In both embodiments, it is advantageous to use elementary delay lines exhibiting delay values which are distributed in accordance with a geometric progression. This permits, for example, the generation of 2 n delays from n basic delays, by considering the linear combinations of these n basic delays.
In a variant of construction of the second embodiment, the means of the generation of the quantified delays are constituted by a delay and frequency-shift line coupled in parallel and in feedback to said delay branch of the interferometer.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will become evident on reading the description, which follows, of certain embodiments of the invention, which are given by way of illustration, and the accompanying drawings, in which:
FIG. 1 diagrammatically represents the configuration of an optical sensor with multiplexing by coherence, of the type associated with the reading device according to the invention;
FIGS. 2a and 2b illustrate two structures which are possible, but unfavourable, of parallel and serial processing respectively of the set of secondary wave trains of the signal analysed;
FIG. 3 diagrammatically represents the first embodiment of the reading device according to the invention, with elementary delay lines which are selectively switchable;
FIGS. 4 and 5 are diagrams illustrating a variant of application of the reading device according to the invention to optical signals incorporating a plurality of fundamental wave trains, permitting either the limitation of the number of active elements or the range of exploration respectively;
FIG. 6 diagrammatically represents a second embodiment of the reading device according to the invention, with elementary delay and frequency-shift lines which are coupled consecutively, in parallel, on the delay branch of the Mach Zehnder interferometer;
FIG. 7 is a diagram illustrating the operation of the embodiment of FIG. 6;
FIG. 8 illustrates a variant of the embodiment of FIG. 6, with a single elementary delay line, which is coupled in parallel and in rear feedback on the delay branch of the Mach Zehnder interferometer;
FIG. 9 illustrates a second variant of the embodiment of FIG. 6, with separators of minimum loss; and
FIG. 10 illustrates a construction of the reading device of the invention in the form of a Michelson interferometer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As represented in FIG. 3, the reading device according to the invention comprises an interferometer, in the present case a Mach Zehnder interferometer, of which:
the first arm 31 contains the signal to be analysed,
the second arm 32 generates delays, in a discrete manner, on the referenced signal, in order to permit interference with the various signals to be analysed.
The source signal to be analysed 33 is divided between the two arms 31, 32 of the Mach Zehnder interferometer by means of a separator 34. An optical component 35 is mounted at the exit of the two arms 31-32, in order to superimpose the secondary wave trains to be analysed as well as the delayed fundamental wave train, towards the detector system 36.
The delay arm 32 comprises elementary delay lines 37, which are selectively switchable into the arm. Switching means 38 ensure selectively, for each elementary delay line 37, either the orientation of the signal in the elementary line or its shunting. These switching means 38 may be, for example, constituted by liquid crystal switches, or preferably integrated optical switches as described in the document: "L'optique guidee monomode et ses applications", [The monomode guided optical system and its applications], published in 1985 at Editions Masson. Any switching means providing the corresponding function is equally appropriate.
In an advantageous manner, the elementary delay lines 37 are distributed in accordance with a geometric progression of the delays.
By way of example, in the case where the delays of the various secondary wave trains are integral multiples of an elementary delay, which corresponds to the case where all the sensors measure the same signal, the succession of the delays to be induced is: t1=t; t2=2t; t3=4; . . . ; tn=2 n-1 t.
With such a distribution of the delay values of the elementary lines 37, it is thus possible to generate 2 n delays from n lines 37 in accordance with the following operating pattern:
______________________________________Delays activated Total delay______________________________________none Ot1 tt2 2tt1 + t2 3tt3 4t______________________________________
Once the principal delays have been induced, it is sufficient to arrange in series (inside or outside the arms) a means for the generation of a variable delay 39 in order to explore a continuous range about the principal delays, which are, by construction, of discrete nature. In order to limit this range of exploration, supplementary discrete delays may be added to the system.
This solution has the merit of limiting the number of optical switches 38 which are necessary (typically of the order of the logarithm of the number of couplings); which gives minimum attenuation of the signal to be analysed, while still permitting a fast exploration of the various couplings in any a priori order.
FIG. 6 corresponds to a second embodiment of the reading device according to the invention, in which the delays of the fundamental wave train are generated by elementary delay lines 67 which are each associated with means (68) for the frequency shifting of the delayed signal. In this manner, each delay t is accompanied by a specific frequency shift df of the delayed signal. Each one of the elementary delay lines 67 is coupled in parallel, by means of optical separators 69, on the delay branch 32 of the Mach Zehnder interferometer.
The frequency shifting means 68 are, for example, constituted by a retarder utilizing the Doppler effect or utilizing an acousto-optical crystal, or again by a thermo-optical and/or electro-optical or other phase modulator.
This embodiment permits the performance of a parallel reading of the delays of each one of the secondary wave trains by virtue of a frequency multiplexing of the various delays.
Thus, for the delay t1, the frequency shift must be df; for t2, 2df; for t3, 3df; etc. . . . In this manner, the frequency shift will be different for each one of the linear combinations of the basic delays.
At the exit of the interferometer there will then be wave trains such as represented in FIG. 7:
the secondary wave trains TO i , originating from the branch 31 of the interferometer, and maintained at the optical frequency f;
the delayed fundamental wave trains TO fi , which have undergone the various delays, as well as the corresponding frequency shifts.
Each interference pair (TO i , TO fi ) is therefore at a specific shifted frequency (i-1) df. An analysis in Fourier series therefore permits the demultiplexing of the various interferences.
In the particular case where the succession of the delays being induced is the following: t, 2t, 3t, 4t, etc . . . , the following table illustrates the combinations of elementary delay lines permitting the obtaining of each one of the quantified delays 0, t, 2t, 3t, 4t, etc, and the corresponding frequency shifts df, 2 df, 3 df, 4 df, . . .
______________________________________Activated delays Total delay Frequency shift______________________________________0 O Ot1 t dft2 2t 2dft1 + t2 3t 3dft3 4t 4df______________________________________
FIG. 8 illustrates a compact version of the embodiment with quantified delay and frequency shift. In this embodiment, a single elementary delay line 87 is connected in parallel and in rear feedback to the delay branch 32 of the interferometer. A frequency shift df 88 is generated at each traverse of the line 87.
In the embodiment of FIG. 9, the elementary delay lines 87 are connected to the separating means 90 having two inputs and two outputs, permitting the ensuring of a minimum loss, and thus an optimal energy balance in the delay branch 32.
In a variant of the embodiment of FIG. 3, it may be beneficial to replace the whole or part of the switches 38 by passive couplers, for example 50/50 separators, ensuring a division of the signal between the delay branch 32 and the elementary delay lines 37. The use of a plurality of passive couplers permits the multiplication of the number of fundamental wave trains, since a plurality of elementary delay lines 37 operate simultaneously. If the delay between these wave trains is different from the delays which separate the wave trains due to the couplings (TO i ), the measurement remains possible.
This option may be adapted for two different objectives:
to limit the number of active elements. In this case, the principle of operation is illustrated in FIG. 4, for four fundamental wave trains. The reading is then undertaken in the manner of a vernier, by bringing each one of the secondary wave trains TO i into interference with the closest fundamental wave train. Thus, the reading of TO i-1 is carried out by causing this wave train to interfere with TO f1 , the other wave trains (TO f2 , TO f3 , TO f4 ) not being in coincidence with the wave trains TOi and so on.
to limit the range of exploration, as illustrated in FIG. 5. This embodiment assumes that the delay branch 32 of the interferometer of FIG. 3 is equipped, on the one hand, with elementary delay lines incorporating passive couplers (for the generation of a plurality of fundamental wave trains) and, on the other hand, with elementary delay lines incorporating switches (for the fast scanning, by discrete delays, of the entire reading field). Thus, the TO fi values may be of differing amplitude, in order to discern with what wave train TO i interferes.
The reading device according to the invention is particularly attractive on account of the fiber sensors, by reason of the possibility of constructing it as "all fiber":
the switches may be of the "integrated optics" type and/or liquid dielectric switches as described in the French Patent Application 8310914 ("electrically controllable device for displacement of fluid");
the frequency shifting systems of the second embodiment of FIG. 6 may be constituted by phase modulators, of piezo-optical, acousto-optical or integrated-optics type;
the means for the generation of a variable delay 39 may be constructed, for example, in the form of a fiber surrounded by a conductive sheath. By causing a current to circulate within the sheath, it is thus possible to heat the fiber and to cause the optical path thereof to vary (see "Optical Fiber Thermal Modulator", Lightwave Technology; Vol. LT-5 nx 9, September 1987). Another possibility consists in using an optical fibre wound on a piezoelectric ceramic, in such a manner that on the application of a voltage to the ceramic its diameter varies and gives rise to the variation of the length of the fiber and thus of the optical path.
FIG. 10 illustrates an embodiment of the device of the invention utilizing an interferometer operating in accordance with the Michelson principle. In this embodiment, the optical signal is deflected, at the end of each one of the two branches 31, 32, by two mirrors 95 and 96. The relected signals are then placed in coincidence at the exit on the separator plate 34, and passed to a detector 97.
It will be noted that the invention is not limited to the utilization of the Mach Zehnder or Michelson interferometer, but extends to any other type of compatible interferometer. | A reading device operates by the placing in interference of a reference signal, in the form of a fundamental wave train, with delayed wave trains constituting the useful signal. The device comprises an interferometer, a first branch (32) of which is traversed by at least said fundamental wave train (14), the first branch (32) being equipped, with means (37, 67, 87) for the generation of quantified delays of said fundamental wave train (14) with means (39) for the generation of a continuously variable delay of said fundamental wave train (14) over a range about each quantified delay value. | 8 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
FIELD OF THE INVENTION
The present invention relates generally to marine minesweepers and in particular is variable water displacement hull-like segmented structure, which when moved along a course within the range of pressure influence mines, effects a pressure signature that simulates that of a ship to the extent that it causes said pressure influence mines to be detonated, thereby causing said mine to effectively be swept. The sweeping thereof, of course, provides for safe passage for the real ships being simulated thereby. In even greater particularity, the subject invention constitutes a new and unique combination of watertight variable ballast hull segments and magnetic minesweeping apparatus which may be employed simultaneously to effectively clear both pressure and magnetically responsive mines from rivers, bays, estuaries, lakes, seas, oceans, or any other marine environments.
DESCRIPTION OF THE PRIOR ART
Heretofore, air cushion vehicles, wooden ships towing sweep gear, marine vehicles employing underwater pontoons, towed water inflated bags, and the like have been employed in an attempt to simulate actual ship water pressure signatures sufficiently to effect detonation of pressure responsive marine mines. Also, numerous simulated ship hulls having various and sundry flotation apparatus connected thereto and perhaps filled or partially filled with ballast water have been so employed, too. The usual operational procedure used with respect to the aforesaid prior art devices is to tow, push, or drive them along a predetermined channel where it is desired that marine mines be neutralized, so that they will be mistaken for real ships and thereby cause said marine mines to explode in response thereto. For some purposes, the aforesaid prior art devices are quite satisfactory; however, in most instances they leave a great deal to be desired. For example, the hull size is usually limited and, thus, the scope of minesweeping operations is severely limited. Moreover, such hulls and such minesweeping gear could be sunk and, thus, block ship channels intended to be swept or become caught or fouled on other underwater objects, respectively. All are exceedingly difficult to handle and manipulate, navigate, and operate as necessary to be effective. The cost in both time and money is considerable, and usually people with a considerable degree of expertise in such operations are required if any minesweeping of value is to be accomplished.
SUMMARY OF THE INVENTION
The present invention is, in many instances, an improvement over the known prior art devices, in that it overcomes many of the disadvantages thereof. Briefly, it consists of an artificial decoy ship-type vessel which lends itself to being configured to provide simulated ship pressure signature of considerable scope, thereby enabling it to effect the detonation or neutralization of many different types of pressure responsive marine mines. It is constructed of any desired number -- the number depending on the ship signature to be simulated -- of lightweight plastic center sections that are easily connected together in tandem combined with substantially streamlined fore and aft bow and stern sections of substantially ship-like configurations. Said sections are connected together in a unique manner which facilitates the assembly thereof, as well as the repair thereof in the event one or more becomes damaged by mine explosions. Any or all of said sections may contain compartments which are open at the top, within which predetermined water ballast may be disposed, so as to effect the simulation of some particular displacement ship of the type intended to be protected by minesweeping operations.
In order to make the subject mine sweeping device even more versatile, provision may also be made to achieve magnetic mine sweeping operations at the same time pressure mine sweeping operations are accomplished. This may be done very simply by attaching a coil of wire to the assembled fore, center, and aft plastic sections in such manner that it extends around the entire assembled hull simulator at some position near the submerged bottom thereof and then electrically exciting said coil by means of a programmed electric generator.
From the foregoing brief description, it may readily be seen that, compared to most prior art devices, the instant invention is simpler, more versatile, less vulnerable to mine explosion damage, and cheaper to manufacture, operate and maintain, and, accordingly, constitutes an improvement thereover.
It is, therefore, an object of this invention to provide an improved marine minesweeper.
Another object of this invention is to provide an improved method and means for detonating pressure responsive marine mines.
Still another object of this invention is to provide an improved method and means for detonating magnetic responsive marine mines.
A further object of this invention is to provide an improved method and means for simultaneously sweeping pressure responsive, acoustic responsive, and magnetic responsive marine mines along a predetermined course.
Another object of this invention is to provide an improved method of constructing a ship, a ship simulator, or a ship-like decoy.
Still another object of this invention is to provide an improved method and means for simulating the underwater pressure signatures of many different ships and other marine or submarine vehicles.
A further object of this invention is to provide a minesweeper that is less vulnerable to mine explosions than most of the prior art devices.
Another object of this invention is to provide a marine minesweeping device that is easily and economically manufactured, transported, operated, and maintained.
Other objects and many of the attendant advantages will be readily appreciated as the subject invention becomes better understood by reference to the following detailed description, when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a quasi-pictorial view of the subject invention;
FIG. 2 is a perspective view of an intermediate hull section of the device of FIG. 1;
FIG. 3 is a perspective view of another intermediate hull section of the device of FIG. 1;
FIG. 4 is a cross-sectional view of the center portion of an intermediate hull section of the device of FIG. 1;
FIG. 5 is a schematic pictorial view with parts broken away of two adjacent hull sections of the device of FIG. 1;
FIG. 6 is a schematic diagram of a section taken along A--A of the view of FIG. 5;
FIG. 7 is a combination elevational-cross-sectional view of one of the many fasteners incorporated in the subject invention to hold the hull sections thereof together in watertight fashion;
FIG. 8 is an end of the invention, particularly depicting the electromagnetic energy generated thereby;
FIG. 9 is a top view of FIG. 8, showing the mounting arrangement of the electromagnetic generator system thereof; and
FIG. 10 is a schematic pictorial view of the subject invention and the operational effects thereof in a marine environment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown a water displacement type hull 11, which includes a front and bow section 12, a rear end stern section 13, and a plurality of intermediate ballast storing sections 14, the latter of which may be designed as necessary to carry whatever cargo or ballast or other materials are desired. The aforementioned bow and stern sections 12 and 13 are preferably pointedly configured in a ship-like manner, so that they will be sufficiently streamlined for the hull to be moved through sea water or the like with minimum power required therefor. Minesweeping hull 11, of course, contains a suitable propulsion and steering system, which, for example, may take the form of a simple outboard motor arrangement 15 shown as being mounted on the aforesaid stern section 13. Each of the aforementioned plurality of intermediate hull sections 14 are respectively connected to adjacent ones thereof in a unique manner which provides a secure fastening between each thereof, so as to maintain the overall hull configuration. The method and means for effecting the fastening thereof is considered to be unique and, therefore, will be disclosed in greater detail subsequently.
The use to which this particular ship hull is put would determine the type of material of which it is made; however, in this particular instance since the subject invention is primarily intended to be a marine minesweeper all of hull sections 12, 13, and 14 are preferably made of a nonmagnetic material, such as, for instance, a foam plastic material which has been molded into the desired hull shape. Mounted on hull 11 is an electrical generator 16 which, as will be more fully discussed below, provides electrical energy via electrical conductor 17 which extend around the lower portion of hull 11 in such manner as, when electrically energized, produces an electromagnetic field thereabout.
The aforementioned intermediate hull sections 14, as previously suggested, are designed to carry water ballast, cargo ballast, or any other suitable ballast materials and, hence, may be designed in whatever manner would be optimum therefor. Furthermore, such intermediate sections may contain inner compartments and covered loading and unloading hatches 18, as required.
FIG. 2 is a representative embodiment of one of the aforesaid intermediate hull sections 14. At the opposite ends thereof are a pair of metallic plates 21 and 22, which include the attachment flanges for attaching adjacent intermediate sections together. Said attachment plates are bonded to a plastic center section 23 which, as previously indicated, is preferably of a molded foam plastic material, which contains closed air bubble cells and is very light in weight, so light in fact, that it would easily float on the surface of water even though the submerged portion thereof contained large holes, such as might be encountered in the event a marine mine is caused to be exploded in proximity thereto.
At this particular time, it would appear to be noteworthy that the size of hull 11 is a matter of design choice, with the selection of the intermediate sections 14 included therein being that number as would produce a hull length that, in turn, when properly ballasted, would stimulate whatever ship signature is believed would cause a marine mine to be exploded thereby. In other words, the design of hull 11 of the entire subject minesweeper should be such that it has a submarine pressure signature that simulates that of an actual ship or other vessel intended to be protected from marine mines.
As seen in FIG. 2, intermediate hull section 14 may be compartmented with several large compartments 24 and 25 having a plurality of small compartments 26 at the bottom thereof. In the event that hull 11 is extremely large, man holes 27 and 28 are located in the deck thereof which enable the human operators to travel down a ladder 29 or the like down to the lower compartment section. Also, the internal section of intermediate hull section 14 is so designed and made as to provide optimum strength characteristics for any given operational circumstances.
In this particular embodiment, end flange plate 22 is shown as having an annular groove 31 extending around the periphery thereof and bolt holes 32, through which fastening bolts will be mounted in the manner discussed more fully below. The intermediate hull section 14 shown in FIG. 3 likewise has a plurality of compartments adapted for storing ballast or other items necessary to the operation of the invention. In this particular arrangement, end flange 21 is shown having the lower portion thereof extending upwardly from the bottom of the hull section, so as to provide a water repelling section to within a given depth, that is dependent upon the amount of ballast used. Also, in this embodiment, an annular groove 34 is shown in the end of said flange plate 21 which is complementary with the annular groove of, say, any other intermediate hull section 14 fastened thereto.
As may be readily seen from the embodiment of intermediate section 14 of hull 11, the hull section shown is divided by a center wall 35 running vertically between the upper deck and the bottom thereof. This wall is, of course, optional, like that shown but not referenced in the section of FIG. 2 (which is also optional).
FIG. 4 discloses a typical cross-section taken through the foam plastic portion of one of the intermediate hull sections 14. Hence, it depicts the aforementioned center vertical wall 35, and, likewise, it shows that the hull section itself has, in this particular arrangement, a pair of cargo spaces 36 and 37 in which ballast materials 38 and 39 are respectively disposed. As a general rule, for minesweeping purposes, said ballast 38 and 39 are water, sea water, or the like. In such instance, the levels thereof within cargo spaces 36 and 37 would most likely be substantially identical; however, in the event different types of ballast materials are employed as ballast 38 and 39, the level of one could be different from the level of the other, say, because the density of one might be different from the density of the other. Obviously, by one skilled in the art having the benefit of the teachings presented herewith would readily be able to make whatever selection of ballast materials as is necessary to effect a desired minesweeping or other pressure signature below the entirety of hull 11. Moreover, it would obviously be well within the purview of the artisan to select the proper ballast and/or cargo compartments and the structures for effecting the desired configurations thereof for any given operational purposes from this disclosure. Therefore, with the exception of the unique hull section attachment means (which will be discussed subsequently), this disclosure is not intended to be limiting in any manner whatsoever but, rather, it is intended to show one preferred representative embodiment of that portion of the invention.
Referring now to FIG. 5, there is shown an exploded view, with parts broken away, of two adjacent sections of hull 11 which more readily disclose annular groove 41, which is comparable to the aforementioned annular groove 34 of the structure of FIG. 3, and the elastic sealer, such as an O-ring 42 or the like, inserted therein. Interflange plate 43 is connected in any suitable manner -- as by bonding or the like -- to the plastic foam section 44. Also shown is a representation of typical means for fastening the two disclosed hull sections together in such manner that they will form a watertight joint thereat. For this purpose, a plurality of bolts 45 are illustrated schematically which will extend through mating holes in the flange plate of the other intermediate hull section (not shown).
FIG. 6 is also a view of a typical fastening means that is shown as section A--A which is taken along section A--A of FIG. 5. Hence, it may be seen that bolts 45 extend through flange 43 and would extend through mating holes 46 if sections 47 and 48 are placed in abutment configuration with O-ring 42 inserted within peripheral grooves 41 and 49, respectively, of those end plates of hull sections herewith defined as being sections 47 and 48, but which may, in fact, be either of bow and stern sections 12 and 13, as well as intermediate section 14 of the hull of the subject minesweeper, as it is depicted in FIG. 1.
An exceedingly important aspect of the instant invention is the particular means that is used for fastening the hull sections together in such manner that they will be secure and waterproof. For the purpose of describing an imminently suitable device for effecting such fastening means, various and sundry reference numerals previously employed were also used in the structure of FIG. 7 for purposes of clarity. With this in mind, FIG. 7 discloses end plates or end frames 21 and 22 which are the respective end frames of say the aforementioned intermediate hull section embodiment of FIGS. 2 and 3. As a result, said frames are intended to be attached in abutment with each other in such manner that a resilient O-ring 51 of rubber, neoprene, or the like, is compressed therebetween in grooves 34 and 35 thereof for fluid sealing purposes. When so structured, of course, as depicted in FIG. 7, the lower ends of frames 21 and 22 constitute those portions thereof that are in proximity with the outer surface thereof (not shown).
A metallic cup 52 having an end flange 53 is attached as by welding 54 or any other suitable attachment means to frame 21. Disposed within said cup 52 is a resilient membrane or plug 55 which is attached to the inner surface of said cup 52 in a secure manner. Although any securing means may be employed for such purpose, the inside configuration of cup 52 may be such that it has one or more inner extensions 56 having shoulders 57 which effectively prevent the movement of membrane 55 out of cup 52 when relative forces are applied thereto. A suitable bolt 58 is molded within resilient membrane 55 so that it, too, is securely mounted therein in such manner that, due to the resilience of membrane 55, relative movement may occur therebetween without breaking apart, even though considerable forces are respectively applied thereto. A pair of holes 61 are respectively located in plates 21 and 22 in alignment with each other and in alignment with the inside diameter of the aforementioned cup 52. Disposed therein is a metallic plug 63 having an end flange 64 and a tapered end 65, the former of which is intended to be in abutment with the surface of plate 22, and the latter of which is intended to be extended through hole 61 and 62 to the extent that it is in abutment with the aforesaid resilient member 55. Bolt 58, of course, has threads 66 over which is mounted a lock washer 67, and on which is screwed a suitable complementary nut 68.
When assembled as shown in FIG. 7, the combination of disclosed elements thereof, in actuality, becomes a new and unique method and means 69 for fastening any two objects together in such manner that there is some flexibility therebetween but, yet, is sufficiently rigid to constitute a very secure fastening thereof. In addition, in the event grooves similar to the aforesaid grooves 34 and 35 and a resilient sealer such as the aforementioned O-ring 51 is incorporated therein as shown, a fluid tight seal is effected thereat. Accordingly, the fastening means of FIG. 7 appears to constitute a new and unique device which is highly effective in securely attaching the various and sundry hull sections of the subject minesweeper 11. Hence, it may readily be seen, that the structure of FIG. 7 is a specific and detailed structural assembly which is equivalent of the symbolically represented fastener assembly depicted in FIG. 6. Consequently, it is imminently satisfactory for the purpose of effecting the assembly of the particular sections of hull 11.
In order to be a more effective marine minesweeper -- that is, in order to provide an improved method and means of simultaneously sweeping pressure responsive, acoustic responsive, and electromagnetic responsive marine mines -- the hull of minesweeper 11 contains the aforementioned electrical generator 16 which supplies electrical energy to insulated electrical wires 17, the latter of which extend around the periphery of the hull at some suitable location below the water line thereof. Such arrangement is illustrated schematically in FIGS. 8 and 9, wherein the reference numerals for the various parts thereof are respectively similar to those used for like parts in the aforementioned FIG. 1.
By referring to FIG. 8, it may be seen that the aforesaid electrical motor generator 16 is mounted on the top deck of hull 11 and electrical wires 17 extend down along the side thereof and then around the bottom of the hull thereof in such manner as when electrically energized produces electromagnetic fields 71.
FIG. 9, of course, is a top view of the device of FIG. 8 and, thus, illustrates how electrical wires 17 are disposed around the hull of ship 11 so that an electromagnetic field will be generated thereby when they are electrically energized. Of course, being only a schematic embodiment, the mounting means for said motor generator 16 and wires 17 may be any that are conventional and that will be suitable for such mounting purposes.
Referring now to FIG. 10 there is schematically shown a representative operational embodiment of the subject invention combined with its typical ambient environment. Also shown therein is some of the physical phenomena which are effected thereby and some of the particular devices that are, in turn, effected by said physical phenomena. Hence, minesweeper 11 which is constructed as previously disclosed in FIGS. 1 through 9 is shown as being driven through water 72 and along a course therein having say a magnetically responsive marine mine 73 laying on or partially submerged in the sea floor 74 and, perhaps, a pressure responsive marine mine 75 likewise laying on or submerged in said sea floor 74.
For reasons which will become obvious during the discussion of the operation of the subject invention, a typical underwater pressure signature 76 is graphically portrayed under minesweeper 11, so as to show how the subject invention is effective in detonating pressure responsive marine mines. Furthermore, the aforementioned electromagnetic field 71 are likewise shown symbolically in FIG. 10, in order to disclose how they are transmitted or broadcast toward magnetically responsive marine mines, so as to effect the detonation thereof.
MODE OF OPERATION
In the art of marine minesweeping, it has been determined that it is exceedingly difficult to safely sweep, neutralize, or detonate marine mines which have been deployed and activated in such bodies of water as oceans, bays, estuaries, rivers, lakes, and the like. Therefore, it becomes exceedingly important to be able to sweep enemy mines during military operations and even our own mines when said military operations cease without involving extremely hazardous duty for those concerned and without necessitating the use of complex, expensive ship or ship-like structures which could be destroyed by the very mines which they are trying to sweep. Accordingly, the more simple and economical substitute for such minesweeping ships has been implemented by means of this invention and has been done so in a manner which is considerably more effective under some circumstances.
During actual minesweeping operations, as may be seen best in FIG. 10, hull 11 is driven through water 72 by means of motor 15. Of course, as would be obvious to any one skilled in the art, hull 11 may be steered either by human or remote control, depending upon the particular situation involved. As minesweeping hull 11 is navigated along its predetermined course, due to the fact that it contains ballast 38 and ballast 39 it sinks to some particular draft depth, and, thus, generates pressure within the water below it in a manner somewhat similar to that depicted graphically by pressure signature curve 76. Of course, when the pressures thereof, the varying pressures thereof, or the relatively lack of pressures thereof, come in contact with the pressure responsive marine mine 75, due to its initial programming, it senses said pressures and interprets them as being produced by a real ship. As a result, it explodes as if it were destroying a real ship. However, due to the unique construction of hull 11, the explosion thereof does not ordinarily cause hull 11 to sink or even be damaged sufficiently to be put out of operation. This is primarily due to the fact that hull 11 is constructed of a plurality of plastic foam sections, each of which contain a large plurality of cellular trapped air bubbles within the plastic foam portions thereof. Hence, even if a hole is blown in the bottom of hull 11 within one or even several of the sections thereof, the buoyancy of hull 11 is still sufficient to enable it to float on water 72. In addition, in the event only a few of the, say, intermediate sections of hull 11 are damaged, they may be readily replaced in dry dock merely by the unfastening thereof and the substituting of new ones therefor. Due to the simplicity of this particular inventive concept, it is entirely possible that such minesweeping ship repair could be effected at or near the site of operations without too much difficulty, expense, or ancillary equipment needed therefor. Also, damaged hull sections requiring replacement can be removed and replacements therefor installed on station without the use of drydocking facilities. This can be accomplished by the proper ballasting and de-ballasting of the sections to be assembled together, with the fayings surfaces being drawn together by the securing bolts and tapered inserts. Accordingly, this increases the utility of the subject invention to a considerable extent over that which might occur with respect to the minesweepers of the prior art.
While minesweeping hull 11 is traversing its minesweeping course, it also generates and broadcasts electromagnetic energy 71 which impacts upon magnetically responsive marine mine 73 and causes it to detonate. Like the detonation of mine 75, the detonation of mine 73 may or may not damage the sections of hull 11; however, it has been found that, even though damaged, the damage thereto is usually not severe enough to put hull 11 out of commission, as far as minesweeping and cargo carrying operations are concerned.
At this time, it may also be noteworthy that although the subject invention is primarily intended as being an improved method and means of sweeping, detonating, neutralizing, and the like of marine mines, it has other utility, too. For example, due to its relative indestructability, under some circumstances it will facilitate the carrying of cargo within its ballast compartments over waters that have been mined in such manner as would otherwise destroy conventional boats or ships. Hence, it should be understood that the utility of the subject invention is not intended to be limited to minesweeping alone.
Moreover, as an adjunct to this invention, it would appear to be noteworthy that all inherent noises made thereby -- such as engine noise, propeller noise, towing noise, and the like -- tends to broaden the spectrum of signals which would contribute to the destruction of marine mines. Hence, when employed in conjunction with the aforementioned pressure and electromagnetic signatures, a composite minesweeping signature is effected.
In view of the foregoing, it may also be seen that the subject invention constitutes a new and unique hull assembly which constitutes an improvement over the various and sundry types of hull assemblies incorporated in various and sundry boats, ships, and other water vehicles, and especially in marine minesweepers.
Obviously, other embodiments and modifications of the subject invention will readily come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing description and the drawings. It is, therefore, to be understood that this invention is not to be limited thereto and that said modifications and embodiments are intended to be included within the scope of the appended claims. | A simulated marine vehicle is disclosed as being a sweeper of acoustic, psure, and magnetic energy responsive mines. It includes an exceedingly lightweight, substantially unsinkable hull composed of a plurality of air foam plastic compartments tandemly connected by means of unique fasteners, with a resilient fluid tight sealant therebetween. A suitable ballast material is disposed in the compartments of said hull, an insulated electromagnetic energy generating wire is mounted around said hull, and a motor-generator is mounted on said hull for timely effecting the electrical excitation of said wire. | 1 |
CROSS REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a continuation of International Patent Application No. PCT/EP2009/051518, filed on Feb. 10, 2009, which claims priority to Swiss Application No. CH 00246/08, filed Feb. 20, 2008. The entire disclosure of both applications is incorporated by reference herein.
FIELD
[0002] The present invention relates to the field of thermal machines.
BACKGROUND
[0003] Modern industrial gas turbines (IGT) as a rule are designed with annular combustors. In most cases, smaller IGTs are constructed with so-called “can-annular combustors”. In the case of an IGT with annular combustor, the combustion chamber is delimited by the side walls and also by the inlet and outlet planes of the hot gas. Such a gas turbine originates from FIGS. 1 and 2 . The gas turbine 10 which is shown in detail in FIGS. 1 and 2 has a turbine casing 11 in which a rotor 12 which rotates around an axis 27 is housed. On the right-hand side, a compressor 17 for compressing combustion air and cooling air is formed on the rotor 12 , and on the left-hand side a turbine 13 is arranged. The compressor 17 compresses air which flows into a plenum 14 . In the plenum, an annular combustor 15 is arranged concentrically to the axis 27 and on the inlet side is closed off by means of a front plate 19 which is cooled with front-plate cooling air 20 , and on the outlet side is in communication via a hot gas passage 25 with the inlet of the turbine 13 .
[0004] Burners 16 , which for example or preferably are designed as premix burners and inject a fuel-air mixture into the combustor 15 , are arranged in a ring in the front plate 19 . Such premix burners originate for example from EP-A1-321 809 or from EP-A1-704 657, wherein these publications and the development which is derived from them form an integrated constituent part of this application. The hot air flow 26 which is formed during the combustion of this fuel-air mixture reaches the turbine 13 through the hot gas passage 25 and is expanded in the turbine, performing work. The combustor 15 with the hot gas passage 25 is enclosed on the outside, with a space, by an outer and inner cooling shroud 21 or 31 which by means of fastening elements 24 are fastened on the combustor 15 , 25 and between which and the combustor 15 , 25 an outer and inner cooling passage 22 or 32 is formed. In the cooling passages 22 , 32 , cooling air, flows in the opposite direction to the hot gas flow 26 along the walls of the combustor 15 , 25 into a combustor dome 18 , and from there flows into the burners 16 , or as front plate cooling air 20 , flows directly into the combustor 15 . The outer cooling shroud 21 , as shown in FIG. 3 , can be extended by means of an impingement cooling plate 30 which is provided with holes through which the cooling air jets enter the cooling passage 22 and impinge perpendicularly upon the outer shell 23 .
[0005] The side walls of the combustor 15 , 25 in this case are constructed either as shell elements or are formed as complete shells (outer shell 23 , inner shell 33 ). When using complete shells, for installation reasons the necessity arises of providing a parting plane ( 34 in FIG. 4 ) which allows an upper half of the shell 23 , 33 ( 23 a in FIG. 4 ) to be detached from the remaining lower half of the shell ( 23 b in FIG. 4 ), for example in order to install or to remove the gas-turbine rotor 12 . The parting plane 34 correspondingly has two parting-plane welded seams which in the example of the gas turbine are located at the level of the machine axis 27 ( FIG. 1 ).
[0006] A flange 28 with an encompassing groove 29 ( FIG. 3 ) is attached at the ends of the shells 23 , 33 and for reasons of mechanical strength can be reinforced by means of a connecting element in the form of a bridge 37 ( FIG. 4 ) which reaches across the parting plane 34 .
[0007] For the mechanical connection between the annular combustor 15 , 25 and a subsequent turbine vane carrier TVC (pos. 47 in FIGS. 8 to 13 ), which carries the stator vanes of the subsequent turbine 13 , and for dividing the plenum 14 into different chambers, sealing segment are provided, which are hooked on the combustor and on the turbine vane carrier in a movable manner and together form a sealing ring, which is arranged concentrically to the axis 27 , between combustor and turbine vane carrier.
[0008] The sealing segments (similar to pos. 35 ′ in FIG. 4 and to pos. 35 in FIG. 5 ) should ideally feature the following functions or characteristics:
They seal two chambers of the plenum. They should therefore also seal in relation to each other (requiring installation of a sealing lip between adjacent segments). They mechanically interconnect two construction modules (combustor vs. turbine vane carrier). They form an intermediate piece/transition piece between two construction modules (combustor vs. turbine vane carrier). They are axially-symmetrically constructed (with exception of the segments on the parting plane). They are able to have cooling holes/bores (for a specific mass flow of cooling air). They should absorb large axial and radial forces. They should have a large axial and radial movement clearance, especially during transient operations. They should be resistant to temperature (fatigue strength-creep strength). They should be simply and inexpensively producible. They must not rotate in the circumferential direction during operation—this necessitates the installing of circumferential locking means.
[0020] The sealing segments are to be installed before inserting the outer shells 23 into the flange 28 which is provided for it, but they could also first be installed in the gas turbine. The sealing segments can have a circumferential locking means. For the circumferential locking means, for example a groove is provided and a locking pin, having already been welded in, is located in the flange 28 of the outer shell 23 .
[0021] The sealing segments can furthermore have a groove or a slot for narrow seals (knife-edge seals) in the side faces (“wedge faces”). During installation, these seals also have to be inserted. The inserting of the seals into the grooves, and additionally the inserting of the sealing segments into the flange which is provided for them, can prove to be exceptionally awkward and is directly dependent upon the geometric design of the sealing-segment foot (pos. 44 in FIG. 4 ), and also upon the design of the outer-shell flange 28 . The outer shells 23 , which are thermally very severely stressed, move transiently axially and radially; in doing so, high compressive and tensile stresses ensue.
[0022] The sealing segment forms the (mechanical) linking element from the combustor 15 , to the turbine vane carrier 47 , which element moves transiently in a predominantly axial manner. The operating period which is required by the outer shell 23 is typically two so-called service intervals (“service intervals/service cycles”). An operating interval describes the time between the (re-)commissioning of the combustor and the reconditioning of the components.
SUMMARY OF THE INVENTION
[0023] It has now become apparent in practice that during operation the outer shells 23 begin to break down, often at the end of the parting-plane welded seams. It is assumed that the breaking down can also be caused by the outer shell, especially during the transient movements, not having adequate clearance and additional mechanical stresses acting upon the outer shell as a result.
[0024] An aspect of the invention is to create a thermal machine, especially a gas turbine, which avoids the aforementioned disadvantages of known machines and absolutely minimizes by constructional measures the risk of breaking down of the welded combustor shells.
[0025] In an embodiment, the sealing segments are mounted so that the combustor or the outer shell can move relative to the turbine vane carrier independently of each other in the axial direction and in the radial direction.
[0026] One development of the gas turbine according to the invention is characterized in that the sealing segments are mounted by the head in a locating space on the turbine vane carrier in such a way that they are radially movable there and pivotable around the head. In particular, the sealing segments can be mounted by the foot on the outer shell of the combustor in such a way that they are pivotable around the foot.
[0027] Another development of the invention is characterized in that the outer shell at the turbine-side end has a flange, in that the flange on the outer side is provided with an encompassing groove, and in that the sealing segments are pivotably mounted by the foot in the groove. The groove preferably has an L-shaped cross-sectional profile with an undercut, wherein the foot is formed in the shape of a hook and fits behind the undercut.
[0028] Furthermore, the foot can advantageously have first means for circumferential locking which especially comprise a locking groove which is provided in the foot, extends in the axial direction, and in which engages a locking pin which is fixed on the flange.
[0029] A further development of the invention is characterized in that the foot has second means for it, which preferably comprise a multiplicity of cooling slots which are arranged in the foot next to each other in the circumferential direction.
[0030] Another development is characterized in that between adjacent sealing segments sealing means are provided for sealing the gaps between the sealing segments. The sealing means preferably comprise sealing grooves in the side faces and knife-edge seals which are inserted in the sealing grooves.
[0031] According to a further development of the invention, the locating space on the turbine vane carrier is formed between the turbine vane carrier and a holding plate which is fastened on the turbine vane carrier (pos. 47 in FIG. 8 ), wherein the locating space has a rectangular cross section and an opening which extends inwards in the radial direction and through which the sealing segments extend by their head into the locating space, wherein the axial width of the locating space is approximately equal to the width of the head of the sealing segments, and wherein the radial height of the locating space is a multiple of the radial height of the head, and the locating space in the region of the opening is formed so that the sealing segments in the installed state are secured against slipping out of the locating space. Rectangular as used herein means essentially rectangular. In particular, the locating space in the region of the opening has a shoulder, behind which the sealing segments are hooked in by the head.
[0032] The sealing segments preferably have abutment faces on the head which abut against the walls of the locating space and are constructed in a cambered manner. The turbine-side abutment face in this case is advantageously constructed so that it has a straight contact line with the wall of the locating space. In this case, this straight contact line is machined so that it is ensured that the sealing segment can roll upon it as a result.
[0033] Another development is characterized in that bridges which overlap the parting plane are arranged in the groove of the flange for mechanical stabilization of the welded outer shell, and in that the sealing segments which are adjacent to the parting plane have a corresponding recess for adapting to the bridges.
[0034] Furthermore, according to requirement provision can be made for the sealing segments to be equipped with cooling holes, which are arranged in the segment surface, for the passage of cooling air.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The invention is to be explained in more detail in the following based on exemplary embodiments in conjunction with the drawing. All features which are not essential for the direct understanding of the invention have been omitted. Like elements are provided with the same designations in the various figures. The flow direction of the media is indicated with arrows. In the drawing
[0036] FIG. 1 shows the longitudinal section through a cooled annular combustor of a gas turbine according to the prior art;
[0037] FIG. 2 shows in detail the annular combustor from FIG. 1 with the cooling shrouds fastened on the outside;
[0038] FIG. 3 shows in longitudinal section the turbine-side end of the outer shell of the combustor from FIG. 1 with the flange fitted;
[0039] FIG. 4 shows in a detail the halves of an outer shell, which abut against each other in a parting plane, according to FIG. 3 , with the specially formed sealing segments which are adjacent to the parting plane, according to a preferred exemplary embodiment of the invention;
[0040] FIG. 5 shows in a perspective view a sealing segment, which is similar to FIG. 4 , which is not adjacent to the parting plane;
[0041] FIG. 6 shows the sealing segment according to FIG. 4 from another angle of view;
[0042] FIG. 7 shows the sealing segment according to FIG. 4 as seen from the bottom; and
[0043] FIGS. 8-13 for illustrating the large movement clearance, show in longitudinal section different positions of combustor and turbine vane carrier relative to each other, and the associated position of a sealing segment according to FIGS. 5-7 .
DETAILED DESCRIPTION
[0044] A new-type sealing segment with an additional, widened movement clearance with simultaneous ensuring of adequate mechanical strength and required aerodynamic air-tightness, is disclosed. The sealing segment is constructed so that on the foot of the segment it is locally cooled in a directed manner over the entire circumference of the flange. The mass flow of cooling air in this case in no longer interrupted, not even in the transient extreme positions of the sealing segment.
[0045] As already mentioned above, the new-type sealing segments are characterized by the following constructional details:
They can be cast They seal in relation to each other, wherein the installation of a sealing lip is required for this. They mechanically interconnect two constructional modules (combustor vs. turbine vane carrier). They form an intermediate piece/transition piece between two constructional modules (combustor vs. turbine vane carrier). They are axially symmetrically constructed, with exception of the segments on the parting plane. They are able to have cooling holes (for a specific mass flow of cooling air). They absorb large axial and radial forces. They have a large axial and radial movement clearance, especially in the transient ranges. They are resistant to temperature (fatigue strength-creep strength). They have circumferential locking means.
[0056] The feet of the sealing segments are designed so that these accurately fit into the respective flange geometry, and during operation, despite the thermal deformation of the shells and of the flange, are furthermore able to support the flange and at the same time allow an adequate mass flow of cooling air.
[0057] The head of the sealing segment is constructed so that on the rear side the cambered (convex) face can roll linearly on the turbine vane carrier. The front side, on the other hand, ordinarily sometimes hangs transiently in the retaining plate which in its turn is screwed to the turbine vane carrier. This greatly increased movement clearance, with the same functionality of the sealing segment in its extreme positions, in this case is the center of interest of the present invention.
[0058] The exemplary embodiment which is shown in FIGS. 4 to 13 refers to the use of the invention in the outer shell of a gas turbine. Uses are shown here which can be applied during various transient states of the gas turbine. The design principles according to the invention, however, naturally also apply to a comparable use in the case of a constructionally new design.
[0059] As already further explained in the above, in the case of a gas turbine with annular combustor 15 , 25 the combustion chamber is delimited by the side walls 23 , 33 and also by the inlet and outlet planes of the hot gas ( FIGS. 1 , 2 ). The combustor side walls in this case are constructed either as shell elements or as complete shells. When using complete shells, for installation reasons the necessity of a parting plane ( 34 in FIG. 4 ) arises, which allows the upper section (for example the upper half 23 a of the outer shell 23 ) to be detached, for example in order to install or to remove the gas-turbine rotor 12 . The parting plane 34 correspondingly has two parting-plane welded seams which in the example of a gas turbine are located at the level of the machine axis 27 . The parting-plane flange 28 , especially in the case of these gas turbines, is reinforced with bridges (pos. 37 in FIG. 4 ) and so the adjacent sealing segments 35 ′ at the level of the bridges 37 must have a corresponding recess. Therefore, there are a greater number of normal sealing segments 35 ( FIGS. 5-7 ) in the circumference, and on the parting plane 34 there are two so-called parting-plane sealing segments 35 ′ which are arranged on the left and on the right of the parting plane 34 ( FIG. 4 ).
[0060] The sealing segments 35 , 35 ′ according to FIGS. 4-7 have the form of circular segments which at the lower end have a foot which is formed in the shape of a hook, and at the upper end have a head 38 which is formed in the shape of a hook. Head 38 and foot 44 are connected via a wall which in the upper section extends in a straight line and in the lower section is double-curved. In the region of the upper first curve, cooling holes 42 , which are distributed in the circumferential direction and through which the cooling air can pass, are arranged in the wall. In the region of the lower second curve, a strip which projects to the side is provided, which in specific operating states ( FIG. 10 ) forms a stop.
[0061] The sealing segments 35 , 35 ′ according to FIGS. 4-7 have a circumferential locking means. For the circumferential locking means, a locking groove 45 is provided on the underside of the foot 44 (see especially FIG. 7 ). In the installed state of the sealing segments, a locking pin, which is not shown in the figures and which, having already been welded in, is located in the flange 28 of the outer shell 23 , engages in the locking groove 45 ( FIG. 4 ).
[0062] In the side faces (“wedge faces”), the sealing segments 35 , 35 ′ have a sealing groove (slot) for narrow seals (knife-edge seals 51 , FIG. 4 ). During installation, the knife-edge seals 51 must also be inserted. FIG. 4 shows the knife-edge seals in the installed state. FIGS. 5-7 show the sealing grooves 41 , which are made for the knife-edge seals, in the side faces.
[0063] As already further mentioned above, the inserting of the knife-edge seals 51 into the sealing grooves 41 , and additionally the inserting of the sealing segments 35 , 35 ′ into the flange 28 which is provided for them, can prove to be exceptionally awkward, and it is directly dependent upon the geometric design of the sealing-segment foot 44 ( FIGS. 5-7 ) and also upon the design of the outer-shell flange 28 . The cross-sectional profiles and the geometry of the two parts are evident for example from FIG. 9 .
[0064] The feet 44 of the sealing segments 35 , 35 ′ must be designed so that these fit accurately into the respective flange geometry of the flange 28 and during operation, despite the thermal deformation of the shells 23 , 33 and of the flange 28 , are furthermore “able to support” the flange 28 and consequently the combustor, and allow a mass flow of cooling air. From FIGS. 8-13 , which refer to different operating states of the gas turbine and are correspondingly characterized by different axial and radial distances B, C and A between combustor 15 , 25 and turbine vane carrier 47 (B, C), or sealing segment 35 , 35 ′ and turbine vane carrier 47 (A), the associated positions of the sealing segments 35 , 35 ′ are apparent.
[0065] In the operating states according to FIGS. 9 and 10 , the axial distance B between flange 28 and turbine vane carrier 47 is zero, whereas the radial distance A between the head 38 of the sealing segments 35 , 35 ′ and the top of the locating space 49 , as well as the radial distance C between combustor and turbine vane carrier, are maximum ( FIG. 9 ) or minimum ( FIG. 10 ). In the case of the minimum distance A=0, the sealing segments 35 , 35 ′ make contact with the head 38 and with the strip 43 ( FIG. 10 ). In the case of the maximum distance A ( FIG. 9 ), the sealing segments 35 , 35 ′ hang by their hook-shaped head 38 on the shoulder 50 in the locating space 49 .
[0066] In the operating state according to FIG. 8 , the axial distance is B>0, whereas the radial distance C is slightly reduced compared with FIG. 9 . The sealing segments 35 , 35 ′ are slightly tilted to the left, which corresponds to a pivoting around the foot 44 .
[0067] In the operating state according to FIG. 11 , the axial distance B has been further increased and the radial distance is once again reduced. The sealing segments 35 , 35 ′ are tilted further to the left until at the top they abut by the head 38 in the locating space 49 and by the straight part of the wall abut against the lower end of the holding plate 48 .
[0068] A further (maximum) tilting according to FIG. 12 is then possible if at the same time the radial distance C is maximum.
[0069] An average operating state is finally shown in FIG. 13 , all the distances A, B and C having an average value in this case.
[0070] The head 38 of the sealing segment 35 , 35 ′ is constructed so that (on the rear side) the cambered (convex) sealing face 39 can roll linearly on the turbine vane carrier 47 ( FIG. 8 ). The front side, specifically the hooking strip 40 , on the other hand ordinarily sometimes “hangs” transiently in the holding plate or retaining plate 48 which in its turn is screwed to the turbine vane carrier 47 ( FIG. 9 and FIG. 12 ).
[0071] The sealing segment 35 , 35 ′ in this case is constructed so that on the foot 44 of the segment it is locally cooled in a directed manner over the entire circumference of the flange 28 . The mass flow of cooling air is no longer interrupted, even in transient extreme positions of the sealing segment 35 , 35 ′ ( FIG. 12 ). This is achieved inter alia by a multiplicity of cooling slots 46 being provided in the foot 44 and distributed in the circumferential direction, and by the foot 44 being delimited on the underside by means of a corrugated surface which leaves room for the cooling air flow between flange 28 and foot 44 .
LIST OF DESIGNATIONS
[0000]
10 Gas turbine
11 Turbine casing
12 Rotor
13 Turbine
14 Plenum
15 Combustor
16 Burner (double-cone burner or EV-burner)
17 Compressor
18 Combustor dome
19 Front plate
20 Front-plate cooling air
21 Outer cooling shroud
22 Outer cooling passage
23 Outer shell
23 a Upper half of the outer shell
23 b Lower half of the outer shell
24 Fastening element
25 Hot gas passage
26 Hot gas flow
27 Axis
28 Flange
29 Groove (flange)
30 Impingement cooling plate
31 Inner cooling shroud
32 Inner cooling passage
33 Inner shell
34 Parting plane
35 , 35 ′ Sealing segment
36 Recess
37 Bridge (connecting element)
38 Head (sealing segment), head section
39 Sealing face
40 Hook-in strip
41 Sealing groove
42 Cooling hole
43 Strip
44 Foot (sealing segment), foot section
45 Locking groove
46 Cooling slot
47 Turbine vane carrier
48 Holding plate
49 Locating space
50 Shoulder
51 Knife-edge seal
A, B, C Distance | A gas turbine includes a turbine section; an annular combustor disposed upstream of the turbine section and configured to discharge a hot gas flow on an outlet side to the turbine section; an outer shell delimiting the combustor and splittable at a parting plane; a plenum enclosing the outer shell; a rotor; a turbine vane carrier encompassing the rotor; a plurality of stator vanes disposed on the vane carrier, and at least two sealing segments forming a ring, each of the at least two sealing segments having an inner edge and a head and a foot section and being movably mounted on the inner edge by the foot section to the outer shell and by the head section to the turbine vane carrier so as to mechanically connect the combustor to the turbine vane carrier. | 5 |
TECHNICAL FIELD
The present invention relates to a two stage pressure swing adsorption process to produce high purity (99+%) oxygen from a feed air stream comprising (1) passing the feed air stream through a first stage adsorption zone containing one or more adsorbents selective for the retention of impurities comprising carbon dioxide and water; (2) passing the impurity-depleted effluent stream from step (1) through a second stage adsorption zone containing an adsorbent selective for the retention of oxygen; (3) rinsing the second stage adsorption zone with oxygen in order to purge from the stage adsorption zone any co-adsorbed or void space impurities comprising argon; and (4) depressurizing the second stage adsorption zone to produce an effluent stream containing said high purity oxygen.
BACKGROUND OF THE INVENTION
A two stage pressure swing adsorption process to produce high purity oxygen from a feed air stream comprising steps (1) through (4) as described above is taught in the art. For example, U.S. Pat. No. 5,137,549 by Stanford et al. teaches such a process. The present invention is an improvement to Stanford whereby the effluent streams from steps (2) and (3) are used to regenerate the first stage adsorbent(s) in a specific regeneration scheme.
SUMMARY OF THE INVENTION
The present invention is a two stage pressure swing adsorption process for producing high purity oxygen from a feed air stream wherein carbon dioxide, water and preferably nitrogen are removed in the first stage and wherein an oxygen selective adsorbent is used to adsorb oxygen in the second stage. The oxygen product is recovered upon depressurization of the second stage. The high purity of the oxygen product is achieved by rinsing the oxygen selective adsorbent with oxygen prior to the depressurization step. A key to the present invention is that the effluent streams from the second stage feed and rinse steps are used to regenerate the first stage adsorbent(s) in a specific regeneration scheme.
The specific steps of the present invention comprise:
(a) passing the feed air stream through a first stage adsorption zone containing one or more adsorbents selective for the retention of impurities comprising carbon dioxide and water to produce an impurity saturated adsorption zone and an impurity-depleted effluent stream;
(b) regenerating the first stage adsorption zone via:
(i) depressurizing the first stage adsorption zone to produce an impurity-containing effluent stream which is discarded as waste;
(ii) purging the first stage adsorption zone with a first purge gas in order to purge the adsorption zone of any impurities comprising carbon dioxide and water still remaining in the adsorption zone at the end of step (b) (i) wherein the effluent stream from this step is discarded as waste;
(iii) further purging the first stage adsorption zone with a second purge gas in order to purge the adsorption zone of any impurities comprising carbon dioxide and water still remaining in the adsorption zone at the end of step (b) (ii) wherein the effluent stream from this step is discarded as waste; and
(iv) repressurizing the first stage adsorption zone with a repressurization gas;
(c) passing the impurity-depleted effluent stream from step (a) through a second stage adsorption zone containing an adsorbent selective for the retention of oxygen to produce an oxygen saturated adsorption zone and an oxygen-depleted effluent stream wherein at least a portion of said oxygen-depleted effluent stream is used as the second purge gas in step (b)(iii); and
(d) regenerating the second stage adsorption zone via:
(i) rinsing the second stage adsorption zone with a first rinse gas consisting of essentially pure oxygen in order to purge from the adsorption zone any co-adsorbed or void space impurities comprising argon wherein at least a portion of the effluent from this step (d)(i) is used as the repressurization gas in step (b)(iv);
(ii) further rinsing the second stage adsorption zone with a second rinse gas consisting of essentially pure oxygen in order to further purge from the adsorption zone any co-adsorbed or void space impurities comprising argon still remaining in the adsorption zone at the end of step (d)(i) wherein at least a portion of the effluent from this step (d)(ii) is used as the first purge gas in step (b)(ii); and
(iii) depressurizing the second stage adsorption zone to produce an effluent stream containing said high purity oxygen wherein a portion of said effluent stream is used as the first and second rinse gases in steps (d)(i) and (d)(ii).
In one embodiment of the present invention, steps (a) through (b) are performed on the first stage adsorption zone as a continually repeating cycle of steps; steps (c) through (d) are performed on the second stage adsorption zone as a continually repeating cycle of steps; and the process is effected in a system comprising a plurality of first stage adsorption zones and a plurality of second stage adsorption zones which each undergo their respective cycle of steps while collectively operated sequentially in parallel with one another.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is drawing illustrating one embodiment of the process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described in detail with reference to the drawing of FIG. 1. FIG. 1 is a schematic diagram illustrating one embodiment of the present invention wherein the process is effected in a system comprising two first stage adsorption zones and two second stage adsorption zones which each undergo their respective cycle of steps while collectively operated sequentially in parallel with one another. Table 1 summarizes FIG. 1's adsorption zone step sequence and valve sequence for one complete cycle. Table 1 utilizes 6 time intervals and a total elapsed time of 16 time units to cover the steps of the cycle so that the relative times for each step can be clearly indicated. It should be recognized that FIG. 1's embodiment and Table 1's operation sequence is only an example. Other embodiments, such as embodiments which use more or less adsorption zones per stage than does FIG. 1, can be easily designed by one skilled in the art.
TABLE 1______________________________________ Time Interval 0-4 4-7 7-8 8-12 12-15 15-16______________________________________AdsorptionZoneOperation*First Stage (a) (b)(i) (b)(ii) (b)(iii) (b)(iv) idleZone 1AFirst Stage (b)(iii) (b)(iv) idle (a) (b)(i) (b)(ii)Zone 1BSecond Stage (c) (d)(i) (d)(ii) (d)(iii) (d)(iii) (d)(iii)Zone 2ASecond Stage (d)(iii) (d)(iii) (d)(iii) (c) (d)(i) (d)(ii)Zone 2BValvePosition**Valve 1 0Valve 2 0Valve 3 0 0 0Valve 4 0 0 0Valve 5 0 0 0Valve 6 0 0 0Valve 7 0Valve 8 0Valve 9 0 0 0Valve 10 0 0 0Valve 11 0 0Valve 12 0 0Valve 13 0 0 0Valve 14 0 0 0______________________________________ *(a), (b)(i), (b)(ii), (b)(iii), (b)(iv), (c), (d)(i), (d)(ii) and (d)(iii) correspond to steps (a), (b)(i), (b)(ii), (b)(iii), (b)(iv), (c) (d)(i), (d)(ii) and (d)(iii) of the present invention as defined in Claim 1. **0 = open; otherwise closed.
By way of example, Table 1's step sequence and valve sequence will be described as it relates to the operation of FIG. 1's "A" train of adsorption zones comprising first stage adsorption zone 1A and second stage adsorption zone 2A. FIG. 1's "B" train of adsorption zones comprising first stage adsorption zone 1B and second stage adsorption zone 2B undergoes a similar sequence of operation as can be further detailed from Table 1.
During the first time interval (time units 0-4), first stage adsorption zone 1A undergoes its adsorption step or step (a) of the present invention. The feed air stream is passed through 1A (via open valves 1 and 7) containing one or more adsorbents selective for the retention of impurities comprising carbon dioxide and water to produce an impurity saturated adsorption zone and an impurity-depleted effluent stream which is withdrawn through open valve 7. Also during the first time interval, second stage adsorption zone 2A undergoes its adsorption step or step (c) of the present invention. The impurity-depleted effluent stream from 1A is passed through 2A (via open valves 7 and 13) containing an adsorbent selective for the retention of oxygen to produce an oxygen saturated adsorption zone and an oxygen-depleted effluent stream which is withdrawn through open valve 13. The oxygen-depleted effluent stream is used as the second purge gas for 1B which is currently undergoing its further purge step or step (b)(iii) of the present invention.
During the second time interval (time units 4-7), first stage adsorption zone 1A begins its regeneration sequence starting with its depressurization step or step (b) (i) of the present invention. 1A is depressurized to produce an impurity-containing effluent stream which is discarded as a waste stream through open valve 3 and vacuum compressor V1. Also during the second time interval, second stage adsorption zone 2A begins its regeneration sequence starting with its initial rinse step or step (d) (i) of the present invention. 2A is rinsed through open valve 11 with a first rinse gas consisting of essentially pure oxygen (and more specifically consisting of the effluent from 2B which is currently in the middle of its depressurization step or step (d)(iii) of the present invention) in order to purge from the adsorption zone any co-adsorbed or void space impurities comprising argon. The effluent from this step is withdrawn through open valve 13 and is used as the repressurization gas for 1B which is currently undergoing its repressurization step or step (b)(iv) of the present invention.
During the third time interval (time units 7-8), first stage adsorption zone 1A undergoes its initial purge step or step (b)(ii) of the present invention. 1A is purged through open valve 5 with a first purge gas (consisting of the effluent from 2A which is currently undergoing its further rinse step or step (d)(ii) of the present invention) in order to purge 1A of any impurities comprising carbon dioxide and water still remaining in 1A at the end of its depressurization step. The effluent stream from this step is discarded as a waste stream through open valve 3 and vacuum compressor V1. Also during the third time interval, second stage adsorption zone 2A undergoes its further rinse step or step (d)(ii) of the present invention. 2A is further rinsed through open valve 11 with a rinse gas consisting of essentially pure oxygen (and more specifically consisting of the effluent from 2B which is currently finishing its depressurization step or step (d)(iii) of the present invention) in order to purge from the adsorption zone any co-adsorbed or void space impurities comprising argon still remaining in 2A at the end of step (d)(i). The effluent from this step is used as the first purge gas for 1A which is currently undergoing its initial purge step or step (b)(ii) of the present invention.
During the fourth time interval (time units 8-12), first stage adsorption zone 1A undergoes its further purge step or step (b)(iii) of the present invention. 1A is further purged through open valve 5 with a second purge gas (consisting of the effluent from 2B which is currently undergoing its adsorption step or step (c) of the present invention) in order to purge 1A of any impurities comprising carbon dioxide and water still remaining in the 1A at the end of its initial purge step. The effluent stream from this step is discarded as a waste stream through open valve 3 and vacuum compressor V1. Also during the fourth time interval, second stage adsorption zone 2A begins its depressurization step or step (d)(iii) of the present invention. 2A is depressurized to produce an effluent stream containing high purity oxygen which is withdrawn through open valve 9 and vacuum compressor V2 and which is recovered as a product stream.
During the fifth time interval (time units 12-15), first stage adsorption zone 1A undergoes its repressurization step or step (b)(iv) of the present invention. 1A is repressurized through open valve 5 with a repressurization gas consisting of the effluent from 2B which is currently undergoing its initial rinse step or step (d)(i) of the present invention. Also during the fifth time interval, second stage adsorption zone 2A continues its depressurization step or step (d)(iii) of the present invention. 2A is further depressurized to produce an effluent stream containing high purity oxygen which is withdrawn through open valve 9 and vacuum compressor V2 and which is used as the first rinse gas for 2B which is currently undergoing its initial rinse step or step (d)(i) of the present invention.
Finally, during the sixth time interval (time units 15-16), first stage adsorption zone 1A is idle. After the sixth time interval, 1A's cycle is complete and a new cycle can commence. Steps (a) through (b) are performed on 1A as a continually repeating cycle of steps. Also during the sixth time interval, second stage adsorption zone 2A completes its depressurization step or step (d)(iii) of the present invention. 2A is further depressurized to produce an effluent stream containing high purity oxygen which is withdrawn through open valve 9 and vacuum compressor V2 and which is used as the second rinse gas for 2B which is currently undergoing its further rinse step or step (d) (ii) of the present invention. After the sixth time interval, 2A's cycle is complete and a new cycle can commence. Steps (c) through (d) are performed on 2A as a continually repeating cycle of steps.
It should be noted that the steps of the present invention as depicted in FIG. 1 are carried out by the action of a sub-ambient pressure applied to the outlet of the adsorption zones via vacuum compressors V1 and V2. This mode of carrying out the steps saves power because the quantity of gas exiting the each adsorption zone is lower than the quantity of gas feeding it. The concept of drawing a feed gas mixture through an adsorption zone by the action of a sub-ambient pressure applied to the outlet of the adsorption zone in order to save power is taught in British Patent 1,559,325.
It should further be noted in FIG. 1 that, with respect to the second stage adsorption zone's cycle of steps, the adsorption step or step (c) of the present invention immediately follows the depressurization step or step (d)(ii) of the present invention such that repressurization of the second stage adsorption zone occurs during step (c). This enables one to operate the process continuously with only two vacuum compressors and four adsorption zones, two in each stage. The concept of merging adsorption and repressurization into one step is taught in U.S. Pat. No. 3,636,679.
It should still further be noted that a preferred oxygen selective adsorbent to be used in the second stage comprises an equilibrium controlled cobalt-based adsorbent as taught in U.S. Pat. Nos. 5,126,466; 5,141,725; 5,208,335 and 5,239,098 all by Ramprasad et al. As discussed in these patents, the Ramprasad adsorbents are preferred in that they have the following properties:
(a) a reversible isotherm having a Langmuir Type I shape;
(b) fast adsorption and desorption kinetics;
(c) infinite selectivity for oxygen; and
(d) no phase change in oxygenation/deoxygenation cycle.
It should still further be noted that, in addition to carbon dioxide and water, nitrogen can be one of the impurities that the adsorbent(s) contained in the first stage adsorption zone is selective toward. This feature allows for a reduction in the amount of the relatively expensive cobalt-based adsorbent needed in the second stage. This feature also allows for a higher final depressurization pressure when depressurizing the second stage adsorption zone. Finally, this feature produces a relatively concentrated argon stream as the effluent from the second stage adsorption zone, at least a portion of which could be subject to further treatment for argon purification and production. It should be noted, however, that allowing all or a portion of the nitrogen to pass through the first stage unadsorbed is within the scope of the present invention. In this scenario, the effluent stream from the second stage adsorption zone will consist primarily of an argon, nitrogen and any oxygen which remains unadsorbed by the oxygen selective adsorbent contained in the second stage adsorption zone.
Finally it should be noted that the pressure swing between the adsorption pressure and the final depressurization pressure for each of the adsorption zones in FIG. 1 is not limited to a pressure swings from near ambient to sub-ambient pressures (ie vacuum swing adsorption or VSA). The scope of the present invention also encompasses pressure swings from above ambient to near ambient pressures.
The present invention has been described with reference to a specific embodiment thereof. This embodiment should not be seen as a limitation of the scope of the present invention; the scope of such being ascertained by the following claims. | A two stage pressure swing adsorption process is set forth for producing high purity oxygen from a feed air stream wherein carbon dioxide, water and preferably nitrogen are removed in the first stage and wherein an oxygen selective adsorbent is used to adsorb oxygen in the second stage. The oxygen product is recovered upon depressurization of the second stage. The high purity of the oxygen product is achieved by rinsing the oxygen selective adsorbent with oxygen prior to the depressurization step. A key to the present invention is that the effluent streams from the second stage feed and rinse steps are used to regenerate the first stage adsorbent(s) in a specific regeneration scheme. | 8 |
BACKGROUND
[0001] The invention relates generally to a coulter assembly, and more specifically, to a continuously variable depth adjustment system for altering a coulter disk penetration depth.
[0002] Generally, coulters are towed behind a tractor via a mounting bracket secured to a rigid frame of the implement. Coulters are typically configured to excavate a trench into soil, and may assist in delivering a liquid or dry fertilizer into the trench. Specifically, certain coulters include a coulter disk that cuts into the soil as the coulter moves along the terrain. A penetration depth of the coulter disk is generally regulated by a gauge wheel. In a typical configuration, the gauge wheel is positioned adjacent to the coulter disk and rotates across the soil surface. The coulter disk is positioned below the gauge wheel such that the coulter disk penetrates the soil. A vertical offset distance between the coulter disk and the gauge wheel determines the coulter disk penetration depth. As will be appreciated by those skilled in the art, the effectiveness of fertilizer may be dependent upon its deposition depth within the soil. Therefore, precise control of coulter disk penetration depth may be beneficial for crop growth.
[0003] However, typical coulter assemblies only facilitate gauge wheel adjustment in discrete increments. For example, the gauge wheel may only be adjusted between two or three discrete positions. As a result, the coulter may not deposit the fertilizer at a suitable depth to enhance crop growth.
BRIEF DESCRIPTION
[0004] The present invention provides a coulter assembly configured to facilitate continuous adjustment of coulter disk penetration depth. In an exemplary embodiment, the coulter assembly includes a support structure and a coulter disk rotatable coupled to the support structure. A gauge wheel is movably coupled to the support structure and configured to rotate across a surface of the soil to limit a penetration depth of the coulter disk into the soil. A depth adjustment assembly is coupled to the gauge wheel and configured to adjust the penetration depth of the coulter disk by continuously varying the vertical position of the gauge wheel. This configuration enables any coulter disk penetration depth to be selected within the gauge wheel range of motion, thereby facilitating deposition of fertilizer within the soil at a suitable depth to enhance crop growth.
DRAWINGS
[0005] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0006] FIG. 1 is a perspective view of a towable agricultural implement including multiple coulter assemblies;
[0007] FIG. 2 is a detailed perspective view of one coulter assembly, as shown in FIG. 1 ;
[0008] FIG. 3 is a left side view of the coulter assembly of FIG. 2 , showing a support structure, a coulter disk, a gauge wheel, and a swing arm;
[0009] FIG. 4 is an exploded view of the coulter assembly of FIG. 2 , showing the support structure, the coulter disk, the gauge wheel, and the swing arm;
[0010] FIG. 5 is a right side view of the coulter assembly of FIG. 2 , showing the support structure and a depth adjustment assembly; and
[0011] FIG. 6 is an exploded view of the coulter assembly of FIG. 2 , showing the support structure and the depth adjustment assembly.
DETAILED DESCRIPTION
[0012] Turning now to the drawings, FIG. 1 is a perspective view of a towable agricultural implement 10 including multiple left-handed coulter assemblies 12 and right-handed coulter assemblies 14 . As discussed in detail below, the coulter assemblies 12 and 14 may include a coulter disk configured to excavate a trench into soil. A fertilizer delivery assembly positioned behind the coulter disk may then inject a liquid or dry fertilizer into the trench. In such an arrangement, seeds planted adjacent to the trench may receive a proper amount of fertilizer. As illustrated, the coulter assemblies 12 and 14 are secured to shanks 16 that couple the coulter assemblies 12 and 14 to a tool bar 18 . In the present embodiment, the tool bar 18 includes 12 left-handed coulter assemblies 12 and 12 right-handed coulter assemblies 14 . Further embodiments may include more or fewer coulter assemblies 12 and 14 . For example, certain embodiments may include 2 , 4 , 6 , 8 , 10 , 14 , 16 , or more left-handed coulter assemblies 12 and right-handed coulter assemblies 14 . The tool bar 18 is coupled to a tow bar 20 , including a hitch 22 . The hitch 22 may, in turn, be coupled to a tractor such that the towable agricultural implement 10 may be pulled through a field. In certain embodiments, the tool bar 18 , including the coulter assemblies 12 and 14 , precedes row units configured to deposits seeds into the soil. In such embodiments, the row units may be offset from the coulter assemblies 12 and 14 such that the seeds are deposited a desired distance from the fertilizer enriched trench. This configuration may enable the crops to absorb a proper amount of fertilizer as they grow.
[0013] As discussed in detail below, a penetration depth of each coulter disk may be varied by adjusting a vertical position of a gauge wheel. Specifically, the gauge wheel may rotate across a surface of the soil to limit coulter disk penetration. Increasing or decreasing the vertical position of the gauge wheel with respect to the coulter disk varies the penetration depth. In the present embodiment, a depth adjustment assembly is coupled to the gauge wheel to continuously vary its vertical position. Therefore, any coulter disk penetration depth within the gauge wheel range of motion may be selected.
[0014] FIG. 2 is a detailed perspective view of a left-handed coulter assembly 12 . The coulter assembly 12 is coupled to the shank 16 by a tool bar mount 24 . As illustrated, the tool bar mount 24 is rotatably coupled to a support structure 26 by a shaft 28 . The shaft 28 enables the support structure 26 to rotate about an axis 30 in a direction 32 in response to obstructions or variations in the terrain. Specifically, the tool bar mount 24 may be coupled to the shank 16 by fasteners that pass through openings 34 in the tool bar mount 24 . The tool bar mount 24 includes a spring plate 36 configured to limit rotation of the support structure 26 with respect to the tool bar mount 24 . The coulter assembly 12 includes a threaded rod 38 and a compression spring 40 configured to maintain a substantially constant force between the gauge wheel and the soil. Specifically, the threaded rod 38 passes through an opening in the spring plate 36 , and the spring 40 is disposed about the threaded rod 38 . A first spring stop 42 is disposed between the spring 40 and the spring plate 36 , and a second spring stop 44 is disposed adjacent to the opposite end of the spring 40 to ensure that the spring 40 remains disposed about the threaded rod 38 . The second spring stop 44 is secured to the spring 40 by a washer 46 and a pair of fasteners 48 . The threaded rod 38 is coupled to a pin 50 that passes through a hole 52 in the support structure 26 . The pin 50 is secured to the threaded rod 38 by a loop 54 and the support structure 26 by a cotter pin 56 .
[0015] The structure described above enables the support structure 26 to rotate about the axis 30 in the direction 32 in response to variations in field conditions. For example, if the support structure 26 is driven to rotate in the direction 32 by contact with an obstruction, the support structure 26 may rotate about the shaft 28 . As the support structure 26 rotates, the spring 40 is compressed, thereby biasing the support structure 26 toward its initial orientation. Specifically, rotation of the support structure 26 causes the pin 50 to rotate about the axis 30 in the direction 32 . Because the pin 50 is coupled to the threaded rod 38 by the loop 54 , the threaded rod 38 is driven to translate through the opening in the spring plate 36 . The spring 40 is then compressed between the spring stops 42 and 44 by the washer 46 secured to the threaded rod 38 by the fasteners 48 . The spring compression applies a biasing force to the support structure 26 by the previously described linkage, thereby inducing the support structure 26 to return to its initial orientation. Such a configuration may serve to protect the coulter assembly 12 by absorbing the impact of obstructions encountered during cultivation.
[0016] The coulter assembly 12 also includes a coulter disk 58 rotatably coupled to the support structure 26 by a bearing assembly 60 . The bearing assembly 60 enables the coulter disk 58 to freely rotate as it engages the soil and excavates a trench. The coulter assembly 12 also includes a scraper 62 disposed adjacent to the coulter disk 58 and coupled to the support structure 26 by a bracket 64 . The scraper 62 is configured to remove accumulated soil from the coulter disk 58 and may serve to widen the trench. The scraper 62 is coupled to a fertilizer tube 66 configured to deliver liquid or dry fertilizer into the trench.
[0017] A gauge wheel 68 is pivotally coupled to the support structure 26 by a swing arm 70 . The swing arm 70 is, in turn, coupled to a depth adjustment assembly 72 configured to continuously vary the vertical position of the gauge wheel 68 with respect to the support structure 26 . As discussed in detail below, because the gauge wheel 68 travels along the surface of the soil, varying the position of the gauge wheel 68 alters the penetration depth of the coulter disk 58 into the soil. The depth adjustment assembly 72 includes a lever 74 and a shaft 76 . The shaft 76 is rigidly coupled to a first end of the lever 74 , and a linear actuator is coupled to the second end. In this configuration, extension and retraction of the linear actuator induces the lever 74 and the shaft 76 to rotate. In certain embodiments, the linear actuator may include a pneumatic cylinder, a hydraulic cylinder, or an electromechanical actuator, for example. In the present embodiment, the linear actuator includes a rod 78 , a pin 80 , a mount 82 , a first fastener 84 and a second fastener 86 . As discussed in detail below, adjusting the position of the fasteners 84 and 86 with respect to the rod 78 rotates the lever 74 , thereby rotating the shaft 76 coupled to the swing arm 70 . Rotating the swing arm 70 alters the vertical position of the gauge wheel 68 , thereby varying the penetration depth of the coulter disk 58 . Because the fasteners 84 and 86 may be positioned at any location along the length of the rod 78 , extension and/or retraction of the rod 78 with respect to the mount 82 may be continuously varied. Therefore, any coulter disk penetration depth within a range defined by the length of the rod 78 and the geometry of the depth adjustment assembly 72 may be achieved.
[0018] FIG. 3 is a left side view of the coulter assembly 12 , showing the support structure 26 , the coulter disk 58 , the gauge wheel 68 , and the swing arm 70 . As previously discussed, the depth adjustment assembly 72 may rotate the swing arm 70 , thereby adjusting the vertical position of the gauge wheel 68 . Specifically, the swing arm 70 includes a first region 88 and a second region 90 . The first region is rigidly coupled to the shaft 76 by a bolt 92 . In this manner, rotation of the shaft 76 induces the swing arm 70 to rotate. In addition, the gauge wheel 68 is rotatably coupled to the second region 90 by a bolt 94 . The bolt 94 enables the gauge wheel 68 to rotate as it moves across the soil surface.
[0019] In the illustrated embodiment, the gauge wheel 68 includes an outer surface 96 and an inner hub 98 . The outer surface 96 may be composed of rubber to provide traction between the gauge wheel 68 and the soil. The inner hub 98 may be composed of a rigid material (e.g., nylon) capable of supporting the outer surface 96 . As illustrated, a penetration depth D is established between the bottom of the gauge wheel 68 and the bottom of the coulter disk 58 . Specifically, because the gauge wheel 68 rotates along the surface of the soil, the coulter disk 58 may penetrate the soil to the penetration depth D. In addition, because the depth adjustment assembly 72 is configured to lock the swing arm 70 into place during operation of the coulter assembly 12 , the gauge wheel 68 may limit the penetration depth D based on the angle of the swing arm 70 . Moreover, because the depth adjustment assembly 72 is configured to continuously vary the angle of the swing arm 70 with respect to the support structure 26 , the depth adjustment assembly 72 may continuously vary the penetration depth D of the coulter disk 58 into the soil.
[0020] In the present embodiment, the gauge wheel 68 is disposed directly adjacent to the coulter disk 58 . In this configuration, the gauge wheel 68 may serve to remove accumulated soil from the coulter disk 58 as the gauge wheel 68 rotates. In certain embodiments, the gauge wheel 68 is angled about a longitudinal axis of the support structure 26 toward a soil penetrating portion of the coulter disk 58 . This arrangement may serve to enhance soil removal from the coulter disk 58 .
[0021] FIG. 4 is an exploded view of the coulter assembly 12 , showing the support structure 26 , the coulter disk 58 , the gauge wheel 68 , and the swing arm 70 . Specifically, FIG. 4 illustrates the internal parts that enable the swing arm 70 to rotate with respect to the support structure 26 . As previously discussed, the swing arm 70 is rigidly coupled to the shaft 76 . To limit rotation of the swing arm 70 with respect to the shaft 76 , a key 100 is inserted into a recess 102 in the shaft 76 . A bearing 104 is then disposed between the shaft 76 and the support structure 26 to enable the shaft 76 to rotate within the support structure 26 . The first region 88 of the swing arm 70 includes an opening 106 including a recess 108 configured to interlock with the key 100 . Specifically, the recess 108 is aligned with the key 100 prior to disposing the opening 106 about the shaft 76 . Interaction between the key 100 and the recess 108 limits rotation of the swing arm 70 with respect to the shaft 76 . Therefore, rotation of the shaft 76 by the depth adjustment assembly 72 rotates the swing arm 70 , while limiting rotation of the swing arm 70 during operation of the coulter assembly 12 . Finally, the swing arm 70 is secured to the shaft 76 by the bolt 92 and washers 110 and 112 .
[0022] As previously discussed, the gauge wheel 68 is coupled to the second region 90 of the swing arm 70 by the bolt 94 . Specifically, the bolt 94 passes through the gauge wheel 68 and a washer 114 . The bolt 94 then secures to an opening 116 within the second region 90 of the swing arm 70 . This configuration enables the gauge wheel 68 to rotate with respect to the swing arm 70 as it moves across the soil surface.
[0023] FIG. 5 is a right side view of the coulter assembly 12 , showing the support structure 26 and the depth adjustment assembly 72 . As previously discussed, the depth adjustment assembly 72 facilitates continuous adjustment of the penetration depth D of the coulter disk 58 into the soil by adjusting the vertical position of the gauge wheel 68 . Specifically, a position of the rod 78 may be varied by adjusting the position of the fasteners 84 and 86 with respect to the mount 82 . In certain embodiments, the rod 78 may be threaded and the fasteners 84 and 86 may be nuts including complementary threads configured to mate with the threaded rod 78 . In such a configuration, washers 118 and 120 may be disposed between the nuts 84 and 86 , respectively, and the mount 82 . For example, the rod 78 may be translated in a direction 122 by uncoupling the fastener 86 , moving the rod 78 in the direction 122 , and then securing both fasteners 84 and 86 about the mount 82 . Translating the rod 78 in the direction 122 rotates the lever 74 in a direction 124 , thereby rotating the shaft 76 in the direction 124 . As previously discussed, the shaft 76 is rigidly coupled to the swing arm 70 . Therefore, rotating the shaft 76 in the direction 124 induces the swing arm 70 to rotate in the direction 124 , thereby increasing the vertical displacement of the gauge wheel 68 with respect to the support structure 26 and increasing the penetration depth D of the coulter disk 58 .
[0024] Conversely, the rod 78 may be translated in a direction 126 by uncoupling the fastener 84 , moving the rod 78 in the direction 126 , and then securing both fasteners 84 and 86 about the mount 82 . Translating the rod 78 in the direction 126 rotates the lever 74 in a direction 128 , thereby rotating the shaft 76 in the direction 128 . Because the shaft 76 is rigidly coupled to the swing arm 70 , rotating the shaft 76 in the direction 128 induces the swing arm 70 to rotate in the direction 128 . Therefore, the vertical displacement of the gauge wheel 68 with respect to the support structure 26 is decreased, and the penetration depth D of the coulter disk 58 is decreased. In certain embodiments, the penetration depth D of the coulter disk 58 may be continuously varied between approximately 0 to 6 inches. However, further embodiments may have a greater or lesser range of adjustment. Because the fasteners 84 and 86 may be positioned at any location along the rod 78 , any penetration depth D may be established within the range limited by the length of the rod 78 and the geometry of the depth adjustment assembly 72 .
[0025] FIG. 6 is an exploded view of the coulter assembly 12 , showing the support structure 26 and the depth adjustment assembly 72 . As illustrated, the threaded rod 78 includes a loop 130 configured to receive the pin 80 . The loop 130 of the threaded rod 78 may be aligned with openings 132 in the lever 74 . The pin 80 may then be inserted through the openings 132 and the loop 130 to secure the threaded rod 78 to the lever 74 . The pin 80 includes a recess 134 , and the threaded rod 78 includes an opening 136 . The recess 134 may be aligned with the opening 136 , and a pin 138 may be inserted through the opening 136 and into the recess 134 . In this manner, the threaded rod 78 may be rotatably secured to the lever 74 .
[0026] As previously discussed, the lever 74 is rigidly coupled to the shaft 76 including the key 100 . A bearing 140 is disposed about the shaft 76 such that the shaft 76 may rotate within an opening 142 within the support structure 26 . This configuration may enable linear movement of the threaded rod 78 to induce rotation of the shaft 76 within the opening 142 such that the swing arm 70 rotates with respect to the support structure 26 . The threaded rod 78 may be inserted through an opening 144 in the mount 82 . As illustrated, the opening 144 is elongated in the vertical direction to enable vertical movement of the threaded rod 78 as the rod 78 translates in the direction 122 and/or 126 through the opening 144 in the mount 82 . As previously discussed, fastener 84 and washer 118 is disposed on one side of the mount 82 , while fastener 86 and washer 120 are disposed on the opposite side. In this configuration, the threaded rod 78 may be positioned and secured relative to the mount 82 such that the vertical position of the gauge wheel 68 may be continuously varied with respect to the support structure 26 , thereby enabling the penetration depth D of the coulter disk 58 to be continuously adjusted.
[0027] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | A coulter assembly is provided that facilitates continuous adjustment of coulter disk penetration depth. In an exemplary embodiment, the coulter assembly includes a gauge wheel configured to rotate across a soil surface to limit a penetration depth of a coulter disk into the soil. A depth adjustment assembly is coupled to the gauge wheel and configured to adjust the penetration depth of the coulter disk by continuously varying the vertical position of the gauge wheel. This configuration may enable the coulter disk to operate at any penetration depth within the gauge wheel range of motion, thereby facilitating deposition of fertilizer within the soil at a suitable depth to enhance crop growth. | 8 |
BACKGROUND OF THE INVENTION
2. Field of the Invention
This invention relates to RS flip-flops (reset-set type flip-flops), and more particularly to an RS flip-flop having a plurality of set inputs.
2. Description of the Background Art
FIG. 4 is a logic gate diagram showing an ordinary construction of a conventional RS flip-flop. In the drawing, the RS flip-flop has a three-input NOR gate 1 and a two-input NOR gate 2. The three-input NOR gate 1 receives a first set input S1 and a second set input S2 through input terminals 3 and 4. The three-input NOR gate 1 also receives an output of the two-input NOR gate 2. The two-input NOR gate 2 receives a reset input R through an input terminal 5. The two-input NOR gate 2 also receives an output of the three-input NOR gate 1. The outputs of the NOR gates 1 and 2 are applied to output terminals 6 and 7, respectively. Complementary memory state signals or output signals Qand Q ar obtained from the output terminals 6 and 7.
FIG. 5 is a circuit diagram showing the conventional RS flip-flop in greater detail. In the drawing, the three-input NOR gate 1 has p-channel MOS transistors 11-13 and n-channel MOS transistors 14-16. The p-channel MOS transistors 11-13 are connected in series between a power source VDD and an output node N1. The p-channel MOS transistors 11 and 12 receive the set inputs S1 and S2 at the respective gates thereof. The p-channel MOS transistor 13 receives at the gate thereof the output of the two-input NOR gate 2. The n-channel MOS transistors 14-16 are connected in parallel between the output node N1 and ground GND. The n-channel MOS transistors 14 and 15 receive the set inputs S1 and S2 at the respective gates thereof. The n-channel MOS transistor 16 receives at the gate thereof the output of the two-input NOR gate 2. The output node N1 is connected to the output terminal 6.
On the other hand, the two-input NOR gate 2 has p-channel MOS transistors 21 and 22 and n-channel MOS transistors 23 and 24. The p-channel MOS transistors 21 and 22 are connected in series between a power source VDD and an output node N2. The p-channel MOS transistor 21 receives at the gate thereof the output of the three-input NOR gate 1. The p-channel MOS transistor 22 receives at the gate thereof the reset input R. The n-channel MOS transistors 23 and 24 are connected in parallel between the output node N2 and ground GND. The n-channel MOS transistor 23 receives at the gate thereof the output of the three-input NOR gate 1. The n-channel MOS transistor 24 receives at the gate thereof the reset input R. The output node N2 is connected to the output terminal 7.
FIG. 6 is a diagram showing a relationship between input and output of the RS flip-flop shown in FIGS. 4 and 5. An operation of the conventional RS flip-flop will be described with reference to FIG. 6. In the following description, logic "1" corresponds to H level, and logic "0" to L level.
(1) Case of maintaining state of outputs Q and Q:
First, a case will be described in which inputs S1=0, S2=0 and R=0 are applied while the RS flip-flop is outputting Q=1 and Q=0. In this case, the NOR gate 1 receives S1=0, S2=0 and Q=1, whereby the output Qof the NOR gate 1 becomes logic "0". The NOR gate 2 receives R=0 and Q=0, whereby the output Q of the NOR gate 2 becomes logic "1". Thus, the output state will remain unchanged.
Next, a case will be described in which inputs S1=0, S2=0 and R=0 are applied while the RS flip-flop is outputting Q=0 and Q=1. In this case, the NOR gate 1 receives S1=0, S2=0 and Q=0, whereby the output Qof the NOR gate 1 becomes logic "1". The NOR gate 2 receives R=0 and Q=1, whereby the output Q of the NOR gate 2 becomes logic "0". Thus, the output state will remain unchanged.
In this way, the outputs Q and Qmaintain a previous state when the reset input R, set input S1 and set input S2 are all logic "0".
(2) Case of resetting RS flip-flop (Q=0 and Q=1):
First, a case will be described in which inputs S1=0, S2=0 and R=1 are applied when the RS flip-flop is set, i.e. outputting Q=1 and Q=0. In this case, the NOR gate 1 receives S1=0, S2=0 and Q=1, whereby the output Qof the NOR gate 1 becomes logic "1". The NOR gate 2 receives R=1 and Q=0, whereby the output Q of the NOR gate 2 becomes logic "0". Thus, the outputs Q and Qof the RS flip-flop are inverted, which means that the RS flip-flop is reset.
Next, a case will be described in which inputs S1=0, S2=0 and R=1 are applied when the RS flip-flop is reset, i.e. outputting Q=0 and Q=1. In this case, the NOR gate 1 receives S1=0, S2=0 and Q=0, whereby the output Qof the NOR gate 1 becomes logic "1". The NOR gate 2 receives R=1 and Q=1, whereby the output Q of the NOR gate 2 becomes logic "0". Thus, the outputs Q and Qare not inverted and the RS flip-flop maintains the reset state.
(3) Case of setting RS flip-flop (Q=1 and Q=0):
First, a case will be described in which R=0 is inputted and at least one of the set inputs S1 and S2 is changed to logic "1" when the RS flip-flop is set, i.e. outputting Q=1 and Q=0. In this case, the NOR gate 1 receives S1=1, S2=0 and Q=1, or S1=1, S2=1 and Q=1, or S1=0, S2=1 and Q=1, whereby the output Qof the NOR gate 1 becomes logic "0". The NOR gate 2 receives R=0 and Q=0, whereby the output Q of the NOR gate 2 becomes logic "1". Thus, the RS flip-flop maintains the set state.
Next, a case will be described in which R=0 is inputted and at least one of the set inputs S1 and S2 is changed to logic "1"when the RS flip-flop is reset, i.e. outputting Q=0 and Q=1. In this case, the NOR gate 1 receives S1=1, S2=0 and Q=0, or S1=1, S2=1 and Q=0, or S1=0, S2=1 and Q=0, whereby the output Qof the NOR gate 1 becomes logic "0". The NOR gate 2 receives R=0 and Q=0, whereby the output Q of the NOR gate 2 becomes logic "1". Thus, the outputs Q and Qare inverted, which means that the RS flip-flop is set.
The conventional RS flip-flop, as shown in FIG. 5, has many transistors 11-13 connected in series between the power source VDD and output node N1. These transistors 11-13 must all be turned on when inverting the output Qfrom logic "0"to logic "1". However, each of the transistors 11-13 is not turned on immediately upon receipt of an L-level signal at the gate thereof; a predetermined delay time is involved in switching from OFF state to ON state. There occurs a corresponding delay in the change in potential of the output Q. Further, the delay in the potential change of the output Qis passed on to the NOR gate 2 to cause a delay in the potential change of the output Q as well. While the RS flip-flop shown in FIG. 5 has two set inputs, a greater number of set inputs will result in an increase in the number of transistors connected in series between the power source VDD and output node N1, hence a longer delay time.
As described above, the conventional RS flip-flop has the disadvantage of poor response characteristics of the outputs Q and Qto the set inputs and reset input, which is due to the presence of a series circuit of many transistors between the power source and the output terminal. Thus, it has been difficult to employ such conventional RS flip-flops in an electronic circuit required to operate at high speed.
SUMMARY OF THE INVENTION
The object of this invention, therefore, is to provide an RS flip-flop constantly operable at high speed and having excellent response characteristics regardless of an increase in the number of set inputs.
An RS flip-flop according to this invention is constructed to store first and second logic states in response to a reset input and a plurality of set inputs, and includes a logic circuit, a latch circuit and a control signal generating device. The logic circuit includes set input transistors connected in parallel between a first reference potential source and an output node to be turned on and off in response to the set inputs, respectively, and a reset input transistor disposed between a second reference potential source and the output node to be turned on and off in response to the reset input. The logic circuit has a first mode for outputting a first or a second logic level signal based on a logic combination of the set inputs and reset input, and a second mode for placing the output node in high-impedance state. The latch circuit receives the output signal of the logic circuit. The control signal generating device generates a control signal for controlling the latch circuit in response to the reset input and set inputs. The latch circuit outputs memory state signals.
In this invention, the output signal of the logic circuit is obtained as memory state signals through the latch circuit. The logic circuit includes a plurality of set input transistors connected in parallel between a first reference potential source and an output node, and a reset input transistor disposed between a second reference potential source and the output node. Thus, the RS flip-flop of this invention does not include a series circuit of transistors on an output path of the memory state signals. The memory state signals, therefore, have potentials variable at high speed in response to the reset input and set inputs. That is, the RS flip-flop of this invention has excellent output response to the inputs.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram showing an embodiment of this invention.
FIG. 2 is a circuit diagram showing an example of construction of an inverter 101 or 102 in FIG. 1.
FIG. 3 is a circuit diagram showing another embodiment of this invention.
FIG. 4 is a logic gate diagram showing an ordinary construction of a conventional RS flip-flop.
FIG. 5 is a circuit diagram showing the conventional RS flip-flop in greater detail.
FIG. 6 is a diagram showing a relationship between input and output in RS flip-flops.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a circuit diagram showing an embodiment of this invention. In the drawing, an RS flip-flop in this embodiment has a three-input OR gate 8, a logic circuit 9 and a latch circuit 10. The three-input OR gate 8 generates a control signal for application to the latch circuit 10, and includes p-channel MOS transistors 81-83, n-channel MOS transistors 84-86, and an inverter 87. The p-channel MOS transistors 81-83 are connected in series between a power source VDD and a node N8. The p-channel MOS transistors 81 and 82 receive set inputs S1 and S2 at the gates thereof through input terminals 3 and 4, respectively. The p-channel MOS transistor 83 receives a reset input R at the gate thereof through an input 10 terminal 5. The n-channel MOS transistors 84-86 are connected in parallel between the node N8 and ground GND. The n-channel MOS transistors 84 and 85 receive the set inputs S1 and S2 at the gates thereof through the input terminals 3 and 4, respectively. The n-channel MOS transistor 86 receives the reset input R at the gate thereof through the input terminal 5. The node N8 is connected to an input of the inverter 87.
The logic circuit 9 includes n-channel MOS transistors 91-93. The n-channel MOS transistors 91 and 92 are connected in parallel between a power source VDD and an output node N9. These n-channel MOS transistors 91 and 92 receive the set inputs S1 and S2 at the gates thereof through the input terminals 3 and 4, respectively. The n-channel MOS transistor 93 receives the reset input R at the gate thereof through the input terminal 5.
The latch circuit 10 includes an even number of, e.g. two, inverters 101 and 102, and a p-channel MOS transistor 103. The inverter 101 has an input connected to the output node N9 of the logic circuit 9. The output of the inverter 101 is connected to an input of the inverter 102 and to an output terminal 6. The output of the inverter 102 is connected to an output terminal 7. The p-channel MOS transistor 103 is connected between the input of the inverter 101 and the output of the inverter 102. The p-channel MOS transistor 103 receives the output of the inverter 87 in the three-input OR gate 8. As shown in FIG. 2, the inverter 101 or 102 is constructed as a CMOS inverter including a p-channel MOS transistor 100a and an n-channel MOS transistor 100b.
The RS flip-flop in the embodiment shown in FIG. 1 operates on the set inputs S1 and S2 and reset input R as shown in FIG. 6. The operations of the embodiment shown in FIG. 1 will be described hereinafter. In the following description, logic "1"corresponds to H level, and logic "0"to L level.
(1) Case of maintaining state of outputs Q and Q(memory state signals) of RS flip-flop:
First, an operation will be described in which inputs S1=0, S2=0 and R=0 are applied when the RS flip-flop is set or reset. In this case, the transistors 91-93 are all turned off, and the output node N9 becomes high-impedance state. In the OR gate 8, on the other hand, the transistors 81-83 are turned on and the transistors 84-86 turned off. Consequently, a signal of logic "1"is outputted from the node N8. This logic "1"signal is inverted by the inverter 87, and the resulting logic "0"signal is applied to the gate of the transistor 103 in the latch circuit 10. As a result, the transistor 103 is turned on to short-circuit the output of the inverter 102 and the input of the inverter 101. The inverters 101 and 102, therefore, hold the logic of the output signal received from the logic circuit 9 before the output node N9 of the logic circuit 9 becomes high-impedance state. For example, when the output signal of the logic circuit 9 is logic "1"immediately before the output node N9 becomes high-impedance state, the output signal is inverted twice by the inverters 101 and 102 and thereafter returned to the input of the inverter 101. Thus, the latch circuit 10 holds the logic "1" signal as circulating between the inverters 101 and 102. When the output signal of the logic circuit 9 is logic "0"immediately before the output node N9 becomes high-impedance state, the output signal is inverted twice by the inverters 101 and 102 and thereafter returned to the input of the inverter 101. Thus, the latch circuit 10 holds the logic "0"signal as circulating between the inverters 101 and 102.
In this way, the outputs Q and Qremain unchanged when inputs S1=0, S2=0 and R=0 are applied to the RS flip-flop in set or reset state.
(2) Case of resetting RS flip-flop (Q=0 and Q=1):
An operation will be described in which set and reset inputs S1=0, S2=0 and R=1 are applied. In this case, the transistors 91 and 92 are turned off and the transistor 93 turned on. As a result, a logic "0" signal is applied through the output node N9 to the input of the inverter 101 in the latch circuit 10. Thus, output Qof logic "1" is obtained from the output terminal 6, and output Q of logic "0"from the output terminal 7. At this time, only the transistors 83 and 86 are in ON state in the OR gate 8, with the other transistors 81, 82, 84 and 85 turned off. Consequently, a logic "0"signal is outputted from the node N8, resulting in a logic "1"signal applied to the gate of the transistor 103 in the latch circuit 10. This places the transistor 103 in OFF state, whereby the latch circuit 10 loses its latching function and acts only as an output driver.
As described above, inputs S1=0, S2=0 and R=1 result in outputs Q=0 and Q=1 regardless of the previous state of the outputs Q and Q, thereby resetting the RS flip-flop.
(3) Case of setting RS flip-flop (Q=1 and Q=0):
An operation will be described in which inputs R=0, S1=1 and S2=0, or R=0, S1=0 and S2=1, or R=0, S1=1 and S2=1 are applied to the RS flip-flop. In this case, the transistor 93 is turned off and at least one of the transistors 91 and 92 turned on in the logic circuit 9. Thus, the signal of logic "1"is applied to the latch circuit 10 through the output node N9. As a result, output Qof logic "0"is obtained from the output terminal 6, and output Q of logic "1"from the output terminal 7. In the OR gate 8, the transistors 83 and 86 are turned off and at least one of the transistors 84 and 85 turned on at this time. Consequently, logic "0"is outputted from the node N8, resulting in the signal of logic "1"applied to the gate of the transistor 103 in the latch circuit 10. As a result, the transistor 103 is turned off whereby the latch circuit 10 loses the latching function and acts only as an output driver.
Thus, when the reset input R attains logic "0" and at least one of the set inputs S1 and S2 attains logic "1", outputs Q and Qbecome logic "1"and logic "0", respectively, regardless of the previous state, thereby setting the RS flip-flop.
FIG. 3 is a circuit diagram showing an the construction of RS flip-flop in another embodiment of this invention. The embodiment shown in FIG. 3 includes a three-input NOR gate 8' in place of the three-input 0R gate 8 in the embodiment shown in FIG. 1. Output of the three-input NOR gate 8' is applied to an n-channel MOS transistor 104 in a latch circuit 10', and through an inverter 88 to the gate of the p-channel MOS transistor 103. These transistors 103 and 104 are connected in parallel between the input of the inverter 101 and the output of the inverter 102. On the other hand, a logic circuit 9' includes p-channel MOS transistors 91, and 92, in place of the n-channel MOS transistors 91 and 92 in FIG. 1. The transistor 91' receives at the gate thereof an inverted signal of set input S1 from an inverter 94. The transistor 92, receives at the gate thereof an inverted signal of set input S2 from an inverter 95. The embodiment shown in FIG. 3 is the same in the other aspects as the embodiment shown in FIG. 1, and like reference numerals are used to identify like elements without repeating their description.
The embodiment shown in FIG. 3 is simply a CMOS version of the embodiment shown in FIG. 1, and is operable in precisely the same way as the latter. Its operation, therefore, will not be described.
In the foregoing embodiments, the output signal of the logic circuit 9 or 9' is applied to the output terminals 6 and 7 through the latch circuit 10 or 10'. Neither the logic circuit 9 or 9' nor the latch circuit 10 or 10' includes transistors connected in series. The reset input and set inputs are, therefore, transmitted at high speed to the output terminals 6 and 7. Consequently, the RS flip-flops in the foregoing embodiments are a significant improvement upon the conventional RS flip-flop shown in FIG. 5 in respect of output response to input.
While two set inputs are used in each of the foregoing embodiments, the number of set inputs may be three or more. An increase in the number of set inputs will not result in a deterioration in the response characteristic since the logic circuit disposed on the output signal path does not include transistors connected in series; only the number of transistors connected in parallel will be increased. Thus, the greater the number of set inputs, the more salient is the advantage of the foregoing embodiments over the conventional RS flip-flop.
As described above, RS flip-flops according to this invention are operable at high speed with a greatly improved output response to inputs compared with the conventional RS flip-flop.
Although the present invention has been described an illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims. | A logic circuit outputs a logic signal in response to set inputs and a reset input. This logic signal is applied to output terminals through a latch circuit. When outputs Q and Q of the RS flip-flop maintain a previous state, the latch circuit is activated by a control signal applied from an OR gate to hold a previous logic signal received from the logic circuit. Thus, the logic circuit and latch circuit are arranged on a signal path from input terminals to output terminals. These logic circuit and latch circuit do not include a series connection of transistors and, therefore, is operable at high speed in response to the inputs. Consequently, the outputs Q and Q have excellent response characteristics relative to the set and reset inputs, to enable a high-speed operation. | 7 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional, and claims priority from, U.S. Provisional Patent Application U.S. 61/704,082 entitled “PANORAMIC IMAGE VIEWER” filed 21 Sep. 2013 the entirety of which is incorporated herein by reference.
FIELD
[0002] The subject matter relates to image processing and in particular to a panoramic image viewer.
BACKGROUND
[0003] A typical skybox based viewer introduces pincushion distortion when projecting the 3D skybox to a flat display, as shown in FIG. 1 . The projection process is not conformal, as the longitudinal and latitudinal lines are not kept perpendicular to each other. Moreover, due to the perspective projection with the viewer located at the center, current environmental mapping schemes, such as cubic mapping and skydome mapping, can not support a field-of-view (FOV) greater than 90 degrees. Indeed, significant distortion happens whenever the FOV gets close to 90 degrees, and thus the aforementioned conventional environmental mapping methods are limited to about 45 degrees in practice. It would therefore be desirable to correct the pincushion distortion and limited FOV problems to avoid distorting the local shape of objects such as faces.
SUMMARY
[0004] A viewer in accordance with a non-limiting embodiment of the present invention relies on a conformal projection process to perserve local shapes. For example, a rotated cylindriac mapping can be used. In the image generation process, the source panoramic image, which can be elliptical, is placed on a sphere according to the angular location of pixels in the panomorph. The sphere is rotated around its center to a desired orientation before being projected to a cylinder also centered at the sphere's center with its longitudinal axis along the sphere's z-axis. The projected image on the cylinder is unwrapped and displayed by the viewer. Because the new mapping algorithm is based on unwrapping a developable plane with projected panorama, FOV is not particularly limited.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The invention will be better understood by way of the following detailed description of embodiments of the invention with reference to the appended drawings, in which:
[0006] FIG. 1 is an illustration of a pincussion distortion;
[0007] FIG. 2 is a schematic diagram illustrating relationships between spaces;
[0008] FIG. 3( a ) is a schematic diagram illustrating rendering a view of a texture surface on a screen in accordance with the proposed solution;
[0009] FIG. 3( b ) is a schematic diagram illustrating a 2-D geometric mapping of a textured surface in accordance with the proposed solution;
[0010] FIG. 4 is schematic diagram illustrating a schetch of the geometry involved in accordance with the proposed solution;
[0011] FIG. 5 is a table illustrating image processing in accordance with the proposed solution;
[0012] FIG. 6 is an illustration having reduced pincussion distortion compared to the illustration in FIG. 1 in accordance with the proposed solution;
[0013] FIG. 7 is an algorithmic listing illustrating a rotated equirectagular mapping in accordance with a non-limiting example of the proposed solution;
[0014] FIG. 8 is an illustration of a mappping from an elliptic panorama image to a viewer window in accordance with the proposed solution;
[0015] FIG. 9 is an illustration of a 90 degree FOV mappipng from an elliptic panorama image in accordance with the proposed solution; and
[0016] FIG. 10 is another illustration of a 90 degree FOV mappipng from an elliptic panorama image in accordance with the proposed solution,
[0017] wherein similar features bear similar labels throughout the drawings.
DETAILED DESCRIPTION
[0018] To discuss texture mapping, several coordinate systems can be defined. Texture space is the 2-D space of surface textures and object space is the 3-D coordinate system in which 3-D geometry such as polygons and patches are defined. Typically, a polygon is defined by listing the object space coordinates of each of its vertices. For the classic form of texture mapping, texture coordinates (u, v) are assigned to each vertex. World space is a global coordinate system that is related to each object's local object space using 3-D modeling transformations (translations, rotations, and scales). 3-D screen space is the 3-D coordinate system of the display, a perspective space with pixel coordinates (x, y) and depth z (used for z-buffering). It is related to world space by the camera parameters (position, orientation, and field of view). Finally, 2-D screen space is the 2-D subset of 3-D screen space without z. Use of the phrase “screen space” by itself can mean 2-D screen space.
[0019] The correspondence between 2-D texture space and 3-D object space is called the parameterization of the surface, and the mapping from 3-D object space to 2-D screen space is the projection defined by the camera and the modeling transformations ( FIG. 2 ). Note that when rendering a particular view of a textured surface (see FIG. 3( a )), it is the compound mapping from 2-D texture space to 2-D screen space that is of interest. For resampling purposes, once the 2-D to 2-D compound mapping is known, the intermediate 3-D space can be ignored. The compound mapping in texture mapping is an example of an image warp, the resampling of a source image to produce a destination image according to a 2-D geometric mapping (see FIG. 3( b )).
[0020] For an image to be generated by the viewer, a pixel in the display, indexed as (u; v), is mapped to a cylinder with unit radius in 3-dimensional space by equirectangular projection as shown by Eq. (1):
[0000]
{
ϕ
c
=
2
π
w
(
u
-
w
2
)
x
c
=
cos
ϕ
c
y
c
=
sin
ϕ
c
z
c
=
2
π
w
(
h
2
-
v
)
(
1
)
[0021] where φc and zc are the azimuth and height in cylindriac coordinates, respectively, and w and h are the width and height of the view image, respectively. Linear mapping is used to perserve angular uniformity in both directions along the u-indices and v-indices.
[0022] Next, the point on the cylinder (which was just found) is mapped to a unit sphere by normalization of its cartesian coordinates, and the point on the unit sphere is rotated. This can be expressed by:
[0000]
(
x
c
y
c
z
c
)
=
r
c
F
·
(
x
s
y
s
z
s
)
(
2
)
[0023] where xc, yc, zc are respectively the cartesian coordinates of the point on the cylinder, rc is its distance to the origin, F is a rotation matrix, and (xs, ys, zs) are the cartesian coordinates of the point on the unit sphere. It is noted that the rotation matrix F is a function of user input. In other words, navigation throughout the original image will induce changes in F.
[0024] The color of the viewer pixel (which, will be recalled, is at (u; v) in the view window) is the color of a corresponding location within a 2D panoramic image, which can be elliptical (including but not limited to circular). This corresponding location can be obtained by first converting the cartesian coordinates of the aforementioned point on the unit sphere (xs; ys; zs) to spherical coordinates (1; Θs; φs) then recognizing the existence of a mapping between (general) spherical coordinates (1; Θ; φ) on the unit sphere and (general) polar coordinates (r E , Θ E ) on an elliptic (circular or non-circular) panoramic image. In particular, this mapping can be defined as:
[0000]
{
r
E
=
f
(
θ
)
θ
E
=
ϕ
[0025] where f(Θ) is a mapping function defined by the camera lens projection, and may indeed be supplied by the camera in a form of an one-dimensional lookup table.
[0026] As a result, the texture coordinates in the original 2-D elliptic image that correspond to the point (u; v) in the viewing window are given by:
[0000]
{
s
=
1
2
+
f
(
θ
s
)
cos
ϕ
s
t
=
1
2
+
f
(
θ
s
)
sin
ϕ
s
.
(
3
)
[0027] FIG. 4 shows a sketch of the geometry involved in the afoementioned process.
[0028] FIG. 5 shows a summary of the entire mapping process.
[0029] FIG. 6 shows a screenshot from a viewer implemented in accordance with an embodiment of the present invention. It is noted that the pincushion distortion from FIG. 1 has been reduced.
[0030] Implementation
[0031] Algorithm 1 (see FIG. 7 ) finds the texture coordinates for a location within the viewer window. φc and zc are cylindriac coordinates from Eqn. (1), and
[0000]
vc
=
(
x
c
y
c
z
c
)
[0000] is a column vector of the corresponding cartesian coordinates; rc is the length of the 2D vector vc; F is a rotation matrix which has columns holds the direction vectors along x-, y-, z- axes of a frame fixed on the spherical source image;
[0000]
vs
=
(
x
s
y
s
z
s
)
[0000] is a column vector of the cartesian coordinates of the mapped point on the unit sphere.
[0032] One example of mapping from an elliptic panorama image to the viewer window is shown in FIG. 8 .
[0033] FIGS. 9 and 10 show how a portion of the elliptic panorama image is mapped to a viewer window at a 90 degree FOV.
[0034] Those skilled in the art will appreciate that a computing device may implement the methods and processes of certain embodiments of the present invention by executing instructions read from a storage medium. In some embodiments, the storage medium may be implemented as a ROM, a CD, Hard Disk, USB, etc. connected directly to (or integrated with) the computing device. In other embodiments, the storage medium may be located elsewhere and accessed by the computing device via a data network such as the Internet. Where the computing device accesses the Internet, the physical interconnectivity of the computing device in order to gain access to the Internet is not material, and can be achieved via a variety of mechanisms, such as wireline, wireless (cellular, Wi-Fi, Bluetooth, WiMax), fiber optic, free-space optical, infrared, etc. The computing device itself can take on just about any form, including a desktop computer, a laptop, a tablet, a smartphone (e.g., Blackberry, iPhone, etc.), a TV set, etc.
[0035] Moreover, persons skilled in the art will appreciate that in some cases, the panoramic image being processed may be an original panoramic image, while in other cases it may be an image derived from an original panoramic image, such as a thumbnail or preview image.
[0036] Certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are to be considered illustrative and not restrictive. Also it should be appreciated that additional elements that may be needed for operation of certain embodiments of the present invention have not been described or illustrated as they are assumed to be within the purview of the person of ordinary skill in the art. Moreover, certain embodiments of the present invention may be free of, may lack and/or may function without any element that is not specifically disclosed herein. | A viewer relying on a conformal projection process to perserve local shapes is provided employing a rotated cylindriac mapping. In the image generation process, the source panoramic image, which can be elliptical, is placed on a sphere according to the angular location of pixels in the panomorph. The sphere is rotated around its center to a desired orientation before being projected to a cylinder also centered at the sphere's center with its longitudinal axis along the sphere's z-axis. The projected image on the cylinder is unwrapped and displayed by the viewer. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a stapler. In particular, the stapler includes an adjustable firing apparatus for using staples/nails in various sizes.
[0003] 2. Description of the Related Art
[0004] As disclosed in PCT Patent No WO2005/102613 A1, a stapler comprising a main body which includes a seat for a row of staples and/or nails which are urged by a pusher towards an ejection head, wherein a striker can run in a direction substantially perpendicular to the feed direction of the row of staples and/or nails in the seat for pushing and ejecting from the ejection head the first staple and/or nail of the row, wherein a mobile plate is mechanically connected to a slider by means of a pin that is housed in corresponding holes made in the mobile plate and in slider which protrudes outside the main body so that by moving the slider the mobile plate can slide in the main body for being arranged between the ejection head and the striker when the latter pushes the first staple and/or nail.
[0005] Said slider comprises a particular locking mechanism which prevents the accidental sliding of the mobile plate.
[0006] According to the above, for using several kinds of staplers and nails with the stapler, a user should operate the slider to drive the mobile plate to slide relative to the main body as to adjust the space between the pusher and the ejection head for using various kinds of staples and/or nails. And next, the locking mechanism is operated to fix the position of the slider, which may lead to low working efficiency.
[0007] The present invention is therefore intended to obviate or at least alleviate the problems encountered in prior art.
SUMMARY OF THE INVENTION
[0008] According to the present invention there is provided, a stapler includes an adjustable firing apparatus for using staples/nails in various sizes that directs toward simplifying the operation of switch between different staples/nails. The adjustable firing apparatus of the stapler includes an adjusting means, a rotation engaged member having a first and a second engaged portions and an actuating means. The actuating means is operated to press the adjusting means as to adjust the distance between the adjusting means and the front of a magazine assembly of the stapler for adapted to staples/nails in various sizes.
[0009] In one aspect of the prevent invention, it is easy and simple to adjust the distance between the adjusting means and the front of the magazine assembly by operating the actuating means.
[0010] In another aspect of the prevent invention, the stapler is adapted to use four kinds of staples/nails.
[0011] In yet another aspect of the prevent invention, the rotation engaged member is made by punching as to reduce cost of manufacturing thereof.
[0012] Other advantages, objectives and features of the present invention will become apparent from the following description referring to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The detailed description and technical characteristics of the present invention and described together with the drawings as follows.
[0014] FIG. 1 is a perspective view of a stapler in accordance with the preferred embodiment of the present invention.
[0015] FIG. 2 is an exploded view of the stapler in FIG. 1 .
[0016] FIG. 3 is a cross-sectional view taken along 3 - 3 in FIG. 1 , illustrating the actuating means engaged with the rotation engaged member.
[0017] FIG. 4 is a cross-sectional view taken along 4 - 4 in FIG. 3 , illustrating the stapler using with the first staple.
[0018] FIG. 5 is a cross-sectional view taken along 5 - 5 in FIG. 5 , illustrating the stapler using with the first staple.
[0019] FIG. 6 is a cross-sectional view similar to FIG. 4 , but illustrating the stapler using with the nail with head.
[0020] FIG. 7 is a cross-sectional view similar to FIG. 3 , but illustrating the actuating means being operated to rotate clockwise.
[0021] FIG. 8 is a cross-sectional view taken along 8 - 8 in FIG. 7 , illustrating the stapler using with the second staple.
[0022] FIG. 9 is a cross-sectional view similar to FIG. 8 , but illustrating the stapler using with the nails without head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] An embodiment of the present invention will now be discussed with reference to FIGS. 1 through 9 . As shown in FIGS. 1 through 3 , a stapler includes an adjustable firing apparatus 1 , a magazine assembly 2 , a handle assembly 3 and a first and a second shell members 4 and 5 . The first and second shell members 4 and 5 are combined to each other to form main structure of the stapler. The magazine assembly 2 is disposed in the bottom of the first and second shell members 4 and 5 . The handle assembly 3 is pivotally installed to the first and second shell members 4 and 5 . The adjustable firing apparatus 1 is provided in the front of the first and second shell members 4 and 5 , and a user can operate the handle assembly 3 to drive the adjustable firing apparatus 1 for firing staples/nails that are disposed in the magazine assembly 2 .
[0024] Plunger ledges 401 and 501 are defined on the first and second shell members 4 and 5 , respectively and relative to the adjustable firing apparatus 1 . Abutted portions 402 and 502 respectively protrude on the bottom of the plunger ledges 401 and 501 toward the interior of the stapler and correspond to each other. Receiving portions 403 and 503 are defined adjacent to the front of the first and second shell members 4 and 5 , respectively and corresponding to each other. The receiving portions 403 and 503 are provided below the plunger ledges 401 and 501 , respectively. Peep holes 404 and 504 respectively pierce through side wall of the first and second shell members 4 and 5 , and user can observe amount of staples/nails in the magazine assembly 2 via the peep holes 404 and 504 . A through-hole 505 is provided on the front of the second shell member 5 adjacent to the receiving portion 503 and adapted for a pin 506 inserting therethrough. An actuating means hole 507 and a protrusion 508 are defined on the side wall of the second shell member 5 adjacent to the peep hole 504 , with the actuating means hole 507 being long and narrow, with the protrusion 508 formed in the bottom of the actuating means hole 507 .
[0025] The adjustable firing apparatus 1 includes a plunger member 10 disposed in the plunger ledges 401 and 501 , a driving member 20 abutted the abutted portions 402 and 502 , an adjusting means 30 , whose position in the stapler is limited by the receiving portions 403 and 503 , a rotation engaged member 40 and an actuating means 50 , whose position in the stapler is limited by the pin 506 .
[0026] The plunger member 10 includes a connected portion 11 formed an end thereof and a firing portion 12 formed another end thereof opposite to the connected portion 11 . The connected portion 11 is connected to an end of the handle assembly 3 , and while firing staples/nails, user operates the handle assembly 3 and then the firing portion 12 is driven to falls down stably to fire staples/nails.
[0027] The driving member 20 has a first surface and a second surface. A first concavity 21 is defined on the first surface of the driving member 20 and provides the firing portion 12 to slide therealong, with a second concavity 22 formed on the first concavity 21 so that the first concavity 21 is stepped. Protruding from the second surface of the driving member 20 is a protruding portion 23 that abuts against the abutted portions 402 and 502 respectively. A space 24 pierces through the center of the driving member 20 and open to the bottom the driving member 20 .
[0028] The adjusting means 30 includes a main body 31 having a first surface and a second surface and exactly disposed in the space 24 of the driving member 20 . The first surface of the main body 31 is stepped and having a gap 32 formed on a side thereof. A first plate 33 is provided on the second surface of the main body 31 , and a second plate 34 is inserted through the first plate 33 , with the direction of axis of the first plate 33 perpendicular to that of the second plate 34 , with the distance between the top of the first plate 33 and the second side of the adjusting means 30 being larger than the distance between the top of the second plate 34 and the second side of the adjusting means 30 . The second plate 34 is against the second surface of the driving member 20 . A pivot 35 is inserted through the center of the first and second plates 33 and 34 .
[0029] The rotation engaged member 40 is in form of uneven piece and includes a first engaged portion 41 and a second engaged portion 42 defined on two sides of the first engaged portion 41 by punching. The thickness of the first engaged portion 41 is greater than that of the second engaged portion 42 . Teeth 411 is formed on the periphery of the first engaged portion 41 , and teeth 421 is formed on the periphery of the second engaged portion 42 , with the teeth 411 being adjacent to and not overlapping the teeth 421 . A through-hole 43 is provided on the center of the rotation engaged member 40 and inserted by the pivot 35 of the adjusting means 30 so that the rotation engaged member 40 is allowed to rotate relative to the adjusting means 30 , with the position of the rotation engaged member 40 in the stapler limited by the receiving portions 403 and 503 . Moreover, the first plate 33 of the adjusting means 30 is selectively engaged with one of the first engaged portion 41 and the second engaged portion 42 .
[0030] The actuating means 50 is in form of semi-circle with teeth 52 that extends from the periphery of the flat portion thereof outwardly. A through-hole 51 is defined thereon adjacent to the teeth 52 , and a positioned portion 53 is provided on the periphery opposite to the teeth 52 . An arc slot 54 is defined along the periphery of the actuating means 50 relative to the positioned portion 53 for increasing the resilience of the periphery of the actuating means 50 . The through-hole 51 corresponds to the through-hole 505 so that the pin 506 is inserted through the through-hole 505 and the through-hole 51 in sequence for fixing the actuating means 50 in the second shell member 5 . The teeth 52 of the actuating means 50 is selectively engaged with one of the teeth 411 and the teeth 421 . The thickness of the positioned portion 53 exactly fits the width of the actuating means hole 507 so that the positioned portion 53 protrudes from the actuating means hole 507 for user to operate the actuating means 50 to pivot relative to the pin 506 . Further, when the positioned portion 53 is rotated to abut with the lowest position in the actuating means hole 507 , the positioned portion 53 is enable to be pressed inwardly and received in the actuating means hole 507 behind the protrusion 508 .
[0031] Referring to FIGS. 3 through 5 , it shows the first engaged portion 41 of the rotation engaged member 40 is against the adjusting means 30 . The positioned portion 53 is operated to rotate as to engage the teeth 52 of the actuating means 50 with the teeth 421 of the second engaged portion 42 , and then the first engaged portion 41 is adapted to be against the first plate 33 of the adjusting means 30 . Simultaneously, the second engaged portion 42 abuts with the second plate 34 of the adjusting means 30 for adjusting the distance between the first surface of the adjusting means 30 and the front of the magazine assembly 2 to be the maximum as to receive one of a row of first staples A in the second concavity 22 of the driving member 20 , with the first surface of the main body 31 abutted the one of a row of first staples A, with each first staple A is U-shaped.
[0032] Referring to FIG. 6 , while the distance between the first surface of the adjusting means 30 and the front of the magazine assembly 2 is being the maximum, one of a row of nails with head B is also adapted to be received in the second concavity 22 of the driving member 20 , with the first surface of the main body 31 abutted the one of a row of nails with head B, with each nail with head B is T-shaped.
[0033] Referring to FIGS. 7 and 8 , it shows the second engaged portion 42 of the rotation engaged member 40 is against the adjusting means 30 . The positioned portion 53 is operated to rotate as to engage the teeth 52 of the actuating means 50 with the teeth 411 of the first engaged portion 41 , and then the second engaged portion 42 is adapted to be against the first plate 33 of the adjusting means 30 . Simultaneously, the main body 31 of the adjusting means 30 is pressed toward the space 24 of the driving member 20 to adjust the distance between the first surface of the adjusting means 30 and the front of the magazine assembly 2 to be the minimum as to receive one of a row of second staples C in the second concavity 22 of the driving member 20 , with the first surface of the main body 31 abutted the one of a row of second staples C, with each second staple C is U-shaped similar to the first staple A, but the thickness of the cross-section of each second staple C is thinner than that of each first staple A and width of staple boot of each second staple C is greater than that of each first staple A so that one of staple boot of each second staple C is disposed in the first concavity 21 .
[0034] Referring to FIG. 9 , while the distance between the first surface of the adjusting means 30 and the front of the magazine assembly 2 is being the minimum, one of a row of nails without head D is adapted to be received in the gap 32 of the adjusting means 30 . | A stapler includes an adjustable firing apparatus for using staples/nails in various sizes that directs toward simplifying the operation of switch between different staples/nails. The adjustable firing apparatus of the stapler includes an adjusting means and a rotation engaged member having a first and a second engaged portions. The adjusting means can be used to adjust the distance between the adjusting means and the front of a magazine assembly of the stapler for adapted to staples/nails in various sizes. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/122,808, filed May 19, 2008, now U.S. Pat. No. ______, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/941,092, filed May 31, 2007; both of which are incorporated herein by this reference in their entirety.
[0002] The present application is also related to U.S. patent application Ser. No. 11/119,980, entitled PRESSURE RELIEF SURFACE, and U.S. patent application Ser. No. 11/119,991, entitled PATIENT SUPPORT HAVING REAL TIME PRESSURE CONTROL, and U.S. patent application Ser. No. 11/119,635, entitled LACK OF PATIENT MOVEMENT MONITOR AND METHOD, and U.S. patent application Ser. No. 11/120,080, entitled PATIENT SUPPORT, all of which were filed on May 2, 2005, all of which are incorporated herein by this reference.
[0003] The present application is also related to U.S. Provisional Patent Application Ser. No. 60/636,252, entitled QUICK CONNECTOR FOR MULTIMEDIA, filed Dec. 15, 2004, which is incorporated herein by this reference.
[0004] The present application is also related to U.S. Provisional Patent Application Ser. No. 60/697,748, entitled PRESSURE CONTROL FOR A HOSPITAL BED and corresponding PCT application No. PCT/US06/26787 filed Jul. 7, 2006, and U.S. Provisional Patent Application Ser. No. 60/697,708, entitled CONTROL UNIT FOR A PATIENT SUPPORT, and corresponding PCT application No. PCT/US06/26788 filed Jul. 7, 2006, and U.S. Provisional Patent Application Ser. No. 60/697,748 entitled PATIENT SUPPORT and corresponding PCT Application No. PCT/US06/26620 filed Jul. 7, 2006 and PCT application No. PCT/US05/14897 entitled PATIENT SUPPORT filed May 2, 2005, all of which are incorporated herein by this reference.
[0005] The present application is also related to U.S. Provisional Patent Application Ser. No. 60/821,494, entitled PATIENT SUPPORT, which was filed on Aug. 4, 2006, the disclosure of which is incorporated herein by this reference.
BACKGROUND
[0006] The present disclosure relates to support surfaces, such as mattresses. More particularly, the present invention relates to support surfaces used to support a patient on a bed frame, such as in a hospital or other patient care environment. Even more particularly, the present invention relates to support surfaces for patients that require pulmonary therapy.
[0007] Known hospital beds and mattresses are disclosed, for example, in U.S. Pat. No. 4,949,413 to Goodwin, U.S. Pat. No. 5,647,079 to Hakamiun et al., U.S. Pat. No. 5,731,062 to Kim et al., U.S. Pat. No. 6,269,504 to Romano et al., U.S. Pat. No. 6,701,556 to Romano et al., U.S. Pat. No. 6,708,352 to Salvatini et al., and U.S. Pat. No. 6,820,630 to Hand et al., all of which are assigned to the assignee of the present invention and all of which are incorporated herein reference herein in their entirety.
SUMMARY OF THE INVENTION
[0008] The present invention may comprise one or more of the features recited in the appended claims and/or one or more of the following features or combinations thereof.
[0009] According to one aspect of the present invention there is provided a patient support surface including a cover defining an interior region, a layer of three dimensional material, located at the interior region, the three-dimensional material including a network of thermoplastic fibers, an air circulation device disposed adjacent the layer of three dimensional material, and at least one of a percussion and a vibration device, located at the interior region.
[0010] According to another aspect of the present invention there is provided a patient support surface including a cover defining an interior region, a layer of three dimensional material, located at the interior region, the three-dimensional material including a network of thermoplastic fibers, an air circulation device disposed adjacent the layer of three dimensional material, and a hose, located at the interior region, including at least one connector adapted to couple to an external device.
[0011] Pursuant to another aspect of the present invention there is provided a hospital bed including a frame, to support a patient, and a support surface; located on the frame. The support surface includes a cover defining an interior region and a layer of three dimensional material, located at the interior region. The three-dimensional material includes a network of thermoplastic fibers, an air circulation device disposed adjacent the layer of three dimensional material, and at least one of a percussion and a vibration device, located at the interior region.
[0012] According to still another aspect of the present invention there is provided a patient support surface having a head end and a foot end. The patient support surface includes a cover defining an interior region, a layer of three dimensional material, located at the interior region, the three-dimensional material including a network of thermoplastic fibers, an air circulation device disposed adjacent the layer of three dimensional material, and a head elevation device, located at the head end of the patient support surface, the head elevation device including a support surface to elevate the head end of the patient support surface.
[0013] Features and other aspects of the present disclosure will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments, which exemplify the best mode as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The detailed description particularly refers to the accompany figures in which:
[0015] FIG. 1 illustrates a perspective view of a pressure relief support surface including a slot for an x-ray cassette;
[0016] FIG. 2 illustrates an exploded perspective view of a multi-layered pressure relief support surface;
[0017] FIGS. 3 , 4 , and 5 illustrate a perspective view a pressure relief support surface and an x-ray cassette at is passes through a slot;
[0018] FIG. 6 illustrates a perspective view of a multi-layered pressure relief support surface including percussion and vibration bladders;
[0019] FIG. 7 illustrates an exploded perspective view of sensors with respect to cushion sections;
[0020] FIG. 8 illustrates a perspective view of a multi-layered pressure relief support surface with turn assist bladders;
[0021] FIG. 9 illustrates a sectional view of the support surface of FIG. 1 along a line 9 - 9 ;
[0022] FIGS. 10-12 illustrate perspective view of a controller including user interface;
[0023] FIG. 13 illustrates a perspective view of an airway clearance system integrated with a pressure relief support surface through a control unit;
[0024] FIG. 14 illustrates a perspective view of an airway clearance system integrated directly with a pressure relief support surface;
[0025] FIG. 15 illustrates a perspective view of a control unit with a holder for a deep vein thrombosis device;
[0026] FIGS. 16-18 illustrate user interface screens of the present invention;
[0027] FIG. 19 illustrates an end view of one embodiment of an elevation device;
[0028] FIG. 20 illustrates a side view of one embodiment of an elevation device;
[0029] FIG. 21 illustrates a schematic illustration of FIG. 19 ;
[0030] FIG. 22 illustrates a pressure relief support surface and a frame including integrated device;
[0031] FIG. 23 illustrates a block diagram of a control and communication system; and
[0032] FIGS. 24-30 illustrate additional user interface screens of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 illustrates a perspective view of a pressure relief support surface 10 , or mattress, including a slot 26 for inserting an x-ray cassette 27 . The pressure relief support surface 10 includes a cover 12 which surrounds a plurality of components to be described later herein. The cover 12 includes a top surface 14 and a bottom surface 16 , each of which is coupled together by longitudinal sides 18 and 20 . A first end portion 22 located at a head end 23 of the surface 10 and a second end portion 24 located at a foot end 25 of the surface 10 complete the cover 12 . Slot 26 includes an aperture located along at least one of the longitudinal sides 18 , 20 . Slot 26 provides for placement of an x-ray cassette 27 beneath the top surface 14 of the cover 12 .
[0034] Such pressure relief support surfaces are typically used in health care facilities such as hospitals, nursing homes, and extended care facilities. The use of such surfaces is not limited to such facilities, however, and can be used where there is a need, including the home.
[0035] In the illustrated embodiment, the slot 26 extends from one side 18 of surface 10 to the other side 20 . The slot 26 includes a second aperture located along the longitudinal side 20 and provides for passage of the x-ray cassette 27 from a first side 18 of the mattress 10 to a second side 20 of the mattress 10 . The interior region of the slot 26 , located between sides 18 , 20 of the mattress 10 , includes a low friction material to facilitate insertion and removal of the x-ray cassette 27 without disturbing a patient positioned on the mattress 10 . The slot 26 includes a length, L, which is greater than a width, W, of the x-ray cassette 27 . In addition, the longitudinal slot 26 is disposed along a central portion of the support surface 10 . Accordingly, the x-ray cassette 27 can be positioned at a number of locations along the support surface and beneath a patient. While the longitudinal slot 26 is shown disposed towards a central portion of the support surface 10 , the longitudinal slot can be disposed closer to the head end or the foot end portions of the support surface 10 . Additional slots can be included as well. Also, the length L of the slot is not fixed but can be selected to accommodate a variety of sizes of x-ray cassettes 27 as well as to accommodate a variety of positions of the x-ray cassette 27 beneath a patient. For instance, the slot 26 as illustrated enables the caregiver to position the x-ray cassette 27 along or underneath the torso portion of a patient.
[0036] The pressure relief support surface 10 includes a head of bed indicator 30 . The head of bed indicator 30 includes a light 32 or other illumination device which indicates when the head of the bed (HOB) elevation passes a certain predetermined elevation. In one instance, when the head of bed elevation passes thirty degrees, the indicator 32 will light thereby indicating that the desired elevation has been reached. Because the pressure relief support service 10 can be used on any number of bed frames, including those which are fixed in a horizontal plane and those which are continuously or partially adjustable, the head of bed indicator 30 can be either permanently or detachably coupled to the support surface 10 .
[0037] FIG. 2 illustrates an exploded perspective view of the multilayered pressure relief support surface 10 . As illustrated in FIG. 2 , the cover 12 including the slot 26 is shown at the bottom of the figure and is separated from the remaining layers or components of the pressure relief support surface 10 . A perimeter cushion system is disposed within the cover 12 and includes a first section or portion 40 , a second section or portion 42 , and a third section or portion 44 . The perimeter cushion system provides a side and end support of the support surface 10 such that a patient subjected to either turn assist or rotational therapy, to be described later herein, can be cradled to help maintain the patient's location within a central portion of the surface 10 .
[0038] The first section 40 includes a plurality of pieces as illustrated each of which can be either completely separated from an adjacent piece or coupled thereto but still including therebetween a separation line. The use of distinct individual pieces either completely separated or coupled to adjacent pieces provides for articulation of the support surface 10 when used on an articulateable frame. As can be seen, the first section 40 includes first and second end portions 46 , first and second head end portions 48 , first and section foot end portions 50 , first and second thigh portions 52 , and first, second, third, and fourth middle portions 54 . While a predetermined number of individual portions are illustrated, it is possible to incorporate more or less portions than shown depending on the application of the mattress and its use with a bed frame.
[0039] Each of the portions 48 , 50 , 52 , and 54 include an angled side wall which creates an interfacing surface with angled side walls of the individual portions of the second section 42 . The second section 42 includes first and second head end portions 56 , first and second foot end portions 58 , first and second thigh portions 60 , and first, second, third, and fourth middle portions 62 .
[0040] Each of the portions of the second section 42 include angled side walls which cooperate with and which contact the angled side walls of the portions of the first section 40 corresponding thereto. The height of the portions of the second section 42 are less than the height of the individual portions of the first section 40 . When the second section 42 is placed within the first section 40 , each of the portions 42 cooperate to define a substantially horizontal surface 64 upon which the third section 44 can be placed.
[0041] The third section 44 includes a plurality of perimeter bolsters including first and second head end portions 66 , first and second foot end portions 68 , first and second head end side portions 70 , first and second foot end side portions 72 , first and second thigh portions 74 , and first, second, third and fourth middle portions 76 . Each of the portions of the third section 44 are separable from adjacent portions or are coupled for flexibility when used with an articulated deck. In addition, the first and second parts of the portion 66 are spaced apart to define a gap 67 and a similar space or gap 69 exists between the first and second portions 68 . When the first section 40 , the second section 42 , and the third section 44 are assembled together, the space 67 between the portions 66 and the space 69 between the portions 68 correspond to spaces, respectively 80 and 82 of the first section. The spaces 67 , 69 , 80 and 82 define an aperture to locate a first air circulation device or fan 84 and a second fan or circulation device 86 , to be described later herein.
[0042] A plurality of pressure sensors 88 are located and disposed above turning/rotation air bladders 90 and 92 . Force sensing transducers can also be used. The turning/rotation bladders 90 and 92 provide for turning a patient and/or rotating a patient under continuous lateral rotation as would be understood by one of ordinary skill in the art. The plurality of pressure sensors 88 include a first section 94 , a second section 96 , a third section 98 , a fourth section 100 , and a fifth section 102 . Each of the plurality of pressure sensor sections provide a single signal which indicates a pressure amount being supported by respective sections 110 of air cushions. In particular, each section 110 can include a plurality of upstanding air cushions having a cylindrical shape. Other types of cushions or bladders are possible.
[0043] Each of the sections of upstanding cells or air cushions includes a plurality which is disposed directly upon a corresponding pressure sensor section. Consequently, when a patient lies upon the pressure relief support surface 10 , patient pressures upon different portions of the surface 10 can be individually determined by the pressure or force sensor located therebelow. Consequently, pressures for head portions, upper body portions, middle portions, side portions, and leg portions, and other portions of a patient can be individualized for each patient's body.
[0044] Each of the sections 110 of cells includes upstanding cylinders or inflatable cushions which have spaces disposed therebetween. Within the spaces of the upper body section, a thermo-regulation device 112 can be disposed. The device 112 provides for thermal regulation of a patient and can cool and warm a patient. The device 112 can include any number of thermal regulation mechanisms, however, the present device 112 includes a plurality of fluid filled or water filled chambers which are disposed between the spaces of the head end section 110 for the upper body portion. As fluid or water is moved through the thermal regulation device 112 , it is circulated beneath a patient to provide cooling or heating to the patient's upper body. Fluid flow or water flow can move in one direction throughout the device, as would be understood by one skilled in the art, and passes through a controlling device (not shown) which includes a pump and a mechanism for thermal regulation of the fluid.
[0045] A topper 114 is located above the sections 110 . The topper includes a three dimensional material or a three dimensional fiber network made of a breathable fabric or other known three dimensional materials. One such material is known as SPACENET® material. For a further discussion of three dimensional materials, see U.S. Pat. Nos. 7,191,482; 6,701,556; and 6,269,504; all of which are incorporated by reference herein in their entirety.
[0046] The three dimensional material 114 enables the air circulators 84 and 86 to circulate air through the topper 114 . The air circulators 84 and 86 can be configured such that one of the circulators 86 is used to push air through the topper and the other air circulator is used to pull air through the topper. Consequently, air flow can be directed in a single direction.
[0047] A percussion and vibration system 116 is included and disposed at an upper body portion of the support surface 10 . The percussion and vibration system provides for the percussion and vibration of a chest portion of a patient as is understood by one of ordinary skill in the art. Percussion and vibration systems are known and can include a plurality of air bladders, three of which are illustrated.
[0048] FIGS. 3 , 4 , and 5 illustrate a partial perspective view of the x-ray cassette 27 as it passes through the slot 26 . While FIGS. 3 and 4 do not illustrate one of the portions of the topper 114 , the x-ray cassette 26 when in use can be located above the upper body portion of the topper 114 .
[0049] FIG. 6 illustrates a perspective view of the multi-layered pressure relief support surface 10 without the cover 12 . In this illustration, the percussion and vibration bladder 116 is located in the upper body portion of the mattress 10 to provide percussion and/or vibration to the chest area of a patient.
[0050] FIG. 7 illustrates the arrangement of the pressure sensors 88 with respect to the cushion sections 110 . The individual sections 110 have been moved closer together to illustrate that the upstanding cushions when assembled provide a substantially continuous support surface without gaps between sections as is illustrated in FIG. 2 . The individual sections of the pressure sensors 88 have also been moved closer together and the entire combination fits within the cavity defined by the first section 40 , second section 42 , and third section 44 of the perimeter cushion system of FIG. 2 . In other embodiments, horizontal, laterally-oriented or log-shaped bladders may be used in place of one or more of the upstanding cushion sections.
[0051] FIG. 8 illustrates the various portions and layers of FIG. 2 excluding the cover 12 and the x-ray cassette 27 . The turning/rotation bladders 90 and 92 are substantially located within a central portion of the mattress for providing turning as well as continuous lateral rotation.
[0052] FIG. 9 illustrates a sectional view of the support surface 10 of FIG. 1 along a line 9 - 9 . As previously described, and as seen here in additional detail, the portions 58 are in contact with the portions 50 of the first section 40 and define an interface therebetween along the angled side walls of each. The section 72 of the third section 44 sits upon a substantially flat and horizontally disposed top surface of the portion 50 . Also, as can be seen, the upstanding cushions 110 are located above the pressure sensors 102 .
[0053] FIGS. 10-12 illustrate a controller 120 including a user interface 122 . The user interface 122 is coupled to the controller 120 through a swiveling mechanism 124 which enables the 122 to lay substantially flat against a top portion 126 of the controller 120 . The swiveling mechanism 124 enables the pivoting screen to move about an axis substantially parallel to the long dimension of the controller 120 . The swiveling mechanism also includes a rotating portion 128 which enables the interface 122 to rotate about an axis substantially vertical with respect to the plane of the top portion 126 . The swiveling mechanism 124 and rotating portion 128 in combination provide an adjustment capability which allows the pivoting interface to be moved in a variety of positions for improving access of the interface 122 to a user or caregiver. The user interface can include a variety of selectors which can include touch screen selectors, pressure sensitive buttons, and/or mechanical switches. Other later described screens can include the same selectors. The user interface can also include an electronic display, such as an liquid crystal diode (LCD) display which can display user interface screens to be described later herein.
[0054] FIG. 13 illustrates a perspective view of an airway clearance system 130 integrated with a support surface through a control unit 131 . The mattress or support surface 10 is illustrated with the cover 12 but not including the slot 26 , which can be optional. The airway clearance system 130 includes a high frequency chest wall oscillation device 132 which is coupled to the control unit 131 . One example of such a device is available from Hill-Rom, Inc. as The Vest® airway clearance system.
[0055] The control unit 131 provides for chest wall oscillation through the use of forced air which is moved through first and second tubes 136 , 138 which are coupled to the controller 131 through first and second couplers 140 , 142 . The tubes 136 and 138 are coupled to an upper body portion 144 which surrounds the chest wall and provides high frequency chest wall oscillations for the purpose of airway lung clearance and ventilation as described in U.S. Pat. No. 6,736,785, which is incorporated in its entirety by reference herein.
[0056] As illustrated in FIG. 13 , the controller 131 is coupled to the upper body portion 144 and enables a patient or other user who may or may not be located on the support surface 10 to use the airway clearance system 130 . For instance, when a patient is sufficiently mobile to move within a facility and to sit in a chair within a hospital room, the patient can wear the upper body portion 144 when seated in a chair. As further illustrated in FIG. 14 , the controller 134 can also be coupled directly to the support surface 10 through a hose 150 . The hose 150 is coupled to a connector 152 which is in turn coupled to an internal hose device 154 which passes through and is incorporated in the support surface 10 . A first and a second connector 156 and 158 respectively terminate the hose 150 . Using this connection 156 , 158 to couple to an external device, a patient lying with his or her head located at the head of the bed (HOB) can wear the upper body portion 144 when lying in bed to provide the chest wall oscillation. When controller 131 detects connection of an airway clearance system 132 , controller 131 automatically disables or bypasses the mattress pulmonary therapy functions and the controller user interface 123 is automatically updated to visually indicate the status of a connection or disconnection of the airway clearance system. In this way, controller 131 can be used to control inflation and deflation of bladder portions of mattress 10 and/or to control operation of the airway clearance system 132 . As such, the need to provide multiple separate control units (i.e., a mattress controller and an airway clearance system controller) may be eliminated.
[0057] Alternatively or in addition, controller 131 is sized and shaped so that a separate airway clearance system controller is stackable on top of or underneath controller 131 , to thereby conserve space in the patient's healthcare environment. Controller 131 may include all or a portion of the features of control unit 120 or control unit 160 .
[0058] FIG. 15 illustrates a perspective view of a control unit 160 having a holder 162 which can be used to support a deep vein thrombosis device (DVT) 164 by insertion into holder 162 as indicated by arrow 163 . A cuff is generally provided with DVT device 164 but is not illustrated. The controller 160 includes a first attachment device 166 and second attachment device 168 . Devices 166 , 168 can include a first and second hook, which can be used to hang the controller 160 on a footboard, headboard, and/or side rail of a patient support frame. The controller 160 includes a user interface 170 which is fixed and coupled to the controller 160 . The DVT device 164 can be used to provide pneumatic pressure to a body limb to reduce or to prevent deep vein thrombosis. For additional details, please see U.S. Pat. No. 6,447,467 and U.S. Pat. No. 6,494,852 which are incorporated herein by reference in their entirety.
[0059] FIGS. 16-18 illustrate various user interface screens displayed on a user interface 170 such as previously described. In the illustrated embodiments, a touch screen, including a liquid crystal display (LCD) and touch sensors are used, however, it will be understood by those skilled in the art that other suitable displays and/or input-output devices may also be used. Also, in the embodiment of FIGS. 16-18 , status information is generally displayed on the left-hand side of the screen while activatable buttons are generally located on the right-hand side of the screen. Each of the tabs listed down the right-hand side of the screen, i.e., “home”, “rotation”, “percussion”, “vibration”, “chest device”, “max inflate”, “turn assist”, and “opti-rest” relates to another user interface screen comprising information and user-activatable controls relating to the identified functional capabilities. In this way, all of the available functions are displayed at all times for easy access by the user. However, in the illustrated embodiment the screen that is currently in use or active is emphasized or offset from the inactive screens by highlighting or contrasting color.
[0060] For example, as illustrated in FIG. 16 , the user interface screen includes a portion 171 which is entitled “HOME”. The “HOME” section enables a user to select certain tabs which initiate therapies. Those tabs can include rotation, percussion, vibration, and chest device corresponding to the chest wall oscillation device. Additional tabs are provided for adjusting mattress functions such as maximum inflate, turn assist, and Opti-rest. Opti-rest is a wave-like comfort modality with cushion pressures alternating to enhance patient comfort. A status section 172 indicates the status of rotation, percussion and/or vibration depending on which tabs have been selected on the right hand portion of the user interface 170 .
[0061] As further illustrated in FIG. 17 , should the rotation tab be selected, a rotation screen 170 indicates and provides the amount or percentage of rotation for a right, a center, and a left position at a status area 172 . FIG. 17 illustrates an “empty” status area 172 in which no pulmonary therapy options have been initiated. FIG. 18 illustrates a status area 172 in which rotation percentages have been set and a rotation therapy is in progress. In such event, status area 172 indicates the amount of time remaining until the therapy is complete.
[0062] Slider bars, or arrows 173 and 174 , can be used to select the desired settings. For instance, as illustrated in the right tab in which the right side of the body is lower than the left side, the rotation is set at 50% with the up down arrow 173 . The pause time can be set to 15 minutes with the up down arrow 174 . An enter button 175 is provided to finalize or to accept the settings made for pause and rotation. In addition to the right screen, a center screen and a left screen are also provided which can be selected by touching the desired center or left tab. As described with respect to the right screen, the rotation percentage and pause time can be set for both center and left. Once the right, center and left settings have been selected, the enter button 175 is selected to enter the data into the controller. The rotation screen, located below the status screen 172 , indicates the values of rotation, pause, as well as time remaining. If either percussion and/or vibration is selected, the settings are made similarly as described with respect to the rotation screen and entered as necessary with the enter button. Once entered, the status screen 172 which includes a section for percussion and vibration shall illustrate the selected settings. A pause button 176 can be used to pause the selected treatments and then return to those treatments by touching the pause button a second time. Also, if it is desired to completely stop the selected treatment, the stop button 177 can be selected to stop the selected treatment as well as to clear the previously established settings.
[0063] The max inflate tab can be selected to inflate the cushions of the support system 10 to a maximum inflation, for instance, to enable a patient to enter and exit the bed more easily or to provide for cardio-pulmonary resuscitation. A turn assist tab is included and can be selected to elevate a left side or a right side of a patient to move a patient on one side or the other such that clothing and/or bed linens can be changed or removed. An Opti-Rest tab can be pressed to provide the wavelike comfort modality.
[0064] FIG. 19 illustrates a head-end view of one embodiment of an elevation device 180 , which may be used in place of turning/rotation bladders 90 , 92 . The elevation device 180 has two hinge points 191 and 193 and thereby provides a function of alternatingly elevating each lateral side of the head end of the support surface. The elevation device 180 includes a bellows type of construction as illustrated in a side view of FIG. 20 and a schematic view of FIG. 21 . The elevation device 180 of FIGS. 19-21 , illustrated in FIG. 19 as an end view from the head end of the mattress and in FIG. 20 as a side view from one of the sides of the mattress, includes first, second, third, and fourth compartments 182 , 184 , 186 , and 188 . Each compartment 182 , 184 , 186 , and 188 has a first width 185 , and a second width 187 .
[0065] As shown in FIG. 21 , an outer layer of the bellows 180 includes a first length L 1 and an inner layer includes a length L 2 . Each compartment 182 , 184 , 186 , and 188 has length L 2 . The bellows 180 includes at least one fill port 190 which is used to fill the bellows or a portion thereof with a fluid such as air. A reinforcer 192 is used around the outer compartments of the bellows 180 to help prevent distortion due to pressure variations.
[0066] In the illustrated embodiment, device 180 is configured to elevate one lateral side of mattress 10 , relative to the other side, and another device 180 may be positioned laterally adjacent the first device 180 to elevate the other lateral side of the mattress 10 . For instance, one instance of device 180 is positioned to provide turning assistance or rotational therapy to a patient's left side while another instance of device 180 is positioned opposite the first instance of device 180 , across the width of the mattress 10 , to provide turning assistance or rotational therapy to a patient's right side. In this embodiment, the first width 185 of compartments 182 , 184 , 186 , 188 is larger than the second width 187 so that when fluid is provided through port 190 the bellows shape is created such that the height of the device 180 on the side of the compartments 182 , 184 , 186 , 188 containing the first width 185 is higher than the height of the device on the side containing the second width 187 , in order to provide the specified turning or rotation angle “A”.
[0067] In one alternative embodiment, referred to herein as the “dual hinge” embodiment, reinforcer 192 also comprises an internal air flow barrier along the dashed line between points 189 and 192 of FIG. 21 , which extends into the interior region of compartments 182 , 184 , 186 , and 188 to control air flow between first and second portions 195 , 197 of the compartments 182 , 184 , 186 , and 188 . As a result, air can be held in either portion 195 or portion 197 to provide turning assistance, or air can be alternatingly exchanged between portion 195 and 197 to provide rotational therapy. In the dual hinged embodiment, when portion 195 of compartments 182 , 184 , 186 , and 188 is inflated, device 180 is hinged at point 193 . When portion 197 of compartments 182 , 184 , 186 , and 188 is inflated, device 180 is hinged at point 191 . In the dual hinged embodiment, first and second widths 185 , 187 are substantially the same.
[0068] As can be seen in FIGS. 19 and 20 , device 180 comprises a pair of longitudinally spaced bellows 181 , 183 that may be operable either in concert or independently to provide turning assistance or rotational therapy. Each device 181 , 183 includes a substantially rigid support 194 , 195 , which rests upon the top portion of the bellows 180 and is held thereto by straps 196 , 197 . The substantially rigid support 194 provides for a supporting surface during elevation and rotation of the head or torso portion of the patient support 10 .
[0069] The device 180 is not limited to elevation of the head or torso, but may also be used to elevate the lower extremities if placed at the foot end of the support surface. For example, either or both of sections 181 , 183 of device 180 may be positioned underneath leg, calf or foot portions of a patient, and portions 195 , 197 may be alternatively inflated and deflated, independently or at the same time, to exercise either or both of the knee joints of a patient positioned on mattress 10 .
[0070] In one embodiment, the elevation device 180 is constructed to provide an elevation of about thirty degrees from horizontal. Other elevations are also possible, for example by inflating less than all of the compartments 182 , 184 , 186 , and 188 . To achieve a greater degree of rotation, i.e., in the range of about 45°, a portion of the surface bladders 110 may be deflated under one side 195 while the opposite bellows 197 are inflated, or vice versa. In such event, one or more perimeter bladders/supports 40 , 42 , 44 provide additional support to the non-elevated side of the patient. A string potentiometer, one or more ball switches, or other suitable device may be operably connected to the mattress and control unit to measure and monitor the degree of rotation provided by the portions 181 , 183 of device 180 .
[0071] FIG. 22 illustrates another embodiment of the present invention in which the support surface 10 is placed upon a frame 200 which includes and integrated device or a number of integrated components and features which interact with and provide support for the features of the support surface 10 . For instance, all or a portion of the surface controls and user interfaces previously described with respect to the controllers 120 , 131 , 160 and also described later herein of FIGS. 16 , 17 , and 18 can be integrated into the one or more of the frame siderails 209 , 211 . In addition, the frame 200 includes an integrated control system 199 including first and second connection ports 202 and 204 into which a high frequency chest wall oscillation device 215 can be connected via hoses 217 , 219 . Vest device 132 may similarly be connected to ports 202 , 204 . In the embodiment of FIG. 22 , aspects of the controller 131 of FIG. 13 are incorporated into the frame control system 199 . Because the support surface 10 includes an integrated percussion and vibration, rotational therapy, and low air loss wound care/prevention surface, the surface/frame combination can provide a plurality of healthcare features in an integrated surface/frame combination.
[0072] FIG. 23 illustrates a block diagram of a bed frame or pressure relief surface control and communication system, such as controllers 120 , 131 , 160 , 199 , including controlling and communication devices to communicate with an integrated chest wall oscillation device such as device 132 or device 215 . The communication system includes a liquid control display (LCD) device or other user interface device 210 which receives from a user a selection of mode, mode parameters and alarm resets. This information is displayed to the user. The parameters can include, for example, comfort adjust, percussion, vibration, and settings for the chest wall oscillation device. The user interface screen is coupled to an algorithm control unit 212 which processes pressure relief algorithms for the pressure relief surface. In addition, pressure setpoints are determined by the algorithm control unit 212 and also algorithm control unit 212 also processes patient position monitoring, motion monitoring, and controls a compressor. The unit 212 also communicates with the chest wall oscillation device, power printed circuit board (PCB) and provides the control settings for the chest wall oscillation device.
[0073] The algorithm control unit 212 communicates and is coupled to the chest wall oscillation device power board 214 by a connection 224 , described further below. The power board 214 receives amplitude and frequency signals and directly stimulates the air generator for the chest wall oscillation device. The power board 214 also provides feedback to the algorithm control unit 212 .
[0074] An air control board 216 , which can be located within the pressure relief surface 10 or which can be located in one or more of the previously described controllers, is also coupled to the algorithm control unit 212 . The air control board 216 receives pressure setpoints which have been set in the algorithm control unit 212 as well as controls the valves in response to instructions either provided by the algorithm control unit 212 or which have been set by a user at the user interface or LCD 210 . The air control board 216 also generates requests to the algorithm control unit 212 to turn the pump ON and OFF which controls the pressure in the individual air cushions or bladders.
[0075] The support surface 10 , as previously described, includes pressure sensing or force sensing transducers 218 . These pressure sensing or force sensing transducers 218 are coupled to a multiplexor hub 220 which is, in turn, coupled to the algorithm control unit 212 . The multiplexor hub 220 receives data from the transducers or sensors and retransmits the data on a bus which is located in the communication system described in FIG. 23 . The bus is a network bus and the network can be of one or more types, including an ECHELON network and/or controller area network (CAN). To provide communication between the bed frame and various other described features, a gateway device 222 receives data from the bed frame first network and provides information on a second network. The second network transmits signal information such as head angle, side rail status, side rail button, switch presses, and patient weight. The first network in the described embodiment can include an ECHELON network and the second network can include a CAN.
[0076] Interfacing an airway clearance system as a component in the mattress system may reduce the number of components required to be provided in the airway clearance system controller or eliminate the need for a separate controller. For instance, a local display may not be required at the airway clearance controller since the mattress controller display can be used to show airway clearance information and controls. Also, power and motor control may be shared by the two systems. This combined architecture requires isolation and grounding issues to be addressed.
[0077] Accordingly, connection 224 may include an AC isolation transformer and be configured to use the local ground as the system reference. For example, a 5 Amp AC isolation transformer may be used to isolate the airway clearance system board 214 from the AC supply, and allow the connection of the airway clearance system board 214 to the mattress system ground. If an isolation transformer is used, and an additional power relay is used to control the power to the airway clearance system board 214 , Table 1 illustrates signals that may be used to communicate from the algorithm board 212 to the airway clearance system board 214 .
[0000]
TABLE 1
SIGNAL
TYPE
DESCRIPTION
BLOWER_REQ
OUT
PWM to DC signal - control
blower speed
BLOWER_HALL
IN
Hall sensor - blower motor speed
DIAPHRAGM_REQ
OUT
PWM to DC signal - control
diaphragm speed
DIAPHRAGM_HALL
IN
Hall sensor - diaphragm motor
speed
POWER_RELAY
OUT
Relay control for VEST power
relay
VEST_PRESENT
IN
VEST system is present/powered
signal
GND
GROUND
Signal ground - mattress side
[0078] The POWER_RELAY signal may be used to power the airway clearance system, when requested, and the VEST_PRESENT may be used to verify that the airway clearance system is present and powered. The BLOWER_REQ signals control the blower motor voltage, and the BLOWER_HALL returns the motor speed. The DIAPHRAGM_REQ signals control the blower motor voltage, and the DIAPHRAGM_HALL returns the motor speed. Software algorithms correlate the speed and pressure.
[0079] An additional input to the algorithm processor 212 may also be needed, to detect when the airway clearance system air supply is connected to the mattress air system, rather than the actual airway clearance.
[0080] Connection 224 may alternatively include opto isolators and mechanical isolation. Optically isolated signals may be used to provide the needed airway clearance system isolation from the AC system. This configuration allows the airway clearance system board 214 to remain directly connected to the AC supply, and provides an interface with opto isolators in each direction to provide an isolated communication path between the algorithm board 212 and the airway clearance system board 214 . This approach may require a level of mechanical isolation to ensure isolation. A relay controlled by the algorithm board 212 may be provided between the AC source and the airway clearance system board 214 , for additional safety and to remove power to the airway clearance system when not in use. A signal indicates the connection and/or powering of the airway clearance system board 214 .
[0081] If the opto isolator approach is used, and an additional power relay is used to control the power to the airway clearance system board, Table 2 illustrates signals that may be used to communicate from the algorithm board 212 to the airway clearance system 214 .
[0000]
TABLE 2
SIGNAL
TYPE
DESCRIPTION
+5 V
POWER
Interface power - mattress side
BLOWER_REQ
OUT
PWM to DC signal - control
blower speed
BLOWER_HALL
IN
Hall sensor - blower motor speed
DIAPHRAGM_REG
OUT
PWM to DC signal - control
diaphragm speed
DIAPHRAGM_HALL
IN
Hall sensor - diaphragm motor
speed
POWER_RELAY
OUT
Relay control for VEST power
relay
VEST_PRESENT
IN
VEST system is present/powered
signal
GND
GROUND
Signal ground - mattress side
[0082] The POWER_RELAY signal is used to power the airway clearance system, when requested, and the VEST_PRESENT is used to verify that the airway clearance system is present and powered. The BLOWER_REQ signals controls the blower motor voltage, and the BLOWER_HALL returns the motor speed. The DIAPHRAGM_REQ signals controls the blower motor voltage, and the DIAPHRAGM_HALL returns the motor speed. Software algorithms correlate the speed and pressure. Each side of the interface provides local +5V power and ground.
[0083] As additional input to the algorithm processor 212 may also be needed, to detect when the airway clearance air supply is connected to the mattress air system, rather than the actual airway clearance unit.
[0084] The opto isolators and relay may be located on the same circuit board, and may be associated with the airway clearance board 214 to minimize the exposure of the circuitry at a high voltage.
[0085] Two possible configurations for the mattress—airway clearance system interface are described above. Each approach has associated pro and cons. The opto isolated approach may have a lower electrical cost, but may have an increased mechanical cost to ensure sufficient airway clearance system isolation. The isolation transformer approach may provide a simpler mechanical design and better isolation, but may have an additional cost associated with the isolation transformer. The cost and risk associated with each approach will need to be evaluated to determine the best system approach for a particular implementation of the present invention.
[0086] The airway clearance system board interface is designed to communicate with the user interface board 210 in close proximity. If the cable distance between the algorithm board 212 and the airway clearance system board 214 is a significant distance, signal conditioning may be required, using digital signals, and an interface board may need to be located physically closer to the airway clearance system board 214 . Low voltage drivers, or RS232 drivers may be used to boost the signal level. The PWM to DC filtering should be done close to the airway clearance system board 214 to minimize noise on this signal. If the opto isolated approach is used, then the signals between the daughter board and airway clearance system board may need additional optical elements.
[0087] FIG. 24 illustrates one embodiment of a user interface screen which can be used on any of the previously described controllers and interfaces as well as with the bed frame described herein with reference to FIG. 22 , where the interface can be embodied or incorporated into a siderail, head board, and/or footboard. As illustrated in FIG. 24 , the user interface screen 300 can include a variety of selectors which can be touch screen selectors, pressure sensitive buttons, and/or mechanical switches. The features which can be accessed from the user interface screen of FIG. 24 via selectors include a standard operating mode 302 , an Opti-Rest mode 304 , a rotation mode 306 , an airway clearance system mode 308 , a percussion mode 310 , a vibration mode 312 , a maximum inflate mode 314 , a turn assist mode 316 , and a cardio pulmonary resuscitation (CRR) assist mode 318 . In addition, start and stop buttons 320 , 322 as well as back 332 and edit buttons 324 are available. Likewise, the user interface screen can be used to access other therapy and controls 326 , setting alarms 328 , and settings for a variety of features including pressure settings 330 .
[0088] FIG. 25 illustrates one example of a user interface screen 400 where percussion and vibration parameters can be set for the mattress support 10 . While FIG. 24 illustrates a single selector 310 for percussion and a single selector 312 for vibration, the user interface screen of FIG. 24 may alternatively or in addition include a single button for both percussion and vibration (P&V), which upon selection accesses the user interface screen of FIG. 25 .
[0089] The user interface screen 400 of FIG. 25 enables an individual to select percussion therapy only 402 , vibration therapy only 404 , or both percussion and vibration therapy 406 with a P & V selector. In addition, the frequency 408 , 416 intensity 410 , 418 and duration 412 , 420 can be set for percussion and/or vibration by selecting or activating a change selector 414 , 422 , respectively. The change selectors 414 , 422 access a second user interface screen (not shown) where frequency, intensity, and duration can be selected or changed for the percussion and/or vibration therapy. Once the settings for frequency and/or vibration have been changed, the selected values are displayed on the user interface screen of FIG. 25 . For instance, in the illustrated embodiment, percussion frequency 408 and vibration frequency 416 are selected as a function of beats per second (bps), percussion intensity 410 and vibration intensity 418 are selected as being a low, medium, or high intensity, and percussion duration 412 and vibration duration 420 are selected as a value based on the number of minutes desired for the duration to occur. The percussion and vibration screen 400 of FIG. 25 also enables the user to select and to change the values for continuous lateral rotation therapy (CLRT) via button 424 . Once button 424 is selected, the preselected values for percussion, vibration and continuous lateral rotation therapy can be started by pressing the start selector 428 . A help button 430 can be activated to provide user information for additional details and a close button 432 can be activated to close the displayed screen 400 and return to the screen 300 of FIG. 24 .
[0090] FIG. 26 illustrates one example of a rotation user interface screen 500 which has been accessed through the selection of the CLRT selector 424 of FIG. 25 . The turn (rotation) percentages 502 , 504 can be selected for a patient at a left turn and a right turn and the pause 506 , 508 , 510 in minutes can be selected to place the patient at a particular position for the selected period of time. Additionally, a use rotation training button 512 can be used to acclimate the patient to continuous lateral rotation therapy. By selection of this particular selector 512 , the angle of rotation therapy is gradually increased to the maximum turn which has been selected. A rotation monitor 514 is also included and indicates the amount of time the patient has been under the rotation therapy in the most previous 24 hours.
[0091] If the airway clearance selector 308 of FIG. 24 is selected, the user interface screen 600 of FIG. 27 is displayed. At this screen, a user can select the pulse frequency 602 in beats per second, the intensity 604 of pressure applied by the airway clearance system to the chest of a patient, and time duration 608 of the airway clearance therapy in minutes. Screen 600 also includes a help/training graphic and/or visual feature 612 to aid the caregiver in administering the airway clearance therapy.
[0092] FIG. 28 illustrates a therapy reminder user interface screen 700 in accordance with the present invention. By selecting the therapy and controls selector 326 of FIG. 24 , the therapy reminder screen 700 of FIG. 28 is displayed. At this screen, a user can select reminders 702 , 706 , 710 for the therapies of rotation, percussion and vibration, and airway clearance. The length of time between the last therapy session and the reminders is specified at areas 704 , 708 , 710 for each of the rotation, percussion and vibration, and airway clearance therapies, respectively. This length of time is adjusted using button 714 to increase the delay and by using button 716 to decrease the delay. Other reminders are also possible. For instance, it is possible to provide an alert if rotation has been stopped for a selected period of time, which in this case is shown to be 90 minutes. Likewise, percussion and vibration as well as airway clearance reminders can be selected for every eight hours, for instance. Once the selected time period has elapsed, an alarm, such as a visual or aural alert is made to indicate that it is time to provide the therapy. While the figures show reminders and other parameters configured for each of the available therapies, it will be understood by those skilled in the art that any combination of the available therapies may be activated or deactivated at a given time.
[0093] By selecting the alarm selector 328 of FIG. 24 , an alarm settings user interface screen 800 as illustrated in FIG. 29 is displayed. Upon selection of this particular interface screen 800 , a user can select a bed exit alarm for a sitting up position 802 , a sitting on edge of bed position 804 , or an out of bed condition 806 . For instance, if a patient sits up and the sitting up selector 802 has been selected, whenever a patient sits up an audio or visual alarm will be activated. The volume level of the audio alarm which is activated can be selected by an alarm volume selector 812 which includes a negative or down volume selector 810 and a positive or up volume selector 812 . If the bed exit alarm of sitting on edge 804 has been selected, even though a patient sits up in bed, an alarm will not sound. However, when a patient moves to sitting on the edge of the bed, an alarm will sound or otherwise be activated. Should the user select the out of bed condition alarm 806 , a patient in a sitting up position or a sitting on edge position will not trigger the alarm. Only when a patient exits the bed will an alarm be activated. An edge lying alarm 808 is also included which indicates to a user that a patient is lying on the bed and is close to an edge which can be a condition that is not desirable.
[0094] FIG. 30 illustrates a therapy log user interface screen 900 which can be selected by the therapy and controls button 326 of FIG. 24 . The therapy log user interface screen 900 can be used to review data which has been stored regarding the various selected therapies over a period of time, for instance, 24 hours as illustrated in FIG. 30 . The details of rotation 902 , head elevation 904 , percussion and vibration 906 , alarms activated 908 , and airway clearance 910 can be displayed. A visual bar graph of rotation is shown in area 902 as well as the actual hours and minutes of time a patient has experienced rotation. Head elevation is also shown in area 904 as a series of icons which show a horizontal state, a partially elevated state and a more highly elevated state or sitting up state for the patient. Percussion and vibration is illustrated in area 906 by a bar located along a time line of zero to 24 hours to indicate when the percussion and vibration has been applied to a patient. In this instance, three treatments have been applied over a period of 24 hours. In the alarms portion 908 of the user interface screen 900 , one alarm occurred over the 24 hour period as shown by the 24 hour time line and as indicated by the statement of one alarm. In the airway clearance portion 910 of the therapy log 900 , there have been no treatments over the last 24 hours. However, the portion of the airway clearance area 910 indicates that the last treatment was five days ago. Consequently, if there has been no airway clearance procedures performed over the last 24 hours, the system can display when the last treatment occurred. It is also possible to display similar information for the other four displayed functions. For instance, if there have been no percussion and vibration treatments over the last 24 hours, it is possible to display the number of days which has elapsed since the last treatment.
[0095] Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of the present invention. For instance, while the figures illustrate a surface including a plurality of upstanding air cushions having a cylindrical shape, other air cushions are within the scope of the present invention. Air bladder assemblies having horizontally disposed or transversely disclosed bladders are within the scope of the invention. Other pressure or force sensing transducers than those disclosed herein are also within the scope of the present invention. For additional details of such bladders or sensing transducers, please see U.S. Provisional Patent Application Ser. No. 60/821,494, the disclosure of which is incorporated herein by this reference. | A patient support surface including a cover defining an interior region, a layer of three dimensional material, located at the interior region, and an air circulation device disposed adjacent the layer of three dimensional material. The patient support surface includes at least one of a percussion device and a vibration device, located at the interior region. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates generally to an air filter system. In particular, the present invention relates to structure and method for removing moisture from gas turbine inlet air.
Filter systems for gas turbine inlet air are known. One such known system includes a housing defining chamber. The chamber has an air inlet side and an air outlet side separated by an array of filters for removing particulates from the inlet air flow. Air enters the chamber through a plurality of vertically spaced inlet hoods positioned along the air inlet side. The inlet hoods are configured such that air entering the inlet hoods is first directed in an upward direction and then deflected by deflector plates in a downward direction. Air flow contact with the deflector plates causes some particulate material and moisture from the moving air to separate from the air flow and settle or accumulate on the inlet hoods or in the bottom of the chamber.
Another known gas turbine air filter system is similar to that described above. It further includes a mist eliminator located in each hood. A pleated element is positioned on top of the mist eliminator. Relatively large drops of moisture in the inlet air stream is removed by inertial separation in the mist eliminator. Smaller droplets of moisture are removed by the pleated media. The removed moisture droplets fall onto hoods below and onto the ground.
Such known gas turbine filter systems may be rather large. That is, they occupy a relatively large “footprint” adjacent to the gas turbine which may be undesirable in some applications. Such known filter systems may also not be as effective as desired and have other disadvantages, for example leakage around mounting structure. Accordingly, there is a need for improvements to gas turbine inlet filter systems.
BRIEF DESCRIPTION OF THE INVENTION
The invention offers an improved moisture removal for filter systems. The improvements include a relatively smaller housing package, consistent moisture removal over time by a filter with simple and reliable mounting structure.
One aspect of the invention is a moisture removal structure for a filtration system. The structure includes a housing. A hood is attached to the housing. The hood has a surface disposed at an acute angle relative to horizontal. A preliminary filter is supported above the hood and extends in a downward direction. The preliminary filter comprises media capable of separating moisture from the air flowing through the preliminary filter at an exterior portion of the preliminary filter. Separated moisture agglomerates into a drop incapable of being carried by the flow of air so the drop falls onto the hood and directed away from the flow of air.
Another aspect of the invention is a moisture removal system for a gas turbine. The moisture removal system comprises a housing for supporting a primary air filter. The housing is operably connected with a gas turbine. A hood is attached to the housing. The hood has a surface disposed at an acute angle relative to horizontal. A preliminary filter is supported above the hood and extends in a downward direction. The preliminary filter comprises media capable of separating moisture from the air flowing through the preliminary filter at an exterior portion of the preliminary filter. Separated moisture agglomerates into a drop incapable of being carried by the flow of inlet air so the drop falls onto the hood and directed out of the flow of inlet air.
Another aspect of the invention is a method of removing moisture from inlet air flowing to a gas turbine. The method comprises the steps of providing a housing for supporting a primary air filter. The housing is operably connected with a gas turbine. A hood connected with the housing is provided. The hood has a surface disposed at an acute angle relative to horizontal. Inlet air flow is directed into a preliminary filter supported above the hood and extending in a downward direction. The preliminary filter comprises media capable of separating moisture from the inlet air flowing through the preliminary filter at an exterior portion of the preliminary filter. Separated moisture agglomerates into a drop incapable of being carried by the flow of inlet air so the drop falls onto the hood to be directed out of the flow of inlet air.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the invention will become apparent to those skilled in the art to which the invention relates from reading the following description with reference to the accompanying drawings, in which:
FIG. 1 is a schematic view, partly in section, of a moisture removal system, constructed according to one aspect of the invention for a gas turbine air inlet;
FIG. 2 is an enlarged view of a housing of the moisture removal system illustrated in FIG. 1 ;
FIG. 3 is a enlarged view of a portion of the housing of the moisture removal system illustrated in 2 ;
FIG. 4 is view of a preliminary filter array of the housing of the moisture removal system; and
FIG. 5 is a perspective view of a filter assembly illustrated in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
A filter system 20 constructed according to one aspect of the invention for filtering inlet air of a gas turbine 22 is illustrated in FIG. 1 . The gas turbine 22 can be used for any desired purpose, such as powering an electrical generator 24 . The gas turbine 22 uses a relatively large quantity of air that is directed to a compressor portion 40 , gets ignited and where expanding gases ultimately drive a turbine portion 42 . The large quantity of inlet air must be filtered of particulates, salt and moisture in order to prevent damage and accelerated wear to components of the gas turbine 22 .
Various aspects of the invention are described with respect to an inlet system for a gas turbine 22 . It will be appreciated that the aspects of the invention are also applicable to a variety of other applications that are prone to damage by moisture and particulates. For example, the various aspects of the present invention are applicable to applications such as internal combustion engine intake systems, clean room intake systems, heating ventilating and air conditioning (HVAC) systems, hospital HVAC systems and air compressor intake systems.
Moisture contamination is particularly problematic in environments having relatively high humidity, such as in marine or off-shore applications, or in conditions such as rain, mist or fog. If the air passing into an air filtration system is relatively humid it then migrates through the filter media. This type of moisture migration can cause substantial problems with gas turbine operations and is a particular problem addressed by at least one aspect of the invention. It is well known that light rain, mist and fog create very small moisture droplets that are easily carried in a fast moving stream of air, such as inlet air for a gas turbine 22 . This is the main type of moisture that is addressed by this aspect of the invention. Generally, heavy rain has drops that are too large to be easily carried in a flow of air.
According to one aspect of the invention, improved moisture removal is provided for the air inlet filter system 20 . The filter system 20 ( FIG. 2 ) includes a first preliminary stage or moisture removal system 60 and a second stage or primary filter 62 positioned downstream from the preliminary filter structure. Ducting 64 directs filtered air from the filter system 20 to the gas turbine 22 .
The filter system 20 includes a housing 80 defining a chamber 82 . The chamber 82 has an inlet side 84 and an outlet side 86 . The housing 80 is constructed of any suitable material, such as metal framing and sheet. The housing 80 can be constructed to have a relatively small footprint. This results because the chamber 82 does not have to provide for collection areas for moisture separated from the air flow since the majority of the moisture removal is accomplished outside the housing 80 .
Inlet air enters the chamber 82 through the moisture removal system 60 . The housing 80 supports the primary air filter 62 . The primary filter 62 functions mainly to remove particulates from the inlet air that could be harmful to the gas turbine 22 . The primary filter 62 can be of any suitable construction, but is illustrated as an array of panel filters. The panel filters are made from any suitable material selected for the application they are used in. It will be appreciated that any suitable filter construction may be used as the primary filter 62 , such as without limitation cartridges or bags.
The moisture removal system 60 includes a plurality of vertically spaced inlet hoods 100 positioned along the inlet side 84 of the chamber. The hoods 100 are attached to the housing 80 . Each of the hoods 100 has a surface disposed at an acute angle relative to horizontal. This orientation forces the air flow to move initially in an upward direction, as illustrated in FIG. 3 . The orientation of the hood 100 also serves to keep relatively large moisture drops, as encountered in heavy rain or snow, from the inlet air flow, as viewed in FIG. 3 .
Preliminary filters 120 are supported above each of the hoods 100 , except the uppermost hood as viewed in FIGS. 1-3 . The preliminary filters 120 extend in a substantially downward direction. Each preliminary filter 120 ( FIG. 5 ) includes a relatively rigid plastic frame 122 that extends around the periphery of the preliminary filter and internal support and reinforcing ribs 124 . Bags or “pocket filters” 126 are supported by the frame 122 and ribs 124 . It will be appreciated that any suitable filter construction may be used for the preliminary filter 120 , such as without limitation bags or cartridges. It will also be appreciated that any suitable frame material may be used, such as without limitation stainless steel.
It will further be appreciated that the orientation of the pocket filters 126 may be different than that shown for illustration purposes in FIGS. 1-5 . For example, the apex of the pocket filter 126 may be oriented parallel to the direction of inlet air flow in order to minimize the chance of the pocket filter deforming, folding or collapsing under the force of inlet air movement. It is contemplated that the sides of the pocket filters 126 may have to be connected together, such as by sewing, at appropriate locations. This connection is to maximize the aerodynamic efficiency of the pockets within a particular pocket filter 126 configuration and to minimize contact between adjacent pockets that would inhibit air flow.
Each pocket filter 126 is made from suitable filter media with hydrophobic properties. One such filter media is a single layer of 100% polypropylene fiber material. It will be appreciated that other suitable materials may be used, such as a mixture of polypropylene and polyester fibers, and thermally bonded polypropylene or polyester bi-component fibers (and mixtures thereof). The media may be non-woven, air laid, carded or needle punched. The media preferably has an average thickness in the range of about 4 mm (0.157 inch) to 18 mm (0.709 inch). The media may have a graded density to improve filter life. If the fiber material is not inherently hydrophobic, the fibers are coated to provide hydrophobic properties to the media.
The pocket filters 126 of the preliminary filter 120 are made from filter media capable of separating moisture droplets from the air flowing through the preliminary filter. The separated moisture droplets collect on an exterior surface of the bags 126 if the preliminary filter 120 . Separated moisture droplets agglomerate into a relatively larger drop 128 ( FIG. 3 ). The drop 128 has a size and mass that's incapable of being carried by the flow of inlet air. The drop 128 falls onto the hood 100 below and is directed out of the flow of inlet air by creating a stream 140 or sheet of water that runs down the hood 100 .
The stream 140 runs to the lowermost edge of the hood 100 . The stream 140 is collected in a conduit 142 attached to the hood 100 . The conduit 142 conducts the collected water in a direction laterally away from the direction of flow of the inlet air.
Several preliminary filters 120 ( FIG. 4 ) are mounted in the underside of the hoods 100 . The preliminary filters 120 are slid into mounting channels 160 . The mounting channels 160 are closely sized to fit the frames 122 of the preliminary filters 120 to provide a good seal to inhibit leakage through the interface. Adjacent preliminary filters 120 may engage one another when installed in a row, as illustrated in FIG. 4 , or be in separate mounting channels. The preliminary filters 120 may also be installed in more than a single row, for example in an array or matrix of multiple rows and columns.
In general, during filtering, inlet air flow is directed to the preliminary air filters 120 . Moisture is separated from the inlet air flow at the exterior of the preliminary filters 120 . The moisture-free inlet air flows into the interior of the hoods 100 and then into the chamber 82 through inlet openings 184 in the inlet side 84 . The air flows from the chamber 82 and through the primary filters 62 to remove particulates. Air the flows out of the filter system through openings 186 in the outlet side 86 of the housing 80 and into the ducting 64 to the gas turbine 22 .
The primary filters 62 preferably have relatively high filtering efficiencies with respect to particulate material. The primary filters 62 may be of any suitable construction and made from any suitable media. For example, primary filters 62 having filtration efficiencies in the range of 65-75%, or greater than 65% may be used.
It will be appreciated that a variety of filtering configurations and materials for one or both of the filters can be used to reduce the concentration or level of moisture and salt if present, in an air stream. By way of non-limiting example, illustrative hydrophobic/moisture filtering materials or fibers include polytetrafluoroethylene, polypropylene, polyethylene, polyvinyl chloride, polysulfone, polystyrene and expanded polytetrafluoroethylene (ePTFE) membrane. Materials and fibers can also be made hydrophobic through the use of surface treatments. Illustrative surface treatments include fluorocarbons and silicones. Of course, the particular hydrophobic materials listed herein are strictly examples, and other materials can also be used in accordance with the principles of the present invention.
From the above description of at least one aspect of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims. | A method of removing moisture from inlet air flowing to a gas turbine. The method comprises the steps of providing a housing for supporting a primary air filter. The housing is operably connected with the gas turbine. A hood connected with the housing is provided. The hood has a surface disposed at an acute angle relative to horizontal. Inlet air flow is directed into a preliminary filter supported above the hood and extending in a downward direction. The preliminary filter comprises media capable of separating moisture from the inlet air flowing through the preliminary filter at an exterior portion of the preliminary filter. Separated moisture agglomerates into a drop incapable of being carried by the flow of inlet air so the drop falls onto the hood to be directed out of the flow of inlet air. | 5 |
This invention was made with Government support under Grant Nos. CA40003 and 40004, awarded by the N.C.I. (NIH). The U.S. Government has certain rights in this application.
RELATED APPLICATIONS
This application is a continuation-in-part of copending application, Ser. No. 074,126, filed Jul. 17, 1987, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to novel peptides which inhibit the release of gonadotropins by the pituitary gland in mammals without inducing edematous reactions. More specifically, the present invention relates to analogs of the luteinizing hormone releasing hormone (LHRH), which has the structure:
p--Glu--His--Trp--Ser--Tyr--Gly--Leu--Arg--Pro--Gly--NH.sub.2,
salts thereof, and to pharmaceutical compositions and methods of use pertaining to these analogs.
DISCUSSION OF THE PRIOR ART
For more than 15 years, investigators have been searching for selective, potent antagonists of the LHRH decapeptide (M. Karten and J. E. Rivier, Endocrine Reviews, 7, 44-66 (1986)). The high degree of interest in such antagonists is due to their usefulness in the fields of endocrinology, gynecology, contraception and cancer. A large number of compounds have been prepared as potential LHRH antagonists. The most interesting antagonists to date have been compounds whose structure is a modification of the structure of LHRH.
The first series of potent antagonists was obtained by introduction of aromatic amino acid residues into positions 1, 2, 3 and 6, or, 2, 3, and 6. The compounds are expressed as LHRH modified by replacement of the original amino acid residues by others at the position indicated by the superscript numbers. The known antagonists include:
[Ac-D-Phe(4-Cl) 1 ,2, D-Trp 3 ,6 ] LHRH (D. H Coy, et al., In: Gross, E. and Meienhofer, J. (eds) Peptides, Proceedings of the 6th. American Peptide Symposium, pp. 775-779, Pierce Chem. Co., Rockville Ill., 1979);
[Ac-Pro 1 , D-Phe(4-Cl) 2 D-Nal(2) 3 ,6 ] LHRH (U.S. Pat. No. 4,419,347); and [Ac-Δ 3 Pro 1 ,D-Phe(4-Cl) 2 ,D-Trp 3 ,6 ]LHRH (J. L. Pineda, et al., J. Clin. Endocrinol. Metab. 56, 420, 1983).
Later, in order to increase the water solubility of antagonists, basic amino acids, such as D-Arg, were introduced into position 6. For instance, [Ac-D-Phe(4-Cl) 1 ,2, D-Trp 3 , D-Arg 6 , D-Ala 10 ]LHRH (ORG-30276) (D. H. Coy, et al., Endocrinology, 100, 1445, 1982); and [Ac-D-Nal(2) 1 , D-Phe(4-F) 2 , D-Trp 3 , D-Arg 6 ]LHRH (ORF-18260) (J. E. Rivier, et al., In: Vickery B. H., Nestor, Jr. J. J., Hafez, E.S.E. (eds), LHRH and Its Analogs, pp. 11-22, MTP Press, Lancaster, UK, 1984).
These analogs not only possessed the expected improved water solubility but also showed increased antagonistic activity. However, these highly potent, hydrophilic analogs containing D-Arg and other basic side chains at position 6 proved to produce transient edema of the face and extremities when administered subcutaneously in rats at 1.25 or 1.5 mg/kg (F. Schmidt, et al., Contraception, 29, 283, 1984; J. E. Morgan, et al., Int. Archs. Allergy Appl. Immun. 80, 70, (1986). Since the occurrence of edematogenic effects after administration of these antagonists to rats cast doubts on their safety for the use in humans and delayed the introduction of these drugs for clinical use, it is desirable to provide antagonistic peptides which are free of these side effects.
SUMMARY OF THE INVENTION
The present invention deals with LHRH antagonists which possess an improved water solubility and high antagonist potency of the basic peptides, and are free of the edematogenic effects. These compounds are highly potent in inhibiting the release of gonadotropins from the pituitary gland in mammals, including humans.
The compounds of this invention are represented by formula I
X--R 1 --R 2 --R 3 --Ser--Tyr--R 6 --Leu--Arg--Pro--R 10 --NH 2 I
wherein
X is an acyl group derived from straight or branched chain aliphatic or alicyclic carboxylic acids having from 1 to 7 carbon atoms, or a carbamyl (H 2 N--CO) group.
R 1 is D-- or L--Pro, D-- or L--Δ 3 --Pro, D--Phe, D--Phe(4--Hl), D--Ser,
D--Thr, D--Ala, D--Nal(1) or D--Nal(2),
R 2 is D--Phe or D--Phe(4--Cl)
R 3 is D--Trp, D--Phe, D--Pal(3), D--Nal(1) or D--Nal(2),
R 6 is D--Cit, D--Hci, D--Cit(Q) or D--Hci(Q) and
R 10 is Gly or D--Ala
where Q is lower alkyl of 1-3 carbon atoms and Hl is fluoro, chloro or bromo, and the pharmaceutically acceptable acid addition salts thereof.
The compounds of Formula I are synthesized by any suitable method. For example, exclusively solid-phase technique, partial solid-phase technique or by classical solution couplings Preferably, the compounds of Formula I are prepared by a known solid-phase technique. Such method provides intermediate peptides and/or intermediate peptide-resins of Formula II.
X.sup.1 --R.sup.1 --R.sup.2 --R.sup.3 --Ser(X.sup.4)--Tyr(X.sup.5)--R.sup.*6 (X.sup.6)--Leu--Arg(X.sup.8)--Pro--R.sup.10 --NH--X.sup.10 II
wherein
X 1 is an acyl group derived from straight and branched chain aliphatic or alicyclic carboxylic acids having from 1 to 7 carbon atoms, t-Boc, carbamyl or hydrogen,
X 4 is hydrogen or a protecting group for the Ser hydroxyl group,
X 5 is hydrogen or a protecting group for the Tyr phenolic hydroxyl group,
X 6 is hydrogen or a protecting group for the Lys or Orn side chain amino group,
X 8 is hydrogen or a protecting group for the Arg guanidino group,
X 10 is hydrogen or a resin support containing benzhydryl or methylbenzhydryl groups
R 1 is D-- or L--Pro, D-- or L--Δ 3 --Pro, D--Phe, D--Phe(4--Hl), D--Ser, D--Thr, D--Ala, D--Nal(1) or D--Nal(2),
R 2 is D--Phe or D--Phe(4--Cl),
R 3 is D--Trp, D--Phe, D--Pal(3), D--Nal(1) or D--Nal(2),
R *6 is D--Lys or D--Orn, D--Cit and D--Hci
and R 10 is Gly or D--Ala
where Hl is fluoro, chloro or bromo.
One process comprises reacting a peptide of Formula II wherein R *6 is D-Lys or D-Orn and X 6 is hydrogen, with a source of cyanate to yield a peptide of Formula III:
X.sup.1 --R.sup.1 --R.sup.2 --R.sup.3 --Ser(X.sup.4)--Tyr(X.sup.5)--R.sup.**6 --Leu--Arg(X.sup.8)--Pro--R.sup.10 --NH--X.sup.10 III
wherein
X.sup.1, R.sup.1, R.sup.2, R.sup.3, X.sup.4, X.sup.5, X.sup.8, R.sup.10 and X.sup.10 are as defined above, and
R **6 is Cit or Hci. Suitably, the reaction is carried out when X 1 is acyl and all other X moieties are hydrogen. Suitable cyanate sources are alkali metal cyanates, e.g., potassium cyanate, or an N-alkyl isocyanate, e.g., N-ethyl-isocyanate. The peptide of Formula II are preferably synthesized by a known solid phase technique.
Alternatively and preferably, peptides of Formula I wherein X is an acyl or carbamyl group, are directly obtained by cleavage and deprotection of intermediate peptide-resins of Formula II wherein X 1 is an acyl or carbamyl group and R *6 is D-Cit or D-Hci. Peptides of Formula I wherein X is carbamyl (H 2 N--CO) group are also obtained from peptide-resins of Formula II wherein X 1 is hydrogen or Boc by cleavage and deprotection followed by carbamoylation.
A gonadotropin antagonizing pharmaceutical composition is provided by admixing the compound of Formula I with a pharmaceutically acceptable carrier including microcapsules (microspheres) for delayed delivery.
There is also provided a method for relieving complications resulting from the physiological availability of amounts of pituitary gonadotropins in a mammal, in excess of the desired amount, which involves administering to the mammal a gonadotropin antagonizing dose of the compound of Formula I.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The nomenclature used to define the peptides is that specified by the IUPAC-IUB Commission on Biochemical Nomenclature (European J. Biochem., 1984, 138, 9-37), wherein in accordance with conventional representation the amino groups at the N-terminus appears to the left and the carboxyl group at the C-terminus to the right. By natural amino acid is meant one of the common, naturally occurring amino acids found in proteins comprising Gly, Ala, Val, Leu, Ile, Ser, Thr, Lys, Arg, Asp, Asn, Glu, Gln, Cys, Met, Phe, Tyr, Pro, Trp and His. The abbreviations for the individual amino acid residues are based on the trivial name of the amino acid and are Ala, alanine; Arg, arginine; Cit, citrulline, Gly, glycine; Hci, homocitrulline; Leu, leucine; Lys, lysine; Pal(3), 3-(3-pyridyl)alanine; Nal(1), Nal(2), 3-(1-naphtyl)alinine, 3-(2-naphthyl)alanine; Orn, ornithine; Phe, phenylalanine; Phe(4-Cl), 4-chlorophenylalanine; Phe (4-F), 4-fluorophenylalanine; Pro, proline; Ser, serine; Trp, tryptophan and Tyr, tyrosine. All amino acids described herein are of the L-series unless stated otherwise, e.g., D-Trp represents D-tryptophan and D-Nal(2) represents 3 -(2-naphthyl)-D-alanine.
Other abbreviations used are:
______________________________________AcOH acetic acidAcOEt ethyl acetateAc.sub.2 O acetic anhydrideBoc- tert.butyloxycarbonyl-DIC diisopropylcarbodiimideDIEA diisopropylethylamineDMF dimethylformamideHOBt 1-hydroxybenzenetriazole hydrateHPLC high performance liquid chromatographyMeOH methyl alcoholTEA triethylamineDCC dicyclohexylcarbodiimideMeCN acetonitrileIpOH isopropanolZ(2-Cl) 2-chloro-benzyloxycarbonylDCB 2,6-dichlorobenzylTos p-toluenesulfonylTFA trifluoroacetic acidZ benzyloxycarbonyl______________________________________
Especially preferred are LHRH analogs of Formula I wherein:
X 1 is acetyl or carbamyl
R 1 is Pro, D--Phe, D--Phe(4--Cl) or D--Nal(2),
R 2 is D--Phe(4--Cl) or D--Phe(4--F),
R 3 is D--Trp or D--Pal(3)
R 6 is D--Cit or D--Hci, and
R 10 is D--Ala.
The peptides are synthesized by a suitable method, such as by exclusively solid-phase techniques, by partial solid-phase techniques, by fragment condensation or by classical solution phase synthesis (See M. Bodanszky, "Principles of Peptide Synthesis", Springer-Verlag, 1984).
For example, the techniques of exclusively solid-phase synthesis are set forth in the textbook "Solid Phase Peptide Synthesis", J. M. Stewart and J. D. Young, Pierce Chem. Company, Rockford, Ill., 1984 (2nd. ed.), G. Barany and R. B. Merrifield, "The Peptides", Ch. 1, 1-285, pp. 1979, Academic Press, Inc.
Classical solution synthesis is described in detail in the treatise "Methoden der Organischen Chemie (Houben-Weyl): Synthese von Peptiden", E. Wunsch (editor) (1974) Georg Thieme Verlag, Stuttgart, W. Germany.
Common to such synthesis is the protection of the reactive side chain functional groups of the various amino acid moieties with suitable protecting groups which will prevent a chemical reaction from occurring at that site until the group is ultimately removed Usually also common is the protection of an alpha-amino group on an amino acid or a fragment while that entity reacts at the carboxyl group, followed by the selective removal of the alpha-amino protecting groups to allow subsequent reaction to take place at that location Accordingly, it is common that, as a step in the synthesis, an intermediate compound is produced which includes each of the amino acid residues located in its desired sequence in the peptide chain with side-chain protecting groups linked to the appropriate residues.
In Formula II:
R 1 , R 2 , and R 3 are as defined hereinabove,
X 1 is hydrogen or an acyl group derived from straight or branched chain aliphatic or alicyclic carboxylic acids having from 1 to 7 carbon atoms, or an alpha-amino protecting group. The alpha-amino protecting groups contemplated by X 1 are those well known to be useful in the art of step-wise synthesis of polypeptides. Among the classes of alpha-amino protecting groups which may be employed as X 1 may be mentioned fluoroenylmethyloxycarbonyl (Fmoc) or t-butyloxycarbonyl (Boc).
X 4 may be a suitable protecting group for the hydroxyl group of Ser such as benzyl (Bzl), and 2,6-dichloro-benzyl (DCB). The preferred protecting group is Bzl.
X 5 may be a suitable protecting group for the phenolic hydroxyl group of Tyr, such as Bzl, 2-Br-Z and 2,6-dichloro-benzyl (DCB). The preferred protecting group is DCB.
X 6 is a suitable protecting group for the side chain amino group of Lys or Orn. Illustrative of suitable side chain amino protecting groups are benzyloxycarbonyl (Z), and 2-chloro-benzyloxycarbonyl ((Z-(2-Cl)).
X 8 is a suitable protecting group for the guanidino group of Arg, such as nitro, Tos, methyl-(t-butyl benzene)-sulfonyl, 4-methoxy-2,3,6-trimethylbenzenesulfonyl; Tos is the preferred group.
X 10 is an amide protecting benzhydryl or methylbenzhydryl group incorporated into resin support; for the synthesis of peptide amides 98% styrene-2% divinylbenzene copolymers containing benzhydryl amine or methylbenzhydryl amine groups are preferred.
The selection of a side chain amino protecting group is not critical except that generally one is chosen which is not removed during deprotection of the alpha-amino groups during the synthesis.
The peptides of Formula I may be from intermediate peptide-resins of Formula II by procedures known in the art. The solid phase systhesis of intermediate peptide-resins of Formula II is essentially carried out as described by Merrifield, J. Am. Chem. Soc., 85, p. 2149 (1963). Solid phase synthesis is commenced from the C-terminal end of the peptide by coupling a protected amino acid to a suitable resin Such a starting material can be prepared by attaching -amino protected Gly or D-Ala by an amide bond to a benzylhydrilamine resin. Such resin supports are commercially available and generally used when the desired polypeptide being synthesized has an carboxamide at the C-terminal.
The selection of an appropriate coupling reagent is within the skill of the art. Particularly suitable as a coupling reagent is N,N'-diisopropyl carbodiimide (DIC).
Each protected amino acid or amino acid sequence is introduced into the solid phase reactor in about a two-three fold excess, and the coupling may be carried out in a medium of DMF:CH 2 Cl 2 (1:1) or in CH 2 Cl 2 alone. In cases where incomplete coupling occurs, the coupling procedure is repeated before removal of the alpha-amino protecting group prior to the coupling of the next amino acid. The success of the coupling reaction at each stage of the synthesis, is preferably monitored by the ninhydrin reaction, as described by E. Kaiser, et al., Anal. Biochem., 34, 595 (1970).
After the desired amino acid sequence of intermediates B has been completed, the terminal Boc group is removed and if desired, N-terminal acylation carried out using the appropriate acyl anhydride or acid chloride in 50-fold excess in a halogenated hydrocarbon solvent; suitably, acetic anhydride in methylene chloride for 30 minutes. The intermediate peptide can be removed from the resin support by treatment with a reagent such as liquid hydrogen fluoride, which not only cleaves the peptide from the resin but also cleaves all remaining side chain protecting groups X 4 , X 5 , X 8 , X 10 and, if present, X 6 .
When using hydrogen fluoride for cleaving, anisole or m-cresol, and, if desired, methylethyl sulfide are included as scavengers in the reaction vessel.
Peptides of Formula II wherein R *6 is D-Lys or D-Orn and X 6 is hydrogen, are converted into peptides of Formula I by treatment with cyanate, suitably an alkali metal cyanate, preferably potassium cyanate, or an N-alkylisocyanate, for instance, N-ethylisocyanate, in DMF or aqueous DMF. The latter reaction, i.e., transformation of Orn/Lys-peptides into the corresponding Cit/Hci-peptides can be readily followed by HPLC using MeCN-aqueous TFA systems because of a characteristic 2.6±0.3 minutes increase of the retention times of Cit/Hci--and, for example, Cit(Et)/Hci(Et)-peptides relative to the corresponding Orn/Lys-peptides respectively.
When acylation is omitted, treatment of peptide-resins of Formula II with hydrogen fluoride yields decapeptides which have free omega-amino and/or alpha-amino groups and correspond to a Formula II where X 1 , X 4 , X 5 , X 8 , X 10 , and, if present, X 6 are hydrogen. These free peptides are converted into peptides of Formula I wherein X is carbamyl by treatment with cyanate, suitably an alkali metal cyanate, preferably potassium cyanate. The latter reaction, i.e., transformation of H 2 N into H 2 N--CO--NH at the amino terminus of peptides and conversion of the Orn/Lys residues into the Cit/Hci residues, can be easily followed by HPLC using MeCN-aqueous TFA systems, because of a characteristic 2-3 min. increase of the retention times of carbamylated peptides, i.e., compounds with H 2 N--CO--NH-- group, relative to their congeners with H 2 N group.
Alternatively and preferably, peptides of Formula I wherein X is an acyl or carbamyl group, are directly obtained by cleavage and deprotection of intermediate peptide-resins of Formula II, where X 1 is an acyl or carbamyl group and R *6 is D-Cit or D-Hci.
Although an exclusively solid-phase synthesis and a partially solid-phase synthesis of compounds of Formula I are disclosed herein, the preparation of the compounds also can be realized by classical solution-phase methods.
The synthetic peptides prepared as described in the Examples are compared with two of the most potent LHRH antagonists reported recently, i.e., [Ac-D-Phe(4-Cl) 1 ,2, D-Trp 3 , D-Arg 6 , D-Ala 10 ] LHRH (ORG-30276) (Coy, et al., Endocrinology, 100, 1445, 1982) and [Ac-D-Nal(2) 1 , D-Phe(4-F) 2 , D-Trp 3 , D-Arg 6 ] LHRH (ORF 18260) (Rivier, et al., In: Vickery, B. H., Nestor, Jr., J. J. Hafez, E. S. E. (eds.), LHRH and Its Analogs, pp. 11-22, MTP Press, Lancaster, UK, 1984), and are found to exert similarly high inhibitory activities both in vitro and in vivo, but, unlike to the control peptides, not to produce the in vivo edematous effects.
Hormonal activities in vitro are compared in superfused rat pituitary cell systems (S. Vigh and A. V. Schally, Peptides. 5 suppl. 1: 241-247, 1984) in which the effectiveness of LHRH (and other releasing hormones) can be accurately evaluated since the amount of LH (or other pituitary hormones) secreted into the effluent medium is not only proportional to the hormone-releasing potency of the peptide applied but also measurable readily by well-characterized radioimmunoassays.
To determine the potency of an LHRH antagonist, mixtures containing LHRH in a constant concentration (usually 1 nM) and the antagonist in varying concentrations are used for the superfusion in order to determine the molecular ratio of the antagonist to LHRH at which the action of LHRH is completely blocked. These ratios are about 5 for both peptides of the present invention and the control peptides when the rat pituitary cell system is preincubated with antagonists for 9 minutes.
In an antiovulatory in vivo assay (A. Corbin and C. W. Beattie; Endocr. Res. Commun. 2, 1-23, 1975; D. H. Coy, et al., Endocrinology, 100, 1445, 1982), the peptides of the present invention are also found to be about equipotent to the control antagonist, namely, 87.5-100% blockade of ovulation can be observed at a subcutaneous dose of 1-3 ug/rat for each peptide.
In the edematogenic test of Schmidt, et al. (Contraception, 29, 283-289, 1984), however, a marked difference can be found between the control peptides and the peptides of the present invention. The control administered subcutaneously in rats at doses of 1.25 or peptides produce edema of the face and extremities when 1.50 mg/kg. No such reaction can be observed with the peptides of the present invention when given at a subcutaneous dose of 1.5 mg/kg.
In the tests as run, the rats were assigned to three groups of five rats per group per compound tested. Comparison was made with a known prior art compound designated ORG 30276 namely (N-Ac-D-p-Cl-Phe 1 ,2,D-Trp 3 , D-Arg 6 ,D-Ala 10 )-LHRH. The groups were injected subcuntaneously once a day on two consecutive days with the LHRH antagonists at a dose level of 1.5 mg/kg. One control group was injected with diluent only. The rats were observed during five hours each day. Reactions of the rats were classified as follows: NR no apparent reaction, PR partial responders: edema of the nasal and paranasal area, FR full responders: facial edema with edematous extremities.
These results are summarized in Table 1 below.
TABLE 1______________________________________LHRH 1st Day 2nd DayAntagonist NR PR FR NR PR FR______________________________________ORG 30276 3 7 0 0 0 10Control 9 0 0 9 0 0EX III 8 0 0 8 0 0EX V 9 0 0 8 1* 0EX IV 9 0 0 9 0 0EX I 8 0 0 8 0 0EX XX 9 0 0 8 1* 0EX XXI 9 0 0 9 0 0EX XXVI 8 0 0 8 0 0EX XXVII 9 0 0 9 0 0______________________________________ *Very light edema of the face.
LHRH secretion in vitro at some reasonable concentration, although most are slightly less potent than the present standard in vitro; however, these peptides are much more potent in vivo.
This was shown by a test on histamine release in vitro from peritoneal mast cells carried out in accordance with the procedure of Morgan et al (Int. Archs. Allergy appl. Immun. 80, 70 1986).
Histamine Release In Vitro
In this test rats were anesthetized with ether and peritoneal exudate cell were harvested by washing with 12 ml. of mast cell medium (MCM) (150m M NaCl; 3.7m M KCl; 3.0m M Na 2 HPO 4 ; 3.5m M KH 2 PO 4 , 0.98m M CaCl; 5.6m M dextrose; 0.1% bovine serum albumin; 0.1% gelatin and 10 units/ml heparin)[9]. Cells from 4 or 5 rats were pooled, centrifuged at 120 g, resuspended with MCM to a concentration of 0.5×10 6 ml and 1 ml was aliquoted into 12×75 mm polyethylene tubes. Tubes were equilibrated to 37° C. for 15 min and incubated alone (background histamine release), with 48/80 (positive control) (Sigma Chemicals, St. Louis, Mo.), or with appropriate concentrations (1 ng through 10 ug/ml) of LHRH antagonists for 60 min. The reaction was terminated by cooling the tubes to 4° C. Tubes were centrifuged; supernatants were recovered and stored at -20° C. until assayed for histamine. Assays were performed in duplicate. Total cell histamine was determined by boiling for 10 min. Histamine released in reponse to antagonist was expressed as a percentage of total release. That concentration that released 50% of total mast cell histamine (HRD 50 ug/ml) was determined for each antagonist. The results are summarized in FIG. 1.
All of the peptides are considered to be effective to prevent ovulation of female mammals at very low dosages. The peptides of the invention are often administered in the form of pharmaceutically acceptable, nontoxic salts, such as acid addition salts. Illustrative of such acid addition salts are hydrochloride, hydrobromide, sulphate, phosphate, fumarate, gluconate, tannate, maleate, acetate, citrate, benzonate, succinate, alginate, pamoate, malate, ascorbate, tartrate, and the like. If the active ingredient is to be administered in tablet form, the tablet may contain a pharmaceutically acceptable diluent which includes a binder, such as tragacanth, corn starch or gelatin; a disintegrating agent, such as alginic acid and a lubricant, such as magnesium stearate.
If administration in liquid form is desired, sweetening and/or flavoring may be used as part of the pharmaceutically-acceptable diluent, and intravenous administration in isotonic saline, phosphate buffer solutions or the like may be effected.
The pharmaceutical compositions will usually contain the peptide in conjunction with a conventional, pharmaceutically-acceptable carrier. Usually, the dosage will be from about 1 to about 100 micrograms of the peptide per kilogram of the body weight of the host when given intravenously; oral dosages will be higher. Overall, treatment of subjects with these peptides is generally carried out in the same manner as the clinical treatment using other antagonists of LHRH.
These peptides can be administered to mammals intravenously, subcutaneously, intramuscularly, orally, intranasally or intravaginally to achieve fertility inhibition and/or control and also in applications calling for reversible suppression of gonadal activity, such as for the management of precocious puberty or during radiation- or chemo-therapy. Effective dosages will vary with the form of administration and the particular species of mammal being treated. An example of one typical dosage form is a physiological saline solution containing the peptide which solution is administered to provide a dose in the range of about 0.1 to 2.5 mg/kg of body weight. Oral administration of the peptide may be given in either solid form or liquid form.
Although the invention has been described with regard to its preferred embodiments, it should be understood that changes and modifications obvious to one having the ordinary skill in his art may be made without departing from the scope of the invention, which is set forth in the claims which are appended thereto. Substitutions known in the art which do not significantly detract from its effectiveness may be employed in the invention.
EXAMPLE I
The synthesis of an analog of the formula:
Ac--D--Nal(2)--D--Phe(4--Cl)--D--Trp--Ser--Tyr--D--Hci--Leu--Arg--Pro--D--Ala--NH.sub.2
was commenced with the preparation of the intermediate peptide Ac-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-D-Ala-NH 2 . The intermediate peptide was built step by step on a benzhydrylamine resin containing about 0.6 m. equiv. NH 2 /g (from BACHEM) on a Beckman 990 synthesizer starting with the Boc-D-Ala in accordance with the procedures set forth below.
Coupling is carried out in accordance with Schedule A as follows:
______________________________________SCHEDULE A Mixing TimeReagent (mins)______________________________________1. Boc Amino Acid 60-90 (0.9-1.2m mole/g. resin) + equiv amt. of DIC2. MeOH (twice) 13. CH.sub.2 Cl.sub.2 (twice) 1______________________________________
Deblocking is carried out in accordance with Schedule B as follows:
______________________________________SCHEDULE B Mixing TimeReagent (mins)______________________________________4. 50% TFA/1% ethanedithiol in 15 & 15 CH.sub.2 Cl.sub.2 (twice)5. IpOH/1% ethane dithiol 16. 10% TEA in CH.sub.2 Cl.sub.2 27. MeOH 18. 10% TEA in CH.sub.2 Cl.sub.2 29. MeOH (twice) 1 & 110. CH.sub.2 Cl.sub.2 (twice) 1 & 1______________________________________
Briefly, Boc is used for N-terminal protection. Tos is used fto protect the guanidino group of Arg. Z(2-Cl) is used as the protecting group for the D-Lys side chain, Bzl for the OH group of Ser and Tyr is protected with DCB.
One and a half to two-fold excess of protected amino acid is used based on the NH 2 -content of the benzhydrylamine-resin, plus one equivalent of DIC in CH 2 Cl 2 or 10-50% DMF/CH 2 Cl 2 , depending on the solubility of Boc-amino acid, for two hours.
N-Terminal acetylation is performed with a 50-fold excess of acetic anhydride in CH 2 Cl 2 for 0.5 hours. The protected intermediate peptide thus obtained has the following composition:
Ac--D--Nal(2)--D--Phe(4--Cl)--D--Trp--Ser(X.sup.4)--Trp--(X.sup.5)D--LYS(X.sup.6 --Leu--Arg(X.sup.8)--Pro--D--Ala--NH--X.sup.10
wherein
X 4 is Bzl and
X 5 is DCB, X 6 is Z(2-Cl),
X 8 is Tos, and
X 10 is a benzhydryl group incorporated into the resin.
In order to cleave and deprotect the protected peptide-resin, it is treated with 1.4 ml. m-cresole and 15 ml. hydrogen fluoride per gram of peptide-resin for 0.5 hours at 0° and 0.5 hours at room temperature. After elimination of hydrogen fluoride under high vacuum, the resin-peptide is washed with diethyl ether and the peptide is then extracted with DMF and separated from the resin by filtration. The DMF solution is concentrated to a small volume under high vacuum, then triturated with diethyl ether. The crude product thus obtained is purified by preparative HPLC as described below, to give the pure free intermediate peptide having the above-mentioned structure wherein X 4 , X 5 , X 6 , X 8 and X 10 are hydrogen.
The free D-Lys 6 -containing intermediate peptide is then reacted with potassium cyanate in 80% aqueous DMF solution (81 mg. KCNO/ml), at ambient temperature for 24 hours. The reaction mixture, after evaporation under high vacuum, is subjected to purification by preparative HPLC to yield the desired D-Hci-containing peptide. The peptide is judged to be substantially (95%) pure by using HPLC. HPLC analyses are carried out in a Hewlett-Packard 1090A gradient liquid chromatographic system on a C18 column (VYDAC 218TP546) eluted with solvents A: 0.1% TFA, B: 0.1% TFA in 70% CH 3 CN with a gradient of 30-60% in 30 minutes. The intermediate peptide and the desired peptide has a retention times of 25.5 minutes and 28.2 minutes respectively.
Purification of peptides is carried out on a Beckman Prep-350 gradient liquid chromatograph using a 41.4×250 mm preparative reversed phase DYNEMAX C18 cartridge (300A, 12 um) with solvents A: 0.1% TFA and B: 0.1% TFA in 70% CH 3 CN and using a gradient of 45-60% in 30 minutes. The pure peptide obtained as TFA salt, if desired, can be converted to the acetate form by passage through an AG3X (Bio-Rad) column in the acetate form followed by lyophilization.
EXAMPLE II
The synthesis of the peptide Ac-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci(Et)-Leu-Arg-Pro-D-Ala-NH2 accomplished by reacting the the intermediate peptide Ac-D-Nal(2)-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-D-Ala-NH2 described in Example I, with N-ethylisocyanate in DMF (0.1 mg. in 0.01 ml. per gm of intermediate) at 0°-10° for 10 hours. Retention time for the desired peptide is 30.8 min.
EXAMPLE III
The synthesis of the peptide Ac-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-Ala-NH2 is conducted as described in Example I with the exception that Boc-D-Orn(Z) is incorporated in place of Boc-D-Lys[Z-(2-Cl)] in position 6 of the intermediate peptide to afford another intermediate peptide having the formula Ac-D-Nal(2)-D-Phe (4-Cl)-D-Trp-Ser-Tyr-D-Orn-Leu-Arg-Pro-D-Ala-NH 2 , which is then similarly converted to the desired peptide. This intermediate peptide and the desired peptide have HPLC retention times of 25.5 min. and 27.8 min., respectively.
EXAMPLE IV
The synthesis of the peptide Ac-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit(Et)-Leu-Arg-Pro-D-Ala-NH 2 is accomplished by reacting the the intermediate peptide Ac-D-Nal(2)-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Orn-Leu-Arg-Pro-D-Ala-NH 2 described in Example III, with N-ethylisocyanate in DMF (0.1 mg. in 10 ml. per gm of intermediate) at 0°-10° for 10 hours. Retention time for the desired peptide is 30.4 min.
EXAMPLE V
The synthesis of the peptide Ac-D-Phe(4-Cl)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example I, with the exception that Boc-D-Phe(4-Cl) is incorporated in place of Boc-D-Nal(2) in position 1 of the intermediate peptide to give another intermediate peptide having ther formula Ac-D-Phe(4-Cl)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-D-Ala-NH 2 , which in then similarly converted to the desired peptide. This intermediate peptide and the desired peptide have retention times of 24.0 min. and 26.6 min., respectively.
EXAMPLE VI
The synthesis of the peptide Ac-D-Phe(4-Cl)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci(Et)-Leu-Arg-Pro-D-Ala-NH.sub.2 is accomplished by reacting the the intermediate peptide Ac-D-Phe(4-Cl)-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-D-Ala-NH 2 described in Example V with N-ethylisocyanate in DMF (0.1 mg. in 10 ml. per gm of intermediate) at 0°-10° for 10 hours. Retention time for the desired peptide is 29.2 min.
EXAMPLE VII
The synthesis of the peptide Ac-D-Phe(4-Cl)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example I, with the exception that Boc-D-Phe(4-Cl) is incorporated in place of Boc-D-Nal(2) in position 1 and that Boc-D-Orn(Z) is incorporated in place of Boc-D-Lys[Z(2-Cl)] in position 6 of the intermediate peptide to yield another intermediate peptide having the formula Ac-D-Phe(4-Cl)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Orn-Leu-Arg-Pro-D-Ala-NH 2 , which is then similarly converted to the desired peptide This intermediate peptide and the desired peptide have retention times of 24.0 min. and 26.3 min., respectively.
EXAMPLE VIII
The synthesis of the peptide Ac-D-Phe(4-Cl)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit(Et)-Leu-Arg-Pro-D-Ala-NH.sub.2 is accomplished by reacting the intermediate peptide Ac-D-Phe(4-Cl)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Orn-Leu-Arg-Pro-D-Ala-NH 2 described in Example VII, with N-ethylisocyanate in DMF 2 (0.1 mg. in 10 ml. per gm of intermediate) at 0°-10° for 10 hours. Retention time for the desired peptide is 28.6 min.
EXAMPLE IX
The synthesis of the peptide Ac-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci-Leu-Arg-Pro-Gly-NH 2 is conducted as described in Example I to afford another intermediate peptide having the formula Ac-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-Gly-NH 2 , which is then similarly converted to the desired peptide. This intermediate peptide and the desired peptide have HPLC retention times of 24.8 min. and 27.4 min., respectively.
EXAMPLE X
The synthesis of the peptide Ac-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci(Et)-Leu-Arg-Pro-Gly-NH 2 is accomplished by reacting the the intermediate peptide Ac-D-Nal(2)-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-Gly-NH 2 described in Example IX with N-ethylisocyanate in DMF 0.1 mg. in 10 ml. per gm of intermediate) at 0°-10° for 10 hours. Retention time for the desired peptide is 30.0 min.
EXAMPLE XI
The synthesis of the peptide Ac-Pro-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example I with the exception that Boc-Pro is incorporated in place of Boc-D-Nal(2) in position 1 of the intermediate peptide to afford another intermediate peptide having the formula Ac-Pro-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-D-Ala-NH 2 , which is then similarly converted to the desired peptide. This intermediate peptide and the desired peptide have retention times of 16.8 min. and 19.3 min., respectively.
EXAMPLE XII
The synthesis of the peptide Ac-Pro-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci(Et)-Leu-Arg-Pro-D-Ala-NH 2 is accomplished by reacting the the intermediate peptide Ac-D-Pro-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-D-Ala-NH 2 described in Example XI, with N-ethylisocyanate in DMF (0.1 mg. in 10 ml. per gm of intermediate) at 0°-10° for 10 hours. Retention time for the desired peptide is 22.0 min.
EXAMPLE XIII
The synthesis of the peptide Ac-Pro-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example I, with the exception that Boc-Pro is incorporated in place of Boc-D-Nal(2) in position 1 and that Boc-D-Orn(Z) is incorporated in place of Boc-D-Lys[Z(2-Cl)] in position 6 of the intermediate peptide to yield another intermediate peptide having the formula Ac-Pro-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Orn-Leu-Arg-Pro-D-Ala-NH 2 . This intermediate peptide and the desired peptide have retention times of 16.85 min. and 18.8 min., respectively.
EXAMPLE XIV
The synthesis of the peptide Ac-Pro-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit(Et)-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example VI, with the exception that the intermediate peptide Ac-Pro-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Orn-Leu-Arg-Pro-D-Ala-NH 2 described in Example XIII is reacted with N-ethylisocyanate The desired peptide has a retention time of 24.9 min.
EXAMPLE XV
The synthesis of the peptide Ac-D-Phe-D-Phe(4-Cl)-D-Trp-Ser-Tyr-Hci-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example I, with the exception that Boc-D-Phe is incorporated in place of Boc-D-Nal(2) in position 1 of the intermediate peptide to yield another intermediate peptide having the formula Ac-D-Phe-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-D-Ala-NH 2 , which is then similarly converted to the desired peptide This intermediate peptide and the desired peptide have HPLC retention times of 20.8 min. and 23.4 min., respectively.
EXAMPLE XVI
The synthesis of the peptide Ac-D-Phe-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci(Et)-Leu-Arg-Pro-D-Ala-NH 2 is accomplished by reacting the the intermediate peptide Ac-D-Phe-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-D-Ala-NH 2 described in Example XV, with N-ethylisocyanate in DMF (0.1 mg. in 10 ml. per gm of intermediate) at 0°-10° for 10 hours. Retention time for the desired peptide is 26.0 min.
EXAMPLE XVII
The synthesis of the peptide Ac-D-Phe-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example I, with the exception that Boc-D-Phe is incorporated in place of Boc-D-Nal(2) in position 1 and that Boc-D-Orn(Z) is incorporated in place of Boc-D-Lys[Z(2-Cl)] in position 6 of the intermediate peptide to yield another intermediate peptide having the formula Ac-D-Phe-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Orn-Leu-Arg-Pro-D-Ala-NH 2 . This intermediate peptide and the desired peptide have retention times of 21.0 min. and 23.1 min., respectively.
EXAMPLE XVIII
The synthesis of the peptide Ac-D-Phe-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit(Et)-Leu-Arg-Pro-D-Ala-NH 2 is accomplished by reacting the the intermediate peptide Ac-D-Phe-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Orn-Leu-Arg-Pro-D-Ala-NH 2 described in Example XVII, with N-ethylisocyanate in DMF (0.1 mg. in 0.01 ml. per gm of intermediate) at 0°-10° for 10 hours. Retention time for the desired peptide is 25.4 min.
EXAMPLE XIX
The synthesis of an analog of the formula:
Ac--D--Nal(2)--D--Phe(4--Cl)--D--Trp--Ser--Tyr--D--Hci--Leu--Arg--Pro--D--Ala--NH.sub.2
peptide was built step by step on a benzhydrylamine resin containing about 1 0 m. equiv. NH 2 /g (from BACHEM) on a Beckman 990 synthesizer starting with the Boc-D-Ala in accordance with the procedures set forth below.
Coupling is carried out in accordance with Schedule C as follows:
______________________________________SCHEDULE C Mixing TimeReagent (mins)______________________________________1. Boc Amino Acid 60-90 (2-3m mole/g. resin) + equiv amt. of DIC2. MeOH (twice) 13. CH.sub.2 Cl.sub.2 (twice) 1______________________________________
Deblocking is carried out in accordance with Schedule B as follows:
______________________________________SCHEDULE D Mixing TimeReagent (mins)______________________________________4. 50% TFA/1% ethanedithiol in 15 & 15 CH.sub.2 Cl.sub.2 (twice)5. IpOH/1% ethane dithiol 16. 10% TEA in CH.sub.2 Cl.sub.2 27. MeOH 18. 10% TEA in CH.sub.2 Cl.sub.2 29. MeOH (twice) 1 & 110. CH.sub.2 Cl.sub.2 (twice) 1 & 1______________________________________
Briefly, Boc is used for the protection of the alpha-amino groups. Tos is used to protect the quanidino group of Arg. DCB is used as the protecting group for the phenolic hydroxyl group of Tyr, and the OH group of Ser is protected with Bzl. Two to three-fold excess of protected amino acid is used based on the NH 2 -content of the benzhydryl-amine-resin, plus one equivalent of DIC in CH 2 Cl 2 or 10-50% DMF/CH 2 Cl 2 , depending on the solubility of Boc-amino acid, for two hours.
N-Terminal acetylation is performed with a 50-fold excess of acetic anhydride in CH 2 Cl 2 for 0.5 hours. The protected intermediate peptide thus obtained has the following composition:
Ac--D--Nal(2)--D--Phe(4--Cl)--D--Trp--Ser(X.sup.4)--Tyr--(X.sup.5)D--Hci--Leu--Arg(X.sup.8)--Pro--D--Ala--NH--X.sup.10
wherein
X 4 is Bzl and
X 5 is DCB,
X 8 is Tos, and X 10 is a benzhydryl group incorporated into the resin.
In order to cleave and deprotect the protected peptide-resin, it is treated with 1.4 ml. m-cresole and 15 ml. hydrogen fluoride per gram of peptide-resin for 0.5 hours at 0° and 0.5 hours at room temperature. After elimination of hydrogen fluoride under high vacuum, the resin-peptide is washed with diethyl ether and the peptide is then extracted with DMF and separated from the resin by filtration. The DMF solution is concentrated to a small volume under high vacuum, then triturated with diethyl ether. The crude product thus obtained is purified by preparative HPLC as described below to yield the desired D-Hci-containing peptide. The peptide is judged to be substantially (95%) pure by using HPLC. HPLC analyses are carried out in a Hewlett-Packard 1090A gradient liquid chromatographic system on a "PHENOMENEX" (W-Porex 5C18) column, eluted with solvents A: 0.1% TFA, B: 0.1% TFA in 70% CH 3 CN with a gradient of 35-75% in 30 minutes. The desired peptide has retention time of 22.9 minutes.
Purification of peptides is carried out on a Beckman Prep-350 gradient liquid chromatograph using a 41.4×250 mm preparative reversed phase DYNAMAX C18 cartridge (300A, 12 um) with solvents A: 0.1% TFA and B: 0.1% TFA in 70% CH 3 CN and using a gradient of 45-60% in 30 minutes. The pure peptide obtained as TFA salt, if desired, can be converted to the acetate form by passage through an AG3X (Bio-Rad) column in the acetate form followed by lyophilization.
EXAMPLE XX
The synthesis of the peptide H 2 N-CO-D-Nal(2)-D-Phe(4Cl)-D-Trp-Ser-Tyr-D-Hci-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example XIX, with the exception that H 2 N-CO-D-Nal(2) is incorporated in place of Boc-D-Nal(2) in position 1, and the N-terminal acetylation is omitted to yield the desired peptide with retention time of 24.0 min.
EXAMPLE XXI
The synthesis of the peptide Ac-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example XIX, with the exception that Boc-D-Cit is incorporated in place of Boc-D-Hci in position 6 to give the desired peptide with a retention time of 22.5 min.
EXAMPLE XXII
The synthesis of the peptide Ac-D-Phe(4-Cl)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example XIX with the exception that BOC-D-Phe(4-Cl) is incorporated in place of Boc-D-Nal(2) in position 1 to give the desired peptide with a retention time of 24.0 min.
EXAMPLE XXIII
The synthesis of the peptide Ac-D-Phe(4-Cl)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example XIX, with the exception that Boc-D-Phe(4-Cl) is incorporated in place of Boc-D-Nal(2) in position 1 and that Boc-D-Cit is incorporated in place of Boc-D-Hci in position 6 to yield the desired peptide having a HPLC retention time of 20.8 min.
EXAMPLE XXIV
The synthesis of the peptide Ac-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci-Leu-Arg-Pro-Gly-NH 2 is conducted as described in Example XIX, with the exception that Boc-Gly is incorporated in place of Boc-D-Ala in position 10. The desired peptide thus obtained has a HPLC retention time of 22.4 min.
EXAMPLE XXV
The synthesis of the peptide Ac-D-Nal(2)-D-Phe(4-Cl)-D-Pal(3)-Ser-Tyr-D-Hci-Leu-Arg-Pro-D-Ala-NH 2 is conducted as described in Example XIX with the exception that Boc-D-Pal(3) is incorporated in place of Boc-D-Trp in position 3. The desired peptide has an HPLC retention time of 13.6 min.
EXAMPLE XXVI
The synthesis of the peptide Ac-D-Nal-D-Phe(4-Cl)-D-Pal(3)-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-AlaNH 2 is conducted as described in Example XIX, with the exception that Boc-D-Cit is incorporated in place of D-Hci in position 6 and that Boc-D-Pal(3) is incorporated in place of Boc-D-Trp in position 3. The desired peptide has an HPLC retention time of 13.3 min.
EXAMPLE XXVII
The synthesis of the peptide H N-CO-D-Nal(2)-D-Phe(4-Cl)-D-Pal(3)-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-Ala-NH.sub.2 is conducted as described in Example XIX, with the exception that Boc-D-Cit is incorporated in place of Boc-D-Hci in position 6, that Boc-D-Pal(3) is incorporated in place of Boc-D-Trp in position 3, and that N-terminal acetylation is omitted to yield the intermediate peptide H-D-Nal(2)-D-Phe(4-Cl)-D-Pal(3)-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-Ala-NH 2 . The free peptide thus obtained is then reacted with potassium cyanate in 80% aqueous DMF (81 mg. KOCN/300 mg. peptide/ml.) at ambient temperature for 24 hours. The reaction mixture, after evaporation under high vacuum, is subjected to purification by preparative HPLC to yield the desired peptide having HPLC retention time of 14.4 min.
EXAMPLE XXVIII
The synthesis of the peptide H N-CO-D-Nal(2)-D-Phe(4-Cl)-D-Pal(3)-Ser-Tyr-D-Hci-Leu-Arg-Pro-D-Ala-NH.sub.2 is conducted as described in Example XIX, with the exception that Boc-D-Pal(3) is incorporated in place of Boc-D-Trp in position 3 and that N-terminal acetylation is omitted to yield the intermediate peptide H-D-Nal(2)-D-Phe(4-Cl)-D-Pal(3)-Ser-Tyr-D-Hci-Leu-Arg-Pro-D-Ala-NH 2 . The free peptide thus obtained is then reacted with potassium cyanate in aqueous DMF (81 mg. KOCN/300 mg. peptide/ml.) at ambient temperature for 24 hours. The reaction mixture, after evaporation under high vacuum, is subjected to purification by preparative HPLC to give the desired peptide having a HPLC retention time of 14.7 min.
EXAMPLE XXIX
The synthesis of the peptide H N-CO-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-Ala-NH 2 is commenced with the preparation of intermediate peptide H-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Cit-Leu-Arg-Pro-D-Ala-NH 2 . The synthesis of the intermediate peptide is accomplished as described in Example XIX, with the exception that Boc-D-Orn(Z) is incorporated in place of Boc-D-Hci in position 6 and that N-terminal acetylation is omitted The free D-Orn 6 -containing peptide is then reacted with potassium cyanate in 80% aqueous DMF (162 mg. KPCN/300 mg. peptide/ml.) at ambient temperature for 24 hours. The reaction mixture, after evaporation under high vacuum, is subjected to purification by preparative HPLC to yield the desired peptide with a HPLC retention time of 23.6 min.
EXAMPLE XXX
The synthesis of the peptide H 2 N-CO-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Hci-Leu-Arg-Pro-D-Ala-NH 2 is commenced with the preparation of intermediate peptide H-D-Nal(2)-D-Phe(4-Cl)-D-Trp-Ser-Tyr-D-Lys-Leu-Arg-Pro-D-Ala-NH 2 . The synthesis of the intermediate peptide is accomplished as described in Example XIX, with the exception that Boc-D-Lys[Z(2-Cl)] is incorporated in place of Boc-D-Hci in position 6 and that N-terminal acetylation is omitted. The free D-Lys 6 -containing peptide is then reacted with potassium cyanate in 80% aqueous DMF *164 mg. KOCN/300 mg. peptide/ml.) at ambient temperature for 24 hours. The reaction mixture, after evaporation under high vacuum, is subjected to purification by preparative HPLC to yield the desired peptide with a HPLC retention time of 24.0 min.
EXAMPLE XXXI
Tablet formulation for buccal (e.g., sublingual) administration:
1. LHRH Antagonist 10.0 mg. Compressible Sugar, USP 86.0 mg. Calcium Stearate 4.0 mg.
2. LHRH Antagonist 10.0 mg. Compressible Sugar, USP 88.5 mg. Magnesium Stearate 1 5 mg.
3. LHRH Antagonist 5.0 mg. Mannitol, USP 83.5 mg. Magnesium Starch, USP 1.5 mg.
4. LHRH Antagonist 10.0 mg. Pregelatinized Starch, USP 10.0 mg. Lactose, USP 74.5 mg. Pregelatinized Starch, USP 15.0 mg. Magnesium Stearate, USP 1.5 mg.
Method A. LHRH Antagonist is dissolved in a sufficient quantity of water to form a wet granulation when mixed with the sugar portion of the excipients. After complete mixing the granulation is dried in a tray of fluid-bed dryer. The dry granulation is then screened to break up any large aggregates and then mixed with the remaining components. The granulation is then compressed on a standard tableting machine to the specific tablet weight.
Method B. In this manufacturing method, all formulations would include 0.01% gelatin, USP. The gelatin would be first dissolved in the aqueous granulation solvent followed by the LHRH analog. The remaining steps are as in (a) above.
EXAMPLE XXXII
Long Acting Intramuscular Injectable Formulation
Long Acting iM. Injectable--Sesame Oil Gel LHRH Antagonist 10.0 mg. Aluminum Monostearate, USP 20.0 mg. Sesame oil g.s. ad 1.0 ml.
The aluminum monostearate is combined with the sesame oil and heated to 125° C. with stirring until a clear yellow solution forms. This mixture is then autoclaved for sterility and allowed to cool. The LHRH antagonist is then added aseptically with trituration. Particularly preferred LHRH antagonists are salts of low solubility, e.g., zinc salts, zinc tannate salts, pamoate salts, and the like. These exhibit exceptionally long duration of activity.
EXAMPLE XXXIII
Long Acting IM Injectable--Biodegradable Polymer Microcapsules
LHRH Antagonists 1% 25/75 glycolide/lactide copolymer (0.5 intrinsic viscosity) 99%
Microcapsules (0°-150°) of above formulation suspended in:
Dextrose 5.0% CMC, sodium 0.5% Benzyl alcohol 0.9% Tween 80 0.1% Water, purified q.s. 100.0% 25 mg. of microcapsules are suspended in 1.0 ml. of vehicle.
EXAMPLE XXXIV
Aqueous Solution for Intramuscular Injection
LHRH Antagonist 500 mg. Gelatin, nonantigenic 5 mg. Water for injection g.s. ad 100 ml.
The gelatin and LHRH antagonist are dissolved in water for injection, then the solution is sterile filtered.
EXAMPLE XXXV
Formulation for Rectal Administration
Suppository Vehicle for Rectal Administration
LHRH Antagonist 5 0 mg. Witepsol H15 20.0 mg.
The LHRH antagonist is combined with the molten Witepsol H15, mixed with and poured into 2 gm. molds. | The present invention deals with LHRH antagonists which possess improved water solubility and while having the high antagonist potency of the basic peptides, are free of the edematogenic effects. These compounds are highly potent in inhibiting the release of gonadotropins from the pituitary gland in mammals, including humans.
The compounds of this invention are represented by the formula
X--R.sup.1 --R.sup.2 --R.sup.3 --Ser--Tyr--R.sup.6
--Leu--Arg--Pro--R 10 --NH 2
wherein
X is an acyl group derived from straight or branched chain aliphatic or alicyclic carboxylic acids having from 1 to 7 carbon atoms, or H 2 N--CO,
R 1 is D-- or L--Pro, D-- or L--Δ 3 --Pro, D--Phe, D--Phe(4--H1), D--Ser, D--Thr, D--Ala, D--Nal(1) or D--Nal (2),
R 2 is D--Phe or D--Phe(4--C1)
R 3 is D--Trp, D--Phe, D--Pal(3), D--Nal(1) or D--Nal(2),
R 6 is D--Cit, D--Hci, D--Cit(Q) or D--Hci(Q) and
R 10 is Gly or D--Ala
where Q is lower alkyl of 1-3 carbon atoms and H1 is fluoro, chloro or bromo, and the pharmaceutically acceptable acid addition salts thereof and methods of use pertaining to these compounds. | 8 |
TECHNICAL FIELD
This invention relates to the preparation of 2-methallyloxyphenol by the selective monoetherification of catechol.
BACKGROUND OF THE INVENTION
The monoether 2-methallyloxyphenol (MOP) is useful as an intermediate in the synthesis of benzofuranyl insecticides as disclosed in U.S. Pat. No. 3,474,170. As also described in the patent, MOP is commonly produced by the reaction of methallyl chloride (MAC) with catechol (also known as "pyrocatechol"). However, significant amounts of undesired diether, 1,2-dimethallyloxybenzene, are also obtained. Furthermore, secondary (ring) alkylation reactions also occur, characterized by direct substitution of the methallyl radical onto the aromatic nucleus to form 3-methallylcatechol and/or 4-methallylcatechol. The formation of diether and 4-alkylated derivatives reduces the yield of the desired monoether (MOP) and results in a mixture of compounds from which it is difficult and expensive to isolate the monoether.
Formation of undesirable amounts of by-products is commonly controlled by the use of a large excess of catechol and by limiting catechol conversion. However, this process is inefficient and uneconomical because it requires recovery and recycling of large proportions of the catechol charge, typically about 50%. In another process, described in U.S. Pat. No. 4,252,985, methallyl chloride is reacted with catechol in the presence of a basic agent and a catalyst, using a stirred, two-phase liquid reaction medium comprising water and a water-immiscible, inert organic solvent. The catalyst is a quaternary ammonium or phosphonium derivative. The preferred organic solvent is anisole, although methallyl chloride can act as both the reactant and the water-immiscible solvent. Despite the benefit of selective mono-etherification, the reaction is complicated by the aqueous phase because unreacted catechol collects therein as well as in the anisole phase and must be extracted for later recovery and recycling. Moreover, some of the catechol remains in the product MOP, thereby requiring further purification.
SUMMARY OF THE INVENTION
It has now been found, in one aspect of the invention, that 2-methallyloxyphenol (MOP) can be produced with improved purity and high yield in an uncatalyzed, substantially anhydrous two-phase reaction system by the reaction of a molar excess of methallyl chloride (MAC) with a catecholate, the reaction system optionally, but preferably, containing a polar organic solvent.
In another aspect of the invention, high purity 2-methallyloxyphenol is produced (in some cases on the order of 80-85% on a solvent-free basis) in an anhydrous, two-phase reaction system by the reaction of a molar excess of methallyl chloride with a catecholate in the presence of a quaternary catalyst, the reaction system optionally, but preferably, containing a polar organic solvent.
In a preferred anhydrous two-phase etherification reaction of the present invention, a substantially non-aqueous mixture of catechol, base and a polar organic solvent (in which MAC is substantially insoluble) is formed. The mixture is then combined with a molar excess of MAC with agitation, whereupon the mixture separates into two phases: an upper, organic first phase comprising product MOP dissolved in excess MAC, and a lower, polar (hydrophilic) second phase comprising unreacted catechol, base and solvent. More preferably, a quaternary catalyst is added to the initial mixture or during the agitation. Because the product MOP has greater solubility in the methallyl chloride phase, it may be continuously extracted as formed, thereby reducing the opportunity for secondary (ring) alkylation and facilitating recovery of the product.
The process of the invention thus produces the desired monosubstituted ether in high yield (based on conversion of catechol) and with high purity, and avoids the inconvenience and expense of recovering substantial quantities of catechol as in prior processes.
DETAILED DESCRIPTION
As indicated above, the process of the invention takes place in a substantially anhydrous reaction medium. It will be appreciated, however, that as in reactions of most organic compounds wherein a base is present, particularly as an alkali metal compound, some water will be in the system. Water in substantial amounts in the process of the present invention is undesirable because it contaminates the polar phase, requiring additional processing to separate and to purify the product. Water may be eliminated entirely, or at least further reduced, by preforming the catecholate (by reaction of catechol and an alkali metal compound in a mole ratio of about 1:2 to 2:1) and/or by refluxing the water out of the system as it is formed. Some water can be tolerated in the second, polar phase, but amounts of water sufficient to form a separate, aqueous phase should be avoided.
The substantially anhydrous character of the process optimizes the effect of the relative solubilities of the reactants and product, since the product MOP is soluble in the MAC but unreacted catechol is not. Consequently, the catechol forms a separate phase or, stated another way, remains behind in the pot as the product MOP separates into the top phase. The MOP is then recovered, as by decanting, followed by stripping off of MAC.
In one mode of practice of the process, a substantially non-aqueous mixture of an alkali metal catecholate and a molar excess of MAC is formed. The amount of MAC is sufficient to provide an easily stirrable slurry, e.g., at least 5 moles of MAC per mole of catecholate, preferably a mole ratio of about 10:1 to 20:1 or more, most preferably about 10:1 to 15:1. The mixture is then agitated, such as by stirring. The upper, organic phase comprises product MOP dissolved in MAC. The second (lower) polar phase comprises the remaining reagents.
In another mode of practice, an inert, polar organic solvent is added to the reaction mixture to operate as the primary reaction medium. Suitable organic solvents are those in which the MAC is substantially insoluble. Such solvents include polyhydroxy organic compounds, preferably containing 2 to 5 carbon atoms, of which alkylene glycols, glycol ethers, and certain tri, tetra and penta hydroxy compounds are representative. Suitable solvents of this class include ethylene glycol, diethylene glycol, propylene glycol, glycerol, pentaeryritol, and the like, including mixtures thereof.
If the catecholate is to be formed in situ by reaction of an alkali metal base and catechol, it is convenient to disperse the base in the organic solvent, and then add catechol. The resulting mixture may then be combined with the MAC in any suitable manner, preferably by adding the mixture to the MAC with agitation.
Suitable bases for use in the process include any basic alkali metal compounds such as alkali metal carbonates, bicarbonates, hydroxides and methylates, including any mixture thereof. Sodium and potassium are the preferred alkali metals and sodium carbonate and bicarbonate are the preferred bases. The base is added in at least equimolar amounts with respect to catechol, but preferably in molar excess, e.g., 10% to 50% excess, in order to assist in driving the reaction to completion. Of course, if the catecholate is preformed, a lesser amount of alkali metal base will be effective than in the case of forming the catecholate in situ.
In a further mode of practice of the process of the invention, a quaternary catalyst is added to, or produced in situ in, the reaction mixture prior to or in conjunction with formation of the two phases. The quaternary catalyst may be formed in situ by addition to the mixture of an amino compound capable of quaternizing with MAC. Suitable amino compounds are liquid amines including alkylamines such as trialkyl (C 1 -C 4 ) amines, e.g., triethylamine, and N-heterocyclic amines such as pyridine and quinoline. If the catalyst is preformed and added separately, suitable catalysts are the well-known quaternary ammonium and phosphonium phase transfer catalysts such as described in U.S. Pat. No. 4,252,985, the disclosure of which is incorporated herein by reference. Another quaternary catalyst is methallyl pyridinium chloride, which may be formed in situ from pyridine in the presence of MAC.
The catalyst is employed in a catalytically effective amount, e.g., from about 0.01 to about 1.0 mole per equivalent of catechol or catecholate in the reaction mixture, preferably about 0.1 to about 0.25 mole on the same basis. Mixtures of quaternary salts can also be used as the catalyst. The catalyst helps to reduce or eliminate formation of ring-alkylated by-products. However, when the catalyst is formed in situ by addition to the reaction mixture of an amino compound, it is preferred to include a polar organic solvent in the reaction mixture because amino compounds tend to form pasty mixtures. Such mixtures are more difficult to handle than the more fluid mixtures obtained with polar organic solvents.
The reactants and other reagents of the process, including the catalyst, may be added in any sequence and either incrementally or all at once, with the exception that conditions should be selected such that catechol or catecholate is never present in excess with respect to MAC, in order to avoid or minimize dietherification. Preferably, the catechol or catecholate is added incrementally to the methallyl chloride.
Any combination of temperature and pressure effective for controlled reaction can be used. In an open system, room temperature to reflux (about 130° C.) is suitable. In a pressurized or autogenous reactor, reaction temperature can be higher, depending on the pressure. Reaction time can vary considerably, depending on the solvent system, temperature and pressure, and whether or not a catalyst is used. Generally, a reaction time of about 1-5 hours for an atmospheric pressure process is suitable.
An oxygen scavenger, such as sodium dithionite, may be added to the reaction mixture to prevent oxidation of the catechol or catecholate. The reaction preferably is conducted in an inert atmosphere for the same purpose.
As the phases form and separate in the reaction mixture, the MOP product is conveniently recovered by decanting and then distilling off the residual MAC in the MOP. The product MOP may be further purified in a known manner, if desired. As indicated above, the success of the process depends on the substantially anhydrous reaction medium and relative solubilities of the reactants and reagents. By maintaining MAC in large excess with respect to catechol, the unreacted catechol (which is insoluble in MAC) concentrates in a phase (polar) separate from the MOP product phase. Concentration in a separate phase is also promoted by alkali metal base in the reaction mixture because the resulting catecholate is insoluble in MAC. Accordingly, the small amount of remaining unreacted catechol is easily removed from the reaction mixture, following recovery of the MOP product, thereby avoiding the inconvenience and expense of recovery of large amounts of catechol from an aqueous phase as in the process of U.S. Pat. No. 4,252,985.
The process of the invention makes it possible to achieve, simultaneously, at least 50% conversion of catechol and a product purity of more than 85%. In some cases 80% or more catechol conversion is obtained.
The following examples further illustrate the invention but are not intended to limit the scope thereof. Examples 1-4 are uncatalyzed etherifications. Examples 5-7 represent catalyzed etherifications of the invention. In the Examples all parts and percentages are by weight unless otherwise indicated.
EXAMPLE 1
A mixture of 25 g catechol, 25 g sodium carbonate, 250 g anhydrous glycerol and 250 g MAC was stirred and heated for 30 minutes at 60° C. The MAC layer was decanted. To the glycerol layer was added another charge of 25 g catechol, 25 g sodium carbonate and 250 g MAC. After 20 minutes at 60° C., the MAC layer was decanted. 250 g of fresh MAC was added, heated and decanted. This step was repeated to give 5 MAC treatments of this second charge of catechol in sodium carbonate to make a total of 6 MAC treatments in all. The last 5 MAC extracts were combined- and distilled to give 75 g of residue which was dissolved in 100 ml toluene and washed with water to remove glycerol. GC analysis of the residue indicated a yield of approximately 58% MOP and approximately 100% conversion of catechol.
EXAMPLE 2
A mixture of 50 g catechol, 2.5 g sodium methoxide, 200 g MAC and 100 g anhydrous glycerol was stirred vigorously and heated at 60 to 70° C. for 15 minutes. After decanting the MAC layer, another 200 g of MAC was added and the mixture was heated and stirred. The MAC layer was decanted and a third 200 g charge of MAC was added. The mixture was heated and stirred for 30 minutes at 70°-75° C. The MAC layer was decanted for a third time and a fourth 200 g charge of MAC was added. The mixture was stirred vigorously and heated at 70 to 75° C. The MAC layers were combined, washed with water and distilled to yield 46.2 g of liquid having a catechol conversion of approximately 60% and area purity of approximately 66%.
EXAMPLE 3
A mixture of 10 g catechol, 9.3 g potassium carbonate, 40 g ethylene glycol and 300 g MAC was refluxed at 70° C. for 30 minutes. The MAC layer was decanted and stripped on a rotary evaporator to give 14 g of liquid which was approximately 77% MOP. Catechol conversion was approximately 98%.
EXAMPLE 4
A mixture or 20 g catechol, 13 g potassium carbonate, 40 g ethylene glycol and 300 g MAC was heated at 50-55° C. for 11/2 hours. The MAC layer was decanted and stripped to give 4.9 g of liquid which was approximately 91% MOP and 2.4% catechol on a solvent-free basis. To the glycerol layer was added a second 300 g of MAC and the mixture was heated at 50°-60° C. for 11/2 hours. Decanting and stripping gave 7.3 g of liquid which was 82% MOP and 5% catechol on a solvent-free basis. The combined MAC charges yielded approximately 85% catechol conversion and 85% MOP purity.
EXAMPLE 5
A mixture of 10 g catechol, 10.8 g pyridine, 300 g MAC and 7.6 sodium bicarbonate was stirred vigorously for 2 hours. The MAC was decanted, washed with water and stripped to give 10.9 g of liquid which was 90% MOP and 8% diether. To the thick residue left after the MAC layer was decanted was added 10 g catechol, 7.6 g sodium bicarbonate and 300 g MAC. This mixture was refluxed for one hour. The MAC was decanted and stripped to give 11 g of liquid which assayed 74% MOP. This process was repeated and the MAC layer decanted after one hour. To the thick pot residue was then added an additional 300 g MAC (without additional catechol or carbonate). This mixture was refluxed for two hours, decanted and stripped to give 9 g of liquid which was 78% weight MOP. In this experiment, catechol conversion was approximately 70% and MOP yield was approximately 90%.
EXAMPLE 6
A mixture of 40 g ethylene glycol, 7.1 g pyridine and 20 g MAC was heated at 80° C. for about one hour, until the odor of pyridine had dissipated. To the mixture was added 7.6 g sodium bicarbonate and the resultant mixture was heated at 80° C. for 90 minutes. 10 g catechol was then added and the mixture was stirred until carbon dioxide evolution had ceased. The mixture was refluxed for 90 minutes, the MAC decanted and stripped. The product was 11.2 g of liquid which assayed 80% MOP and 2.5% catechol.
To the residue left after decanting of the MAC layer was added 10 g catechol, 5.8 g sodium bicarbonate and 300 g MAC. After refluxing for 30 minutes the MAC layer was decanted and stripped down to give 14.4 g product which assayed 80 wt % MOP and 3.3 wt % catechol. To the pot residue was added 10 g catechol, 5.8 g sodium carbonate and 150 g of MAC. After 30 minutes reflux the MAC was decanted and stripped to give 14.1 gram of liquid which assayed 76 wt % MOP and 4.6 wt % catechol. To the pot residue was added 40 g water, 5.8 g (0.055 mole) sodium carbonate and 300 g MAC. After 30 minutes reflux, the MAC was decanted and stripped to give 11.1 g of liquid which assayed 66 wt % MOP and 5.8 wt % catechol.
EXAMPLE 7
A mixture of 7.1 g (0.09 mole) pyridine in 300 g MAC was refluxed overnight. The product was a yellow liquid which crystallized upon cooling. The MAC layer was decanted, and to the crystallized product was added 7.4 g (0.09 mole) sodium bicarbonate, 50 ml methanol and a small amount of water. When this mixture was heated, carbon dioxide evolved. After carbon dioxide evolution ceased, the mixture was stripped at reduced pressure and yielded 20 g of residue. To the residue was added 40 g ethylene glycol, 10 g catechol and 300 g MAC. After one hour at reflux, the MAC was decanted, washed and stripped to give 11.4 g liquid which assayed 80 wt % MOP and 3.5 wt % catechol. This is approximately 78% conversion. | 2-Methallyloxyphenol is produced selectively in good yield, high purity and without having to separate and recycle large amounts of catechol, in the reaction of methallyl chloride with catechol, by forming a substantially non-aqueous mixture of an alkali metal catecholate and a molar excess of methallyl chloride perferably in a polar organic solvent in which the methallyl chloride is substantially insoluble, agitating the mixture to produce a two-phase system comprising an organic first phase containing product 2-methallyloxyphenol dissolved in methallyl chloride and a polar second phase containing unreacted catecholate, and recovering product 2-methallyloxyphenol from the first plase. The presence of a quaternary ammonium or phosphonium catalyst in the reaction mixture further reduces undesired ring-alkylated by-products. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates generally to electric machines and more particularly to a segmented magnet component for use in an electric machine and methods of assembling the segmented magnet component and electric machine.
Manufacturing of permanent magnets (PM) for use in electric machines, such as interior permanent magnet (IPM) machines, typically requires a cost-intensive mold and sinter process. Additionally, in order to provide the various PM shapes for the various shapes and configurations of slots, the magnets must be cut or milled Often multiple shapes and sizes of magnets are required for a single model of IPM machine. The magnets, once manufactured, are placed or inserted into the various slots in the rotor laminations. For example, as shown in FIG. 1 , what often occurs is standard magnet sizes 170 (e.g., rectangles) are placed in the rows 160 of voids 165 of a rotor lamination 150 . Often the magnets 170 end up inefficiently filling the spaces 165 . This inefficient and expensive process further results in undesirable empty spaces or voids remaining in the slots between the inserted magnets and the lamination of the rotor. This inefficiency and cost also creates a disincentive in manufacturing rotor laminations that have curved rows of curved voids due to the difficulty in efficiently filling the curved voids.
Accordingly, there is an ongoing need for improvement of current electric machine manufacturing technologies that address at least one of complexity, cost, efficiency, and/or performance.
BRIEF DESCRIPTION
The present invention overcomes at least some of the aforementioned drawbacks by providing improvements to electric machines, such as IPM machines, so the machines may be both manufactured more efficiently in addition to providing a more technically efficient electric machines. More specifically, the present invention is directed to a segmented magnet component for use in an electric machine and a method of assembling the component into the electric machine. In an embodiment, a vehicle, such as an underground mining vehicle, may employ compact traction motors that utilize aspects of the present invention.
Therefore, in accordance with one aspect of the invention, a component comprises a plurality of magnet elements adjoined to each other, thereby defining an arced segmented magnet section, wherein the arced segmented magnet section is configured to fit in an a curved rotor slot gap of an electric machine.
In accordance with another aspect of the invention, an electric machine comprises: a rotor core comprising a plurality of laminations; a stator configured with a plurality of stationary windings therein; a plurality of curved rotor slot gaps disposed within the plurality of rotor laminations; and a segmented magnet component disposed in each of the plurality of curved rotor slot gaps.
In accordance with another aspect of the invention, a method comprises: adjoining a plurality of magnetizable segments next to each other, thereby defining an arced segmented magnet section, wherein each of the plurality of magnetizable segments are a same size and shape; inserting said arced segmented magnet section into a curved rotor slot gap of an electric machine rotor lamination; and magnetizing the arced segmented magnet section.
Various other features and advantages of the present invention will be made apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
FIG. 1 is a plan view of a portion of a rotor of the related art.
FIG. 2 is a plan view of a segmented magnet component and portion of a rotor according to an embodiment of the present invention.
FIG. 3 is a top perspective view of a segmented magnet component according to an embodiment of the present invention.
FIGS. 4A-4E are plan views of various embodiments of a single segment of a segmented magnet component, according to various embodiments of the present invention.
FIG. 5 is a flowchart of a method of assembly, according to embodiments of the present invention.
DETAILED DESCRIPTION
Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art with respect to the presently disclosed subject matter. The terms “first”, “second”, and the like, as used herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a”, “an”, and “the” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item, and the terms “front”, “back”, “bottom”, and/or “top”, unless otherwise noted, are used for convenience of description only, and are not limited to any one position or spatial orientation.
If ranges are disclosed, the endpoints of all ranges directed to the same component or property are inclusive and independently combinable (e.g., ranges of “up to about 25 wt. %,” is inclusive of the endpoints and all intermediate values of the ranges of “about 5 wt. % to about 25 wt. %,” etc.). The modified “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity). Accordingly, the value modified by the term “about” is not necessarily limited only to the precise value specified.
Referring to FIG. 2 , a plan view of a rotor structure component and portion of a rotor, according to an embodiment of the present invention, is depicted. The rotor component, or termed a segmented magnet component, or termed as component, is denoted by 10 and is shown in a portion of a electric machine 100 . The portion of the electric machine 100 shown is a portion of a rotor lamination 30 . As depicted, the portion of the electric machine 100 may comprise a portion of an interior permanent magnet (IPM) machine.
The rotor lamination 30 may comprise a plurality of rows of curved rotor slot gaps 32 . As shown, there are four (4) rotor slot gaps 32 , with the outermost curved rotor slot gap 32 being empty. The other three inward curved rotor slot gaps 32 each receive a curved rotor structure component 10 . The unique configuration of the elements 12 and components 10 result in a significantly smaller remaining space, or void 34 in the rotor slot gap 32 after placement of the component 10 . This smaller space, or void 34 between rotor slot gap 32 , component 10 , and lamination 30 ultimately leads to improved performance of the electric machine 100 (partially shown).
It should be noted that while the configuration shown in FIG. 2 depicts four rows of rotor slot gaps 32 wherein three of the four rows of rotor slot gaps 32 are filled with components 10 , there are other embodiments and configurations possible. Clearly, other quantities of rows of rotor slot gaps 32 are possible. So too can other quantities, or ratios, of filling the rotor slot gaps 32 with components 10 be possible under aspects of the present invention. By non-limiting example, all of the rows of rotor slot gaps 32 may be filled with components 10 , just as only a single row of the rows of rotor slot gaps 32 may be filled with a component 10 . The fill (or non-fill) ratio of components 10 in (or not in) the rotor slot gaps 32 may be virtually any value.
Referring to FIG. 3 , a perspective view of a portion of the rotor structure component, according to an embodiment of the present invention, is depicted. The component 10 is an arced magnetic segment comprised of a plurality of magnetizable elements, or elements, 12 . Each of the plurality of magnetizable elements 12 comprises an element 12 having a first end, or concave end, 14 and a second end, or convex end, 16 . As shown, each of the elements 12 may be the same size and shape. The plurality of elements 12 may be adjoined (e.g., placed, located, and/or connected) next to each other such that the first end 14 of a first element 12 is adjacent to the second end 16 of an adjacent second element 12 . In this manner, an arced segment component 10 can be constructed of virtually any length and/or curvature suitable to fit inside a curved rotor slot gap 32 of a rotor lamination 30 of a machine 100 (See e.g., FIG. 2 ). Advantageously, aspects of the present invention allow for an improved filling factor of the curved rotor slot gaps 32 . Further, aspects of the present invention allow for further capability and flexibility by constructing curved components 10 of virtually any angle that can readily fill any angle curved slot including curved slots that have curvature that changes over the length of the slot as well as uniform curvature. This may be achieved by the use of a magnetizable element 12 of a single shape and size.
The magnetizable elements 12 may comprise any suitable material including but not limited to, for example, Ferrite, Alnico, or rare earth metals, such as, NdFeB, Somarium-Cobalt, and the like. In certain embodiments, the magnetizable elements 12 may be adhered to each other via any suitable glue, adhesive, resin, and the like. Similarly, in other embodiments, the magnetizable elements 12 may be adjoined (but not adhered), to each other such that the magnetizable elements are dry fit, or friction fit, into the rotor slot gap(s) 32 (See e.g., FIG. 2 ).
Referring to FIGS. 4A-4E , plan views of various embodiments of the magnetizable elements 12 are shown. As depicted, different shapes for the element 12 may be employed without departing from aspects of the present invention. Each magnetizable element 12 may comprise a first end 14 and a second end 16 . The magnetizable element 12 is configured in shape and size such that the first end 14 of a first element 12 is compatible with fitting with the adjoining second end 16 of an adjacent, second element 12 . In this manner, a component 10 (See e.g., FIGS. 2 and 3 ) may be constructed from a plurality of adjoined magnetizable elements 12 .
For example, FIG. 4A shows an embodiment of an element 12 having a concave first end 14 and a convex second end 16 , wherein the shape may be termed “half-mooned”. FIG. 4B shows an embodiment of an element 12 having a flat first end 14 and a slanted, or angled, second end 16 , wherein the shape may be termed “right trapezoid”. FIG. 4C shows an embodiment of an element 12 having both first end 14 and second end 16 that are slanted, wherein the shape may be termed “trapezoidal”. In some embodiments, the angles of the first end 14 and second end 16 need not match. FIG. 4D shows an embodiment of an element 12 having a first end 14 being angled concave and a second end 16 being angled convex, wherein the shape may be termed “chevron”. FIG. 4E shows two different elements 12 a , 12 b wherein the first element 12 a is circular and the second element 12 b that could be termed “double half-mooned” shape. The first element 12 a has a first end 14 and a second end 16 that are both curved. Similarly, the second element 12 b has a first end 14 and a second end 16 that are both convex. In this particular embodiment, it should be apparent that the two different shaped elements 12 a , 12 b may be placed adjoining each other, in an alternatingly pattern so that the first end 14 of the first (circular) element 12 a is adjoined, or adjacent, to the second end 16 of the second element 12 b , such that a curved component 10 may be constructed. Clearly, other shapes and configurations are possible without departing from aspects of the present invention.
The embodiments depicted in FIGS. 4A and 4E , for example, offer an advantage of providing the ability to readily construct segmented magnet components that are curved and can fit into curved slots of virtually any machine that has curved rotor slots (lamination or solid rotor core) from, in the case of the embodiment in FIG. 4A , a single sized/shaped component 12 , and in the case of the embodiment in FIG. 4E , merely two sized/shaped components 12 a , 12 b.
Under aspects of the present invention, the components 10 and the electric machines 100 discussed herein may be used as a traction motor for virtually any vehicle. A vehicle support frame (not shown) may be connected to the one or more electric machine 100 . Suitable vehicles for use include, but are not limited to, an off-highway vehicle (OHV), a locomotive, a mining vehicle, electric-motorized railcar, automobiles, trucks, construction vehicles, agricultural vehicles, airport ground service vehicles, fork-lifts, non-tactical military vehicles, tactical military vehicles, golf carts, motorcycles, mopeds, all-terrain vehicles, and the like.
Note that while various embodiments discussed herein describe a rotor core lamination 30 (see e.g., FIG. 2 ), it should be noted that other types of electric machine 100 constructs may be used without departing from aspects of the present invention. For example, the rotor core may, instead of be constructed of a plurality of laminations 30 , be a solid rotor core (i.e., no laminations). In this type of solid rotor core embodiment, the magnetizable elements 12 , for example, would typically be substantially deeper than the magnetizable elements 12 depicted in FIG. 3 for example. In this manner, the magnetizable elements 12 would have a length the same, or similar to, the length of the entire solid rotor core and/or the rotor slot gaps in the solid rotor core.
A flowchart depicting a method of assembly, according to aspects of the present invention, is depicted at FIG. 5 . A method may comprise adjoining magnetizable segments to each other at 202 . The magnetizable segments may be all of uniform size and shape. The bonding thereby forms an arced section at 204 . Then at 206 the arced section is magnetized. At 208 , the arced section (now magnetized) is inserted into a curved rotor slot on a rotor lamination. Alternatively, as shown in the flowchart, after 204 , the arced section may be inserted into the curved rotor section on a rotor lamination at 208 . Then, the arced slot (now inserted) is magnetized in situ at 206 .
Therefore, according to one embodiment of the present invention, a component comprises a plurality of magnet elements adjoined to each other, thereby defining an arced segmented magnet section, wherein the arced segmented magnet section is configured to fit in an a curved rotor slot gap of an electric machine.
According to another embodiment of the present invention, an electric machine comprises: a rotor core comprising a plurality of laminations; a stator configured with a plurality of stationary windings therein; a plurality of curved rotor slot gaps disposed within the plurality of rotor laminations; and a segmented magnet component disposed in each of the plurality of curved rotor slot gaps.
According to another embodiment of the present invention, a method comprises: adjoining a plurality of magnetizable segments next to each other, thereby defining an arced segmented magnet section, wherein each of the plurality of magnetizable segments are a same size and shape; inserting said arced segmented magnet section into a curved rotor slot gap of an electric machine rotor lamination; and magnetizing the arced segmented magnet section.
While only certain features of the invention have been illustrated and/or described herein, many modifications and changes will occur to those skilled in the art. Although individual embodiments are discussed, the present invention covers all combination of all of those embodiments. It is understood that the appended claims are intended to cover all such modification and changes as fall within the intent of the invention. | A component includes magnet elements adjoined to each other to form an arced segmented magnet section that is configured to fit in an a curved rotor slot gap of an electric machine. An electric machine that employs the component and method of assembly of the component are also disclosed. The present invention has been described in terms of specific embodiment(s), and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/269,243, filed Oct. 11, 2003.
TECHNICAL FIELD
[0002] The invention disclosed herein is directed to wipes, preferably wipes for use in cleansing applications, made from a hydroentangled nonwoven fabric, whereby the outer surface fibers of a single fibrous batt are highly hydroentangled and the inner fibers of the single fibrous batt are lightly entangled, the resulting fabric thus exhibits a low linting, lofty structure, and favorable tactile and ductile softness while obtaining sufficient physical strength.
BACKGROUND OF THE INVENTION
[0003] The use of natural fiber materials in industrial applications has been found to be highly advantageous in situations where a nonlinting, absorbent pad or wiper is required. A material that has been employed in such applications is found in the Webril material registered to the Kendall Company of Massachusetts. The Webril material is a compressed, mercerized cotton fibrous batt. The mercerization process involves the swelling of the natural cotton's ribbon like profile into an approximately round profile of larger diameter. Typically, caustic washes are utilized while the cotton batt is under tension to induce the swelling of the cotton fiber. Because of the use of a caustic solution, it is necessary to subsequently treat the cotton material with an acidic solution so as to neutralize the material and render it useable. A number of complicated steps are required to successfully perform the process, with a significant amount of environmentally harmful effluent being produced.
[0004] In the interest of forming natural fiber nonwoven pads or wipers without the by- products of mercerization, the application of a resin binder in conjunction with hydroentanglement was explored as evidenced by U.S. Pat. Nos. 2,862,251, 3,033,721, 3,769,659, and 3,931,436 to Kalwaites et al, and U.S. Pat. Nos. 3,081,515 and 3,025,585 to Griswold et al. The application of resin binder was found to have a deleterious effect on the softness of the corresponding nonwoven fabric.
[0005] The findings by Evans, U.S. Pat. No. 3,485,706, suggested that the impedance of energetic water streams on a fibrous batt could produce a nonwoven fabric by the entanglement of those fibers with one another through the depth of the fibrous batt, thus obviating the need for a resin binder. However, the action of the water streams upon the fibrous batt and the action of entangling the fibers result in a fabric having significantly decreased bulk, and correspondingly decreased tactile and ductile softness.
[0006] Various attempts have been made in order to obtain a durable natural fiber nonwoven fabric while maintaining sufficient strength and softness. In U.S. Pat. No. 5,849,647 to Neveu, a hydrophilic cotton stratified structure is formed by interceding an air-randomized core in between two previously formed, highly fiber oriented carded layers. The stratified layers are subsequently treated with a soda liquor which is then boiled off to render an integrated structure. While a cotton structure performed by the manner described can render an ultimate material that is low linting, the material must undergo substantial processing in the forming of separate and distinct layers and the juxtaposition of those layers during the caustic integration step. U.S. Pat. No. 4,647,490 to Bailey et al., formed an apertured, cotton fiber nonwoven material by hydroentanglement induced by oscillating water streams. In the Bailey process, the fibers of the fibrous batt are washed down and through the fibrous batt in order to entangle the fibers and form apertures in the fabric. U.S. Pat. No. 4,426,417 to Meitner et al., incorporated the use of thermoplastic meltblown during the formation of a fibrous batt as a means for attaining the loft for absorbency and maintain sufficient physical strength by bonding the fibers together. As the nature of the Meitner process is based upon the total and effective binding of the fibers to the thermoplastic meltblown there are potential issues with unbound or loosely bound fibers being disengaged from the meltblown.
[0007] Given the prior art attempt to form a nonlinting, soft and yet strong absorbent materials, there remains a need for a nonwoven fabric exhibiting these characteristics and yet is formed in an expeditious and uncomplicated manner.
[0008] A method for forming a suitable nonwoven fabric meeting the aforementioned requirements has been identified in the application of fluidic energy such that a single fibrous batt is imparted with a highly entangled surface of outer fibers, while retaining the loft and absorbency of a lightly entangled central layer of core fibers. Further, the incorporation of a functional additive, such as an aqueous or non-aqueous soap or cleansing composition provides for a cleansing wipe particularly suited for hygienic end-uses, in addition to home care and end-use wipe applications.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a method of forming a nonwoven fabric suitable for various wipe applications, the outer surface of highly entangled fibers provides for a low lint wipe, while the lightly entangled fibers of he inner layer promotes the flow of air through the fabric so as to enhance lather formation. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired.
[0010] In accordance with the present invention, a method of making a nonwoven fabric embodying the present invention includes the steps of providing a fibrous batt comprising a fibrous matrix. While use of natural fibers is common, the fibrous matrix may comprise synthetic fibers or blends of natural and synthetic fibers. The synthetic fibers are chosen from the group consisting of viscose cellulose, polyacrylates, polyolefins, polyamides, polyesters and combinations thereof. Further, the synthetic fibers may comprise homogeneous, bicomponent and/or multi-component profiles, and the blends thereof.
[0011] In a particularly preferred form, the fibrous batt is carded and crosslapped to form a fibrous batt. The fibrous batt is then continuously indexed through a station composed of a rotary foraminous surface and a fluidic manifold. Fluid streams from the fluidic manifold impinge upon the fibrous batt at a controlled energy level so as to integrate a portion of the overall fibrous content. The energy level is controlled such that the energy is sufficient to induce high levels of entanglement in the surface fibers, but has insufficient transmitted energy to induce high levels of entanglement of the inner fibers. A plurality of such stations can be employed whereby fluid streams are at the same or differing energy levels, impinging one or alternately both surfaces of the fibrous batt. The resulting differentially entangled nonwoven web exhibits a highly entangled fibrous outer surface and a lightly entangled fibrous core.
[0012] Subsequent to hydroentanglement, the present method further contemplates the provision of a three-dimensional image transfer device having a movable imaging surface. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, hereby incorporated by reference. In a typical configuration, the image transfer device may comprise a drum-like apparatus that is rotatable with respect to one or more hydroentangling manifolds.
[0013] It is within the purview of this invention that tension control means can be employed to further enhance the physical performance of the resulting lofty material.
[0014] A further aspect of the present invention is directed to a method of forming a nonwoven fabric which exhibits a sufficient degree of softness and nonlinting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications. The fabric exhibits a high degree of loft and absorbency, thus permitting its use in those applications in which the fabric is applied as a cleaning wipe.
[0015] In one embodiment of the present invention, the lightly entangled inner layer may comprise large denier fibers so as to lend to the bulkiness and resiliency of the nonwoven fabric. In a second embodiment of the present invention, the outer surfaces may comprise dissimilar fibers, wherein one outer surface may utilize splittable fiber or sub-denier fibers and the opposing outer surface may utilize a larger denier trilobal fiber. The various fibers selected for the outer surfaces are not to be a limitation of the present invention.
[0016] A method of making the present durable nonwoven fabric comprises the steps of providing a fibrous matrix or batt, which is subjected to controlled levels of hydraulic energy. A homogeneous cotton fibrous batt has been found to desirably yield a fabric with soft hand and good absorbency. The fibrous batt is formed into a differentially entangled nonwoven fabric by the application of sufficient energy to entangle only the outer layers of the fibrous batt. Subsequently, the fabric can be passed over an image transfer device defined by three-dimensional elements against which the differentially entangled nonwoven fabric is forced during further application of further energy, whereby the fibrous constituents of the web are imaged and patterned by movement into regions between the three-dimensional elements of the transfer device.
[0017] In accordance with the present invention, the end-use nonwoven fabric wipes include the use of various aqueous and non-aqueous compositions. The performance specific chemistries can be incorporated into or topically applied to the resulting differentially entangled fabric. Such chemistries can be durably applied to the constituent fibers of the fibrous batt, to the fibrous batt during manufacture, and/or to the resulting fabric.
[0018] Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a diagrammatic view of an apparatus for manufacturing a differentially entangled nonwoven fabric, embodying the principles of the present invention; and
[0020] [0020]FIG. 2 is a diagrammatic view of five consecutive entangling sections and an image transfer station.
DETAILED DESCRIPTION
[0021] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
[0022] The present invention is directed to a method of forming nonwoven fabrics by hydroentanglement, wherein the outer surface of the fabric is substantially more entangled than the core layer. Hydroentanglement by this method is controlled by the application of fluidic energy such that the energy imparted into fibers of the fabric is sufficient to highly entangle only the outer fibers. The inner fibers are lightly entangled such that the overall structure is resistant to separation of the layers, yet retain much of the loftiness or bulk of the fibrous core layer that is responsible for tactile and ductile softness, absorbency, as well as the promotion of air flow through the fabric. By advancing the fibrous batt with a relatively low tension through one or more entanglement stations, differential fiber entanglement is achieved, with the physical properties, both aesthetic and mechanical, of the resultant fabric being desirably achieved.
[0023] In accordance with a further aspect of the present invention, a nonwoven fabric for application as a wipe can be produced such that the level of surface entanglement can be controlled resulting in surface layers that are extremely resistant to Tinting while the fabric retains some loft of the fibrous inner layer, which allows for a desirable circulation of air through the wipe, assisting with lather formation. A material of this nature may be used as a wet wipe or dry, wherein the wipe is particularly suitable for cleansing applications. The level of entanglement energy can be continuously varied to modify the physical properties of the wipe material to meet the required performance. It is within the scope of the present invention to control the level of entanglement in the resulting fabric to obtain materials with varying degrees of loft, absorbency, strength, and Tinting performance.
[0024] Nonwoven fabrics are frequently produced using staple length fibers, the fabric typically has a degree of exposed surface fibers that will lint if not sufficiently retained into the structure of the fabric. The present invention provides a finished fabric that can be cut, processed or treated, and packaged for retail sale. The cost associated with forming and finishing steps can be desirably reduced.
[0025] With reference to FIG. 2, therein is illustrated an apparatus for practicing the present method for forming a nonwoven fabric. The fabric is formed from a fibrous batt that typically comprises natural fibers, but may comprise synthetic staple fibers and natural/synthetic fiber blends. The fibrous batt is preferably carded and cross-lapped to form a fibrous batt, designated P. In a current embodiment, the fibrous batt comprises 100% cross-lap fibers, that is, all of the fibers of the web have been formed by cross-lapping a carded web so that the fibers are oriented at an angle relative to the machine direction of the resultant web. In this current embodiment, the fibrous batt has a draft ratio of approximately 2.5 to 1. U.S. Pat. No. 5,475,903, hereby incorporated by reference, illustrates a web drafting apparatus.
[0026] [0026]FIG. 2 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention. The apparatus includes a foraminous forming surface in the form of belt 02 upon which the fibrous batt P is positioned for pre-entangling by entangling manifold 01 into a wetted, lightly entangled fibrous web P′. Pre-entangling of the fibrous web is subsequently effected by movement of the web P′sequentially over a drum 10 having a foraminous forming surface, with entangling manifold 12 effecting entanglement of the web. Further entanglement of the web may be effected on the foraminous forming surface of a drum 20 by entanglement manifold 22 , with the web subsequently passed over successive foraminous drums 30 , 40 and 50 , for successive entangling treatment by entangling manifolds 32 , 42 and 51 . The total, optimal energy input to the fibrous batt to give the desired level of surface entanglement is in the range of about 0.040 to 0.060 hp-hr/lb.
[0027] The entangling apparatus of FIG. 2 may further include an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now-entangled precursor web. The image transfer device includes a moveable imaging surface which moves relative to a plurality of entangling manifolds 61 , 62 , 63 and 64 , which act in cooperation with three-dimensional elements defined by the imaging surface of the image transfer device to effect imaging and patterning of the fabric being formed. The total energy applied to the fibrous batt of the imaging manifolds is adjusted to maintain the energy input in the range of about 0.040 to 0.060 hp-hr/lb.
[0028] The present invention contemplates that the fibrous web P′ be advanced onto the moveable imaging surface of the image transfer device at a rate which is substantially equal to the rate of movement of the imaging surface. A J-box or scray can be employed for supporting the precursor web P′ as it is advanced onto the image transfer device to thereby minimize tension within the fibrous web. By controlling the rate of advancement of the fibrous batt P and the web P′ through the process so as to minimize, or substantially eliminate, tension within the web, differential hydroentanglement of the fibrous web is desirably effected.
[0029] Manufacture of a durable nonwoven fabric embodying the principles of the present invention is initiated by providing the precursor nonwoven web preferably in the form of natural and/or synthetic fibers, most preferably a cotton or cotton blend, which desirably provides good tactile and ductile softness and absorbency. During development, it was ascertained that fabric weights on the order of about 1 to 8 ounces per square yard, with the range of 2 to 5 ounces per square yard being most preferred, provided the best combination of loft, softness, drapeability, absorbency, and durability.
[0030] In accordance with the present invention, the various nonwoven wipe applications include the use of aqueous and non-aqueous compositions. In one embodiment of the present invention, the lightly entangled inner layer may comprise large denier fibers so as to lend to the bulkiness and resiliency of the nonwoven fabric. In a second embodiment of the present invention, the outer surfaces may comprise dissimilar fibers, wherein one outer surface may utilize splittable fiber or sub-denier fibers and the opposing outer surface may utilize a larger denier trilobal fiber. The various fibers selected for the outer surfaces are not to be a limitation of the present invention.
[0031] The nonwoven wipe embodying the principles of the present invention is suitable for home care cleaning or cleansing wipes. The nonwoven wipe may be used in various home care applications, wherein the end use article may be a dry or wet hand held sheet, a mitt formation, or a cleaning implement capable of retaining the article. The nonwoven wipe is suitable for cleaning various household surfaces such as, kitchen and bathroom countertops, sinks, bathtubs, showers, appliances, and fixtures.
[0032] Cleansing compositions suitable for such end use applications include those that are described in U.S. Pat. No. 6,103,683 to Romano, et al., U.S. Pat. No. 6,340,663 to Deleo, et al., U.S. Pat. No. 5,108,642 to Aszman, et al., and U.S. Pat. No. 6,534,472 Arvanitidou, et al., all of which are hereby incorporated by reference. Selected cleaning compositions may also include surfactants, such as alkylpolysaccharides, alkyl ethoxylates, alkyl sulfonates, and mixtures thereof; organic solvent, mono- or polycarboxylic acids, odor control agents, such as cyclodextrin, peroxides, such as benzoyl peroxide, hydrogen peroxide, and mixtures thereof, thickening polymers, aqueous solvent systems, suds suppressors, perfumes or fragrances, and detergent adjuvants, such as detergency builder, buffer, preservative, antibacterial agent, colorant, bleaching agents, chelants, enzymes, hydrotropes, and mixtures thereof. The aforementioned compositions preferably comprise from about 50% to about 500%, preferably from about 200% to about 400% by weight of the nonwoven cleaning article.
[0033] The nonwoven wipe embodying the principles of the present invention is also suitable for personal cleaning or cleansing articles. Nonlimiting examples of such applications include dry or wet facial wipes, body wipes, and baby wipes. Suitable methods for the application of various aqueous and non-aqueous compositions comprise aqueous/alcoholic impregnates, including flood coating, spray coating or metered dosing. Further, more specialized techniques, such as Meyer Rod, floating knife or doctor blade, which are typically used to impregnate cleansing solutions into absorbent sheets, may also be used. The following compositions preferably comprise from about 50% to about 500%, preferably from about 200% to about 400% by weight of the nonwoven cleaning article.
[0034] The nonwoven may incorporate a functional additive, such as an alphahydroxycarboxylic acid, which refers not only the acid form but also salts thereof. Typical cationic counterions to form the salt are the alkali metals, alkaline earth metals, ammonium, C 2 -C 8 trialkanolammonium cation and mixtures thereof. The term “alpha-hydroxycarboxylic acids” include not only hydroxyacids but also alpha-ketoacids and related compounds of polymeric forms of hydroxyacid.
[0035] Amounts of the alpha-hydroxycarboxylic acids may range from about 0.01 to about 20%, preferably from about 0.1 to about 15%, more preferably from about 1 to about 10%, optimally from about 3 to about 8% by weight of the composition which impregnates the substrate. The amount of impregnating composition relative to the substrate may range from about 20:1 to 1:20, preferably from 10: 1 to about 1:10 and optimally from about 2:1 to about 1:2 by weight.
[0036] Further, a humectant may be incorporated with the aforementioned alpha-hydroxycarboxylic compositions. Humectants are normally polyols. Representative polyols include glycerin, diglycerin, polyalkylene glycols and more preferably alkylene polyols and their derivatives. Amounts of the polyol may range from about 0.5 to about 95%, preferably from about 1 to about 50%, more preferably from about 1.5 to 20%, optimally from about 3 to about 10% by weight of the impregnating composition.
[0037] A variety of cosmetically acceptable carrier vehicles may be employed although the carrier vehicle normally will be water. Amounts of the carrier vehicle may range from about 0.5 to about 99%, preferably from about 1 to about 80%, more preferably from about 50 to about 70%, optimally from about 65 to 75% by weight of the impregnating composition.
[0038] Preservatives can desirably be incorporated protect against the growth of potentially harmful microorganisms. Suitable traditional preservatives for compositions of this invention are alkyl esters of para-hydroxybenzoic acid. Other preservatives which have more recently come into use include hydantoin derivatives, propionate salts, and a variety of quatemary ammonium compounds. Preservatives are preferably employed in amounts ranging from 0.01% to 2% by weight of the composition.
[0039] The composition may further include herbal extracts. Illustrative extracts include Roman Chamomile, Green Tea, Scullcap, Nettle Root, Swertia laponica, Fennel and Aloe Vera extracts. Amount of each of the extracts may range from about 0.001 to about 1%, preferably from about 0.01 to about 0.5%, optimally from about 0.05 to about 0.2% by weight of a composition.
[0040] Additional functional additives may also include vitamins such as Vitamin E Acetate, Vitamin C, Vitamin A Palmitate, Panthenol and any of the Vitamin B complexes. Anti-irritant agents may also be present including those of steviosides, alpha-bisabolol and glycyhrizzinate salts, each vitamin or anti-irritant agent being present in amounts ranging from about 0.001 to about 1.0%, preferably from about 0.01 to about 0.3% by weight of the composition.
[0041] These impregnating compositions of the present invention may involve a range of pH although it is preferred to have a relatively low pH, for instance, a pH from about 2 to about 6.5, preferably from about 2.5 to about 4.5.
[0042] In addition to cosmetic compositions, lotions may be incorporated into the nonwoven wipe. The lotion preferably also comprises one or more of the following: an effective amount of a preservative, an effective amount of a humectant, an effective amount of an emollient; an effective amount of a fragrance, and an effective amount of a fragrance solubilizer.
[0043] As used herein, an emollient is a material that softens, soothes, supples, coats, lubricates, or moisturizes the skin. The term emollient includes, but is not limited to, conventional lipid materials (e.g. fats, waxes), polar lipids (lipids that have been hydrophylically modified to render them more water soluble), silicones, hydrocarbons, and other solvent materials. Emollients useful in the present invention can be petroleum based, fatty acid ester type, alkyl ethoxylate type, fatty acid ester ethoxylates, fatty alcohol type, polysiloxane type, mucopolysaccharides, or mixtures thereof.
[0044] Fragrance components, such as perfumes, include, but are not limited to water insoluble oils, including essential oils. Fragrance solubilizers are components which reduce the tendency of the water insoluble fragrance component to precipitate from the lotion. Examples of fragrance solubilizers include alcohols such as ethanol, isopropanol, benzyl alcohol, and phenoxyethanol; any high HLB (HLB greater than 13) emulsifier, including but not limited to polysorbate; and highly ethoxylated acids and alcohols.
[0045] Preservatives prevent the growth of micro-organisms in the liquid lotion and/or the substrate. Generally, such preservatives are hydrophobic or hydrophilic organic molecules. Suitable preservatives include, but are not limited to parabens, such as methyl parabens, propyl parabens, and combinations thereof.
[0046] The lotion can also comprise an effective amount of a kerotolytic for providing the function of encouraging healing of the skin. An especially preferred kerotolytic is Allantoin ((2,5-Dioxo-4-Imidazolidinyl)Urea), a heterocyclic organic compound having an empirical formula C 4 H 6 N 4 O 3 . Allantoin is commercially available from Tri-K Industries of Emerson, N.J. It is generally known that hyperhydrated skin is more susceptible to skin disorders, including heat rash, abrasion, pressure marks and skin barrier loss. A premoistened wipe according to the present invention can include an effective amount of allantoin for encouraging the healing of skin, such as skin which is over hydrated.
[0047] U.S. Pat. No. 5,534,265 issued Jul. 9, 1996; U.S. Pat. No. 5,043,155 issued Aug. 27, 1991; and U.S. Pat. No. 5,648,083 issued Jul. 15, 1997, are incorporated herein by reference for the purpose of disclosing additional lotion ingredients.
[0048] The lotion can further comprise between about 0.1 and about 3 percent by eight Allantoin, and about 0.1 to about 10 percent by weight of an aloe extract, such as aloe vera, which can serve as an emollient. Aloe vera extract is available in the form of a concentrated powder from the Rita Corporation of Woodstock, Ill.
[0049] Further, latherants may be incorporated within the nonwoven wipe. Nonlimiting examples of anionic lathering surfactants useful in the compositions of the present invention are disclosed in McCutcheon's, Detergents and Emulsifiers, North American edition (1986), published by allured Publishing Corporation; McCutcheon's, Functional Materials, North American Edition (1992); and U.S. Pat. No. 3,929,678, to Laughlin et al., issued Dec. 30, 1975, all of which are incorporated by reference herein in their entirety. A wide variety of anionic lathering surfactants are useful herein. Nonlimiting examples of anionic lathering surfactants include those selected from the group consisting of sarcosinates, sulfates, isethionates, taurates, phosphates, lactylates, glutamates, and mixtures thereof.
[0050] Nonlimiting examples of nonionic lathering surfactants and amphoteric surfactants for use in the compositions of the present invention are disclosed in McCutcheon's, Detergents and Emulsifiers, North American edition (1986), published by allured Publishing Corporation; and McCutcheon's, Functional Materials, North American Edition (1992); both of which are incorporated by reference herein in their entirety.
[0051] Nonionic lathering surfactants useful herein include those selected from the group consisting of alkyl glucosides, alkyl polyglucosides, polyhydroxy fatty acid amides, alkoxylated fatty acid esters, lathering sucrose esters, amine oxides, and mixtures thereof.
[0052] The term “amphoteric lathering surfactant,” as used herein, is also intended to encompass zwitterionic surfactants, which are well known to formulators skilled in the art as a subset of amphoteric surfactants.
[0053] A wide variety of amphoteric lathering surfactants can be used in the compositions of the present invention. Particularly useful are those which are broadly described as derivatives of aliphatic secondary and tertiary amines, preferably wherein the nitrogen is in a cationic state, in which the aliphatic radicals can be straight or branched chain and wherein one of the radicals contains an ionizable water solubilizing group, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate. Nonlimiting examples of amphoteric or zwitterionic surfactants are those selected from the group consisting of betaines, sultaines, hydroxysultaines, alkyliminoacetates, iminodialkanoates, aminoalkanoates, and mixtures thereof.
[0054] Additional compositions utilized in accordance with the present invention can comprise a wide range of optional ingredients. The CTFA International Cosmetic ingredient Dictionary, Sixth Edition, 1995, which is incorporated by reference herein in its entirety, describes a wide variety of nonlimiting cosmetic and pharmaceutical ingredients commonly used in the skin care industry, which are suitable for use in the compositions of the present invention. Nonlimiting examples of functional classes of ingredients are described at page 537 of this reference. Examples of these functional classes include: abrasives, anti-acne agents, anticaking agents, antioxidants, binders, biological additives, bulking agents, chelating agents, chemical additives, natural additives, colorants, cosmetic astringents, cosmetic biocides, degreasers, denaturants, drug astringents, emulsifiers, external analgesics, film formers, fragrance components, humectants, opacifying agents, plasticizers, preservatives, propellants, reducing agents, skin bleaching agents, skin-conditioning agents (emollient, humectants, miscellaneous, and occlusive), skin protectants, solvents, foam boosters, hydrotropes, solubilizing agents, suspending agents (nonsurfactant), sunscreen agents, ultraviolet light absorbers, and viscosity increasing agents (aqueous and nonaqueous). Examples of other functional classes of materials useful herein that are well known to one of ordinary skill in the art include solubilizing agents, sequestrants, and keratolytics, and the like.
[0055] The aforementioned classes of ingredients are incorporated in a safe and effective amount. The term “safe and effective amount” as used herein, means an amount of an active ingredient high enough to modify the condition to be treated or to deliver the desired skin benefit, but low enough to avoid serious side effects, at a reasonable benefit to risk ratio within the scope of sound medical judgment.
[0056] In addition to home care and personal care end uses, the nonwoven wipe may be used in industrial and medical applications. For instance, the article may be useful in paint preparation and cleaning outdoor surfaces, such as lawn furniture, grills, and outdoor equipment, wherein the low linting attributes of the fabric may be desirable. Further, the nonwoven wipe may be suitable for cleaning, waxing, and polishing the exterior and/or interior of cars, wherein the wipe may impregnated or coated with a soap or wax. Other aqueous or non-aqueous functional industrial solvents include, oils, such as plant oils, animal oils, terpenoids, silicon oils, mineral oils, white mineral oils, paraffinic solvents, polybutylenes, polyisobutylenes, polyalphaolefins, and mixtures thereof, toluenes, sequestering agents, corrosion inhibitors, abrasives, petroleum distillates, and the combinations thereof
[0057] A medical wipe may incorporate an antimicrobial composition, including, but not limited to iodines, alcohols, such as such as ethanol or propanol, biocides, abrasives, metallic materials, such as metal oxide, metal salt, metal complex, metal alloy or mixtures thereof, bacteriostatic complexes, bactericidal complexs, and the combinations thereof.
[0058] The differentially entangled wipe of the present invention is particularly suitable for dispensing from a tub of stacked, folded wipes, or for dispensing as “pop-up” wipes, in which the cleaning article is stored in the tub as a perforated continuous roll, wherein upon pulling a wipe out of the tub, an edge of the next wipe is presented for easy dispensing. The wipes of the present invention can be folded in any of various known folding patterns, such as C-folding, but is preferably Z-folded. A Z-folded configuration enables a folded stack of wipes to be interleaved with overlapping portions. The wipe may be packaged in various convenient forms, whereby the method of packaging is not meant to be a limitation of the present invention.
EXAMPLES
Example 1
[0059] Using a forming apparatus as illustrated in FIG. 1, a nonwoven fabric was made in accordance with the present invention by providing a fibrous batt comprising 100 weight percent cotton fiber. The fibrous batt had a basis weight of 3.4 ounces per square yard (plus or minus 7%). The fibrous web was 100% carded and cross-lapped, with a draft ratio of 2.8 to 1.
[0060] The fabric comprised 100 weight percent cotton as available from Barnhardt Manufacturing Company under code number RMC#2811. The fibrous batt was entangled by a series of entangling manifold stations such as diagrammatically illustrated in FIG. 1 and in greater detail in FIG. 2. FIG. 2 illustrates disposition of fibrous batt P on a foraminous forming surface in the form of belt 02 , with the batt acted upon by a pre-entangling manifold 01 operating at 55 bar to form a wetted and lightly entangled fibrous web. The web then passes through a series of entangling stations comprising drums having foraminous forming surfaces, for entangling by entangling manifolds, with the web thereafter directed about the foraminous forming surface of a drum 10 for entangling by entanglement manifold 12 operating at 40 bar. The web is thereafter passed over successive foraminous drums 20 , 30 , 40 and 50 , with successive entangling treatment by entangling manifolds 22 , 32 , 42 and 51 . In the present examples, each of the entangling manifolds included 120 micron orifices spaced at 42.3 per inch, with manifolds 22 , 32 , 42 and 51 successively operated at 55, 40, 55, and 0 bar, with a line speed of 45 meters per minute. The total energy input into the fibrous batt is calculated to be 0.052 hp-hr/lb. A web having a trimmed width of 127 inches was employed.
Comparative Example
[0061] The comparative example is selected from a commercially available product in the form of Webril 100% Cotton Handi-Pad as available from the Kendall Company. This product is formed by compression forming cotton fiber during a mercerization process.
[0062] The accompanying Table 1 sets forth comparative test data for a fabric made by the present invention compared against a commercially available mercerized cotton fabric. Testing was done in accordance with the following test methods.
Test Method Basis weight (ounces/yd 2 ) ASTM D3776 Bulk (inches) ASTM D5729 Tensiles MD and CD Grabs (lb/in) ASTM D5034 Elongation MD and CD Grabs (%) ASTM D5034
[0063] The physical test data for Example 1 and the Comparative Example are given in Table 1. The data in Table 1 show that the two materials have similar basis weights, but the nonwoven fabric manufactured by the present invention has much greater tensile strength in both the machine and cross direction, 20 and 40 times greater, respectively, than that of the Comparative material. In addition, the tensile properties of Example 1 are more uniform when comparing the machine direction to the cross direction tensile and elongation properties.
[0064] From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.
TABLE 1 Comparative Physical Property Units Example 1 Example Basis Weight osy 3.4 3.2 Bulk inches 0.033 0.061 Grab Tensile-MD lb./in. 23.3 1.3 Grab Tensile-CD lb./in. 23.3 0.5 Combined Grab 13.7 0.6 Tensile/Basis Weight Grab Elongation-MD % 32.9 35.4 Grab Elongation-CD % 76.1 118.7 Combined Grab 32.1 48.2 Elongation/ Basis Weight | The invention is directed to a hydroentangled nonwoven wipe, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired. Wipes formed in accordance with the present invention exhibit a sufficient degree of strength, softness, non-linting performance, and air flow so as to promote the formation of lather, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of wipe applications. | 3 |
FIELD OF THE INVENTION
The field of the invention relates to systems and methods for surface treatments, and more particularly to systems and methods for surface treatments, modifications or coatings using nanostructure materials for both super-hydrophobic and super-oleophobic properties.
BACKGROUND OF THE INVENTION
Coatings and surface modifications are used for a variety of applications including environmental protection, metal refinement, lubrication between moving parts, and maintenance. For example, large metal surfaces, antennas, and windows are coated to prevent the build-up of snow, ice, and fog. Boats are often treated with an anti-fouling paint to protect against materials that accumulate on wetted structures. Building and glass surfaces can be modified to become anti-soiling and stain resistant, respectively. Surface modifications can also render automobile windshields, airplane canopies, and optical devices self-cleaning. The advantages of appropriate surface coatings and modifications are well understood and appreciated. Recently, a number of recognized techniques for surface treatment use nanomaterials to produce effects that are more efficient and longer lasting than conventional coatings. For example, metallic stainless steel coatings sprayed with nanocrystalline powders demonstrate increased hardness when compared to traditional treatments. Hard ceramic nanocoatings made with titanium dioxide and a plasma torch renders metals very resistant to corrosion.
The extremely high ratio of surface area to volume of nanoparticles is a unique characteristic that provides for the synthesis and control of materials in nanometer dimensions. Accordingly, extensive work in the field of nanotechnology has been done to exploit new material properties and device characteristics through nanostructuring.
Among these new material properties, water-repelling hydrophobic surfaces and their production are extremely beneficial, for example, in the area of corrosion inhibition for metal, chemical and biological agent protection for non-metals, and so on. Over the past decade, research has been conducted to engineer the surface chemistry and roughness of solids to mimic the natural super-hydrophobic characteristics found in the lotus leaf. Super-hydrophobic surfaces and coatings possessing a so called “lotus leaf effect” have unique properties with very high water repellency. For example, the surfaces of many structures, such as aircraft surfaces, glass and plastics are susceptible to the buildup of ice, water, fog and other contaminants that can interfere with ordinary use. Super-hydrophobic surfaces on such structures can prevent or mitigate the buildup of ice, water fog and other contaminants by creating a microscopically rough surface containing sharp edges and air pockets in a material that sheds water well.
A super-hydrophobic surface is defined as possessing a water surface contact angle (CA) greater than 150° and a surface tension of approximately one-fourth of water. Since the surface tension of water is approximately 70 mNM −1 , the coated super-hydrophobic surface tension should be no more than several mNM −1 .
The first example of a super-hydrophobic surface was demonstrated in 1998 using an anodically oxidized fractal structured aluminum plate. Subsequently, engineers have developed several different textured surfaces with local surface geometries having super-hydrophobic surface CAs greater than 160°, even with octane. An example is disclosed in U.S. patent application Ser. No. 12/599,465, U.S. Publication No. 2010/0316842 A1, filed Apr. 14, 2008, for a “Tunable Surface” to Tuteja, et al., which is hereby incorporated by reference in its entirety. This application contemplates modifying surfaces to include a protruding portion to protrude toward a liquid and a re-entrant portion opposite the protruding portion to enhance the resistance/contact angle with any liquid. However, fabricating the necessary re-entrant angles and local surface geometric structures using this method is both time consuming and expensive. Specifically, the fabrication requires a Silicon dioxide (SiO 2 ) deposition followed by a costly two-step etching process comprising reactive ion etching of SiO 2 and subsequent isotropic etching of Si with the use of vapor-phase Xenon difluoride (XeF 2 ). Furthermore, this fabrication technology is only feasible for creation of the necessary re-entrant angles in localized surface geometric structures of micron sizes (e.g., approximately 20 μm).
Additionally, while a super-hydrophobic surface can provide excellent ice repellency on a clean surface, oil, dirt, salt and other contaminants already existing on the surface could enable additional ice accumulation. Therefore, the best surface modification technology for ice repellency will impart both super-hydrophobic and super-oleophobic properties. Such surfaces would be highly self-cleaning since they would tend to shed not only oil-based contaminants, but also water-based contaminants, thereby providing additional benefits such as anti-corrosion and ease of cleaning.
Similar to super-hydrophobic surfaces, a super-oleophobic surface is defined as any surface that reduces the tendency for an oil to attach to that surface or form a film on that surface. In particular, a super-oleophobic surface possesses an oil CA greater than 150°.
In another example of super-hydrophobic surface modifications, a biomimetic procedure was used to prepare super-hydrophobic cotton textiles. This procedure is discussed further in a paper by Hoefnagel et al., for “Biomimetic Superhydrophobic on Highly Oleophobic Cotton Textiles” (Hoefnagels, H. F., Wu, D., With, G. de, Ming, W. (2007) Langmuir, 23, 13158-163), which is hereby incorporated by reference in its entirety. This publication discloses a method for creating a super-hydrophobic (i.e., having a water CA greater than 155°) cotton textile by introducing silica particles in situ to cotton fibers to generate a dual-scale surface roughness, followed by hydrophobization with polydimethylsiloxane (PDMS). Although this approach can obtain moderately oleophobic surfaces (e.g., having an oil CA of approximately 140°), the resulting coating was not super-oleophobic (i.e., having an oil CA greater than 150°) because the coverage of the silica nanoparticles was not uniform in structure (e.g., low and out of control). Furthermore, the scalability of this process is limited and excludes various surface types including, for example, the surface of aircraft wings, because the thickness and roughness of the coated layer results in clustering of the nanoparticles and yields a very irregular surface morphology in micron scale.
Accordingly, an improved system and method for low-cost surface treatments having both super-hydrophobic and super-oleophobic properties to alleviate the problems discussed above is desirable.
SUMMARY OF THE INVENTION
The field of the invention relates to systems and methods for surface treatments, and more particularly to systems and methods for surface treatments, modifications or coatings using micro- and nano-structure particles for both super-hydrophobic and super-oleophobic properties. In one embodiment, a method of treating surfaces to impart both super-hydrophobic and super-oleophobic properties includes the steps of producing chemically active peroxides on a substrate surface; synthesizing mono-dispersed silica nanoparticles of differing sizes to obtain dual-scale nanoparticles; capping the dual-scale nanoparticles to render them hydrophobic; dipping the pre-treated substrate into a Langmuir-Blodgett (LB) trough filled with a water based subphase, the trough further having a particle layer spread over the surface of the water based subphase, the particle layer comprising the dual-scale nanoparticles for assembly of an ordered monolayer onto the surface of the substrate; raising the substrate into dry air to de-hydrate the surface of the substrate and obtain a chemical covalent bond between said ordered monolayer and the substrate surface; and treating the dual-scale nanoparticle coated surface with SiCl 4 to cross-link the nanoparticles to each other and to the surface of the substrate creating a robust nano-structured topographic surface having both super-hydrophobic and super-oleophobic properties.
Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to better appreciate how the above-recited and other advantages and objects of the inventions are obtained, a more particular description of the embodiments briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the accompanying drawings. It should be noted that the components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. However, like parts do not always have like reference numerals. Moreover, all illustrations are intended to convey concepts, where relative sizes, shapes and other detailed attributes may be illustrated schematically rather than literally or precisely.
FIG. 1 a is a diagram of a liquid drop on a flat substrate;
FIG. 1 b is a diagram of a wetted contact between a liquid drop and a rough surface;
FIG. 1 c is a diagram of a non-wetted contact between a liquid drop and a rough surface;
FIG. 1 d is a diagram of a non-wetted contact between a liquid and a rough surface with appropriate local surface geometry having a re-entrant angle.
FIG. 2 is a functional schematic of a computer controllable Langmuir-Blodgett (LB) trough system for use with an exemplary embodiment of the present invention.
FIG. 3 is another functional schematic of a LB trough system for use with the present invention.
FIG. 4 is a flowchart of a process in accordance with a preferred embodiment of the present invention.
FIG. 5 a is a diagram illustrating an exemplary nanoparticle synthesis in accordance with a preferred embodiment of the present invention;
FIG. 5 b is a diagram illustrating an exemplary application of a dual-scale nanoparticle onto a substrate surface in accordance with a preferred embodiment of the present invention.
FIG. 6 is a diagram illustrating an exemplary reaction resulting from a mechanical enhancement in accordance with a preferred embodiment of the present invention.
FIG. 7 is another diagram illustrating the structure of a super-hydrophobic/super-oleophobic surface in accordance with a preferred embodiment of the present invention.
FIG. 8 is another flowchart of a process in accordance with an alternative embodiment of the present invention; and
FIG. 9 is a diagram illustrating an exemplary reaction resulting from a mechanical enhancement in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As described above, ice repellency, water repellency, anti-fog, non-stick, and dirt resistance behavior of a solid substrate typically depends on the wetting behavior of the solid surfaces by a liquid. On contact with a surface, adhesion forces between a liquid droplet and a solid substrate result in either complete or incomplete wetting. The liquid droplet will either remain as a droplet or spread out on the surface to form a thin liquid film. This hydrophobicity of the surface typically is characterized by the contact angle (CA) of the surface.
Generally, higher CAs produce surfaces with a higher hydrophobicity. For a solid substrate, when the CA of water or oil on the surface is larger than 90°, it is called hydrophobic or oleophobic, respectively. Surfaces with a CA of water or oil larger than 150° are referred to as super-hydrophobic or super-oleophobic. In contrast, surfaces with a CA of water or oil less than 90° are referred to as hydrophilic or oleophilic while surfaces with a CA of approximately 0° are referred to as super-hydrophilic or super-oleophilic. Some plants—for example, the lotus discussed above—can reach a contact angle of 170° introducing a self-cleaning effect.
CA may refer to the equilibrium CA when the surface is smooth or to the apparent CA when the surface is rough. Turning to FIG. 1 a , a liquid drop (e.g., water) is shown on a smooth surface illustrating equilibrium CA θ E . In order to predict the CA θ E of a liquid droplet on a flat substrate, equation (1) may be used.
cos θ E =(γ sv −γ sl )/γ lv (1)
where:
γ sv =surface tension of the solid-vapor involved
γ sl =surface tension of the solid-liquid involved
γ lv =surface tension of the liquid-vapor involved
It is well known that the wettability of solid substrates is governed by their surface free energy and surface geometrical structure (i.e., roughness). Therefore, controlling one of these two factors can modulate the surface wettability. FIGS. 1 b - d illustrate the apparent CA θ A of a rough surface. Two different models are commonly used to explain the effect of roughness on the apparent CA of liquid drops.
The first model, developed by Robert Wenzel, describes a homogenous wetting regime. Additional information can be found in an article for “Resistance of Solid Surfaces to Wetting by Water” (Wenzel, R. N., Ind. Eng. Chem. 1936, 28, 988), which is hereby incorporated by reference in its entirety. This model contemplates that liquid completely fills into the grooves of a rough surface where they are in contact. Higher surface roughness increases the available surface area of the solid, which modifies the surface CA according to equation (2):
cos θ A =r cos θ E (2)
where:
θ A =apparent CA on a textured surface
r=surface roughness factor
θ E =equilibrium CA on a smooth surface of the same material
An example of this model is provided with reference to FIG. 1 b . In FIG. 1 b , a wetted contact between a liquid and a rough substrate is illustrated. The rough substrate is a surface of a hydrophilic material. However, the apparent CA θ A has a value between 150° and 90° demonstrating the hydrophobic behavior of the rough surface despite the hydrophilic material.
Alternatively, when dealing with a heterogeneous surface of various materials, a second model is needed to measure the apparent CA θ A . Additional information can be found in an article for “Wettability of Porous Surfaces” (Cassie, A. B. D., Baxter, S., Trans. Faraday Soc. 1944, 40, 546), which is hereby incorporated by reference in its entirety. This model assumes that vapor pockets are trapped underneath the liquid creating a composite surface. Accordingly, microscopic pockets of air remaining trapped underneath the liquid droplet create the super-hydrophobic nature of a rough surface. The chemical heterogeneity of the rough surface modifies the apparent CA θ A according to equation (3-1):
cos θ A =f s cos θ s +f v cos θ V (3-1)
where:
f s =area fractions of the solid on the surface
f s =area fractions of the solid on the surface
As f s +f v =1, θ S =θ E , and θ V =180°, equation (3-1) can be rewritten as equation (3-2):
cos θ A =f s (cos θ E +1)−1 (3-2)
Unlike equation (2), the relationship described in equation (3-2) allows for the possibility that the apparent CA θ A can be greater than 90° even with an equilibrium CA θ E less than 90° due to the effects of surface roughness. Specifically, the surface roughness will increase the apparent angle even when the intrinsic CA of a liquid on a smooth surface is less than 90° because the trapped super-hydro-oleophobic vapor pockets can still enhance the CA. For example, FIG. 1 c illustrates a non-wetted contact between a liquid and a rough substrate of a hydrophilic material. As shown, the apparent CA θ A of an oil droplet is greater than 90° even with an equilibrium CA θ E less than 90° due to the effects of the surface roughness. Therefore, in order to modify a solid surface to increase the apparent CA θ A in one embodiment of the present invention, a particular textured surface exhibiting characteristics modeled in equation (3-2) is desirable.
A series of rough substrates with progressively increasing equilibrium CAs exhibits a transition from surfaces modeled by equation (2) to surfaces modeled by equation (3-2). Relating equations (2) and (3-2) in equation (4), a threshold equilibrium CA θ C is determined:
cos θ C = ( f s - 1 ) ( r - f s ) ( 4 )
Because r>1>f s , the critical value of the equilibrium CA θ C for this transition is necessarily greater than 90°. Therefore, the creation of highly non-wetting surfaces (i.e., θ A >>90°) requires the equilibrium CA θ E to be larger than the apparent CA θ A that is greater than 90° (i.e., θ E >θ A >90°). However, there are no reports of natural or artificial surfaces with a low enough surface energy to enable a equilibrium CA θ E that is greater than 90° when in contact with alkanes such as decane or octane in developing super-hydrophobic/oleophobic surfaces.
In an attempt to create a surface with a low enough surface energy as discussed above, a third parameter—re-entrant local surface geometry—was combined with the parameters of surface energy and roughness. FIG. 1 d shows a non-wetted contact between liquids and a rough substrate with appropriate local surface geometry having a re-entrant angle θ. This surface has both super-hydrophobic and super-oleophobic properties (i.e., θ A >150° for both water and oil). Fabricating different re-entrant local surface geometries is beneficial for constructing extremely non-wetting surfaces that can be modeled by equation (3-2) with water and various organic liquids. However, conventional methods generally require a silicon dioxide (SiO 2 ) deposition followed by a two-step etching process as discussed above. This process is both time-consuming and cost-inefficient. Furthermore, these methods only modify flat, hard surfaces and not curved or irregular surfaces such as convex or concave shapes. The process is also only feasible for creation of the necessary re-entrant angles in localized surface geometric structures of micron sizes (e.g., 20 μm).
One approach to address these issues is shown in FIG. 2 , which illustrates a computer controllable Langmuir-Blodgett (LB) trough system 200 for use with an exemplary embodiment of the present invention. The system 200 includes a LB trough 201 filled with a subphase 202 (e.g., water). A nanoparticle layer 203 is spread over the surface of the subphase 202 . The nanoparticle layer 203 may be a series of mono-layers of one or more types of amphiphilic micro-/nanoparticles spread at the interface between water and air typically consisting of a regular planar array of molecular layers having a well-defined and predetermined thickness. Automated step motors 205 control barriers 204 , which are movable during a deposition process, in order to maintain a controlled surface pressure. The layer 203 's effect on the surface pressure of the subphase 202 is measured through the use of a plate 207 coupled to a microbalance 206 , which is configured to control the movable barriers 204 . As one of ordinary skill in the art would appreciate, plate 207 may be a Wilhelmy plate, electronic wire probes, or other types of detectors.
The system 200 further includes a dipping device 208 operatively coupled to a control box 209 for lowering or raising a substrate 211 through the gas-liquid interface (i.e., layer 203 and subphase 202 ). The control box 209 is further coupled to both the microbalance 206 and step motors 205 . A microprocessor computer 210 that provides control signals to the control box 209 allows automatically transferring an LB film to the solid substrate 211 by the successive deposition of a series of layers 203 onto the substrate 211 .
Both the movement of the dipping device and the step motors are controlled and monitored by computer 210 to provide very high contact angles and very low surface tension (e.g., less than 5 mN/m). As is known in the art, the computer 210 may include a computer-usable medium having a sequence of instructions which, when executed by a processor, causes said processor to execute a process that controls the elements above. The system 200 may further include a user interface console, such as a touch screen monitor (not shown), to the computer 210 to allow the operator to preset various system parameters. User defined system parameters may include, but are not limited to, surface pressure, substrate submersion time, oxygen flow rate, and vacuum level.
Accordingly, one benefit of system 200 is the flexibility to accommodate multiple substrates 211 of various shapes. Ultra-thin and uniform (at atomic levels) layers can be deposited on non-flat surfaces in a controllable, scalable, and low-cost manner. Turning to FIG. 3 , an LB trough system, such as system 200 , is shown configured to accommodate and dip different shapes and multiple substrates 211 at the same time, thereby alleviating both time and cost. In one example, substrate 211 can be carbon fiber, aluminum, or titanium as used in, for example, aircraft surfaces, antennas, wings, car surfaces, and boats; however, as one of ordinary skill in the art can appreciate, substrate 211 may include other metals, plastics, glass, textiles and other materials.
In a preferred embodiment of the present invention, FIG. 4 illustrates a process 4000 for a self-assembly nanocoating that may be executed by system 200 . The process 4000 consists of three major processes: (1) plasma glow discharge surface treatment (action block 4001 ); (2) assembly of dual-scale nanoparticles on the surface (action block 4002 ); and (3) mechanical enhancement to increase surface durability and robustness (action block 4003 ).
Process 4000 provides additional benefits over conventional approaches for preparing various super-hydrophobic surfaces. In practice, conventional approaches for preparing super-hydrophobic surfaces can be categorized into two directions: top-down and bottom-up. Examples of top-down approaches include lithographic and template-based techniques, and plasma treatment of surfaces. Conversely, bottom-up approaches mostly involve self-assembly and self-organization. Examples of bottom-up approaches include chemical deposition, layer-by-layer (LBL) deposition, hydrogen bonding, and colloidal assemblies. Methods also exist based on the combination of both bottom-up and top-down approaches including polymer solution casting, phase separation, and electro-spinning
As one of ordinary skill in the art would appreciate, a bottom-up approach most effectively modifies surfaces of aluminum, titanium, carbon fiber, glass and plastic. Although chemical deposition, including atomic layer deposition, can synthesize nanostructures in situ on the surface, to obtain the required re-entrant local surface geometry is costly and hard to control. Alternatively, traditional LBL and hydrogen bonding is not able to form the required nanostructure on the surface as well. Colloidal assemblies are able to assemble pre-synthesized nanostructures on the surface and are effective glass surface modifiers; however, conventional colloidal assemblies, including self-assembling and self-organization, require complex chemical reactions between the substrate surface and the nanoparticles. These reactions are limited to certain types of materials such as gold surfaces and molecules with thiol groups.
Conventional self-assembly methods rely on hard-to-control chemical reactions between micro-/nanoparticles and the treated surface to spontaneously form a 2-dimensional (2D) crystal structure on the treated surface. In contrast, process 4000 provides a highly controllable, bottom-up assembly method that can create the desired surface coating structure with far more precision. Using this approach, the precise nano-architecture is formed as part of the LB process. Once the desired uniform nanostructure is in place, a self-assembly related dehydration process is used to lock-in the structure by forming stronger chemical bonds between the micro-/nano-particles and the treated surface without interference with the nanostructure. An additional gas phase chemical (SiCl 4 ) treatment cross-links the nanoparticles to each other, and the nanoparticles to the surface. This produces the desired permanent, stabilized, scratch-resistant film on the substrate 211 surface. Thus, process 4000 is a surface engineering method that can precisely control the application of micro-/nonoparticles, metal particles, silica particles and colloidal particles onto the treated surface of many common materials—including, for example, metal, glass, plastic and fiber composites—in a manner that is controllable using an engineering process rather than a spontaneous chemical reaction method.
In order to activate the substrate 211 surface for self-assembly, the process begins with a plasma-glow discharge pre-treatment of a substrate 211 surface (action block 4001 ) to produce peroxides on the surface. The surface will undergo oxidation when exposed to these oxidative plasmas and brought into contact with air after exposure to gas plasmas (action block 4004 ). The extent of oxidation greatly depends on the composition of gas, the acrylic substrate and discharge conditions (action block 4005 ). The effect of plasma exposure time on the concentration of generated peroxides is adjusted when the applied power and pressure are fixed to obtain a maximum concentration of peroxides (action block 4006 ).
In one example, a small standard plasma reactor consisting of a stainless steel chamber with a pair of stainless steel discharge electrodes is used to pre-treat the substrate surface. The upper electrode may be connected to a 13.56 MHz radio frequency generator via an impedance matching circuit and the lower electrode will be grounded. The system pressure before discharge may be monitored by a Hoyt thermocouple vacuum gauge connected downstream from the reactor. The rate of oxygen may be measured by a mass flow controller with nitrogen calibration of the gauge reading for oxygen gas.
Once the substrate 211 surface has been treated, the process 4000 may proceed in assembling dual-scale nanoparticles onto the pretreated surface (action block 4002 ). The synthesis of dual-scale nanoparticles begins with mono-dispersed silica nanoparticles of differing sizes (e.g., 20 nm and 300 nm-10 μm), as shown in FIG. 5 a . The silica nanoparticles are then modified with different functional groups. Finally, the particles are synthesized by attaching small particles onto large particles via reactions between functional groups (action block 4007 ).
In one embodiment, amino-functionalized small silica nanoparticles may be used for synthesis. FIG. 5 shows an amine 501 attaching to a larger mono-dispersed silica nanoparticle 502 to obtain a synthesized dual-scale silica nanoparticle 503 via reactions between functional groups. A mixture of Tetraethyl orthosilicate (TEOS) and 3-aminopropyltriethoxysilane (APS) in a volume ratio of 9:1 (e.g., 4.5 mL TEOS and 0.5 mL APS), 4:1 or 1:1 is added, drop-wise, under magnetic stirring, to a flask containing 15 mL of ammonia solution and 200 mL of ethanol. The reaction is carried out at approximately 60° C. for about 16 hours under N 2 atmosphere. The small nanoparticles (approximately 20 nm) are separated by centrifugation and the supernatant is discarded. These particles are washed with ethanol and vacuum-dried at approximately 50° C. for about 16 hours.
In an alternative embodiment, epoxy-functionalized large silica nanoparticles may be used. At room temperature (e.g., 20-25° C.), 10 ml of TEOS may be added, drop-wise, under magnetic stirring, to a flask containing 21 mL of ammonia solution, 75 mL of isopropanol, and 25 mL of methanol. Silica microparticles less than 10 μm (e.g., 300 nm to 10 μm) in diameter can be used. After about 5 hours, the particles will be separated by centrifugation, washed with distilled water, ethanol, and vacuum-dried at approximately 50° C. for about 16 hours. About 1.5 grams of silica nanoparticles are redispersed into 40 mL of dry toluene and 0.2 g of 3-glycidoxypropyl (GPS) in 5 ml dry toluene can be added, drop-wise, to the silica suspension under vigorous stirring. The suspension may be stirred at about 50° C. under N 2 atmosphere for about 24 hours. The particles are then separated by centrifugation, washed with toluene, and vacuum-dried at approximately 50° C. for about 16 hours.
In yet another embodiment, an aldehyde-amine approach may be used to synthesize dual-scale nanoparticles. Approximately 0.1 g of amino-functionalized small silica nanoparticles may be suspended in 100 mL of a phospate buffer solution and about 0.5 g of aldehyde-functionalized large silica nanoparticles may be suspended in 100 mL of phosphate buffer solution, respectively. Subsequently, the silica nanoparticle suspension may be added, drop-wise under vigorous stirring, into the silica nanoparticle suspension. The suspension is stirred under N 2 atmosphere for about 24 hours. The particles are then separated by centrifugation and washed with distilled water.
As part of the synthesis of action block 4007 , the dual-scale particles are further functionalized to render them hydrophobic. For example, 2 mL of the cleaned dual-scale silica nanoparticles solution is diluted into 14 mL of absolute ethanol, 1 mL water, and 100 μL 3-aminopropyl (diethoxymethylsilane). 97% 3-aminopropylmethyldiethoxysilane (APDES) is added with vigorous stirring. The solution is stirred overnight and then heated at 100° C. for one hour while covered in aluminum foil. The functionalized sample is cleaned by centrifugation into ethanol and methanol, in 15-minute intervals for a total of 5 intervals. The solution-based sample is then used for deposition.
After the synthesized hydrophobic nanoparticles are obtained, a surface with a dual-scale hierarchical structure is developed by depositing the dual-scale nanoparticles on the pretreated surface (action blocks 4008 ). The highly purified dual-scale nanoparticles having a diameter of less than 10 μm (the diameter of the mono-dispersed dual-scale particles can be in the range of a few tens of nanometers to a few hundred microns) is spread under air/water suspension and the typical isotherm will be measured using the LB trough 201 of system 200 . An appropriate surface pressure is selected for the deposition and the dual-scale nanoparticles are assembled onto the activated substrate 211 surface, as shown in FIG. 5 b.
Once the uniform dual-scale silica nanoparticles are assembled onto the target surface containing peroxides, process 4000 continues with a mechanical robustness enhancement 4003 . The surface of substrate 211 is dried at room temperature (e.g., 20-25° C.) to eliminate water and form covalent bonds between the nanoparticles and surface (action block 4009 ). To further increase the robustness of the coating, the surface is treated with SiCl 4 , which cross-link the nanoparticles to each other as well as to the surface (action block 4010 ). An example reaction creating cross-links is shown in FIG. 6 . As illustrated, the dual-scale-Silica nanoparticle matrix undergoes dehydration to remove a hydrogen bond and to form covalent bonds between the nanoparticles and the surface. Subsequently, the dual-scale nanoparticle matrix monolayer is further polymerized to cross-link the nanoparticles to each other as well as to the surface by means of SiCl 4 treatment. As silica is a very salt stable material that is commonly used in biomedical devices, the silica-based nanostructuring additionally possesses highly salt-tolerant and nonhazardous properties that are beneficial in marine environments. Turning to FIG. 7 , the resultant dual-scale nanoparticle matrix is strongly bonded to the surface. This lightweight, thin-film coating creates a super-hydrophobic and super-oleophobic surface that is permanent, durable and highly scratch resistant.
Turning to FIG. 8 , another process 8000 that provides for a self-assembly nanocoating that may be executed by system 200 is shown. Like with process 4000 , process 8000 consists of three major processes: (1) partially polymerized carboxylic-terminated polydimethylsiloxane (PDMS) surface treatment (action block 8001 ); (2) assembly of dual-scale nanoparticles on the surface (action block 8002 ); and (3) mechanical enhancement to increase surface durability and robustness (action block 8003 ).
Similar to process 4000 , process 8000 begins with a pre-treatment of the substrate 211 surface. In this alternative embodiment, activating the substrate 211 surface for self-assembly comprises a modification of the substrate 211 surface with a partially polymerized carboxylic-terminated PDMS film (action block 8001 ). The surface is first cleaned to remove possible impurities (action block 8004 ). In one example, millipore water and ethanol can be used to clean substrate 211 . The substrate surface is then pre-modified with a partially polymerized carboxylic-terminated PDMS film (action block 8005 ) in order to obtain a robust binding between the silica or polycarbonate-based surface and the assembled nanoparticles as discussed in process 4000 . This thin film can be applied through LB monolayer deposition (e.g., using an LB system such as system 200 ) or spin coating (e.g., on flat substrates).
As an example of pre-treating the substrate 211 surface, a PDMS solution is prepared in chloroform (4 mg/mL). Using an LB system—e.g., system 200 —the solution (approximately 100 μL) is spread onto a water based sub-phase containing CdCl 2 (2×10 −4 ) and KHCO 3 (2.4×M); the sub-phase has a pH of about 7.65 and a temperature of about 19° C. The computer-controlled barriers 204 of system 200 compresses the floating LB film at approximately 5 mm/min to a surface pressure of about 25 mN/m. The substrate 211 is vertically dipped at a speed of about 10 mm/min. Microbalance 206 monitors surface pressure and transfer ratios for these films and computer 210 adjusts the appropriate deposition parameters. Following the uniform PDMS film deposition, substrate 211 is dried for further enhancement of the binding between the glass surface and the LB PDMS layer.
Following the alternative method for pre-treatment of the substrate 211 surface, process 8000 proceeds, like process 4000 , in assembling dual-scale nanoparticles onto the pretreated surface (action block 8002 ). Mono-dispersed silica nanoparticles of differing sizes (e.g., 20 nm and 300 nm-10 μm as shown in FIG. 5 a ) are modified with different functional groups. The silica nanoparticles are synthesized by attaching small particles onto large particles via reactions between functional groups (action block 8006 ). As described in process 4000 , amino-functionalized small silica nanoparticles, epoxy-functionalized large silica nanoparticles, and aldehyde-amine nanoparticles may be used for synthesis. Capping the dual-scale nanoparticles with functional groups renders the nanoparticles hydrophobic for deposit onto the substrate surface.
After the synthesized hydrophobic nanoparticles are obtained, a surface with a dual-scale hierarchial structure is developed by depositing the dual-scale nano-particles on the pretreated surface (action blocks 8007 ). The highly purified dual-scale nanoparticles having a diameter of less than 10 μm (the diameter of the mono-dispersed dual-scale particles can be in the range of a few tens of nanometers to a few hundred microns) is spread under air/water suspension and the typical isotherm will be measured using the LB trough 201 of system 200 . An appropriate surface pressure is selected for the deposition and the dual-scale nanoparticles are assembled onto the pre-treated substrate 211 surface.
Once the uniform dual-scale silica nanoparticles are assembled onto the target surface containing the partially polymerized carboxylic-terminated PDMS monolayer, process 8000 continues with a mechanical robustness enhancement 8003 . The surface of substrate 211 is thermally cured at about 50° C. for a few minutes (action block 8008 ) to fully polymerize the PDMS coating. As the PDMS layer becomes fully polymerized, the nanoparticles will be partially embedded in the PDMS matrix while sustaining local surface nano-structure geometry. To further increase the robustness of the coating, the surface is treated with SiCl 4 , which cross-link the nanoparticles to each other, the nanoparticles to the thin PDMS layer, and the PDMS layer to the substrate surface (action block 8009 ). An example reaction creating cross-links is shown in FIG. 9 . As illustrated, the dual-scale nanoparticle matrix monolayer is polymerized to cross-link the nanoparticles to each other as well as to the PDMS layer by means of SiCl 4 treatment. The PDMS layer is similarly cross-linked to the substrate surface (not shown). As PDMS and silica are very salt stable materials that are commonly used in micro-fluidic devices, the PDMS and silica-based nanostructuring additionally possess highly salt-tolerant and nonhazardous properties that are beneficial in marine environments. The resultant dual-scale nanoparticle matrix is strongly bonded to the surface as shown in FIG. 7 . This lightweight, thin-film coating creates a super-hydrophobic and super-oleophobic surface that is permanent, durable and highly scratch resistant.
In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. For example, the reader is to understand that the specific ordering and combination of process actions described herein is merely illustrative, and the invention may appropriately be performed using different or additional process actions, or a different combination or ordering of process actions. For example, this invention is particularly suited for coating metallic substrates, such as aluminum; however, the invention can be used for a variety of substrate materials, shapes and sizes. Additionally and obviously, features may be added or subtracted as desired. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. | The field of the invention relates to systems and methods for surface treatments, and more particularly to systems and methods for surface treatments, modifications or coatings using micro- and nano-structure particles for both super-hydrophobic and super-oleophobic properties. In one embodiment, a method of treating surfaces to impart both super-hydrophobic and super-oleophobic properties includes the steps of pre-treating a substrate surface; assembling dual-scale nanoparticles onto the surface of the substrate; and treating the dual-scale nanoparticle coated surface with SiCl 4 to cross-link the nanoparticles to each other and to the surface of the substrate creating a robust nano-structured topographic surface having both super-hydrophobic and super-oleophobic properties. | 1 |
LATIN NAME OF THE GENUS AND SPECIES OF THE PLANT CLAIMED
[0001]
Petunia hybrida
VARIETY DENOMINATION
[0002] ‘Drama Queen’
BACKGROUND
[0003] The present application relates to a new and distinct variety of petunia named ‘Drama Queen’. ‘Drama Queen’ is a chance seedling from a group of mixed colored petunias of various origin (an open pollenated mix) discovered in Mount Vernon, Wash. Seed and pollen parents are unknown.
[0004] The ‘Drama Queen’ variety is distinguished from other petunia varieties due to its strong, stable variegated foliage with a flower color and habit unseen in previously existing petunia clones (for example see FIG. 3 ).
[0005] Asexual reproduction of this new variety was achieved using tip and stem cutting from vegetative stock plants.
[0006] Certain characteristics of this variety may change with changing environmental conditions (such as photoperiod, temperature, moisture, soil conditions, nutrient availability, or other factors). Color descriptions and other terminology are used in accordance with their ordinary dictionary descriptions, unless the context clearly indicates otherwise. Color designations (hue/value/chroma) are made with reference to The Royal Horticultural Society Colour Chart (R.H.S.).
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIGS. 1 and 2 are photographs showing the new variety ‘Drama Queen’ taken in June and October 2013, respectively.
[0008] FIG. 3 is a photograph showing the variety ‘Glamouflage Grape’.
[0009] FIG. 4 is a photograph comparing the flowers of the variety ‘Glamouflage Grape’ (left) and the new variety ‘Drama Queen’ (right).
[0010] FIGS. 5 and 6 are photographs showing the side of the immature and mature flower, respectively, of the new variety ‘Drama Queen’.
[0011] FIG. 7 is a photograph showing the calyx of the new variety ‘Drama Queen’.
[0012] FIG. 8 is a photograph showing the branching habit of the new variety ‘Drama Queen’.
[0013] The color photographs show typical specimens of the plant; structure and form, leaf color and flower color, and an overall comparison to existing clones on the NAFTA market. The color photographs shows typical specimens and depict the color as nearly true as is reasonably possible to make the same in a color illustration of this character. It should be noted that colors may vary, for example due to lighting conditions at the time the photograph is taken. Therefore, color characteristics of this new variety should be determined with reference to the observations described herein, rather than from the photograph alone.
DETAILED DESCRIPTION
[0014] The following detailed description of the ‘Drama Queen’ variety is based on observations of asexually reproduced progeny. The observed progeny are plants which were 1 to 45 weeks of age. The following detailed description concerns the plants growing in open ground, (sandy loam), in full sun, (southern exposure) in La Conner, Wash., between Mar. 17, 2013 and Oct. 4, 2013. The original plant and progeny have been observed growing in a cultivated area Mount Vernon, Wash.
[0015] The chart used in the identification of colors described herein is The R.H.S. Colour Chart of The Royal Horticultural Society, London, England, 2001 edition, except where general color terms of ordinary significance are used. The color values were determined in July and August 2013 under natural light conditions in La Conner, Wash.
Scientific Name: Petunia בDrama Queen’ Plant:
Form, growth and habit .—Spreading/prostrate habit with upward and outward facing inflorescence. Plant height.— 5 cm to 10 cm. Plant height ( inflorescence included ).—10 to 20 cm. Plant width.— 60 cm to 120 cm. Rooting .—Number of days to initiate roots 5 to 10, and 15 to 21 days to produce a 10×20, 105 cell.
Leaves:
Type .—obovate. Color .—variegated. Foliage .—Arrangement. alternate. Immature, leaf color .—Upper surface, RHS outer 50 to 70% 11D/ inner 30 to 50% 138B; Lower surface, RHS same as upper. Mature, leaf color .—Upper surface, same as Immature. Length.— 3 cm to 4 cm. Width.— 1.5 cm to 2 cm. Shape .—obovate. Base shape. rounded. Apex shape. acute. Margin .—entire. Texture .—upper and lower surface is sticky, finely prunose. Color of veins on upper and lower surface .—undeterminable, masked by variegation. Petiole .—Color. RHS outer 50 to 70% 11D/ inner 30 to 50% 138B. Length. 3 cm to 4 cm; Diameter.1 mm to 2 mm; Texture. same as leaf. Stem .—Color of stem. RHS 11D. Length of stem. 40 cm to 70 cm. Diameter. 2 mm to 4 mm. Length of internodes 1 cm to 5 cm. Texture. Same as foliage. Color of peduncle .—RHS 11D. Length of peduncle.— 2 cm to 3 cm. Peduncle diameter.— 1 cm to 2 mm. Texture .—Consistent with other plant structure.
Flowers:
Size .—Length, 4 cm to 6 cm; width 4 cm to 4.5 cm. Shape .—solitary trumpet. Color : Unopened bud: RHS N89D in color Opened flower: RHS N89D in color. Petals.— 5 petals per flower; trumpeted in shape; 3 cm to 5 cm in length. N89D in color. Stamen.— 5 in number, 1 cm to 2 cm in length. Anthers.— 96B in color, 1 mm to 2 mm in length. Pistil .—Stigma is about 3 mm long; tubular/oval in shape; single styles, and 149C in color. Sepals .—About 5 mm long and about 2 mm wide (at base); oblong in shape; variegated as foliage in color. Inflorescence .—Type: perfect trumpet. Floret type: solitary. Blooming habit .—Upright and out facing 3 cm to 5 cm above foliage. Quantity of inflorescences per plant.— 40 to 60. Longevity of individual blooms on the plant.— 3 to 5 days. Immature inflorescence .—Diameter, 1 cm to 2 cm. Color, upper surface RHS N89D ; midveins, RHS N89D ; lower surface, RHS N89D; mid-veins RHS N89D. Mature inflorescence .—Floret horizontal diameter 5 cm to 7 cm. Vertical depth. 7 cm to 9 cm. Petal color: upper surface, RHS N89D with mid-veins and veining of RHS N89D; lower surface RHS N89D with mid-veins of RHS N89D. Corolla tube color .—inside, RHS N89D with veins RHS N89D, outside, RHS N89D with veins RHS N89D. Corolla tube length.— 2 cm to 3 cm. Corolla texture .—fine velvet. Calyx .—Color, all surfaces variegated in ratios consistent with foliage. Length: 5 mm. Width: 2 mm. Shape: oblong. Apex shape: obtuse. Floral arrangement .—see FIG. 8 . Base .—acute. Margin: entire. Texture, upper surface prunose and lower surface prunose. Pollen .—RHS 116A in color. Fragrance .—Sweet petunia. Bloom season .—Late April through mid-October.
Disease/pest resistance. None noted, typical of other petunias | A new Petunia variety distinguished by its strong, stable variegated foliage with a flower color and habit unseen in previously existing petunia clones. | 0 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] The United States Government has rights in this invention pursuant to Contract No. DE-AC52-07NA27344 between the U.S. Department of Energy and Lawrence Livermore National Security, LLC, for the operation of Lawrence Livermore National Laboratory.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to magnetically levitated rotating systems, and more specifically, it relates to momentary-contact “touchdown” bearings that will restrain the rotating component from excessive displacements.
[0004] 2. Description of Related Art
[0005] Magnetically levitated rotating systems, e.g., the rotors of flywheel energy storage units for stationary or vehicular use, can be subjected to acceleration loads that are too large to be restrained by the magnetic bearing system. In stationary systems these g loads would come from seismic events; in vehicular uses they would come from normal operation of the vehicle and, in the extreme, from collisions. In all such cases it is necessary to provide momentary-contact “touchdown” bearings that will restrain the rotating component from excessive displacements. However, the design of the touchdown bearing must be such that when it is in action, that is, when contact is made between the rotating element of the bearing and its stationary components, the system remains stable against rotor-dynamic “whirl” instabilities.
SUMMARY OF THE INVENTION
[0006] This invention takes advantage of stabilizing techniques to prevent whirl-type instabilities during the operation of magnetically levitated rotating systems. One such technique employs a “foil”-based design, where a restraining force arises from contact between a rotating shaft and tensioned thin ribbons (or an array of tensioned wires) of either metallic or non-metallic composition. Another stabilizing technique provides a variation with azimuth in the tension of an array of foils (or wires) so as to create anisotropic stiffness for displacements that are 90° apart in azimuth. In still another technique, a touchdown bearing is described that restrains displacements that have components that are transverse to (i.e., parallel with) the axis of rotation. This dual-displacement function is accomplished by making the rotating contacting element conical in shape, at the same time using tensioned foils the planes of which correspond to the conical angle of the rotating part.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The accompanying drawings, which are incorporated into and form a part of the disclosure, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0008] FIG. 1A is top view of a foil-based touchdown bearing.
[0009] FIG. 1B shows a cross-sectional side view of an embodiment of FIG. 1A .
[0010] FIG. 1C shows a cross-sectional view of an embodiment similar to FIG. 1A .
[0011] FIG. 2 is a schematic top view drawing of a touchdown bearing in which the tensioned elements are arrays of high-strength steel wires.
[0012] FIG. 3 shows a cross-sectional view of an embodiment that restrains displacements that have components that are transverse to the axis of rotation.
[0013] FIG. 4 shows a cross-sectional view of an embodiment that restrains displacements that have components that are transverse to the axis of rotation.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Embodiments of the present anti-whirl touchdown bearing operate without conventional lubrication and in vacuo. Thus, since the touchdown bearing may be used with rotors that are revolving at rotation rates approaching 100,000 RPM, frictional heating of the surface of the foils must be taken into account. To quantify this effect it is necessary to know the intensity and duration of the acceleration loads that are expected to be accommodated by the flywheel unit. Low acceleration levels, such as those encountered in traffic, or when traversing rough roads, can be accommodated by a combination of springs-supporting the flywheel module, together with the projected high stiffness passive magnetic bearing system of the particular flywheel to be used. High acceleration loads, such as those encountered in “fender-bender” collisions, ones in which the airbags deploy but the speeds are low, of order 15 km/hr, can be accommodated by the present touchdown bearing system. Collisions at high speed, where the vehicle is badly damaged or destroyed cannot be expected to be accommodated entirely by the touchdown bearings, and will rely on the structure surrounding the flywheel rotor to be designed to contain the rotor as it spins down, off its bearings, following the accident.
[0015] If metallic foils are used in the touchdown bearing, and if the need arises, a technique following one of the teachings of U.S. Pat. No. 5,495,221, “Dynamically Stable Magnetically Stable Suspension/Bearing System” could be employed. U.S. Pat. No. 5,495,221 is incorporated herein by reference. Specifically, if the rotating shaft contains embedded permanent magnetic material positioned so as to create an array of narrow-gap magnetic poles, when the rotating shaft approaches a metallic ribbon foil, localized eddy currents will be set up in the ribbon that will create a repulsive force. If this force is strong enough, the touchdown action can be accomplished without frictional contact between the ribbon foil and the shaft. Because of the narrowness of the magnetic gaps, the magnetic field will decrease rapidly with distance from the gap. Thus there should be minimal eddy currents generated in the foils when the shaft is centered, at which point the distance between the magnetic gap and the foil has its largest value.
[0016] FIG. 1A is top view of a foil-based touchdown bearing. The figure shows a rotatable cylinder 10 surrounded by foils 12 - 19 . The rotatable cylinder may be the rotor of a magnetically levitated flywheel energy storage system as known in the art. It may also be the shaft that supports the rotor. The cylinder may also be replaced with a solid disc. Alternates will be apparent to those skilled in the art based on the teachings herein. In this exemplary embodiment, each foil is supported by a foil support and tensioner pair. For example, foil 14 is supported by foil support and tensioners 20 and 22 . The support and tensioner simply function to hold the foil and to induce a desired tension. For example, a rotatable rod or screw functioning as tensioner 20 is fixedly attached to an end of foil 14 . The rotatable rod or screw is located within a fixed body that axially holds the tensioner in place, while allowing the tensioner to rotate about its axis. When tensioner 20 is rotated in one direction, the foil tension is increase when tensioner 20 is rotated in the opposite direction, the foil tension is decreased. A rotatable solid disc can be substituted for rotatable cylinder 10 . While under rotation, if the cylinder moves from its centered position and comes in contact with one or more of foils 12 - 19 , a re-centering force will be exerted upon the cylinder.
[0017] FIG. 1B shows a cross-sectional side view of an embodiment of FIG. 1A . The figure shows the rotatable cylinder 10 and foils 14 and 18 . A rotatable shaft 30 is fixedly attached to the rotatable cylinder 10 . FIG. 1C shows a cross-sectional view of an embodiment similar to FIG. 1A . In this embodiment, periodically spaced permanent magnets are affixed to the cylinder. Although the magnets are periodically spaced all the way around the cylinder, since the figure is a cross-sectional view, it only shows two of these magnets. Accordingly, the figure shows a rotatable cylinder 40 with permanent magnets 42 and 44 located around its perimeter. The figure includes a similar foil and foil support and tensioner system and rotatable shaft as described in FIGS. 1A and 1B , and therefore uses the same reference numbers. When the rotating cylinder encounters whirl instability, the gap between the cylinder and the foils will decrease at some point, wherein the magnets will induce eddy currents in the foil and exert a repelling force, thereby centering the rotor.
[0018] FIG. 2 is a schematic top view drawing of a touchdown bearing in which the tensioned elements are arrays of high-strength steel wires. The figure shows the rotor 50 contact surface and tensioned wire arrays 51 - 58 . Each tensioned wire is supported at each end by a wire tensioning element. For example, wire 51 is supported by wire tensioning elements 60 and 62 . The wire array based touchdown bearing can include a shaft as in FIG. 1B . The rotor 50 can include the permanent magnet configuration of FIG. 1C , in which case, the magnets will induce eddy currents in the tensioned wires if the rotor encounters whirl instability. As can be seen from the drawing the use of arrays of tensioned wires allows one to increase the distance between the tensioning supports by interleaving the wire arrays. It thus also allows the generation of a continuous polygonal contact surface for the stationary element of the touchdown bearing.
[0019] Note that by providing a variation with azimuth in the tension of the array of foils of FIGS. 1A-1C or of the wires of FIG. 2 , an anisotropic stiffness is created for displacements that are 90° apart in azimuth. This produces a centering effect against whirl type instabilities.
[0020] FIG. 3 shows a cross-sectional view of an embodiment that can be combined with the embodiments described herein. This embodiment restrains displacements that have components that are transverse to (i.e., parallel with) the axis of rotation. This dual-displacement function is accomplished by making the rotating contacting element conical in shape, at the same time using tensioned foils or wires, the planes of which correspond to the conical angle of the rotating part. The conical rotor 70 and oppositely directed conical rotor by 72 are attached by shaft 74 . Since the figure is a cross-sectional view, it only shows foils 74 and 76 beside rotor 70 ; however, additional foils are spaced around the rotor, e.g., as in FIG. 1A . Likewise, although the figure only shows foils 78 and 80 beside rotor 72 , the foils are spaced around the rotor. As in the embodiments above, wires can be substituted for the foils. A permanent magnet configuration similar to FIG. 1C can also be employed. Thus, for those cases where the touchdown bearings must resist accelerations that are both transverse to and parallel to the axis of rotation of the flywheel, the tensioned foils or wire arrays could be oriented so as to constrain the motion of a conical rotating touchdown surface. As in the previous cases, the foil or wire-array tensions would be varied with azimuthal location, so as to suppress such whirl instabilities. Rotor 72 and foils 78 and 80 may be omitted in some embodiments, e.g., in a vertically oriented system.
[0021] FIG. 4 shows a cross-sectional view of an embodiment that is similar to the one of FIG. 1B but that further restrains displacements that have components that are transverse to (i.e., parallel with) the axis of rotation. As in FIG. 1B , it includes a rotor 10 , foils 14 and 18 and shaft 30 . As in the embodiment of FIG. 1B , it further includes foils spaced around the perimeter of the rotor. The figure shows an array of narrow gap, spaced permanent magnets around the shaft. Magnet 90 is one of the magnet elements. A fixed position metallic sleeve 92 is located around the shaft over the location of the permanent magnets such that if the shaft moves in direction transverse to the axis of rotation, eddy currents will be induced in the metallic sleeve which will produce a centering effect on the shaft. Note that the metallic sleeve can be replaced with wires.
[0022] The foregoing description of the invention has been presented for purposes of illustration and description and 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. The embodiments disclosed were meant only to explain the principles of the invention and its practical application to thereby enable others skilled in the art to best use the invention in various embodiments and with various modifications suited to the particular use contemplated. The scope of the invention is to be defined by the following claims. | Stabilizing techniques are provided that prevent whirl-type instabilities during the operation of magnetically levitated rotating systems. Examples include tensioned foil and tensioned wire based designs, where a restraining force arises from contact between a rotating shaft and the tensioned elements, which elements may be of either metallic or non-metallic composition. Another stabilizing technique provides a variation with azimuth in the tension of an array of foils (or wires) so as to create anisotropic stiffness for displacements that are 90° apart in azimuth. Another exemplary technique restrains displacements that have components that are transverse to (i.e., parallel with) the axis of rotation. | 8 |
This application is a continuation-in-part of co-pending U.S. patent application No. 08/903,395, filed Jul. 22, 1997, U.S. Pat. No. 6,077, 588, which is a division of U.S. patent application Ser. No. 08/813,055, filed Mar. 7, 1997 and issued as U.S. Pat. No. 5,792,513.
FIELD OF THE INVENTION
The present invention relates generally to activated media. More particularly, the present invention relates to a method of stabilizing activated media and media produced thereby.
BACKGROUND OF THE INVENTION
It is often desirable to impregnate, cover, or otherwise treat a base material with an active or activated material, such as an absorbent or adsorbent material. One example would be a non-woven medium coated with agents having fluid adsorption and/or odor adsorption characteristics, as found in children's diapers, adult incontinence products, feminine hygiene products, and other adsorbent articles of clothing. Other examples include coated paper tissues and toweling, as well as surgical bandages and sanitary napkins. Other materials may be used as adsorbent materials, such as cyclodextrins or zeolites for odor control, or other adsorbents such as silicates, aluminas, or activated carbons.
The active, i.e., adsorbent, materials used to coat a base material may be fibrous or particulate materials. However, certain materials known in the art (e.g., fluff pulp fibers) have limited adsorption capacity, and hence perform disappointingly during normal wear. In addition, products containing such materials are often heavy and/or bulky. Thus, it is preferable to use at least some portion of particles composed of super adsorbent polymers (SAP).
Yet, it is difficult to immobilize powdered or small granular particles of SAP. Historically, microscopic active materials were immobilized on foams or on surfaces coated with a thin layer of pressure-sensitive adhesive. U.S. Pat. No. 5,462,538 to Korpman is an example of a method of immobilizing adsorbent material on a surface coated with a thin layer of pressure-sensitive adhesive. Using this method may produce large gaps between individual microscopic adsorbent elements. Also, the resulting adsorbent core has only a single layer of adsorbent material. PCT Publication No. WO 94/01069 to Palumbo is another example of a method of immobilizing particulate adsorbent material. However, the adsorbent particles are not bonded to the substrates. Moreover, the adsorbent particles are not in significant contact with the binder particles. Thus, neither method effectively restrains powdered or small granular particles of an active ingredient.
As a more effective alternative, U.S. Pat. No. 5,792,513, which is fully incorporated herein by reference, discloses a product formed from a composite mixture of adsorbent particles and binder particles fused to a substrate. While this product provides excellent absorption characteristics, the particles swell when exposed to fluid and then separate from the substrate and each other during normal use. This loose material is then free to slump or move.
In light of the foregoing, there remains a need for media, and a method of producing such media, in which the particles of an active ingredient are substantially immobilized even after they have become swollen, while maintaining excellent composite integrity.
SUMMARY OF THE INVENTION
The present invention provides an improved composite medium, in which the particles of an active ingredient are substantially immobilized. A further object is to provide absorbent or adsorbent articles having stabilizing particles dispersed throughout a coalesced composite layer of particles of an active ingredient and binder particles. By substantially immobilizing the particles of an active ingredient the present invention effectively prevents migration of the particles of an active ingredient, thereby creating an adsorbent product with enhanced integrity throughout the use cycle of the product.
Accordingly, the present invention provides composite media and a method of producing them. The composite media contain a coalesced composite mixture of particles of an active ingredient and binder particles. The binder particles preferably also fuse the composite structure to front and back substrates. The composite media also have stabilizing particles that fuse with both the particles of the active ingredient and the substrates, thereby forming a composite medium according to the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side plan-view of the composite media of the present invention; and
FIG. 2 is a schematic diagram illustrating an apparatus for the practice of the method of this invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings and, in particular, FIG. 1, there is provided a composite medium generally indicated as 1 . Composite medium 1 has a backing substrate 10 and a covering substrate 20 .
Backing substrate 10 and covering substrate 20 may be formed of various materials depending upon the application. By way of example, substrates 10 , 20 may be a permeable material, such as a non-woven fibrous material, e.g., spun-bonded polyester or polyolefin. Woven substrates may also be used. Furthermore, substrates 10 , 20 may optionally be formed using cellulosic materials, such as paper, or a combination of cellulosic and thermoplastic fibers. Either substrate 10 or 20 may also be an impermeable material, such as a plastic film (e.g., Mylar®), a permeable backsheet or membrane or another suitable material.
The particular material selected for substrates 10 , 20 can also effect the kinetics of adsorption of composite medium 1 . For example, substrates 10 , 20 can modify the mean pore size and the overall porosity, provide supplemental adsorption, improve tensile strength, flexibility, and pleatability, and effect wicking and fluid distribution.
Between substrates 10 , 20 , there is a layer, generally indicated as 2 . Layer 2 has particles of an active ingredient 30 , binder particles 40 , and stabilizing particles 50 . Particles of an active ingredient 30 are coalesced or fused together by binder particles 40 . An amount of binder particles 40 may also be fused to points on either substrates 10 or 20 , thereby also binding particles 30 to substrates 10 and 20 . However, binding particles 40 will only be fused with one of substrates 10 and 20 , rather than both. Stabilizing particles 50 may also be bonded to particles of an active ingredient 30 and, in contrast to binding particles 40 , are fused to both backing substrate 10 and covering substrate 20 , thereby forming a stabilizing bond or quilting effect.
In other words, as shown in FIG. 1, because of their smaller size, each binding particle 40 may bind to either substrate 10 or substrate 20 , but not both, or to neither of substrates 10 and 20 .
The thickness of layer 2 will vary depending on a variety of factors, including the size of the particles 30 , 40 , and 50 , the quantity of particles 30 , 40 , and 50 , the degree of coalescence between particles 30 , 40 , and 50 , and whether other particles or fibers, such as fluff pulp, are used in layer 2 . Preferably, the thickness of layer 2 is about 0.2 mm to about 5 mm.
Particles of an active ingredient 30 can potentially be formed of any material. For example, particles of an active ingredient 30 may absorb or adsorb fluids or gases. Furthermore, particles of an active ingredient 30 may be used to release fluids or gases held therein, for example, to deliver fluids, such as medicaments. Materials such as iodinated resin, activated carbon, activated alumina, aluminum powders, nickel powders, alumina-silicates, ferromagnetic materials, ion-exchange resins, manganese or iron oxides, zeolites, glass beads, ceramics, diatomaceous earth, and cellulosic materials can also be used as particles of an active ingredient 30 . In addition, particles of an active ingredient 30 may also be polymeric materials, such as SAP. The cross sectional size of particles of an active ingredient 30 is preferably within a range of about 5 microns to about 5000 microns.
Materials forming binder particles 40 may potentially include any material known in the art. In particular, thermoplastic and thermoset materials are useful for the practice of the present invention. For example, binder particles 40 may be polyethers, polyolefins, polyvinyls, polyvinyl esters, polyvinyl ethers, ethylene-vinyl acetate copolymers, or a mixture thereof. Also, suitable binder particles may be produced from particulate thermoset resins known in the art, such as phenol-formaldehyde or melamine resins, with or without additional crosslinking agents. Preferably, binder particles 40 are present in such an amount and at such a size that they do not substantively interfere with the functioning of particles 30 . Binder particles 40 are preferably about 5 microns to about 50 microns in size.
The critical feature of this invention resides in stabilizing particles 50 that are used to form through-web stabilizing bonds within layer 2 . First, stabilizing particles 50 perform a similar function as binder particles 40 , specifically coalescing or fusing together particles of an active ingredient 30 . However, they are extremely limited in their capacity to stabilize the active ingredient particles because they are large and provide limited surface area to interface with the active ingredient and they are generally present in small amounts, again limiting their ability to stabilize other particles. Stabilizing particles 50 are also adhered or fused to both substrates 10 , 20 because they are selected to have a particle size roughly equal to or greater than the thickness of layer 2 . Materials forming stabilizing particles 50 are potentially any suitable material, such as the materials listed in reference to binding particles 40 , e.g., a thermoplastic or a thermoset material. Stabilizing particles 50 are preferably present in such an amount and at such a size that they do not substantively interfere with the functioning of particles of an active ingredient 30 and binder particles 40 . It is preferred that stabilizing particles 50 be both larger in size and fewer in number compared to binder particles 40 . Preferably, stabilizing particles 50 are equal to or larger than the thickness of layer 2 , so as to allow stabilizing particles 50 to span the entire thickness of layer 2 and directly adhere to substrates 10 , 20 . However, stabilizing particles may be smaller than the thickness of layer 2 , for instance, if a ribbed effect for composite medium 1 is desired. In addition, stabilizing particles may be intimately grouped together, thereby binding to both substrates 10 , 20 in the aggregate.
FIG. 2 illustrates an exemplary apparatus for the practice of this invention. A supply roll 100 provides a substrate 120 to be treated, such as a nonwoven tissue or toweling paper. Downstream from supply roll 100 is a knurled roller 130 positioned to receive a mixture of particles of an active ingredient 30 , binder particles 40 , and stabilizing particles 50 , the mixture generally being indicated as 140 and dispensed from a hopper 160 . Mixture 140 is applied to the upper surface of substrate 120 as a continuous coating or, alternatively, as a coating of a specific design such as, for example, stripes. A brush 180 may be employed to aid in removing mixture 140 from knurled roller 130 . Thereafter, substrate 120 is passed through a nip 200 between a heated idler roller 220 and a drive roller 240 . Alternatively, before being passed through nip 200 , substrate 120 may also be preheated, for example, by a convection or infrared oven. A pneumatic cylinder is connected via a rod 280 to the axle of idler roller 220 to maintain a desired pressure on substrate 120 within nip 200 . In passing over the surface of heated roller 220 , mixture 140 is heated to a temperature equal to or greater than the softening temperature of binder particles 40 and stabilizing particles 50 , but lower than the softening temperature of particles of an active ingredient 30 . Within nip 200 , binder particles 40 and stabilizing particles 50 fuse under pressure with particles of an active ingredient 30 , while stabilizing particles 50 also fuse with substrate 120 . An amount of binder particles 40 may fuse with substrate 120 . Furthermore, in a preferred alternative to the above described apparatus, a second supply roll 300 of a substrate 320 , which may be of the same or a different material from that of substrate 120 , is also passed between nip 200 on the top of mixture 140 . Stabilizing particles 50 fuse with substrate 320 and an amount of binder particles 40 may also fuse with substrate 320 . However, while stabilizing particles 50 fuse with both substrate 120 and 320 , binder particles 40 will only fuse with either substrate 120 or 320 . Upon leaving the nip 200 , binder particles 40 and stabilizing particles 50 cool and harden. The composite medium 240 passes onto a takeup roll 360 .
Coalescing particles of an active ingredient 30 with interposed binder particles 40 and stabilizing particles 50 results in more complete coverage of the backing substrate 10 and places particles of an active ingredient 30 in closer proximity to each other. In addition, it is possible to vary the depth and porosity of layer 2 and to have multiple layers of active ingredient fully stabilized by binder particles 40 . When composite layer 1 contains SAP and is wetted, the SAP particles swell and generally break their bonds with binder particles 40 and any bonds that might exist with stabilizing particles 50 . However, the bonds between substrates 10 and 20 and stabilizing particles 50 are retained and prevent the wholesale disassembly of composite layer 1 . These stable bonds do not prevent local swelling of the composite layer 1 , but do provide localized stabilization of composite layer 1 at each point where stabilizing particle 50 spans composite layer 1 . These bonds provide a random quilting effect that prevents the movement of the swollen SAP mass.
Although composite medium 1 , and the method of producing such a medium, has been described with respect to one or more particular embodiments, it will be understood that other embodiments of the present invention may be employed without departing from the spirit and scope of the present invention.
Hence, the present invention is deemed limited only by the appended claims and the reasonable interpretation thereof. | A composite media comprising a backing sheet, a covering sheet, and a layer disposed between said backing sheet and said covering sheet, said layer having particles of active ingredient, binder particles, and stabilizing particles, wherein the active particles are coalesced by the binder particles, wherein each of the stabilizing particles bonds with both the backing sheet and the covering sheet, and wherein the stabilizing particles are larger than the binder particles. | 3 |
PRIORITY CLAIM
[0001] This application claims priority to U.S. Provisional Patent Application No. 62/082,870, filed Nov. 21, 2014, the entire contents of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention is in the field of plumbing connections that connect to fluid inlets and outlets of fluid holding vessels. More particularly, the present invention relates to a plumbing connection useful in the field of beer brewing to connect to a fluid inlet or outlet in which the plumbing connection includes a threaded, compressible bushing that compressibly grips a tube when tightened to make a plumbing connection.
BACKGROUND OF THE INVENTION
[0003] Many consumer and industrial processes involve transferring fluids to and from vessels in which the liquids are stored, reacted, modified, or otherwise handled. Typically, inlet and outlet plumbing components are connected to a vessel in order to feed or withdraw fluids from the vessel. In order to create fluid tight couplings, these coupling structures can be quite complex, involving several tubes or pipes, coupling elements, valves, gaskets, and the like. Manufacture, installation, adjustment, positioning, repair, cleaning and sanitizing, and use are more difficult than desired when so many components are involved.
[0004] The process of brewing beer, either on a commercial or home brewing scale, is an illustrative context in which plumbing components are connected to inlets and outlets of several processing vessels. Typically, beer brewing involves process steps such as malting, milling, mashing, lautering, boiling, fermenting, conditioning, filtering, and packaging. For example, the boiling step typically occurs in a kettle. Ingredients often including water, one or more sugar sources including malted barley, and hops, are boiled to accomplish objectives including sterilization of the wort to remove unwanted bacteria, releasing of hop flavors, stopping enzymatic processes, precipitation of proteins, volatilize off-flavors, and concentration of the wort.
[0005] At the end of the boil, the kettle generally includes the desired liquid phase and a solid phase referred to as the trub. A whirlpool effect may be used to collect solids in the bottom center region of the kettle, while the desired liquid product is drained from the perimeter of the kettle. A kettle generally includes a drain conduit to drain the liquid. A valve typically is provided outside the kettle to open and close the drain. A drain system includes a pickup tube or other inlet structure through which the liquid enters the drain system.
[0006] Kettles marketed for home brewing are supplied with a drain structure included threaded bosses on the inside and outside of the kettle. The bosses are used to connect the desired plumbing components. It is desirable that the plumbing connections at the drain are fluid-tight so that the kettle does not leak. Examples of commercially available brew kettles with such drain fittings are available under trade designations MegaPot 1.2 and Polar Ware.
[0007] A common practice in home brewing is to attach a pick up tube to the inside of the kettle drain for withdrawing the liquid. Conventional practice involves using coupling components, gaskets, and the like to make the plumbing connection. This involves many components to install. The large number of components to connect makes installation, cleaning and sanitizing, use, adjustment, and removal more cumbersome than might be desired. Home brewers actively investigate better ways to couple interior drain components to the drain of a brew kettle. Another concern is to use a pick up strategy that drains as much of the liquid as practically feasible while leaving as much of the solids behind.
[0008] For example, a current beer brewing blog is at www.morebeer.com. Blog participants have discussed strategies for devising a better pick up to attach to the drain boss on a brew kettle. In one discussion, a blog participant described a pick up strategy in which a pick up tube is coupled to the drain boss with a 90 degree elbow. The pick-up tube is aimed sideways. The participant wanted a better strategy, as this one left 1.5 gallons behind in the kettle. The same participant later modified this strategy by aiming the tube downward, but still used the 90 degree elbow and plumbers tape at the connections.
[0009] Another blog participant used a threaded coupling, a 90 degree elbow and a tube aimed sideways. Connections between the components were soldered, making adjustment impractical. A gasketing material was used between the drain boss and the coupling.
[0010] The popularity of home brewing continues to increase. The demand for better fluid coupling strategies for brewing equipment such as boiling kettles remains strong.
SUMMARY OF THE INVENTION
[0011] The present invention is in the field of plumbing connections that connect to fluid inlets and outlets of fluid holding vessels. More particularly, the present invention relates to a plumbing connection useful in the field of beer brewing to connect to a fluid inlet or outlet in which the plumbing connection includes a threaded, compressible bushing that compressibly grips a tube when tightened to make a plumbing connection.
[0012] Embodiments of the present invention are easy to install and use. In one illustrative mode of practice, a tube is used to pick up liquid, e.g., wort, from inside a vessel such as a brew kettle, tank, cooler, reaction vessel, or the like. Initially, the tube is inserted into a compressible bushing with a press fit between the tube and bushing. The bushing is then screwed into a complementary coupling on the vessel. Tightening the bushing causes the bushing to increasingly grip the tube as well, as the coupling. As the bushing is tightened, the tube is rotated within the bushing to aim the tube into the interior volume of the vessel as desired. While holding the tube in the desired aim, the bushing is fully tightened to the degree desired. As a consequence, the tube is coupled to the tank with fluid tight seals between the bushing and the tube and between the bushing and the vessel. The bushing functions as the attachment component, the gripping component, and the gasket component.
[0013] In one aspect, the present invention relates to a brew kettle system, comprising:
(a) a kettle comprising
(i) an interior volume (ii) a boundary between the interior volume and an exterior region; and (iii) a conduit fluidly coupling the interior volume to the exterior region, wherein the conduit comprises a female-threaded portion threadably accessible from the interior volume and a second portion accessible from the exterior region; and
(b) a pick up tube assembly, comprising:
(i) a compressible bushing, comprising:
a compressible body comprising male threads on at least a portion of an exterior surface of the compressible body, wherein the male threads of the compressible body are threadably engaged with the female threads of the female-threaded portion of the conduit; and a through bore extending from a first end of the body to a second end;
(ii) a tube having a first port at a first end that opens toward the interior volume of the kettle and a second port at a second end that opens toward the exterior region, wherein at least a portion of the tube is positioned in the through bore of the compressible bushing, and wherein the compressible body is configured in a manner such that the threadable engagement between the conduit and the compressible bushing compresses the bushing body to cause the compressible body to compressibly and sealingly engage the tube portion that is positioned in the through bore.
[0023] In another aspect, the present invention relates to a method of fluidly coupling an interior volume of a kettle to and an exterior region, comprising the step of providing a kettle system according to the above.
[0024] In another aspect, the present invention relates to a method of heating a wort admixture, comprising the steps of:
(a) providing a kettle system according to claim 1 ; (b) causing the wort admixture to be held in the kettle; (c) while the wort admixture is held in the kettle, heating the wort; and (d) after heating the wort, withdrawing at least a portion of the wort admixture through a fluid pathway comprising at least the tube portion that is compressibly and sealingly engaged by the compressed bushing body.
[0029] In another aspect, the present invention relates to a pick up tube assembly, comprising:
(a) a compressible bushing, comprising:
(i) a compressible body comprising male threads on at least a portion of an exterior surface of the compressible body, wherein the male threads of the compressible body are configured to threadably engage with the female threads of a female-threaded portion of a conduit accessible from an interior volume of a brew kettle; and (ii) a through bore extending from a first end of the body to a second end;
(b) a tube having a first port at a first end that opens toward the interior volume of the kettle and a second port at a second end that opens toward the exterior region, wherein at least a portion of the tube is positioned in the through bore of the compressible bushing, and wherein the compressible body is configured in a manner such that a threadable engagement between the conduit and the compressible bushing compresses the bushing body to cause the compressible body to compressibly and sealingly engage the tube portion that is positioned in the through bore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a schematic side view of a brew kettle system of the present invention shown in cross-section.
[0035] FIG. 2 is a side view of the brew kettle of FIG. 4 with a bottom portion of the brew kettle cut away to better show the drain features.
[0036] FIG. 3 is a perspective view of a pick up tube assembly of the present invention used in the brew kettle system of FIG. 1 .
[0037] FIG. 4 is a front view of the pick up tube assembly of FIG. 3 .
[0038] FIG. 5 is a side view of the pick up tube assembly of FIG. 6 with the pick up tube shown in cross-section.
[0039] FIG. 6 is a perspective view of the compressible bushing used in the pick up tube assembly of FIG. 3 .
[0040] FIG. 7 is a side view of the compressible bushing shown in FIG. 6 .
[0041] FIG. 8 is a side cross section view of the compressible bushing of FIGS. 6 and 7 in which the cross section is taken along line A-A of FIG. 7 .
DETAILED DESCRIPTION
[0042] The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather a purpose of the embodiments chosen and described is so that the appreciation and understanding by others skilled in the art of the principles and practices of the present invention can be facilitated.
[0043] An illustrative embodiment of a brew kettle system 10 of the present invention is shown in FIGS. 7 through 8 . Brew kettle system 10 generally includes kettle 12 and a pick up tube assembly 52 . Kettle 12 can be fabricated from a wide range of material(s). Kettle 12 desirably is fabricated from one or more materials suitable for heating wort (not shown) in the process of beer brewing. Suitable materials are strong and durable, chemically and physically resistant to the wort during heating, and are easy to clean and sterilize. Examples of suitable materials include stainless steel, aluminum, copper, brass, other metal or metal alloys, heat-resistant glass, combinations of these, and the like.
[0044] Kettle 12 includes tub 14 having a generally cylindrical sidewall 16 , floor 24 , and cover 26 . Together, sidewall 16 , floor 24 , and cover 26 provide a housing enclosing interior volume 35 . Although shown with a cylindrical geometry, sidewall 16 can have other geometries if desired. Sidewall 16 extends from top rim 18 to bottom rim 20 . Top rim 18 flares outward to help stiffen sidewall 16 . Top rim 18 defines an opening for accessing interior volume 35 of kettle 12 . Handles 32 are attached to sidewall 16 to facilitate lifting, carrying, moving, tipping, holding, or otherwise handling kettle 12 .
[0045] Floor 24 is attached to sidewall 16 proximal to bottom rim 20 . Floor 24 can be a separate component from sidewall 16 . Alternatively, floor 24 and sidewall 16 can be integrally formed as a single component. In this embodiment, floor 24 is general flat. In other embodiments, floor 24 can be convex, concave, corrugated, or otherwise contoured to help stiffen floor 24 .
[0046] Cover 26 fits over top rim 64 of sidewall 16 and is removable on demand by simply lifting or lowering to open or close kettle 12 as desired. Cover 26 includes panel 28 extending across tub opening 19 and a flange 30 extending downward from panel 28 to fit around top rim 18 . Cover 26 includes handle 34 to help the user hold cover 26 . In many suitable embodiments, cover 26 simply sets down onto top rim 18 and is held in place by gravity. In other embodiments, cover 26 may be sized and/or include features that allow cover 26 to be secured in place onto tub 14 . Examples of securing options include snap fit engagement, threaded engagement, latches, combinations of these, or the like. Because heating wort can generate pressure in the headspace above the wort, kettle 12 desirable is fitted with relief valve features (not shown) in those embodiments in which cover 26 is secured in some fashion to tub 14 .
[0047] After heating wort to the desired degree, the wort is desirably removed from tub 12 and transferred to further apparatus to continue the brewing process. Rather than have to lift and tip kettle 12 to transfer the hot wort, it is more desirable and easier to drain the hot wort from a suitable fluid egress proximal to the floor of 24 . Desirably, the intake for the fluid egress is positioned as close as possible to the floor 24 so that as much wort as practically possible is drained from kettle 12 and as little wort as practically possible is left behind. To this end, tub 14 includes fluid drain coupling 36 positioned on sidewall 16 proximal to floor 24 . Fluid drain coupling 36 provides a fluid egress to allow fluid contents to be drained from and/or transferred into interior volume 35 .
[0048] Fluid drain coupling 36 includes a tube boss 38 projecting into interior volume 35 and a tube boss 40 projecting outward into the exterior region 41 outside of kettle 12 . A channel 42 extends from port 44 on interior tube boss 40 to port 46 on exterior tube boss 40 . Channel 42 allows fluids to flow between interior volume 35 and exterior region 41 . Tube boss 38 includes female threads 48 to allow pick up tube assembly to be easily coupled to tube boss 38 . Similarly, boss 40 also desirably includes one or more coupling features (not shown) to allow plumbing components (not shown) to be coupled to boss 40 . Examples of coupling features include male threads, female threads, barbs, band clamps, quick release fittings, hatches, valves, snap fittings, combinations of these, and the like.
[0049] As illustrated, brew kettle system 10 is shown as including one fluid drain coupling 36 . In alternative embodiments, system 10 optionally may include one or more additional fluid drain couplings or other features to allow fluids to be transferred to and from kettle 12 . Such optional fluid transfer features may be positioned at any location(s) such as on sidewall 16 , floor 24 , and/or cover 26 .
[0050] Pick up tube assembly 52 includes a pick up tube 54 gripped by compressible bushing 66 , which in turn is threadably engaged with tube boss 38 . Pick up tube extends from first end 56 to second end 58 . First end 56 is located inside interior volume 35 . In this embodiment, second end 58 extends toward port 46 of boss 40 .
[0051] Pick up tube has bend 60 with pick up arm 62 extending into interior volume 35 and drain arm 64 extending toward exterior region 41 . Pick up tube 54 is hollow to provide a fluid flow channel 61 extending from a first port 63 to second port 65 . When draining fluid from kettle 12 , first port 63 serves as an inlet into pick up tube 54 , and second port 65 serves as an outlet from pick up tube 54 . As shown in the Figures, tube 54 is oriented so that pick up arm 62 is oriented downward toward floor 24 . In other modes of practice, drain arm 64 can be rotated inside compressible bushing 66 in order to aim pick up arm 62 in an alternative direction, e.g., diagonally downward, to the side, diagonally upward, upward, or the like.
[0052] Compressible bushing 66 is threadably engaged with tube boss 38 and grips pick up tube 54 . The threadable engagement with tube boss 38 occurs a manner such that the interface between tube boss 38 and bushing 66 is fluid tight. Similarly, compressible bushing 66 grips tube 54 also in a manner such that the interface between bushing 66 and tube 54 is fluid tight. In this manner, bushing 66 serves not only as a way to physically couple itself and tube 54 to tube boss 38 , but also as a gasket to help create fluid tight seals. Consequently, fluid such as wort drains from tube 14 through pick up tube 54 and is substantially prevented from, more desirably completely prevented from, seeping out from tub 14 via the interfaces between the tube boss 38 , bushing 66 , and tube 54 . The fluid tight seal at the interfaces is also important to facilitate a siphon action when such an action is desired for drawing fluid up into the pick up tube 54 . The siphon action helps to maximize the amount of wort recovered from the brew kettle after heat treatment of the wort is completed. The siphon action is particularly important when the pick up arm 62 of the pick up tube 54 is aimed downward so that first port 63 is close to the bottom of the kettle 12 and where the level of the wort being withdrawn has dropped below bend 60 .
[0053] Compressible bushing 68 includes a resiliently compressible body 68 extending from first end 70 to second end 72 . The external surface 76 of body 68 includes male threads 74 . The male threads 74 are threadably engaged with the female threads 48 inside tube boss 38 . Head 78 is provided at first end 70 . Head has a faceted external shape so that head can be gripped with a suitable tool, e.g., pliers, wrench, socket, or the like, to threadably engage or disengage bushing 68 with or from bore 38 . Head 78 may be a separate component that is attached to body 68 . More desirably, head 78 and body 68 are integrally formed as a single component.
[0054] Compressible bushing 68 is hollow and includes cylindrical interior wall 80 defining a channel 82 extending through bushing 68 from first end 70 to second end 72 . When compressible bushing has not yet been threadably engaged with bore 38 , channel 82 is sized so that drain arm 64 of pick up tube 54 can be inserted into or pulled from channel 82 with a snug but sliding fit. In the industry, this sometimes is referred to as a “press fit.” A suitable fit is indicated when the tube arm 64 slides back and forth within channel 82 with light to moderate hand force manually applied without use of tools, but is snug enough so that the installed tube 54 does not fall out of compressible bushing 66 when pick up tube assembly 52 is shaken by hand prior to being threadably engaged with boss 38 .
[0055] The cross-section of channel 82 may be constant from first end 70 to second end 72 or it may taper from one end to the other, or have some other smooth or undulating contour. More desirably, the cross section of channel 82 gently tapers from first end 70 to second end 72 . By way of example, a suitable taper is in the range from 0.25 degrees to 5 degrees, preferably 0.5 degrees to 3 degrees, most preferably about 1 degree. In those embodiments including a taper, a suitable taper can be established based upon the outside diameter of drain arm 64 . The opening 86 of channel 82 proximal to first end 70 desirably is just slightly larger than the outside diameter of arm 64 . In some embodiments, the opening 86 is 0.003 inches to 0.03 inches, preferably 0.005 to 0.02, more preferably 0.007 to 0.015 inches larger in diameter than the outside diameter of drain arm 64 . For example, in one embodiment, a difference of 0.015 inches was found to be suitable.
[0056] The taper is created by sizing the opening 88 at second end 72 to be equal to or slightly smaller in diameter than the outside diameter of drain arm 64 with an outside diameter of 0.5 inches. In some embodiments, opening 88 is 0.002 to 0.03 inches, preferably 0.003 to 0.01 inches smaller than the outside diameter of drain arm 64 having an outside diameter of 0.5 inches.
[0057] Body 68 is resiliently compressible. Resilient means that body 68 is able to at least partially and more preferentially substantially regain its original shape after being compressed elastically by threadable engagement with bore 38 for 5 minutes at 25° C. and the compression force is then removed by threadably removing body 68 from bore 38 . Exemplary resiliently compressible materials may have one or more desirable characteristics. In some embodiments, a suitable resiliently compressible material has an elongation at break in the range of 100% to 400%, more preferably 200% to 350%, even more preferably 250% to 350% according to DIN 53504 Si. In one mode of practice, an elongation at break of 290% would be suitable. In some embodiments, a suitable resiliently compressible material has a hardness Shore A in the range from 50 to 90, preferably 60 to 80, more preferably 65 to 75 according to DIN 53505. In one mode of practice, a Shore A hardness of 70 would be suitable. In some embodiments, a suitable resiliently compressible material has a rebound elasticity of 55% to 90%, more preferably 65% to 80% according to DIN 53512. In one mode of practice, a rebound elasticity of 71% would be suitable. In some embodiments, a suitable resiliently compressible material has a tensile strength in the range from 5 N/mm 2 to 15 N/mm 2 , preferably 6.5 N/mm 2 to 10.5 N/mm 2 according to DIN 53504 S 1. In one mode of practice, a tensile strength of 8.6 N/mm 2 would be suitable. In some embodiments, a suitable resiliently compressible material has a density in the range from 0.9 g/cm 3 to 1.3 g/cm 3 , preferably 1.0 g/cm 3 to 1 . 2 g/cm 3 according to ISO 1183-1 A. In one mode of practice a density of 1.14 g/cm 3 would be suitable. In some embodiments, a resiliently compressible material has a tear-strength in the range from 15 N/mm to 35 N/mm, preferably 15 N/mm to 25 N/mm according to ASTM D 624 B. In one mode of practice, a tear strength of 21 N/mm would be suitable. An illustrative example of a resiliently compressible material having such characteristics is a silicone rubber having that is commercially available from Wacker Chemie AG under the Elastosil LR 3003/70 AIB trade designation.
[0058] A wide variety of resiliently compressible materials can be used to form body 66 as well as head 78 if desired. Exemplary materials include one or more rubbers, particularly one or more silicone rubbers. Silicone rubbers are elastomeric polymers generally are non-reactive, stable, and resistant to extreme environments and temperatures from −55° C. to +300° C. while still maintaining useful properties. Silicone rubber also is easy to sterilize and therefore is useful in the practice of brewing beer. More preferred embodiments of silicone rubber are suitable for food contact. More preferred silicone rubbers are approved for food contact use according to one or more of FDA Title 21 CFR 178.3292 and/or 21 CFR 166.2600. More preferred silicone rubbers further are approved for food contact use according to European Union (BfR) standards. The silicone rubber optionally may be used in combination with one or more other polymers. Additives also may be incorporated into the formulation to modulate properties. Examples of polymers include polyesters, polyurethanes, polyethers, polyamides, polyimides, fluorinated polymers, polyolefins, combinations of these, and the like. Examples of additives include inert fillers such as TiO 2 , antioxidants, antistatic agents, fungicides, bactericides, heat stabilizers, coloring agents, stain inhibiting agents, plasticizers, stiffening agents, combinations of these and the like.
[0059] The compressible characteristics of body 68 are advantageous. When body 68 threadably engages female threads of bore 38 , channel 82 is compressed over a wide surface area of drain tube arm 64 . As a consequence, body 68 grips drain tube arm 64 tighter to create a fluid tight seal between the two components. At the same time, the threadable engagement compresses male threads 74 against female threads 48 around the surface area of body 68 to create a fluid tight seal between the components. Body 68 thus serves multiple purposes as a way to couple tube 54 to fluid drain coupling 36 and as a gasket for sealing purposes. This avoids the need for separate gaskets. Body 68 grips tube 54 so tightly, that separate coupling components typically used in conventional practices are not needed. Moreover, adjustment of how pick up arm 62 is aimed are easy to implement. Quite simply, body 68 is loosened from bore 38 to reduce the grip of body 68 on tube 54 . This allows drain arm 64 to be rotated to aim pick up arm 62 in any desired direction. The body 64 is then re-tightened to securely grip tube 54 again. This is contrasted to the conventional approaches in which one or more coupling fixtures are involved in order to accomplish a similar adjustment.
[0060] Brew kettle system 10 is easy to set up and use for beer brewing. The components of kettle 12 and pick up tube assembly are cleaned and sterilized as appropriate. Pick up tube 54 is press fit into compressible bushing 66 . Body 68 of bushing 66 is tightened into bore 38 with pick up arm 62 aimed in interior volume 35 as desired. A valve 84 or other suitable closure is closed so that liquid in kettle 12 is not able to drain through pick up tube assembly 52 . The wort formulation is added to kettle 12 , sometimes in stages, and boiled as desired. At the end of boiling, the valve or closure is opened to allow the heated wort to be drained from kettle 12 for subsequent processing. In a typical next stage of processing, the heated wort is optionally filtered and transferred to a cooling stage (not shown) to lower the temperature of the wort prior to downstream stages such as additional flavoring, fermentation, carbonation, etc.
[0061] The present invention has been described above with respect to boiling wort in a kettle system 10 . Principles of the present invention can be practiced in any context where it is desired to drain fluid contents of a vessel via an easily manufactured, easily installed, easily adjusted, and easily used drain structure. For example, in brewing operations, principles of the present invention may be used to install a drain structure in a mash ton or a sparge/hot liquor tank. In chemical manufacturing, the structure can be used on reaction vessels to drain solvents, reaction products, etc. The structures also can be used to feed solvents, reactants, processing aids, etc. into a reaction vessel. The structures also can be used to add and remove solvents in liquid extraction units. The structures can be easily integrated into existing equipment to add fluid feed and fluid drain characteristics to a tank or other vessel.
[0062] All patents, patent applications, and publications cited herein are incorporated by reference as if individually incorporated. Unless otherwise indicated, all parts and percentages are by weight and all molecular weights are number average molecular weights. The foregoing detailed description has been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. The invention is not limited to the exact details shown and described, for variations obvious to one skilled in the art will be included within the invention defined by the claims. | The present invention relates to a plumbing connection useful in the field of fluid transfer, including in many stages of beer brewing operations, to connect to a fluid inlet or outlet in which the plumbing connection includes a threaded, compressible bushing that compressibly grips a tube when tightened to make a plumbing connection. | 5 |
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